CN110877405A - Prefabricated component production line - Google Patents
Prefabricated component production line Download PDFInfo
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- CN110877405A CN110877405A CN201911005610.XA CN201911005610A CN110877405A CN 110877405 A CN110877405 A CN 110877405A CN 201911005610 A CN201911005610 A CN 201911005610A CN 110877405 A CN110877405 A CN 110877405A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 176
- 238000009415 formwork Methods 0.000 claims abstract description 113
- 238000000034 method Methods 0.000 claims abstract description 73
- 230000008569 process Effects 0.000 claims abstract description 60
- 238000012546 transfer Methods 0.000 claims description 28
- 238000012423 maintenance Methods 0.000 claims description 16
- 230000007246 mechanism Effects 0.000 claims description 14
- 229910001294 Reinforcing steel Inorganic materials 0.000 claims description 8
- 238000004378 air conditioning Methods 0.000 claims description 3
- 238000004321 preservation Methods 0.000 claims description 3
- 239000002131 composite material Substances 0.000 claims description 2
- 238000005034 decoration Methods 0.000 claims 1
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- 230000008901 benefit Effects 0.000 abstract description 12
- 238000003860 storage Methods 0.000 abstract description 7
- 230000008520 organization Effects 0.000 abstract description 6
- 239000000463 material Substances 0.000 description 17
- 239000004744 fabric Substances 0.000 description 9
- 238000009826 distribution Methods 0.000 description 6
- 230000032258 transport Effects 0.000 description 6
- 238000012544 monitoring process Methods 0.000 description 4
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- 230000033764 rhythmic process Effects 0.000 description 3
- 206010063385 Intellectualisation Diseases 0.000 description 2
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- 210000003195 fascia Anatomy 0.000 description 2
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- 238000007788 roughening Methods 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 230000005540 biological transmission Effects 0.000 description 1
- 125000004122 cyclic group Chemical group 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B15/00—General arrangement or layout of plant ; Industrial outlines or plant installations
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Abstract
The invention provides a prefabricated part production line which comprises a first area, a second area and a curing kiln, wherein the curing kiln is closely adjacent to one end of the first area and one end of the second area which are arranged side by side, the first area comprises a plurality of fixed stations which are arranged in rows, a bench formwork which is placed above the fixed stations, a horizontal rail which is parallel to the fixed stations, a vertical rail which is vertical to the horizontal rail and a primary-secondary vehicle are arranged on each fixed station, and the primary-secondary vehicle conveys the bench formwork into the curing kiln through the horizontal rail and the vertical rail; the second area comprises a plurality of flowing stations and a transverse conveying line connected with the plurality of flowing stations, and the bench formwork completing the curing process in the curing kiln flows along the transverse conveying line at each flowing station. The production line of the scheme can be suitable for the production of prefabricated parts with different structural types, is flexible in production organization mode, can perform assembly line operation, enables the bench formwork to enter the curing kiln for three-dimensional storage and curing, and has the advantages of fixed bench formwork production line technology and assembly line production technology.
Description
Technical Field
The invention belongs to the technical field of prefabricated part production, and relates to a prefabricated part production line.
Background
With the rapid development of the assembly type building industry, the assembly rate of buildings is required to be improved in various regions in China, and a large number of prefabricated part production plants are required to be constructed in a matched manner due to the fact that the transportation radius of the prefabricated parts is limited (generally, the prefabricated parts cover the range within 200 kilometers near the plants). The production process form and the process flow of the prefabricated part are main factors influencing the floor area and the unit area energy production of a factory. The main prefabricated part production line process layout forms in the current market have two types: a production line production mode and a fixed bench die production mode.
The production line production mode is characterized in that a bench formwork (i.e. a working platform for producing prefabricated parts) flows to a station corresponding to each process through a conveying system of a production line along with the process sequence; the operators and specific work of each station are relatively fixed, such as placing a mold, placing reinforcing steel bars, placing embedded parts, pouring concrete, vibrating, polishing the concrete surface, napping and the like, and the operations are performed by relatively fixed people and equipment at the fixed stations. The prefabricated parts produced by the assembly line production process have basically consistent structural complexity, otherwise, the prefabricated parts have large structural change, the time for completing the operation of the front and rear different prefabricated parts on the stations of the assembly line is not uniform, some station workers operate at the same time, some station workers are idle, the assembly line cannot flow according to a certain production beat, and the production efficiency is greatly reduced. The relatively single prefabricated component of structure can adopt the production overall arrangement mode of assembly line like single wallboard, sandwich wallboard, two wall and truss-like coincide floor etc. and the relatively complicated changeable special-shaped component of structure is not suitable for production on the assembly line like bay window, balcony, air-conditioning board, beam column etc.. Therefore, the assembly line production has the advantages of high production efficiency and high productivity, and has the disadvantages of being only suitable for producing single type components (such as the production line for producing the wall plate cannot simultaneously produce beams or floor slabs), limited in suitable component types and high in investment cost.
The fixed bench formwork production mode is that the bench formwork is fixed, and all the operation procedures such as formwork placing, reinforcing steel bar and embedded part placing, concrete pouring, vibrating, maintaining, formwork removing, member hoisting and the like are completed on a fixed bench formwork station. Each bench formwork takes 2-3 days to produce a prefabricated part, so that a plurality of bench formworks can be occupied when a plurality of prefabricated parts are produced simultaneously, and the occupied area of a production line is large. The fixed bench formwork has the advantages that the production method is suitable for the production of prefabricated parts with different structural types, and the production organization mode is flexible; the defects are that the operation procedures of workers at a single station are more, the production efficiency is low, and the productivity per unit area is low.
