JP7731764B2 - Formwork installation method - Google Patents

Description

The present invention relates to a formwork installation method.

Patent Document 1 discloses a formwork installation method for installing formwork to pour new concrete over existing concrete.

Japanese Patent Application Laid-Open No. 2018-193724

In the formwork installation method described in Patent Document 1, the formwork is installed on an extension of the existing concrete surface in order to pour new concrete. If the formwork is simply installed on an extension of the existing concrete surface in this way, and the existing concrete surface is slightly offset from the pre-planned design surface, the newly poured concrete surface will also be offset from the design surface. As such offsets accumulate, the difference between the design shape and the actual shape gradually increases, and as a result, there is a risk that the concrete structure will not be constructed as designed.

The purpose of the present invention is to improve the construction accuracy of concrete structures.

The present invention relates to a formwork installation method for installing formwork using a formwork device, the formwork being used to pour new concrete by layering it on top of existing concrete. The formwork device comprises a base supported by the existing concrete, a moving unit that can move on the base toward and away from the existing concrete, a formwork rotatably supported on the moving unit, an angle change unit that can change the angle of the formwork relative to the moving unit, and a control unit that controls the operation of the moving unit and the angle change unit. The formwork installation method includes a formwork moving step of bringing the moving unit closer to the existing concrete and abutting part of the formwork against the existing concrete, a difference detection step of detecting the difference between a pre-planned planned position of the formwork and the current position of the formwork, and a formwork position adjustment step of activating the angle change unit in accordance with the difference to move the formwork closer to the planned position. In the difference detection step, the shortest distance between a planned position display surface that shows the pre-stored planned position of the formwork and a current position display point that shows the current position of the formwork acquired by a formwork information acquirer is detected as the difference.

This invention can improve the construction accuracy of concrete structures.

1 is a diagram showing a schematic configuration of a formwork device used in a formwork installation method according to an embodiment of the present invention. 2 is a view of the formwork device as seen from the direction indicated by arrow A in FIG. 1 . FIG. 10 is a diagram illustrating the process of pouring concrete using a formwork device. 3B is a diagram for explaining the process of pouring concrete using a formwork device, and shows the state following FIG. 3A. FIG. 3B is a diagram illustrating the process of pouring concrete using a formwork device, and shows the state following FIG. 3B. FIG. 3C is a diagram illustrating the process of pouring concrete using a formwork device, and shows the state following FIG. 3C. FIG. FIG. 3D is a diagram illustrating the process of pouring concrete using a formwork device. FIG. 3B is a diagram for explaining the process of pouring concrete using a formwork device, and shows the state following FIG. 3E. FIG. 3B is a diagram for explaining the process of pouring concrete using a formwork device, and shows the state following FIG. 3F. FIG. 3C is a diagram for explaining the process of pouring concrete using a formwork device, and shows the state following FIG. 3G. FIG. 3C is a diagram for explaining the process of pouring concrete using a formwork device, and shows the state following FIG. 3H. FIG. 3B is a diagram for explaining the process of pouring concrete using a formwork device, and shows the state following FIG. 3I. 1 is a block diagram showing the configuration of a control system for a formwork device used in a formwork installation method according to an embodiment of the present invention. 10 is a diagram for explaining an example of a method for detecting a difference between a planned position and a current position of a formwork. FIG. 1 is a flowchart illustrating steps of a formwork installation method according to an embodiment of the present invention.

Embodiments of the present invention will be described below with reference to the drawings.

First, referring to Figure 1, we will explain the formwork device 100 used in the formwork installation method according to an embodiment of the present invention. The formwork device 100 is a device used to construct a concrete structure upward by gradually raising the formwork by a predetermined height and sequentially pouring concrete. Below, we will explain the case where the concrete structure constructed using the formwork device 100 is an embankment such as a dam, as shown in Figure 1. Note that the concrete structure is not limited to an embankment, and may be, for example, a bridge pier or a cylindrical structure for storing coal or the like.

Figure 1 shows the general configuration of the formwork device 100, and Figure 2 shows the formwork device 100 as viewed from the direction of arrow A in Figure 1. In the following explanation, the up-down, front-back, and left-right directions will be defined as shown in Figures 1 and 2.

As shown in Figure 1, the formwork device 100 is a device that installs formwork members 30 (described below) to pour new concrete 2d onto existing concrete 1 (2a, 2b, 2c) that has been poured in layers in the vertical direction, and is equipped with a self-climbing mechanism that allows it to rise by itself along the side surface 1a of the existing concrete 1.

In the example shown in Figure 1, the formwork device 100 is supported by the existing concrete 1 via first anchor members 4 (described below) that are embedded in three layers 2a, 2b, and 2c cast upward in the existing concrete 1. Note that the number of layers of existing concrete 1 supporting the formwork device 100 is not limited to three; it may be two or more, or even four or more.

