CN115351898A - Automatic production line and production method of prefabricated assembled pier caps - Google Patents
Automatic production line and production method of prefabricated assembled pier caps Download PDFInfo
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- CN115351898A CN115351898A CN202210996732.5A CN202210996732A CN115351898A CN 115351898 A CN115351898 A CN 115351898A CN 202210996732 A CN202210996732 A CN 202210996732A CN 115351898 A CN115351898 A CN 115351898A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 52
- 230000002457 bidirectional effect Effects 0.000 claims abstract description 49
- 238000000034 method Methods 0.000 claims abstract description 17
- 238000004140 cleaning Methods 0.000 claims description 32
- 238000005507 spraying Methods 0.000 claims description 24
- 230000002787 reinforcement Effects 0.000 claims description 19
- 239000003795 chemical substances by application Substances 0.000 claims description 16
- 229910000831 Steel Inorganic materials 0.000 claims description 13
- 239000010959 steel Substances 0.000 claims description 13
- 239000000463 material Substances 0.000 claims description 10
- 239000006082 mold release agent Substances 0.000 claims description 7
- 238000006243 chemical reaction Methods 0.000 claims description 3
- 238000003860 storage Methods 0.000 claims description 3
- 238000003908 quality control method Methods 0.000 abstract description 2
- 230000007306 turnover Effects 0.000 abstract 1
- 238000010276 construction Methods 0.000 description 9
- 230000010485 coping Effects 0.000 description 5
- 239000007921 spray Substances 0.000 description 5
- 230000002159 abnormal effect Effects 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000000994 depressogenic effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000009417 prefabrication Methods 0.000 description 1
- 239000004575 stone Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
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Classifications
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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
-
- 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
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/04—Producing shaped prefabricated articles from the material by tamping or ramming
- B28B1/045—Producing shaped prefabricated articles from the material by tamping or ramming combined with vibrating or jolting
-
- 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
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
- B28B11/245—Curing concrete articles
-
- 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
- B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
- B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
- B28B13/0215—Feeding the moulding material in measured quantities from a container or silo
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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
- B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
- B28B13/04—Discharging the shaped articles
- B28B13/06—Removing the shaped articles from moulds
-
- 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
- B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
- B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
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- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Structural Engineering (AREA)
- Bridges Or Land Bridges (AREA)
Abstract
The invention relates to an automatic production line and a production method of an assembled prefabricated pier cap. The existing artificial prefabricated pier cap has the problems of difficult quality control, low work efficiency and the like. The production line comprises a pouring vibration station, a steam curing station, a demolding station, a turning station, a logistics master-slave vehicle set walking line connecting all the stations, a pier cap reverse pouring special-shaped mold and a bidirectional rail-running logistics master-slave vehicle set; the bidirectional rail-mounted logistics master-slave vehicle set runs on a walking line of the logistics master-slave vehicle set, the bidirectional rail-mounted logistics master-slave vehicle set carries a pier cap reverse pouring special-shaped mold to sequentially enter a pouring vibrating station, a steam curing station and a demolding station, and an obtained finished pier cap is hoisted and transported to a turnover station from the demolding station by an in-site gantry crane. The production line provided by the invention has the advantages of reasonable station design, smooth circulation and high automation degree, and relates to the advantages of fewer manual operation procedures, automatic production capacity, effective reduction of manual workload, improvement of on-site safety and improvement of the production efficiency of the assembled prefabricated pier caps.
Description
Technical Field
The invention relates to the technical field of pier cap prefabrication, in particular to an automatic production line and a production method of an assembled prefabricated pier cap.
Background
In bridge construction engineering, bridge structures increasingly adopt assembly type construction modes based on the influences of various factors such as geographic conditions, cost control and construction efficiency, and the construction technology gradually develops towards industrialization, assembly and standardization. The pier cap is the connecting part between pier shaft and the bridge floor, can support superstructure and with load downward transmission, also can adopt prefabricated mode production, assembles through the prefabricated construction mode at the scene.