The fixed bench formwork production method and the assembly line production method of the prefabricated part in the prior art have advantages and disadvantages, and due to scarcity of land resources and imbalance of development of various regions, the layout mode (large occupied area, large investment and large capacity) of the current mainstream prefabricated part production line cannot adapt to all conditions, such as the conditions that the demand of the prefabricated part is insufficient, the land resources are short, the capital investment is limited, and the heavy asset and the cost investment of factory building cannot be met. The existing layout mode of the prefabricated part production line also has the problem of insufficient sustainability, and after the prefabricated part production line stops working, most of equipment such as a conveying system in the production line cannot be recycled, so that high investment cost waste is caused. Therefore, the market demands of novel prefabricated part production lines and factories which have complete prefabricated part production types, high productivity per unit area, small occupied area and small investment are more and more urgent. There is a need to develop a novel prefabricated part production line to overcome the disadvantages of the current fixed bench formwork production mode and the production line production mode.
The invention content is as follows:
the invention aims to provide a prefabricated part production line, which is suitable for the production of prefabricated parts with different structural types, has flexible production organization modes, gives consideration to the advantages of a fixed bench formwork production line process and a production line production process, and solves the technical problem that a proper prefabricated part production line is not available under the condition of land resource shortage and the like in the prior art.
In order to achieve the purpose, the invention adopts the following technical scheme:
a prefabricated part production line comprises a first area, a second area and a curing kiln, wherein the curing kiln is arranged at one end of the first area and one end of the second area in a side-by-side mode, the first area comprises a plurality of fixing stations arranged in rows, a bench formwork placed on the fixing stations, a horizontal rail parallel to the fixing stations, a vertical rail arranged on each fixing station and perpendicular to the horizontal rail, and a primary-secondary vehicle, and the primary-secondary vehicle conveys the bench formwork into the curing kiln through the horizontal rail and the vertical rail; the second area comprises a plurality of flowing stations and a transverse conveying line connecting the flowing stations, and the bench molds completing the curing process in the curing kiln flow along the transverse conveying line at each flowing station. In this scheme, after the bench formwork in the first region accomplished corresponding process on each fixed station, the rethread primary and secondary car transports to the curing kiln and carries out the maintenance, shifts the bench formwork to the second region after the maintenance is accomplished and carries out assembly line work. The curing kiln and the primary and secondary vehicles are the prior art and are not described herein; by arranging the three-dimensional curing kiln, the bench formwork and the prefabricated part are transferred to a curing station of the curing kiln for curing, so that the prefabricated part is prevented from being placed on a fixed station for direct curing and forming, a large amount of bench formwork storage space is saved, the temperature can be intensively heated in the curing kiln to shorten the time required by curing, and the curing efficiency is improved; the transfer from the bench formwork of the fixed station to the curing kiln is realized by arranging the primary and secondary vehicles. After the maintenance is finished, only the processes of form removal and lifting of the prefabricated part are needed, and the operation time of each process is short, so that the bench forms enter the second area from the maintenance kiln to perform streamlined operation, and the operation efficiency of the processes is improved. Because the first area adopts the fixed station, the equipment investment cost is obviously reduced relative to the production line; all the fixed stations do not interfere with each other, so that the prefabricated parts of different types can be produced, and the application range is wide. And the second region adopts the production mode of assembly line, can carry out corresponding process to the bench formwork after the maintenance is accomplished fast, avoids appearing piling up from the bench formwork that the curing kiln internal transfer came out, has improved production efficiency. In conclusion, the scheme is different from a fixed bench die production mode and a flow line production mode in the prior art, overcomes the defects of the fixed bench die production mode and the flow line production mode, has the advantages of the fixed bench die production mode and the flow line production mode, and is low in equipment investment, high in production efficiency and recyclable; the production and production organization modes of the prefabricated parts with different structural types are flexible, the assembly line operation is realized, the bench formwork enters the maintenance kiln for three-dimensional storage and maintenance, the advantages of the fixed bench formwork production line process and the assembly line production process are taken into consideration, and the technical problem that the proper prefabricated part production line is lacked under the conditions of land resource shortage and the like in the prior art is solved.
Preferably, a plurality of curing stations and a stacker are arranged in the curing kiln, and the stacker transfers the table formwork and the prefabricated part after initial setting from the first area to the curing stations and transfers the table formwork from the curing stations to the second area. Because the curing kiln is of a three-dimensional structure comprising a plurality of layers and a plurality of columns, the stacker can transfer the prefabricated parts and the bench formwork to be cured to a specific empty curing station, and the prefabricated parts and the bench formwork are operated to the second area from the curing station after curing is completed. Since the specific structure of the curing kiln is the prior art, the detailed description is omitted here.
Preferably, the prefabricated part production processes executed on the fixed stations in the first area include a mold placing process, a steel bar placing process, a reserved embedded part placing process, a concrete pouring process and an initial setting process, and the production processes corresponding to the flowing stations in sequence are a mold removing process and a prefabricated part lifting process according to the direction away from the curing kiln in sequence in the second area. That is, all the processes before concrete curing are carried out on the fixed stations in the first area, and after the curing of the prefabricated parts in the curing kiln is completed, the subsequent stripping and hoisting processes are completed in the second area. Therefore, different types of prefabricated parts can be produced in the first area at the same time, then the prefabricated parts move to the curing kiln through the primary and secondary vehicles, and the processing procedures of the bench formwork for producing the different types of prefabricated parts at the same time are the same when the bench formwork enters each flow station of the second area, so that the universality and the production efficiency of the whole production line are improved.