A first anchor member 4 and a second anchor member 5 are embedded in each layer 2a, 2b, and 2c of the existing concrete 1. The first anchor member 4 and the second anchor member 5 are internally threaded anchors, and are embedded so that the female threaded holes are exposed on the side surface 1a of the existing concrete 1.

As shown in Figure 1, in each layer 2a, 2b, and 2c, the second anchor members 5 are positioned higher than the first anchor members 4. Also, as shown in Figure 2, the first anchor members 4 are positioned along and facing the rail members 70 (described below). Meanwhile, the second anchor members 5 are positioned facing the vertical end portions 33 of the formwork members 30 (described below), at approximately equal intervals in the left-right direction. Note that in Figure 2, to make the placement of the first anchor members 4 and second anchor members 5 easier to understand, members other than those related to the placement of the first anchor members 4 and second anchor members 5 are omitted from the illustration.

As shown in FIG. 1, the first anchor member 4 is used to attach the support member 6, which supports the rail member 70, to the existing concrete 1, and the second anchor member 5 is used to attach the connecting member 36, which is provided to connect the formwork member 30 to the existing concrete 1, to the existing concrete 1. Note that the support member 6 is detached from the first anchor member 4 in areas where the rail member 70 is not installed. Furthermore, the connecting member 36 is attached to the second anchor member 5 embedded at the top of the existing concrete 1 only while the formwork member 30 is being fixed to the existing concrete 1.

The formwork device 100 comprises a base 10 supported by the existing concrete 1, a moving unit 20 that can move on the base 10 toward and away from the existing concrete 1, a formwork member 30 that is rotatably supported by the moving unit 20, an angle change unit 40 that can change the angle of the formwork member 30 relative to the moving unit 20, a rail member 70 that is supported by the first anchor member 4 via the support member 6, a jack 80 that can move the base 10 upward relative to the existing concrete 1, and a control unit 50 that controls the operation of the moving unit 20, the angle change unit 40, and the jack 80.

As shown in Figure 2, the rail member 70 is a long member with an H-shaped cross section, and as shown in Figure 1, it is placed along the side surface 1a of the existing concrete 1 while being supported by support members 6 attached to first anchor members 4 embedded in each layer 2a, 2b, and 2c. In this way, the rail member 70 is supported by multiple support members 6 while being guided and movable along the side surface 1a of the existing concrete 1. The rail member 70 is provided with locking portions (not shown) that can be locked onto the support members 6, and the locking portions lock onto the support members 6, preventing the rail member 70 from sliding downward.

The base 10 is a frame composed of a first beam member 11 that extends in the fore-and-aft direction and supports the moving part 20, a second beam member 12 that is positioned below the first beam member 11 and extends in the fore-and-aft direction, a third beam member 13 that is positioned below the second beam member 12 and extends in the fore-and-aft direction, and a plurality of diagonal members and beam members that connect these beam members 11, 12, and 13. Work scaffolding (not shown) is provided on each beam member 11, 12, and 13.

A locking portion 14 is provided at the front end of the first beam member 11, i.e., the end facing the existing concrete 1, so that it can be engaged with the support member 6 attached to the first anchor member 4. The locking portion 14 is not only configured to be able to be engaged with the support member 6, but also to be able to be engaged with the rail member 70.

As a result, the base 10 is supported by the existing concrete 1 via the first anchor member 4, as the locking portion 14 on the first beam member 11 locks onto the support member 6 and rail member 70.

The base 10 is also provided with a spacing adjustment member 15 that adjusts the spacing between the side surface 1a of the existing concrete 1 and the base 10 around the second beam member 12. Note that members for adjusting the spacing between the side surface 1a of the existing concrete 1 and the base 10 may be provided in multiple locations, and may also be provided around the third beam member 13, for example.

In addition, the locking portion 14 provided on the first beam member 11 is shaped to sandwich the rail member 70 from the left and right, and as described below, also functions as a guide member that guides the base 10, including the first beam member 11, to move along the rail member 70 when the base 10 is moved upward along the side surface 1a of the existing concrete 1.

The jack 80 is a hydraulic jack that is telescopically positioned along the side surface 1a of the existing concrete 1, and has a cylinder portion 81 and a rod portion 82. The cylinder portion 81 is fixed to the locking portion 14 of the first beam member 11, and the tip of the rod portion 82 that protrudes from the cylinder portion 81 can be locked to the rail member 70 via the locking portion 83. The specific operation of the jack 80 will be explained in the formwork installation method described below. Note that the jack 80 is not limited to a hydraulic jack, and may be any mechanism that has a telescopic configuration, such as an electric screw jack or an electric rack jack.