In the construction process of the assembled bridge of the high-speed railway, as the pier cap prefabricating technology belongs to a new field, the construction mode is not mature, the prefabricating process depends on manpower, the quality of the pier cap is difficult to control, the work efficiency is low, and in order to ensure the production work efficiency and the finished product quality of the prefabricated pier cap, an automatic production line of the prefabricated pier cap needs to be developed, so that a feasible construction method is provided for the construction of the assembled bridge in the future.
Disclosure of Invention
The invention aims to provide an automatic production line and a production method of an assembled prefabricated pier cap, which at least solve the problems of difficult quality control, low work efficiency and the like of the existing artificial prefabricated pier cap.
In order to achieve the purpose, the technical scheme adopted by the invention is as follows:
the automatic production line for the prefabricated assembled pier caps comprises a pouring vibration station, a steam curing station, a demolding station, a turning station, a logistics master-slave vehicle set walking line for connecting all the stations, a reverse pouring special-shaped mold for the pier caps and a bidirectional rail-running logistics master-slave vehicle set;
the bidirectional rail-mounted logistics master-slave vehicle set runs on a running line of the logistics master-slave vehicle set, the bidirectional rail-mounted logistics master-slave vehicle set carries the pier cap reverse pouring special-shaped mold to sequentially enter the pouring vibrating station, the steam curing station and the demolding station, and the obtained finished pier cap is hoisted to the overturning station from the demolding station by an in-situ gantry crane.
Furthermore, the production line also comprises a steel bar cage die-entering station;
the bidirectional rail-mounted logistics master-slave vehicle set carries a pier cap reverse pouring special-shaped mold to enter the pouring vibration station, the bidirectional rail-mounted logistics master-slave vehicle set firstly enters the reinforcement cage mold entering station, and a pier cap reinforcement framework is hoisted into the pier cap reverse pouring special-shaped mold by an in-site gantry crane.
Further, the production line also comprises a mold cleaning station;
and the bidirectional rail-mounted logistics master-slave vehicle set carries the pier cap reverse pouring special-shaped mold to leave the demolding station and then enters the mold cleaning station.
Further, the production line also comprises a release agent spraying station;
and the bidirectional rail-mounted logistics master-slave vehicle set carries the pier cap reverse pouring special-shaped mold, leaves the mold cleaning station and then enters the mold release agent spraying station.
Furthermore, the pouring vibration station, the steam curing station, the demolding station and the overturning station are all on the same walking line of the logistics master-slave vehicle set, the steel reinforcement cage mold entering station, the mold cleaning station and the demolding agent spraying station are all on the same walking line of the other logistics master-slave vehicle set, and the walking lines of the two logistics master-slave vehicle sets are parallel to each other;
a transverse channel is arranged between the walking line of the logistics master-slave vehicle set between the steam curing station and the demolding station and the walking line of the other logistics master-slave vehicle set; and another transverse channel is arranged between the logistics mother-son train set running line before the pouring and vibrating station and the other logistics mother-son train set running line.
Further, the bidirectional rail-mounted logistics master-slave vehicle set comprises a heavy-load master vehicle, a heavy-load slave vehicle and a light-load master vehicle;
the bottom of the heavy-load mother vehicle is provided with a transversely moving walking wheel; a longitudinal first heavy-load sub-vehicle walking guide rail for supporting the heavy-load sub-vehicle is arranged at the top of the heavy-load main vehicle;
the bottom of the heavy-duty sub-vehicle is provided with traveling wheels which move longitudinally; a heavy-load sub-vehicle lifting oil cylinder is arranged at the top of the heavy-load sub-vehicle;
the bottom of the light-load mother vehicle is provided with a transversely moving walking wheel; and the top of the light-load mother vehicle is provided with a second longitudinal heavy-load sub-vehicle walking guide rail for supporting and loading the heavy-load sub-vehicle and a light-load mother vehicle lifting oil cylinder.
Furthermore, a transfer bearing platform is arranged on each station, and the bidirectional rail-mounted logistics master-slave vehicle set completes the position conversion of the mold on the transfer bearing platform;
the transfer bearing platform comprises a light-load bus parking place and a heavy-load bus parking place which are separated by a transverse boss, and a walking guide rail is arranged on the transverse boss.