Preferably, a wired side warehouse and a logistics channel are further arranged at the position, close to the second area, of the first area, so that the die, the reserved embedded part and the reinforcing steel bar material can be stored conveniently. This facilitates the operation of each process at the fixed station of the first zone.
Preferably, a lifting device is further arranged near the flowing water station for lifting the prefabricated parts in the second area. Thus, the hoisting and the transferring of the prefabricated part are convenient.
Preferably, a traverse trolley and a traverse rail are arranged between a flowing station corresponding to the prefabricated part hoisting process in the second area and a fixed station in the first area adjacent to the flowing station, the traverse trolley is provided with a jacking device, and the traverse trolley realizes the transfer of the bench formwork between the flowing station and the fixed station connected with the traverse rail. Like this, accomplish the bench formwork after prefabricated component lifts by crane in the second region, can shift to first region through the sideslip car, realized the circulation of bench formwork on the whole production line, improved the utilization ratio of bench formwork, reduced the idle rate of bench formwork.
Preferably, the process flow direction of the prefabricated part production line is as follows: the single bench formwork sequentially carries out the working procedures of formwork placing, reinforcing steel bar placing, reserved embedded part placing, concrete pouring and initial setting on a fixed station in the first area; then the primary and secondary vehicles transfer the prefabricated parts after the initial setting together with the bench formwork to the stacker, and the stacker transfers the bench formwork to a maintenance station; the stacker transfers the prefabricated parts after the curing together with the bench formwork to a flow station of a second area close to the curing kiln, and the bench formwork drives the prefabricated parts to move to different flow stations along the transverse conveying line and sequentially performs the procedures of formwork removal and prefabricated part lifting; and the transverse moving vehicle transfers the table die after the lifting of the prefabricated part to an adjacent fixed station in the first area. Therefore, the whole production process flow of the prefabricated part is completed through the circulation of the bench formwork among the first area, the curing kiln and the second area, the automation degree is higher, the production line is reasonable in layout, and the whole occupied area is small.
Preferably, the first region still includes concrete conveying track and transports cloth machine/cloth fill, concrete conveying track is including arranging the first track of each fixed station top in first region, transport cloth machine/cloth fill along concrete conveying track removes and emptys the concrete. The track of carrying the concrete like this adopts the line limit to arrange, improves the concrete and changes material efficiency, is provided with a plurality of concrete material receiving points on concrete conveying track, and the cloth fill or transport the cloth machine and can connect the material at concrete material receiving point nearby, shorten the cloth fill or transport the time that the cloth machine transported the concrete, avoid the concrete to change the material cloth and become the production bottleneck.
Preferably, the plurality of fixed stations are arranged in two parallel rows, the horizontal rail is positioned between the two rows of fixed stations, and one end part of the horizontal rail extends to a stacking machine in the curing kiln. By the arrangement, the production yield of the production line is doubled under the condition of only increasing a small amount of floor space; because the processing time of the corresponding process on each fixed station in the first area is longer, under the condition that only one line of fixed stations is arranged, the flowing stations of the curing kiln and the second area have larger idle rate, so that two lines of fixed stations are arranged, the cooperation between the first area and the second area is improved, and the overall efficiency of the production line is improved.
Preferably, the concrete conveying track further comprises a second track, and the first track and the second track are respectively arranged above the two rows of fixed stations and are parallel to the horizontal track. When two lines of fixed stations are arranged, two concrete conveying rails are correspondingly arranged, and concrete supply on each fixed station can be guaranteed.
Preferably, the plurality of fixed stations are arranged in parallel rows, one horizontal rail is arranged between every two rows of fixed stations, and each horizontal rail is provided with one primary vehicle and one secondary vehicle. When the prefabricated part with a simple structure is produced, the idle rate of the flow station in the second area is high due to the fact that the time is short in the processes of arranging the side forms, placing the pre-embedded reserved parts and the like; meanwhile, in the weather with low air temperature, such as winter, the time for initial setting of the fixed stations in the first area is longer, and the idle rate of the mobile stations in the second area is easy to increase. Therefore, the multi-row fixed stations are arranged, the production capacity of the first area can be improved, the matching degree between the first area and the second area is improved, the high idle rate of the flowing stations of the second area is avoided, and the capacity of the whole production line is guaranteed.
Preferably, the primary and secondary vehicles comprise secondary vehicles and primary vehicles, and the secondary vehicles are arranged on the traveling rails on the upper surfaces of the primary vehicles and are provided with lifting mechanisms; the walking track of the upper surface of the main vehicle is parallel to the vertical track, the main vehicle moves along the horizontal track, and the sub-vehicle passes between the walking track of the upper surface of the main vehicle and the vertical track. After the walking track of the upper surface of the main vehicle is aligned with the vertical track on the fixed station, the sub vehicle drives into the vertical track, then the lifting mechanism of the sub vehicle jacks up the bench formwork on the fixed station, then the sub vehicle drives the bench formwork back to the upper surface of the main vehicle, then the sub vehicle and the main vehicle convey the bench formwork into the curing kiln, and thus the bench formwork on the fixed station is transferred into the curing kiln through the matching between the sub vehicle and the main vehicle. As the primary and secondary vehicles are the prior art, the detailed description is omitted.
Preferably, the system also comprises a comprehensive control system which is used for detecting the state of each mould on the fixed station in the first area, detecting the state of each mould on the mobile station in the second area, detecting and controlling the working state of the primary and secondary vehicles, controlling the working state of the cross sliding vehicle, controlling the transfer of the primary and secondary vehicles and the stacking machine, controlling the operation of the stacking machine and controlling the working state of the transfer distributing machine. Through the comprehensive control system, the monitoring of the production process of the prefabricated parts on the whole production line can be realized, the automation and the intellectualization are improved, the mistakes and omissions caused by manual monitoring are avoided, the production efficiency is improved, and the labor intensity of workers is reduced.