The formwork member 30, together with the moving section 20 and the angle changing section 40, is provided on the first beam member 11 of the base 10.

The formwork member 30 has a panel member 31 (formwork) with a smooth surface 31a facing the area where new concrete 2d will be poured, and a reinforcing member 32 attached to the back surface 31b of the panel member 31.

The reinforcing member 32 has multiple vertical end pieces 33 extending in the up-down direction and multiple horizontal end pieces 34 extending in the left-right direction. As shown in Figure 2, the vertical end pieces 33 are arranged parallel to one another at predetermined intervals in the left-right direction, and when viewed in the direction indicated by arrow A in Figure 1, rail members 70 are located between predetermined vertical end pieces 33.

The reinforcing member 32 also has an extension portion 32a that extends downward from the lower end of the panel member 31, and this extension portion 32a is detachably connected to the existing concrete 1 via a connecting member 36 (e.g., a Siebold bolt) attached to a second anchor member 5 embedded in the top of the existing concrete 1.

The vertical end pieces 33 also have extensions 33a that extend further downward than the extensions 32a of the reinforcing members 32, and these extensions 33a are fitted with spacing members 37 made of a highly rigid material to maintain a predetermined gap between the side surface 1a of the existing concrete 1 and the vertical end pieces 33. The extensions 33a and spacing members 37 may be provided on all vertical end pieces 33, or may be provided every two or three pieces in the left-right direction.

When new concrete 2d is poured, pressure acts to push panel member 31 backward, and the part connected by connecting member 36 acts as a fulcrum, reducing the gap between extension 33a of vertical end 33 and side surface 1a of existing concrete 1. As a result, the position of panel member 31 becomes unstable or shifts from its designated position, which could cause the side surface of new concrete 2d to shift relative to side surface 1a of existing concrete 1.

In contrast, in this embodiment, as shown in Figure 1, the spacing member 37 is positioned below the connecting member 36. In other words, the spacing member 37 is positioned on the opposite side of the connecting member 36 from the panel member 31.

For this reason, even if pressure is applied to push the panel member 31 backward, the spacing member 37 prevents the gap between the extension portion 33a of the vertical end portion 33 and the side surface 1a of the existing concrete 1 from becoming smaller.

This prevents the panel member 31 from wobbling or shifting from its designated position during pouring, and as a result, it is possible to position the side of the new concrete 2d on an extension of the side 1a of the existing concrete 1.

The moving unit 20 has a main body 21 that can move back and forth in the forward and backward directions along a rail (not shown) installed on the first beam member 11 of the base 10, and a formwork member support unit 22 that is rotatably supported by the main body 21 and connected to the rear side of the formwork member 30, allowing the formwork member 30 configured as described above to be moved closer to or farther away from the existing concrete 1.

The main body 21 has a movement mechanism, for example, a hydraulic jack (not shown) that is arranged to be freely retractable along the first beam member 11. The cylinder of the hydraulic jack is fixed to the main body 21, and the rod protruding from the cylinder is connected to the first beam member 11, allowing it to move back and forth in the forward and backward directions. Note that the movement mechanism is not limited to a hydraulic jack, and any mechanism may be used as long as it is configured to move the movement part 20 in the forward and backward directions relative to the first beam member 11.

The formwork member support part 22 is supported at its lower end so as to be freely rotatable at the front end of the main body part 21, i.e., the end part facing the existing concrete 1. The inclination of the formwork member support part 22 relative to the main body part 21 is changed by the angle change part 40.

The angle change unit 40 is a hydraulic jack having a cylinder unit 41 and a rod unit 42. The cylinder unit 41 is connected to the main body unit 21 of the moving unit 20, and the rod unit 42 is connected to the formwork member support unit 22 of the moving unit 20. By extending or retracting the hydraulic jack installed in this manner, the inclination of the formwork member support unit 22 relative to the main body unit 21 is changed. In other words, the inclination of the panel member 31 (formwork) can be changed by the angle change unit 40. Note that the angle change unit 40 is not limited to a hydraulic jack, and may be any mechanism capable of changing the inclination of the formwork member support unit 22 relative to the main body unit 21, such as an electric screw jack or an electric rack jack.

In this way, multiple moving units 20 and angle changing units 40 are arranged in the left-right direction to change the inclination of the formwork member 30 or to move the formwork member 30 in the forward/backward direction, i.e., in the direction of moving the formwork member 30 closer to or away from the existing concrete 1.

The control unit 50 controls the operation of the moving unit 20, angle change unit 40, and jack 80 configured as described above in response to operation by the operator. The specific control performed by the control unit 50 will be explained in the formwork installation method described below. The control unit 50 may control the operation of all moving units 20 provided on the formwork device 100, or it may control the operation of only some of the moving units 20 and have the operation of the other moving units 20 follow suit. The same applies to the control of the operation of the angle change unit 40 and jack 80.