In another aspect, there is provided a method for manufacturing an automated production line of prefabricated pier caps, the method comprising:
the bidirectional rail-mounted logistics master-slave vehicle set carries the pier cap reverse pouring special-shaped mold to enter the pouring vibration station, a distributor is used for pouring concrete, and the concrete is vibrated during pouring;
after the pouring vibration is finished, the bidirectional rail-mounted logistics master-slave vehicle set carries the pier cap reverse pouring special-shaped mold to leave the pouring vibration station and enter the steam curing station for steam curing, and anchor bolt loosening is carried out on the bottom of the pier cap reverse pouring special-shaped mold after the steam curing is finished;
after the anchor bolt is loosened, the bidirectional rail-mounted logistics master-slave vehicle set carries the pier cap reverse pouring special-shaped mold to leave the steam curing station, enters the demolding station, and lifts the finished pier cap in the pier cap reverse pouring special-shaped mold for demolding;
after demolding is finished, the finished pier caps are lifted to the overturning station from the demolding station by using the gantry crane in the field, and after the finished pier caps are overturned for 180 degrees, the finished pier caps are lifted to the pier cap storage area by using the gantry crane in the field.
Further, the method further comprises:
the bidirectional rail-mounted logistics master-slave vehicle set carries the pier cap reverse pouring special-shaped mold to firstly enter the steel reinforcement cage mold entering station, an in-site gantry crane is used for hoisting and conveying a pier cap steel reinforcement framework into the pier cap reverse pouring special-shaped mold, and then the bidirectional rail-mounted logistics master-slave vehicle set conveys the pier cap reverse pouring special-shaped mold to the pouring vibration station.
Further, the method further comprises:
after demolding is carried out at the demolding station and finished pier caps are lifted, the bidirectional rail-mounted logistics master-slave vehicle set carries the pier cap reverse pouring special-shaped mold to enter the mold cleaning station, and the pier cap reverse pouring special-shaped mold is opened for cleaning;
after the cleaning is finished, the bidirectional rail-mounted logistics master-slave vehicle set carries the pier caps to reversely pour the special-shaped mold to enter the demolding agent spraying station for demolding agent spraying.
Compared with the prior art, the invention has the following beneficial effects:
the assembled prefabricated pier cap production line provided by the invention has the advantages of reasonable station design, smooth circulation and high automation degree, relates to less manual operation procedures, is used for automatic production of assembled prefabricated pier caps, can effectively reduce the manual workload, improves the field safety and greatly improves the production efficiency of the assembled prefabricated pier caps.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings of the embodiments can be obtained according to the drawings without creative efforts.
Fig. 1 is a floor plan of the present invention.
FIG. 2 is a schematic view of a heavy-duty primary vehicle of a bi-directional rail-mounted logistics sub-primary vehicle group.
FIG. 3 is a schematic view of a heavy-duty sub-train of the bi-directional rail-mounted logistics sub-train cluster.
FIG. 4 is a schematic view of a light-duty parent vehicle of a bi-directional rail-mounted logistics parent vehicle group.
FIG. 5 is a schematic view of a heavy load parent vehicle carrying a heavy load child vehicle and the mold moving to a transfer platform.
FIG. 6 is a schematic view of a heavy-duty sub-vehicle carrying a mold to a light-duty parent vehicle.
FIG. 7 is a schematic illustration of the retraction of a heavy truck.
Fig. 8 is a schematic view of a pier cap reverse pouring special-shaped mold arranged on a frame body.
Fig. 9 is a schematic diagram of an automatic pouring and vibrating device for a pier cap.
Fig. 10 is a schematic view of a coping ejection system.
FIG. 11 is a schematic view of a rail-mounted cleaning cart.
FIG. 12 is a schematic view of a multi-directional automatic release agent spray system.