Preferably, the transverse conveying line comprises a power mechanism, a walking wheel and a driving wheel, the table die is arranged on the upper surfaces of the walking wheel and the driving wheel, and the power mechanism drives the walking wheel and the driving wheel to rotate so as to drive the table die to move. Since the transverse conveyor line is prior art, it is not described herein in detail. The movement of the table die on the flow stations of the second zone is achieved by means of the transverse conveyor lines, so that corresponding processes are carried out at different flow stations.
Preferably, the prefabricated part production line is used for producing one or more of sandwich external wall panel, prefabricated interior wallboard, external wall panel with heat preservation and decorative layer, truss-like coincide floor, full prefabricated floor, prefabricated bay window, prefabricated balcony, prefabricated air conditioner board, precast beam and prefabricated post. Because this scheme production line has the advantage of fixed bench formwork production mode and assembly line production mode concurrently, can produce the prefabricated component of different grade type simultaneously in first region, after getting into maintenance kiln and second region, the required process that goes on of bench formwork of the prefabricated component of production different grade type is all the same, therefore its commonality is strong, and the production productivity is high.
The technical scheme in the aspect at least has the following advantages:
(1) after the bench formwork on the fixed station of the first area finishes each process, the bench formwork is transported to a stacker through a primary and secondary vehicle, the stacker places the bench formwork on a curing station of a curing kiln for three-dimensional storage, and then the next round of operation is immediately carried out on the original fixed bench formwork station; compared with the existing fixed bench formwork production mode in which all processes and prefabricated part in-situ maintenance are required to be completed at the fixed bench formwork station, the production capacity of the unit area of a factory is greatly improved, and substantial breakthrough is made in reducing the area of the factory and saving land resources;
(2) compared with the prior art in a fixed bench formwork production mode, the assembly line work of demolding and hoisting of the kiln is carried out on the assembly line work station in the second area, so that the cross operation of the primary and secondary vehicles and the prefabricated part transport vehicle is avoided, the primary and secondary vehicles can run on a special channel at high speed, and the high efficiency of the prefabricated part production is ensured;
(3) according to the scheme, the work station is fixed in the first area, the material distribution and initial setting processes are carried out, and long-time initial setting does not have great influence on the production efficiency of the production line; compared with the production line mode in which centralized material distribution and initial setting are carried out on stations, the production rhythm of the production line can be seriously influenced by long-time initial setting, and the influence on the production rhythm is reduced by increasing a large number of initial setting stations and reducing the initial setting time of a platform die staying on each station, so that the production facility and the plant area can be increased, and the cost is increased; if concrete is distributed on one fixed station in the first area, the bench formwork on other fixed stations needing concrete distribution is transferred to the distribution station through the primary and secondary vehicles and then returned to the original fixed station for initial setting, so that the operation workload of the primary and secondary vehicles can be increased by times, and the production efficiency is reduced;
(4) in the scheme, the concrete conveying track is arranged at the side of the first area line, so that the material transferring time of a hopper or a material transferring and distributing machine is shortened, and the production efficiency of material transferring and distributing of concrete is ensured;
(5) the scheme can be used for producing various common prefabricated components in the markets such as sandwich wallboards, single wallboards, truss type composite floor slabs, bay windows, balconies, air-conditioning plates, beams, columns and the like, is a comprehensive component production line, has strong universality and wide application range, and can be used for producing most of the prefabricated components on one production line;
(6) the production efficiency and the automation degree of the prefabricated part production line in the scheme are far higher than those of the existing fixed bench formwork production line on the market at present, the investment intensity is far lower than that of the existing assembly line production line on the market, the types of the produced prefabricated parts are complete, and the prefabricated part production line is particularly suitable for medium and small PC factories; the floor space is small, the investment cost is low, and the method is suitable for large-scale popularization.
Drawings
FIG. 1 is a first layout view (arrows indicate the moving direction of the table die) of a prefabricated part production line according to embodiment 1 of the present invention;
FIG. 2 is a second schematic layout of a prefabricated part production line according to embodiment 1 of the present invention;
FIG. 3 is a schematic view showing the layout of a prefabricated part production line according to embodiment 1 of the present invention;
FIG. 4 is a plan view of the parent car and the child car according to embodiment 1 of the present invention;
FIG. 5 is a first side view of the primary and secondary vehicles of embodiment 1 of the present invention;
FIG. 6 is a second side view of the parent and child cars of embodiment 1 of the present invention;
FIG. 7 is a schematic view showing a layout of a production line of a prefabricated part according to embodiment 2 of the present invention;
reference numerals:
1-first zone 2-curing kiln 3-second zone
4-fixed station 5-horizontal rail 6-vertical rail
7-primary and secondary vehicles 8-primary and secondary vehicles 9-primary vehicle
10-lifting mechanism 11-walking track 12-ferrying station
13-mobile station 14-cross sliding vehicle 15-cross sliding track
16-stacker 17-running gear 18-concrete conveying track
19-ground foundation.
Detailed Description
The following preferred embodiments of the present invention are provided to aid in a further understanding of the invention. It should be understood by those skilled in the art that the description of the embodiments of the present invention is by way of example only, and not by way of limitation.