Specifically, the control unit 50 is composed of a microcomputer equipped with a CPU (Central Processing Unit), ROM (Read Only Memory), RAM (Random Access Memory), and I/O interface (Input/Output Interface). The RAM stores data for CPU processing, the ROM stores the CPU's control programs and the like in advance, and the I/O interface is used for inputting and outputting information to and from devices and detectors connected to the control unit 50. The control unit 50 may be composed of multiple microcomputers. Note that, instead of or in addition to the CPU, an MPU (Micro Processing Unit), DSP (Digital Signal Processor), ASIC (Application Specific Integrated Circuit), FPGA (Field Programmable Gate Array), etc. can be used as the operating circuit.

Next, the process of installing the formwork members 30 to pour the new concrete 2d and 2e (formwork installation method) will be described with reference to Figures 3A to 3J in addition to Figure 1. Figures 3A to 3J show the state of the formwork device 100 in the order of the process.

First, to pour new concrete 2d onto existing concrete 1, as shown in Figure 3A, formwork member 30 is installed so that the surface 31a of panel member 31 faces the area where new concrete 2d will be poured. The formwork member 30 is installed by adjusting the amount of forward and backward movement of the moving unit 20 and the amount of extension and contraction of the angle changing unit 40.

After installation of the formwork member 30 is complete, the first anchor member 4 and the second anchor member 5, which will be embedded in the new concrete 2d, are temporarily fixed to the surface 31a of the panel member 31. The first anchor member 4 and the second anchor member 5 may also be temporarily fixed to the surface 31a of the panel member 31 in advance, before installation of the formwork member 30 is complete.

In the state shown in Figure 3A, the lower end portion, which is a part of the lower portion of the panel member 31 (formwork), is in contact with the top layer (2c) of the existing concrete 1, the extension portion 32a of the reinforcing member 32 is connected to the existing concrete 1 via a connecting member 36 attached to a second anchor member 5 embedded in the top layer (2c) of the existing concrete 1, and the extension portion 33a of the vertical end 33 of the reinforcing member 32 is in contact with the existing concrete 1 via a spacing member 37.

In the state shown in Figure 3A, the rail member 70 is engaged and fixed to a support member 6 attached to a first anchor member 4 embedded in the existing concrete 1 (2a, 2b, 2c), and the base 10 is engaged and fixed to the rail member 70 via an engaging portion 14 provided on the first beam member 11, and is also engaged and fixed to a support member 6 attached to a first anchor member 4 embedded in the top layer (2c) of the existing concrete 1.

Next, as shown in Figure 3B, new concrete 2d is poured into the area partitioned off by the panel members 31 of the formwork member 30, and the first anchor members 4 and second anchor members 5 that were temporarily fixed to the surface 31a of the panel members 31 are embedded in the new concrete 2d.

When the new concrete 2d is poured, a load is generated that presses the panel member 31 backward. However, as described above, by providing the spacing member 37 on the extension 33a of the vertical end 33, the part connected by the connecting member 36 acts as a fulcrum, preventing the entire formwork member 30 from tilting. This prevents the panel member 31 from wobbling or shifting from its designated position during pouring, and as a result, the side of the new concrete 2d can be positioned on an extension of the side 1a of the existing concrete 1.

After the poured new concrete 2d has hardened, the temporary fixation of the first anchor member 4 and the second anchor member 5 to the panel member 31 is released, and the fixation of the connecting member 36 to the extension portion 32a of the reinforcing member 32 is released.

Then, as shown in Figure 3C, the angle change unit 40 is contracted and the moving unit 20 is moved rearward, thereby removing the formwork member 30 from the new concrete 2d.

With the formwork member 30 moved away from the existing concrete 1 and the new concrete 2d in this manner, the connecting member 36 attached to the second anchor member 5 embedded in the top layer (2c) of the existing concrete 1 is removed, and the support member 6 is attached to the first anchor member 4 embedded in the new concrete 2d. The support member 6 may be attached to the first anchor member 4 embedded in the new concrete 2d before the formwork member 30 is moved away from the new concrete 2d. For example, this may be done by opening an opening/closing section (not shown) provided on the formwork member 30 corresponding to the installation location of the first anchor member 4.

Next, the process of relocating the rail member 70 will be described with reference to Figures 3D to 3F. Note that, below, the hardened new concrete 2d will be treated as part of the existing concrete 1.

First, as shown in Figure 3D, the locking portion 14 on the first beam member 11 remains locked and fixed to the support member 6, thereby fixing the cylinder portion 81 of the jack 80 to the support member 6. Then, the locking portion 83 on the tip of the rod portion 82 is temporarily released from the rail member 70, and the jack 80 is extended by one stroke. After the jack 80 has been extended in this manner (the state shown in Figure 3D), the locking portion 83 on the tip of the rod portion 82 is again locked and fixed to the rail member 70.