The labels in the figure are:
1-a steel reinforcement cage mould entering station, 2-a pouring vibration station, 3-a steam curing station, 4-a demoulding station, 5-a turning station, 6-a mould cleaning station, 7-a demoulding agent spraying station, 8-a logistics master-slave vehicle group walking line, 9-a special mould for reverse pouring of a pier cap, 10-an automatic pouring vibration device for the pier cap, 11-a pier cap demoulding system, 12-a transverse channel, 13-a bidirectional rail logistics master-slave vehicle group, 14-a rail walking cleaning trolley, 15-a multidirectional automatic demoulding agent spraying system and 16-a transfer bearing platform;
901-bottom die and side die framework; 902-pre-embedding a conical sleeve in a bottom die; 903-anti-falling beam stop block groove; 904-support the stone groove;
1001-walking trolley, 1002-vibrating rod, 1003-vibrating rod hydraulic lifting system and 1004-track beam;
1101-a demoulding oil cylinder, 1102-a demoulding oil cylinder track, 1103-a jacking device;
1301-heavy load mother vehicle, 1302-heavy load child vehicle, 1303-light load mother vehicle, 1304-heavy load child vehicle lifting oil cylinder, 1305-light load mother vehicle lifting oil cylinder, 1306-first heavy load child vehicle walking guide rail, 1307-second heavy load child vehicle walking guide rail, 1308-light load mother vehicle lifting oil cylinder;
1401-rail mounting, 1402-cleaning trolley;
1501-spraying upright posts, 1502-longitudinal rail beams, 1503-transverse rail beams and 1504-spray heads;
1601-light load bus position, 1602-heavy load bus position, 1603-transverse boss and 1604-walking guide rail.
Detailed Description
To facilitate an understanding of the invention, the invention will now be described more fully hereinafter with reference to the accompanying drawings. Preferred embodiments of the present invention are shown in the drawings. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete.
In the description of this patent, it is to be understood that the terms "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", and the like, as used herein, refer to an orientation or positional relationship indicated in the drawings, which is solely for the purpose of facilitating the description of the patent and simplifying the description, and do not indicate or imply that the referenced device or element must have a particular orientation, be constructed and operated in a particular orientation, and thus should not be taken as limiting the patent.
In the description of this patent, it is noted that unless otherwise expressly stated or limited, the terms "configured," "connected," "disposed," and the like are to be construed broadly and can for example be fixedly connected, disposed, detachably connected, disposed, or integrally connected and disposed. The specific meaning of the above terms in this patent may be understood by one of ordinary skill in the art as appropriate.
In addition, in the description of the present patent, the terms "first" and "second" are used only for distinguishing the names of similar structures at different positions, are used for understanding the positional relationship between components in conjunction with the drawings, and should not be construed as limiting the order or position of the components.
The invention provides an automatic production line of an assembled prefabricated pier cap, which is used for the prefabricated production of the assembled pier cap, wherein the pier cap is prefabricated in a reverse pouring mode, namely the bottom surface of the pier cap is arranged above the pier cap, and the top surface of the pier cap is arranged below the pier cap in the prefabricating process. The whole production line can automatically run, and the existing gantry crane in the field is needed in the running process. As shown in fig. 1, the production line comprises a reinforcement cage mold-entering station 1, a pouring vibration station 2, a steam curing station 3, a demolding station 4, a turning station 5, a mold cleaning station 6, a demolding agent spraying station 7 and a logistics primary and secondary vehicle group running line 8 for connecting all the stations. Wherein the pouring vibration station 2, the steam curing station 3, the demoulding station 4 and the overturning station 5 are arranged on a material flow primary-secondary train group running line 8 together, such as a left line in figure 1, from top to bottom in the figure; the steel reinforcement cage mold entering station 1, the mold release agent spraying station 7 and the mold cleaning station 6 are arranged on the other material flow primary and secondary vehicle group running line 8, as shown in the right line of fig. 1, from top to bottom in the drawing. The two logistics mother-son train sets running lines 8 are parallel to each other. A transverse passage 12 is arranged between the material flow primary-secondary vehicle group running line 8 between the steam curing station 3 and the demoulding station 4 and the other material flow primary-secondary vehicle group running line 8. And another transverse channel 12 is arranged between the material flow primary-secondary train running line 8 in front of the pouring and vibrating station 2 and the other material flow primary-secondary train running line 8. The left and right material flow primary and secondary vehicle group running lines 8 are connected into a circulating assembly line by means of two transverse channels 12.