Example 1
Referring to fig. 1 to 3, the prefabricated member production line in the embodiment includes a first area 1, a second area 3 and a curing kiln 2, wherein the first area 1 and the second area 3 are arranged side by side, and the curing kiln 2 is arranged close to the ends of the first area and the second area; the first area 1 comprises a plurality of fixed stations 4 arranged in rows, a platform mould placed above the fixed stations 4, horizontal rails 5 parallel to the fixed stations 4, vertical rails 6 perpendicular to the horizontal rails 5 and a primary-secondary vehicle 7, wherein the primary-secondary vehicle 7 conveys the platform mould into the curing kiln 2 through the horizontal rails 5 and the vertical rails 6; the second zone 3 comprises a plurality of flow stations 13 and a transverse conveyor line connecting the plurality of flow stations 13, along which the bench formwork completing the curing process in the curing kiln 2 circulates in each flow station 13. In this embodiment, the plurality of fixed stations 4 in the first area 1 are arranged in two parallel rows, each fixed station 4 is provided with a base (not shown in the figure) for bearing a stage mold, and the stage mold is placed on the upper surface of the base; the horizontal rail 5 is positioned between the two rows of fixed stations 4, and one end part of the horizontal rail 5 extends to a stacker 16 in the curing kiln 2; each horizontal guide rail is provided with a primary-secondary vehicle 7. Because the process processing time that corresponds on every fixed station 4 is than longer in first region 1, under the condition that only sets up a line fixed station 4, it is lower to meet the weather temperature, and the initial setting time on fixed station 4 is longer, and great idle rate can appear in curing kiln 2 and the mobile station 13 of second region 3, consequently sets up two lines fixed station 4, has improved the cooperation between first region 1 and the second region 3 to the overall efficiency of production line has been improved.
Referring to fig. 4 to 6, the primary-secondary vehicle 7 in the present embodiment includes a secondary vehicle 8 and a primary vehicle 9, the secondary vehicle 8 is disposed on a traveling rail 11 on the upper surface of the primary vehicle 9 and is provided with a lifting mechanism 10; the walking track 11 on the upper surface of the primary vehicle 9 is parallel to the vertical track 6, the primary vehicle 9 moves along the horizontal track 5, and the secondary vehicle 8 passes between the walking track 11 on the upper surface of the primary vehicle 9 and the vertical track 6. The mother vehicle 9 is placed on the ground foundation 19, and the bottom surface of the mother vehicle 9 is provided with rollers which can move along the horizontal rail 5 on the ground foundation 19; the top side of the master vehicle 9 is provided with two pits, the two pits are respectively provided with a walking track 11, the bottom surface of the sub-vehicle 8 is provided with a walking mechanism 17, and the two sub-vehicles 8 are arranged in the two pits and can move along the walking tracks 11; the top side of the sub-vehicle 8 is provided with a lifting mechanism 10 which can lift the bench formwork. In other embodiments, the primary-secondary vehicle 7 may have other specific structures, and in the case that the distance between the platform and the ground foundation 19 is relatively high, the top surface of the primary vehicle 9 is not provided with a pit, and the secondary vehicle 8 is disposed on the traveling track 11 on the top surface of the primary vehicle 9. Referring to fig. 1 and 5, the traveling rail 11 of the primary vehicle 9 has the same width as the vertical rail 6 of the fixed station 4, and when the traveling rail 11 of the primary vehicle 9 is aligned with the vertical rail 6 of the fixed station 4, the secondary vehicle 8 can move back and forth between the two rails. And the height of the primary and secondary cars 7 is lower than the bottom surface of the bench formwork on the fixed station 4, and the power supply of the primary car 9 can be supplied by a sliding contact line or a storage battery. The secondary vehicle 8 can be powered from the primary vehicle 9 in a drag chain mode, and can also be powered by a storage battery. The bench formwork process on the fixed station 4 is transported to primary and secondary car 7 as follows: when the primary and secondary vehicles 7 move to the position near a certain fixed station 4, aligning the traveling track 11 on the surface of the primary vehicle 9 with the vertical track 6 on the fixed station 4, and stopping moving; the two sub-vehicles 8 run along the running rails 11 of the main vehicle 9 to the position right below the bench formwork on the vertical rails 6, and the bench formwork is lifted to leave the base through the lifting mechanisms 10 of the sub-vehicles 8; the sub-vehicle 8 drives the bench formwork to leave the fixed station 4 and drive to the main vehicle 9; the primary and secondary vehicles 7 then travel along the horizontal rails 5 with the molds to the vicinity of the curing kiln 2. With continued reference to fig. 1 and 2, a plurality of curing stations and stackers 16 are provided within the curing kiln 2, the stackers 16 transferring the forms from the first section 1 to the curing stations and from the curing stations to the second section 3. The curing kiln 2 is a three-dimensional structure comprising a plurality of layers and a plurality of columns, and the stacker 16 can transfer the prefabricated parts and the bench formwork to be cured to a specific empty curing station and operate the bench formwork to the second area 3 from the curing station after the curing is finished. Since the curing kiln 2 and the primary and secondary vehicles 7 are prior art, the detailed structure thereof will not be described herein.
With continued reference to fig. 1, the transverse conveying line in the second area 3 of the present embodiment includes a power mechanism, a traveling wheel and a driving wheel, the table mold is disposed on the upper surfaces of the traveling wheel and the driving wheel, and the power mechanism drives the traveling wheel and the driving wheel to rotate so as to drive the table mold to move. Since the transverse conveyor line is prior art, it is not described herein in detail. By means of the transverse conveyor lines, it is achieved that the table molds move in sequence on the flow stations 13 of the second zone 3, so that corresponding processes are carried out at different flow stations 13. Two or three rows of flow stations 13 and transverse conveying lines can be provided in the second zone 3, according to the actual requirements.