Then, after releasing the rail member 70 from the support member 6, the jack 80 is retracted as shown in Figure 3E. As the jack 80 retracts, the rail member 70, which is engaged and fixed to the engaging portion 83 at the tip of the rod portion 82, is pulled upward by the jack 80. Note that the engagement of the rail member 70 with the support member 6 prevents the rail member 70 from sliding downward, but the structure allows the rail member 70 to move upward.

By repeatedly extending and retracting the jack 80 in this manner, the upper end of the rail member 70 eventually reaches the support member 6 attached to the first anchor member 4 embedded in the top layer (2d) of the existing concrete 1, as shown in Figure 3F.

Then, the upper end of the rail member 70 is locked and fixed to the support member 6 attached to the first anchor member 4 embedded in the top layer (2d) of the existing concrete 1, completing the rail member 70 relocation process. Note that once the rail member 70 has been relocated upward, the support member 6 attached to the first anchor member 4 embedded in the lower layer (2a) of the existing concrete 1 is no longer needed to support the rail member 70, and is therefore removed from the first anchor member 4.

Next, with reference to Figures 3F to 3I, we will explain the process of relocating the base 10, which follows the process of relocating the rail member 70.

As shown in Figure 3F, when the relocation process of the rail member 70 is completed, the locking portion 14 of the first beam member 11 is released from the support member 6 and rail member 70, and the cylinder portion 81 of the jack 80 is no longer fixed to the support member 6. Meanwhile, the locking portion 83 provided at the tip of the rod portion 82 is locked and fixed to the rail member 70.

When the jack 80 is extended by one stroke in this state, the entire base 10, together with the cylinder portion 81 of the jack 80, moves upward relative to the existing concrete 1 and rail member 70, as shown in Figure 3G.

After extending the jack 80 in this manner, the locking portion 14 of the first beam member 11 is again locked and fixed to the rail member 70, while the locking portion 83 at the tip of the rod portion 82 is temporarily released from the rail member 70, and the jack 80 is retracted.

When the jack 80 is retracted with the locking portion 83 at the tip of the rod portion 82 disengaged from the rail member 70, only the locking portion 83 at the tip of the rod portion 82 is pulled toward the cylinder portion 81, while the position of the base portion 10 relative to the existing concrete 1 and rail member 70 is maintained, as shown in Figure 3H.

Then, the locking portion 14 of the first beam member 11 is again released from the rail member 70, while the locking portion 83 at the tip of the rod portion 82 is locked and fixed to the rail member 70, and the jack 80 is extended, thereby moving the entire base 10 upward relative to the existing concrete 1 and rail member 70.

By repeatedly extending and retracting the jack 80 in this manner, the engaging portion 14 of the first beam member 11 eventually reaches the support member 6 attached to the first anchor member 4 embedded in the top layer (2d) of the existing concrete 1, as shown in Figure 3I.

Then, the locking portion 14 of the first beam member 11 is locked and fixed to the support member 6 and rail member 70 attached to the first anchor member 4 embedded in the top layer (2d) of the existing concrete 1, completing the relocation process of the base 10.

Next, in order to pour new concrete 2e onto the existing concrete 1, a formwork movement process is carried out in which the formwork member 30 is moved from the state shown in Figure 3I so that the surface 31a of the panel member 31 faces the area where the new concrete 2e will be poured, as shown in Figure 3J.

The formwork moving process is performed by adjusting the amount of forward and backward movement of the moving unit 20 and the amount of extension and contraction of the angle changing unit 40. Specifically, the angle changing unit 40 is extended so that the slope of the surface 31a of the panel member 31 roughly matches the slope of the side surface 1a of the existing concrete 1, and the moving unit 20 is moved forward so that the lower end, which is part of the lower part of the panel member 31 (formwork), abuts against the top layer (2d) of the existing concrete 1.

After the installation of the formwork member 30 is completed, the first anchor member 4 and the second anchor member 5, which will be embedded in the new concrete 2e, are temporarily fixed to the surface 31a of the panel member 31.

Once the installation of the formwork member 30 is completed in this manner, as shown in Figure 3A, the pouring process is carried out to pour new concrete 2e into the area partitioned off by the panel members 31 of the formwork member 30.

After going through the above steps, the formwork device 100 moves upward in sequence relative to the existing concrete 1, and new concrete is poured in sequence onto the existing concrete 1.