The invention adopts the special-shaped mould 9 for reverse pouring of the pier cap to prefabricate the pier cap. As shown in fig. 8, the special-shaped mold 9 for reverse pouring of the coping cap includes a bottom mold and a side mold framework 901, the bottom mold and the side mold framework 901 includes a bottom mold and a side mold, a convex region is formed in the middle of the bottom mold, and sunken regions are formed on two sides of the bottom mold, so that an upward convex platform can be formed on two sides of the top of the coping cap. In the center of the depressed area is a support pad recess 904, which may form a support pad on top of the coping. A bottom die pre-buried tapered sleeve 902 is disposed in the support pad recess 904 to form positioning holes arranged in an array on the support pad. The bottom die embedded conical sleeve 902 is provided with a bolt, and after pier caps are prefabricated, anchor hole loosening operation can be performed at the bottom of a die to achieve loosening and dismounting, so that a hollow hole is formed, and later-stage jacking and demolding are facilitated.
The assembly line of the invention carries out logistics circulation through a bidirectional rail-mounted logistics master-slave train set 13. The bidirectional rail-mounted logistics primary-secondary train set 13 comprises a heavy-load primary train 1301, a heavy-load secondary train 1302 and a light-load primary train 1303. As shown in FIG. 2, the heavy-duty parent car 1301 is provided with laterally moving running wheels at the bottom and a first longitudinal heavy-duty child car running rail 1306 for supporting the heavy-duty child car 1301 at the top. Referring to fig. 3, the bottom of the heavy-duty sub-truck 1302 is provided with traveling wheels moving longitudinally, and the top of the heavy-duty sub-truck 1302 is provided with a heavy-duty sub-truck lifting cylinder 1304. As shown in fig. 4, the bottom of the light-load parent vehicle 1303 is provided with a transversely moving running wheel, the top of the light-load parent vehicle 1303 is provided with a second longitudinal heavy-load parent vehicle running guide rail 1307 for supporting the load parent vehicle 1302, and a light-load parent vehicle lifting cylinder 1308. The two-way rail-mounted logistics child-mother vehicle set 13 can be provided with a positioning device and a positioning bottom plate for mutually sensing the position and accurately positioning. Corresponding positioning bottom plates are also arranged on the logistics primary and secondary train set running line 8, and the bidirectional rail logistics primary and secondary train set 13 can also realize accurate positioning when running on the logistics primary and secondary train set running line 8.
A transfer bearing platform 16 is arranged on each station, and the bidirectional rail-mounted logistics primary-secondary vehicle group 13 completes the position conversion of the mold on the transfer bearing platform 16. The transfer platform 16 comprises a light-load mother vehicle position 1601 and a heavy-load mother vehicle position 1602 which are separated by a transverse boss 1603, and a traveling guide rail 1604 is arranged on the transverse boss 1603. The operation process is as follows: referring to fig. 5, the heavy-duty master car 1301 carries two heavy-duty slave cars 1302 on top of each other, the molds are carried on the two heavy-duty slave cars 1302, and the heavy-duty master car 1301 moves to the outside of the transfer platform 16 to be aligned with the heavy-duty master car position 1602. The light-load mother vehicle 1303 is stopped on the light-load mother vehicle position 1601, and a second heavy-load mother vehicle traveling guide rail 1307 at the top of the light-load mother vehicle 1303 is longitudinally and continuously connected with the traveling guide rail 1604. The heavy-load mother vehicle 1301 moves to the heavy-load mother vehicle position 1602, and the first heavy-load child vehicle walking guide rail 1306 on the top of the heavy-load mother vehicle 1301 is longitudinally and continuously connected with the walking guide rail 1604. Referring to fig. 6, two heavy-duty sub-vehicles 1302 are loaded with molds and moved to a light-duty parent vehicle position 1601 along a first heavy-duty sub-vehicle travel rail 1306, a travel rail 1604, and a second heavy-duty sub-vehicle travel rail 1307. Referring to fig. 7, the light mother vehicle lift cylinder 1308 on the top of the light mother vehicle 1303 is raised to lift the mold and leave the heavy child vehicle 1302, and the heavy child vehicle 1302 is retracted to the heavy mother vehicle position 1602, i.e. the top of the heavy mother vehicle 1301, along the second heavy child vehicle travel rail 1307, the travel rail 1604, the first heavy child vehicle travel rail 1306. Then, a light-load mother vehicle lifting oil cylinder 1308 at the top of the light-load mother vehicle 1303 descends, the mold is placed at the top of the light-load mother vehicle 1303, and the light-load mother vehicle 1303 transversely moves out of the light-load mother vehicle position 1601.