Referring to fig. 3, in the present embodiment, the first area 1 further includes a concrete conveying track 18 and a transfer distributor/distributor hopper (not shown), and the concrete conveying track 18 includes a first track and a second track arranged above the fixing stations 4 of the first area 1, and the first track and the second track are respectively arranged above the two rows of fixing stations 4 and are parallel to the horizontal track 5. The transfer distributor/distributor hopper moves along two concrete conveying rails 18 and pours the concrete. The track for conveying the concrete is arranged along the line, so that the concrete transferring efficiency is improved, a plurality of concrete receiving points are arranged on the concrete conveying track 18, a distributing hopper or a transferring distributing machine can receive the concrete at the nearby concrete receiving points, the time for transferring the concrete by the distributing hopper or the transferring distributing machine is shortened, and the concrete transferring and distributing is prevented from becoming a production bottleneck; two concrete conveying rails 18 are correspondingly arranged on the two rows of fixing stations 4, and concrete supply on each fixing station 4 can be guaranteed.
Referring to fig. 1 to 6, in this embodiment, the production processes of the prefabricated part performed on each fixed station 4 in the first area 1 sequentially include a mold placing process, a steel bar placing process, a pre-embedded part placing process, a concrete pouring process, and an initial setting process, and the production processes sequentially corresponding to each flow station 13 in the second area 3 according to the movement direction of the traverse line are a mold removing process and a prefabricated part lifting process. The process flow direction of the prefabricated part production line is as follows: firstly, completing the processes of placing a mold, placing reinforcing steel bars and placing reserved embedded parts on a bench formwork of the same fixed station 4, then receiving materials on a concrete conveying rail 18 through a material distributing hopper or a material distributing transferring machine, transferring the materials to the fixed bench formwork station for concrete distribution, completing initial setting of the bench formwork for about 1 hour on the original fixed station 4 after the distribution is completed, performing roughening on the surface of a prefabricated part after the initial setting, transferring the prefabricated part after the initial setting and the bench formwork to a stacker 16 by a primary and secondary vehicle 7 after the roughening is completed, and transferring the bench formwork to a maintenance station by the stacker 16; the stacker 16 transfers the prefabricated components and the bench formwork after the curing to the flow stations 13 of the second area 3 adjacent to the curing kiln 2, and the bench formwork drives the prefabricated components to move to different flow stations 13 along a transverse conveying line and sequentially carries out the procedures of form removal and prefabricated component lifting; the transverse trolley 14 transfers the lifted bench formwork to the adjacent fixed station 4 in the first area 1. The whole production process flow of the prefabricated part is completed through the circulation of the bench formwork among the first area 1, the curing kiln 2 and the second area 3, the automation degree is higher, the production line is reasonable in layout, and the whole occupied area is small. Because the first area 1 adopts the fixed station 4, the equipment investment cost is obviously reduced relative to the production line; all the fixed stations 4 do not interfere with each other, so that different types of prefabricated parts can be produced, and the application range is wide; and the second region 3 adopts the production mode of assembly line, can carry out corresponding process to the bench formwork after the maintenance is accomplished fast, avoids the bench formwork that shifts out from the curing kiln 2 to appear piling up, has improved production efficiency. The production line of the embodiment is different from a fixed bench formwork production mode and a flow line production mode in the prior art, and has the advantages of low equipment investment, high production efficiency and cyclic utilization; the production and production organization modes of the prefabricated parts with different structural types are flexible, the assembly line operation can be realized, the bench formwork enters the maintenance kiln 2 for three-dimensional storage and maintenance, the advantages of the fixed bench formwork production line process and the assembly line production process are taken into consideration, and the technical problem that the proper prefabricated part production line is lacked under the conditions of land resource shortage and the like in the prior art is solved.
The prefabricated component production line in this embodiment is used for producing one or more in sandwich side fascia, prefabricated interior wallboard, take the side fascia, truss-like coincide floor, full prefabricated floor, prefabricated bay window, prefabricated balcony, prefabricated air conditioner board, precast beam and the prefabricated post of heat preservation and decorative layer. Because this scheme production line has the advantage of fixed bench formwork production mode and assembly line production mode concurrently, can produce the prefabricated component of different grade type simultaneously in first region 1, after getting into maintenance kiln 2 and second region 3, the required process that goes on of bench formwork of the prefabricated component of production different grade type is all the same, therefore its commonality is strong, and the production productivity is high, can adjust in a flexible way as required, and same kind of prefabricated component can be produced to whole production line, also can produce different prefabricated components simultaneously.
Referring to fig. 1, in the present embodiment, the flow stations 13 in the second area 3 are arranged in two parallel rows, so that the prefabricated parts to be cured in the curing kiln 2 can be emptied of the bench formwork in time, and the turnover rate of the curing stations is increased; in other embodiments, if the production line capacity requirement is low, or the fixed station 4 is provided with only one row, the moving station 13 and the transverse conveyor line may be provided with only one row.
On the basis of the embodiment, in another improved embodiment, a wired side warehouse and a logistics channel are further arranged at the position, adjacent to the second area 3, of the first area 1, so that the moulds, the pre-embedded parts and the reinforcing steel bar materials can be stored. Like this, carry out in the second region 3 and tear the mould back open, can directly place the side forms etc. that pull down in the line limit storehouse, then on the fixed station 4 of first region 1 operation set mould and when placing the reservation built-in fitting, can directly take from the line limit storehouse, strengthened the material circulation efficiency of first region 1 and second region 3.