Here, in order to pour new concrete onto the existing concrete 1, in the formwork movement process described above, the formwork member 30 is installed so that the surface 31a of the panel member 31 is positioned approximately on an extension of the side surface 1a of the existing concrete 1. However, if the side surface 1a of the existing concrete 1 is formed slightly off-center from the pre-planned design surface, the side surface of the new concrete will also be off-center from the design surface. As such deviations accumulate, the difference between the design shape and the actual shape gradually increases, and as a result, there is a risk that the concrete structure will not be constructed as designed.

To prevent such misalignment, workers could check the inclination of the panel member 31 and adjust the amount of forward and backward movement of the moving section 20 and the amount of extension and contraction of the angle change section 40, but such manual adjustments require time and effort, which ultimately increases the construction costs and lengthens the construction period for concrete structures.

In this embodiment, the degree to which the panel member 31 (formwork) is misaligned with the pre-planned design surface of the concrete structure is automatically detected, and the posture of the panel member 31 is automatically adjusted to eliminate the detected misalignment.

In this embodiment, to detect deviations of the panel member 31 from the pre-planned design surface, a camera 60 (formwork information acquirer) is installed in a position where it can capture an image of the surface 31a of the panel member 31, as shown in FIG. 1. The image captured by the camera 60 is transmitted wirelessly or via a wired connection to a control unit 50 that controls the operation of each part of the formwork device 100, as shown in FIG. 4. In addition to the image, camera 60 also transmits camera information such as the camera's 60 position information (latitude, longitude, altitude), the camera's 60 imaging orientation, and the camera's 60 tilt to the control unit 50. FIG. 4 is a block diagram showing the configuration of a control system that controls the operation of the formwork device 100.

As shown in FIG. 4, the control unit 50 has a model storage unit 50a in which 3D model data, which is the design data for the concrete structure, is pre-stored; a difference detection unit 50b that detects the difference between the planned position of the panel member 31 corresponding to the pre-planned design surface and the current position of the panel member 31 based on the 3D model data stored in the model storage unit 50a and the image data captured by the camera 60; and an equipment control unit 50c that controls the amount of expansion and contraction of the angle change unit 40 in accordance with the difference detected by the difference detection unit 50b.

The model storage unit 50a, difference detection unit 50b, and device control unit 50c are virtual units that represent the functions of the control unit 50, and do not represent physical entities. The control unit 50 is also connected to a display device 52 that displays an image captured by the camera 60 superimposed on the 3D model stored in the model storage unit 50a.

Next, we will explain the difference detection performed by the control unit 50 and the associated control of the angle change unit 40.

The difference detection unit 50b of the control unit 50 acquires an image of a predetermined position on the surface 31a of the panel member 31 captured by the camera 60 as current position information, and acquires planned position information from the 3D model (symbol M in Figure 5) stored in the model storage unit 50a, indicating what the planned position of the predetermined position on the surface 31a of the panel member 31 in the acquired image was. Then, based on the acquired current position information and planned position information, the amount of movement (difference) by which the panel member 31 should be moved is detected.

Specifically, as shown in Figure 5, an arbitrary point P1 on the surface 31a of the panel member 31 is extracted from the captured image data, and the shortest distance L1 between the extracted point P1 and the design surface MP of the 3D model M stored in the model storage unit 50a is detected as the amount of movement (difference) by which the panel member 31 should be moved. Note that Figure 5 is an enlarged view of the portion indicated by arrow B in Figure 1 to explain an example method for detecting the difference between the planned position of the panel member 31 and its current position, and differs from the content displayed on the screen of the display device 52.

In the example shown in Figure 5, the design surface MP of the 3D model M corresponds to the planned position display surface that shows the planned position of the panel member 31, and point P1 (extracted point P1) at the top end of the surface 31a of the panel member 31 corresponds to the current position display point that shows the current position of the panel member 31. The shortest distance L1 between the planned position display surface and the current position display point is detected as the difference.

The current position display point (point P1) may be, for example, a point on the line of intersection between the surface 31a of the panel member 31 and the operating plane of the angle change unit 40, which includes the operating axis when the angle change unit 40 is extended and the operating axis when the angle change unit 40 is contracted. In this case, the shortest distance between the extracted point and the straight line on the 3D model that corresponds to the line of intersection is detected as the amount of movement (difference). To make it easier to extract the current position display point, a line that corresponds to the above-mentioned line of intersection may be displayed in advance on the surface 31a of the panel member 31.

Furthermore, the current position display point (point P1) is not limited to the point at the top end of the surface 31a of the panel member 31 shown in Figure 5 or the point on the intersection line described above, but may be any point that is pre-set on the surface 31a of the panel member 31.

The amount of movement detected by the difference detection unit 50b is sent to the equipment control unit 50c, where it is converted into the amount of extension or contraction of the angle change unit 40. The equipment control unit 50c then controls, for example, the amount of hydraulic oil supplied to or discharged from the angle change unit 40 so that the angle change unit 40 extends or contracts by the set amount.