Therefore, the bidirectional rail-mounted logistics master-slave vehicle set 13 runs on the logistics master-slave vehicle set running line 8, the pouring and vibrating station 2, the steam curing station 3 and the demolding station 4 can be sequentially entered by carrying the pier cap reverse pouring special-shaped mold 9, and the obtained finished pier cap is lifted from the demolding station 4 to the overturning station 5 by the gantry crane in the field. The two-way rail-mounted logistics master-slave vehicle group 13 carries the special-shaped mould 9 for reverse pouring of the pier cap and enters the pouring vibration station 2, the special-shaped mould 9 for reverse pouring of the pier cap can enter the steel reinforcement cage entering station 1, and the steel reinforcement framework of the pier cap is hoisted into the special-shaped mould 9 for reverse pouring of the pier cap by the gantry crane in the yard. The bidirectional rail-mounted logistics master-slave vehicle set 13 carries the pier cap reverse pouring special-shaped mold 9, leaves the demolding station 4, and then can sequentially enter the mold cleaning station 6. And a release agent spraying station 7.
The automatic pouring and vibrating equipment 10 for the pier cap is arranged in the pouring and vibrating station 2 and is positioned above the reverse pouring special-shaped mold 9 for the pier cap. As shown in fig. 9, the automated pouring and vibrating device 10 for coping includes two longitudinal track beams 1004 and a frame-type walking trolley 1001, wherein the walking wheels capable of moving on the track beams 1004 are arranged at the bottoms of the two sides of the walking trolley 1001. A vibrating rod hydraulic lifting system 1003 is mounted on the walking trolley 1001, a vertical vibrating rod 1002 is arranged at the bottom of the vibrating rod hydraulic lifting system 1003, and the vibrating rod 1002 is located below the walking trolley 1. After concrete is poured in the pier cap reverse pouring special-shaped mold 9 by using the distributing machine, the walking trolley 1 moves to a corresponding position, and the vibrating rod 1002 is lowered to vibrate the concrete.
Be provided with pier cap drawing of patterns system 11 in drawing of patterns station 4, as fig. 10, pier cap drawing of patterns system 11 includes drawing of patterns hydro-cylinder 1101, drawing of patterns hydro-cylinder track 1102 and top tight device 1103, and top tight device 1103 can be followed the side and tightly poured the abnormal shape mould 9 of pier cap reverse pouring and make somebody a mere figurehead with it, and drawing of patterns can be realized to drawing of patterns hydro-cylinder 1101 along drawing of patterns hydro-cylinder track 1102 entering pier cap reverse pouring abnormal shape mould 9 below, upwards top into the dead hole of mould bottom, and then jack-up finished product pier cap.
A rail-mounted traveling cleaning trolley 14 is arranged in the mold cleaning station 6, and as shown in fig. 11, the rail-mounted traveling cleaning trolley 14 comprises a rail 1401 and a cleaning trolley 1402. The molds are transported under the frame rails 1401 and the cleaning cart 1402 is moved along the frame rails 1401 into position for cleaning the molds by means of the sanding brushes provided on the cleaning cart 1402.
A multi-directional automatic release agent spraying system 15 is arranged in the release agent spraying station 7, and as shown in fig. 12, the multi-directional automatic release agent spraying system 15 comprises a spraying upright 1501, a longitudinal rail beam 1502, a transverse rail beam 1503 and a spray head 1504. Two longitudinal rail beams 1502 are supported by spraying upright 1501, a transverse rail beam 1503 is located between the two longitudinal rail beams 1502, when the die is conveyed to the position below the transverse rail beam 1503, the transverse rail beam 1503 moves along the longitudinal rail beams 1502, a spray head 1504 moves along the transverse rail beam 1503, and finally when the die is moved to a proper position, a release agent can be sprayed into the die through the spray head 1504.