Referring to fig. 1 to 3, in the second area 3 of the present embodiment, a traverse carriage 14 and a traverse rail 15 are disposed between a mobile station 13 corresponding to a prefabricated part lifting process and a fixed station 4 in the first area 1 adjacent to the mobile station 13, wherein the fixed station 4 corresponding to the mobile station 13 of the lifting process is a ferry station 12, and no table die is placed on the ferry station 12 during the actual production process. The traverse car 14 is provided with a jacking device, and the traverse car 14 realizes the transfer of the bench formwork between the mobile station 13 and the fixed station 4 which are connected by the traverse rail 15. The transverse moving rail 15 is a ground rail arranged on the bottom surface base, the transverse moving vehicle 14 is in the prior art, when the transverse moving vehicle 14 moves to the position below a table die of the flowing station 13 in the lifting process, the jacking device jacks up the table die to leave a travelling wheel and a driving wheel of a transverse conveying line after being started, then the transverse moving vehicle 14 travels towards the first area 1 along the transverse moving rail 15, and when the transverse moving vehicle 14 moves to the opposite fixed station 4, the jacking device falls down to place the table die on a base of the fixed station 4. In this way, the bench formwork in the second area 3 after the lifting of the prefabricated parts can be transferred to the ferrying station 12 of the first area 1 through the transverse moving trolley 14, and then transferred to other fixed stations 4 through the primary and secondary trolleys 7 to produce the prefabricated parts; therefore, the circulation of the bench formwork on the whole production line is realized, the utilization rate of the bench formwork is improved, and the idle rate of the bench formwork is reduced.
Referring to fig. 1, in another modified embodiment, the fixing station 4 near the second area 3 and the curing kiln 2 is a second ferry station, and a conveying line connected with the curing kiln 2 is arranged on the second ferry station (an arrow on the second ferry station indicates the transferring direction of the bench formwork). After the bench formwork finishes initial setting on the fixed station 4, the bench formwork can be transported to a second ferry station through the primary and secondary vehicles 7, then the corresponding transmission line is started, and the bench formwork is transported to the stacking machine 16 of the curing kiln 2. Because the butt joint of the stacker 16 and the conveying line belongs to the prior art, the two are mutually connected stably, the transfer efficiency can be improved, and the running step of the sub-vehicle 8 existing in the butt joint of the sub-vehicle 7 and the stacker 16 is avoided.
Example 2
Referring to fig. 7, the production line in this embodiment is substantially the same as that in embodiment 1 except that: the plurality of fixing stations 4 are arranged in parallel rows, a horizontal rail 5 is arranged between every two rows of fixing stations 4, and a primary-secondary vehicle 7 is arranged on each horizontal rail 5. When the prefabricated part with a simple structure is produced, the idle rate of the flow station 13 in the second area 3 is high due to the fact that the time consumption of procedures of arranging the side forms, placing the pre-embedded reserved parts and the like is short; meanwhile, in the weather with low air temperature, such as winter, the time for the fixed station 4 in the first area 1 to perform initial setting is relatively long, and the idle rate of the mobile station 13 in the second area 3 is easily increased. Therefore, the multi-row fixed station 4 is arranged, the production capacity of the first area 1 can be improved, the matching degree between the first area 1 and the second area 3 is improved, the high idle rate of the flowing station 13 of the second area 3 is avoided, and the capacity of the whole production line is ensured.
In this embodiment, the prefabricated part production line further comprises a comprehensive control system, which is used for detecting the state of each mold on the fixed station 4 in the first area 1, detecting the state of each mold on the flowing station 13 in the second area 3, detecting and controlling the working state of the primary and secondary vehicles 7, controlling the working state of the traverse vehicle 14, controlling the transfer of the primary and secondary vehicles 7 and the stacker 16, controlling the operation of the stacker 16, and controlling the working state of the transfer stacker. After the bench formwork finishes the procedures of formwork placing, reinforcing steel bar placing, pre-embedded part placing and initial setting galling at the fixed station 4, the fixed station 4 sends an operation completion state information to the comprehensive control system, and after the comprehensive control system receives the operation completion state information sent by the fixed station 4, the system controls the primary and secondary cars 7 to move to the fixed station 4 according to a bench formwork kiln entering scheduling algorithm, such as a time sequence or a shortest path principle; the prefabricated part after initial setting and the bench formwork can be transferred to a second ferry station by a primary and secondary vehicle 7, and then the bench formwork after operation is transferred to a stacker 16 by a driving wheel of the second ferry station; or directly conveying the bench formwork on the fixed station 4 after completing the operation to the stacker 16 through the primary and secondary vehicles 7. And then conveyed to a target bin of the curing kiln 2 through a stacker 16 for curing. After the curing of the prefabricated parts is completed, the prefabricated parts are taken out of the curing kiln 2 through the stacker 16, and then the comprehensive control system controls the stacker 16 to transfer the formworks to the flow station 13 close to the curing kiln 2. Referring to the attached drawings 1 and 3, two mold stripping stations and 1 lifting station are arranged from left to right in sequence, and a motor, a travelling wheel and a driving wheel are arranged below the flowing stations 13 to form a transverse conveying line. The mould stripping stations and the lifting station form a mould stripping and lifting assembly line; two lines of form removal hoisting assembly lines are arranged in the embodiment, and 1 or 3 or a plurality of corresponding assembly lines can be arranged according to the actual production beat in other embodiments. The table dies on the stations can be controlled to circulate through the comprehensive control system, and the assembly line operation is realized. If the complexity of the components produced by each fixed station 4 is very different, the time span of the operation completion state information sent to the comprehensive control system is large; if the complexity of the prefabricated parts on each fixed station 4 is approximate, the time of the operation completion state information sent to the comprehensive control system is relatively close. According to the actual plant layout, a form removal lifting assembly line can be arranged, and only the form removal stations on the assembly line can be more according to a plurality of production beats. Through the comprehensive control system, the monitoring of the production process of the prefabricated parts on the whole production line can be realized, the automation and the intellectualization are improved, the mistakes and omissions caused by manual monitoring are avoided, the production efficiency is improved, and the labor intensity of workers is reduced.