The detected difference is displayed in real time on the display device 52 using so-called augmented reality (AR), along with the extracted point P1, the image captured by the camera 60, and the design surface MP of the 3D model. Therefore, by looking at the display device 52, the worker can grasp the extent to which the panel member 31 (formwork) deviates from the design surface, and as the angle change unit 40 expands and contracts in accordance with the difference, the worker can confirm that the distance between the panel member 31 captured by the camera 60 and the design surface of the 3D model displayed as augmented reality is gradually decreasing.

The above-described control performed by the control unit 50 is carried out following the formwork movement process of the above-described formwork installation method.

Next, the above-mentioned control flow performed by the control unit 50 will be explained with reference to the flow diagram in Figure 6.

First, in step S11, it is determined whether the form movement process performed in the above-described form installation method has been completed, that is, whether the lower end of the panel member 31 (form) has come into contact with the existing concrete 1 by bringing the moving unit 20 closer to the existing concrete 1. Whether the lower end of the panel member 31 is in contact with the existing concrete 1 is detected, for example, by a proximity sensor or pressure switch.

When it is determined that the formwork movement process is complete, the process proceeds to step S12, where the surface 31a of the panel member 31 is imaged by the camera 60.

In the following step S13, the difference between the pre-planned position of the panel member 31 and the current position of the panel member 31 is detected based on the 3D model data pre-stored in the model storage unit 50a and the image data captured by the camera 60 in step S12 (difference detection process).

Specifically, as described above, the shortest distance L1 between an arbitrary point P1 on the surface 31a of the panel member 31 extracted from the captured image data and the design surface MP of the 3D model M stored in the model storage unit 50a is detected as the difference.

When a difference is detected in step S13, it is determined in step S14 whether the difference is greater than a preset threshold, i.e., whether the deviation of the surface 31a of the panel member 31 relative to the plan surface is so great that the position of the panel member 31 must be corrected.

If it is determined in step S14 that the difference is greater than the threshold, it is determined that the position of the panel member 31 needs to be corrected and the process proceeds to step S15; if it is determined that the difference is less than or equal to the threshold, it is determined that the position of the panel member 31 does not need to be corrected and the control of the angle change unit 40 is terminated.

In step S15, the angle change unit 40 is operated in accordance with the detected difference, thereby bringing the position of the panel member 31 closer to the pre-planned position of the panel member 31, i.e., the design surface MP of the 3D model M stored in the model storage unit 50a (formwork position adjustment process). Specifically, the angle change unit 40 is extended or contracted by the amount of extension or contraction converted from the difference, in the direction that reduces the difference detected in step S13.

When the extension and contraction of the angle change unit 40 is completed in step S15 and the position of the panel member 31 is changed, the process proceeds to step S16, where the camera 60 again captures an image of the surface 31a of the panel member 31. Note that the image capture by the camera 60 may begin in step S12 and continue throughout the above-mentioned steps S13 to S15.

In the following step S17, similar to step S13, the difference between the pre-planned planned position of the panel member 31 and the current position of the panel member 31 is detected as the post-adjustment difference after the position adjustment of the panel member 31 has been performed.

If a difference after adjustment is detected in step S17, it is verified in step S18 whether the misalignment has been sufficiently resolved by extending or retracting the angle change unit 40 in step S15 (post-adjustment difference confirmation process). Specifically, as in step S14, it is determined whether the difference is greater than a preset threshold value.

If it is determined in step S18 that the difference is greater than the threshold value, it is determined that the position of the panel member 31 needs to be corrected again, and the process returns to step S15, where a process of again bringing the position of the panel member 31 closer to the previously planned position of the panel member 31 (formwork position readjustment process) is performed. On the other hand, if it is determined that the difference is less than or equal to the threshold value, it is determined that the correction of the position of the panel member 31 is complete, and control of the angle change unit 40 is terminated.

Note that if step S18 determines that the difference is greater than the threshold value multiple times and steps S15 to S18 are repeated multiple times, there may be an abnormality in the angle change unit 40 or in the detection of the difference. In such cases, it may be determined that some abnormality has occurred and control of the angle change unit 40 may be terminated.

In this way, through this series of steps, the degree to which the panel member 31 (formwork) is misaligned with the pre-planned design surface is automatically detected, and the angle change unit 40 is appropriately controlled to expand and contract so as to eliminate the misalignment, automatically adjusting the panel member 31 to be positioned in line with the pre-planned design surface.

The above-described embodiment provides the following advantages:

In this embodiment, the panel member 31 (formwork) undergoes a formwork movement process, a difference detection process, and a formwork position adjustment process, and is brought closer to the pre-planned position of the panel member 31, i.e., the design surface MP of the 3D model M stored in the model storage unit 50a. In this way, the position of the panel member 31 installed to pour new concrete is automatically adjusted to the pre-planned position, even if the existing concrete 1 is formed slightly off-center from the plan. This prevents the accumulation of deviations, and as a result, the construction accuracy of the concrete structure constructed using the panel member 31 can be improved.

In addition, in this embodiment, the degree to which the panel member 31 (formwork) is misaligned with the pre-planned design surface MP of the concrete structure is automatically detected, and the inclination of the panel member 31 is automatically adjusted to eliminate the misalignment. By automatically adjusting the inclination of the panel member 31 in this way, adjustment work can be performed more efficiently than when a worker manually adjusts the operation of the moving unit 20 and angle change unit 40 while checking the inclination of the panel member 31. As a result, the construction costs of concrete structures can be reduced and the construction period can be shortened.

In addition, in this embodiment, an arbitrary point P1 on the surface 31a of the panel member 31 is extracted from the captured image data, and the shortest distance L1 between the extracted point P1 and the design surface MP of the 3D model M stored in the model storage unit 50a is detected as the amount of movement (difference) by which the panel member 31 should be moved.

Here, one possible method for correcting the position of extracted point P1 is to determine the coordinates of where extracted point P1 should have been in the plan from the 3D model M, and then compare the determined coordinates with the coordinates of extracted point P1.

However, even if the coordinates are misaligned in the front-to-back, up-down, or left-to-right directions, slightly moving the panel member 31 in each direction to eliminate the misalignment would require a complex mechanism and would require a great deal of effort and time, making this unrealistic.

In contrast, in this embodiment, as described above, the amount of movement of the panel member 31 is determined from the shortest distance between the point and the surface. Therefore, it is possible to easily adjust the position of the panel member 31 to a pre-planned position using a relatively simple mechanism.

Next, we will explain modified examples of this embodiment. Note that the following modified examples are also within the scope of the present invention, and it is possible to combine the configuration shown in the modified example with the configuration described in the above embodiment, or to combine the configurations described in the different modified examples below.

In the above embodiment, a camera 60 capable of capturing an image of the surface 31a of the panel member 31 is used as the formwork information acquirer. The formwork information acquirer is not limited to a camera 60, and a total station capable of acquiring positional information of a visual target provided on the surface 31a of the panel member 31 using light waves such as laser light may also be used.

In this case, a visual target capable of reflecting light waves emitted from the total station is provided at a predetermined position on the surface 31a of the panel member 31. For example, multiple visual targets are arranged on the intersection between the surface 31a of the panel member 31 and the operating plane of the angle change unit 40, which includes the operating axis when the angle change unit 40 is extended and the operating axis when the angle change unit 40 is retracted.

The control unit 50 then detects the difference between the position of the target measured by the total station and the design line along which the target should be located in design. The design line along which the target should be located in design is a line on the design surface MP of the 3D model M described above, and is stored in advance in the control unit 50 as a linear equation.

When a difference is detected in this way, the angle change unit 40 is controlled to expand and contract appropriately to reduce the difference, as in the above embodiment, and the panel member 31 is automatically adjusted so that it is positioned along the pre-planned design surface.

The above describes embodiments of the present invention, but these embodiments merely illustrate some of the application examples of the present invention, and are not intended to limit the technical scope of the present invention to the specific configurations of the above embodiments.

100: Formwork device 1: Existing concrete 10: Base 20: Moving part 30: Formwork member 31: Panel member (formwork)
40: Angle changing unit 50: Control unit 60: Camera (formwork information acquisition device)

Claims (2)

A formwork installation method for installing a formwork for pouring new concrete by layering it on existing concrete using a formwork device,
The formwork device is
a base supported by the existing concrete;
a moving unit that is movable on the base in a direction toward and away from the existing concrete;
The formwork is rotatably supported by the moving part;
an angle change unit that can change the angle of the formwork relative to the moving unit;
a control unit that controls the operation of the movement unit and the angle change unit,
The formwork installation method includes:
a form moving process in which the moving part is brought close to the existing concrete so that a part of the form is brought into contact with the existing concrete;
a difference detection step of detecting a difference between a previously planned position of the formwork and a current position of the formwork;
a form position adjustment step of activating the angle change unit in accordance with the difference to bring the position of the form closer to the planned position ,
In the difference detection step, the shortest distance between a planned position display surface indicating the pre-stored planned position of the formwork and a current position display point indicating the current position of the formwork acquired by a formwork information acquirer is detected as the difference.
Formwork installation method. a difference confirmation process for confirming a difference after adjustment between the planned position of the formwork and the current position of the formwork after the formwork position adjustment process is performed;
and a form position readjustment step of activating the angle change unit in accordance with the post-adjustment difference to bring the position of the form closer to the planned position.
The formwork installation method according to claim 1 .