The production organization form of the production line in this embodiment: the operation area of the fixed station 4 in the first area 1 can adopt the original fixed bench formwork operation production mode, for example, if each station fixed operator finishes all the working procedures of the station or different operators finish different working procedures of the station, which station finishes the operation first, and the bench formwork of which station enters the curing kiln 2 in advance; then, the comprehensive control system dispatches an empty platform mold to the fixed station 4 for the next production, and the production rhythm of other stations is not influenced; the mould removing station in the second area 3 adopts a production line operation production mode, so that too heavy or blocked conveying tasks of the primary and secondary vehicles 7 caused by mould removing, hoisting and plate conveying at the fixed station 4 are avoided; the curing kiln 2 adopts several layers of height at the lower part to meet the height of the special-shaped component, and several layers of height at the upper part to meet the thickness of the wallboard and the floor slab component.
Finally, it should be noted that the above embodiments are only used for illustrating the technical solutions of the present application and not for limiting the protection scope thereof, and although the present application is described in detail with reference to the above embodiments, those of ordinary skill in the art should understand that: numerous variations, modifications, and equivalents will occur to those skilled in the art upon reading the present application and are within the scope of the claims as issued or as granted.
Claims (10)
1. A prefabricated part production line is characterized by comprising a first area, a second area and a curing kiln, wherein the curing kiln is arranged at one end of the first area and one end of the second area side by side, the first area comprises a plurality of fixing stations arranged in rows, a table die placed on the fixing stations, a horizontal rail parallel to the fixing stations, a vertical rail arranged on each fixing station and perpendicular to the horizontal rail, and a primary-secondary vehicle, and the primary-secondary vehicle conveys the table die into the curing kiln through the horizontal rail and the vertical rail; the second area comprises a plurality of flowing stations and a transverse conveying line connecting the flowing stations, and the bench molds completing the curing process in the curing kiln flow along the transverse conveying line at each flowing station.
2. The prefabricated member production line of claim 1, wherein a plurality of curing stations and a stacker are provided in the curing kiln, the stacker transferring the form from the first area to the curing stations and transferring the form from the curing stations to the second area.
3. The prefabricated member production line of claim 2, wherein the prefabricated member production processes performed on the fixing stations in the first area comprise a mold placing process, a reinforcement placing process, a pre-embedded part placing process, a concrete pouring process and an initial setting process; and the production processes corresponding to the flowing stations in sequence in the second area are the processes of form removal and prefabricated part lifting according to the direction away from the curing kiln in sequence.
4. The prefabricated member production line of claim 3, wherein a traverse car and a traverse rail are arranged between a flow station corresponding to the prefabricated member hoisting process in the second area and a fixed station in the first area adjacent to the flow station, and the traverse car is used for realizing the table die transfer between the flow station and the fixed station connected with the traverse rail.
5. The prefabricated member production line of claim 4, wherein the process flow direction of the prefabricated member production line is as follows: the single bench formwork sequentially carries out the working procedures of formwork placing, reinforcing steel bar placing, reserved embedded part placing, concrete pouring and initial setting on a fixed station in the first area; then the primary and secondary vehicles transfer the prefabricated parts after the initial setting together with the bench formwork to the stacker, and the stacker transfers the prefabricated parts after the initial setting together with the bench formwork to a maintenance station; the stacker transfers the prefabricated parts after the curing together with the bench formwork to a flow station of a second area close to the curing kiln, and the bench formwork drives the prefabricated parts to move to different flow stations along the transverse conveying line and sequentially performs the procedures of formwork removal and prefabricated part lifting; and the transverse moving vehicle transfers the table die after the lifting of the prefabricated part to an adjacent fixed station in the first area.
6. The precast element production line of any one of claims 1 to 5, characterized in that the first area further comprises a concrete conveying track comprising a first track arranged above each fixed station of the first area and a transfer spreader/spreader hopper moving along the concrete conveying track and pouring concrete.
7. The prefabricated member production line of claim 6, wherein the primary and secondary vehicles comprise primary and secondary vehicles, the primary and secondary vehicles are arranged on a traveling rail on the upper surface of the primary vehicle and are provided with lifting mechanisms; the walking track of the upper surface of the main vehicle is parallel to the vertical track, the main vehicle moves along the horizontal track, and the sub-vehicle passes between the walking track of the upper surface of the main vehicle and the vertical track.
8. The prefabricated member production line of claim 6, wherein a line bank and a logistics channel are further provided at a position of the first area adjacent to the second area.
9. The prefabricated component production line of claim 6, wherein the transverse conveying line comprises a power mechanism, a traveling wheel and a driving wheel, the table mold is arranged on the upper surface of the traveling wheel and the driving wheel, and the power mechanism drives the traveling wheel and the driving wheel to rotate so as to drive the table mold to move.
10. The prefabricated component production line of claim 6, wherein the prefabricated component production line is used for producing one or more of sandwich external wall panels, prefabricated internal wall panels, external wall panels with heat preservation and decoration layers, truss-type composite floor slabs, full prefabricated floor slabs, prefabricated bay windows, prefabricated balconies, prefabricated air-conditioning panels, prefabricated beams and prefabricated columns.
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| CN115229963A (en) * | 2022-06-23 | 2022-10-25 | 丹棱县圳棱混凝土有限公司 | Concrete overall-process intelligent safety production line and control method thereof |
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Application publication date: 20200313 |