Based on the above-mentioned prefabricated pier cap's of assembly automation line of putting up, can carry out the prefabricated production of pier cap, the concrete method is:
1. the bidirectional rail-mounted logistics master-slave vehicle group 13 carries a pier cap reverse pouring special-shaped mold 9 to enter a pouring vibration station 2, a disc top mold is installed, concrete is poured by using a material distributor, and the automatic pouring vibration equipment 10 for the pier cap is used for vibrating the concrete during pouring.
2. After pouring and vibrating, the bidirectional rail-mounted logistics master-slave vehicle set 13 carries the pier cap reverse pouring special-shaped mold 9 to leave the pouring and vibrating station 2, enters the steam curing station 3, performs steam curing, and performs anchor bolt loosening on the bottom of the pier cap reverse pouring special-shaped mold 9 after the steam curing is finished.
3. After the anchor bolts are loosened, the bidirectional rail-mounted logistics master-slave vehicle set 13 carries the pier cap reverse pouring special-shaped mold 9, leaves the steam curing station 3, enters the demolding station 4, firstly removes the ring top mold, opens the mold, and then lifts the finished pier cap in the pier cap reverse pouring special-shaped mold 9 by using the pier cap demolding system 11 to perform demolding about 20 cm.
4. After demoulding is finished, the gantry crane in the factory is used for hoisting the finished pier caps from the demoulding station 4 to the overturning station 5, and after the finished pier caps are overturned for 180 degrees, the gantry crane in the factory is used for hoisting the finished pier caps to the pier cap storage area.
In addition, a pier cap reinforcement cage is processed in advance, before the bidirectional rail-mounted logistics master-slave vehicle set 13 carries the pier cap reverse pouring special-shaped mold 9, the bidirectional rail-mounted logistics master-slave vehicle set 13 firstly enters the reinforcement cage mold entering station 1, the pier cap reverse pouring special-shaped mold 9 is opened, the pier cap reinforcement cage is hoisted into the pier cap reverse pouring special-shaped mold 9 through an in-site gantry crane, and then the pier cap reverse pouring special-shaped mold 9 is transported to the pouring vibration station 2 through the bidirectional rail-mounted logistics master-slave vehicle set 13.
After demoulding is carried out at the demoulding station 4 and finished pier caps are lifted, the bidirectional rail-mounted logistics master-slave vehicle set 13 carries the pier cap reverse pouring special-shaped mold 9 to enter the mold cleaning station 6, the pier cap reverse pouring special-shaped mold 9 is opened, and the frame rail traveling cleaning trolley 14 is used for cleaning. After cleaning, the mold is closed, the bidirectional rail-mounted logistics master-slave vehicle set 13 carries a pier cap to pour the special-shaped mold 9 reversely to enter a mold release agent spraying station 7, and mold release agent spraying is carried out by using a mold release agent multidirectional automatic spraying system 15.
The assembled prefabricated pier cap production line provided by the invention has the advantages of reasonable station design, smooth circulation, high automation degree and controllable finished product quality, relates to less manual operation procedures, is used for the automatic production of the assembled prefabricated pier caps, can effectively reduce the manual workload, improve the field safety, improve the finished product quality of prefabricated components and greatly improve the production efficiency of the assembled prefabricated pier caps.
The present invention has been described in terms of specific examples, which are provided to aid understanding of the invention and are not intended to be limiting. For a person skilled in the art to which the invention pertains, several simple deductions, modifications or substitutions may be made according to the idea of the invention.
Claims (10)
1. The automation line of prefabricated pier cap of assemblization, its characterized in that:
the production line comprises a pouring vibration station (2), a steam curing station (3), a demolding station (4), a turning station (5), a logistics master-slave vehicle group routing line (8) for connecting each station, a pier cap reverse pouring special-shaped mold (9) and a bidirectional rail-running logistics master-slave vehicle group (13);
the bidirectional rail-mounted logistics master-slave vehicle set (13) runs on the logistics master-slave vehicle set running line (8), the bidirectional rail-mounted logistics master-slave vehicle set (13) carries the pier cap reverse pouring special-shaped molds (9) to sequentially enter the pouring vibration station (2), the steam curing station (3) and the demolding station (4), and the obtained finished pier caps are hoisted to the overturning station (5) from the demolding station (4) by an in-site gantry crane.
2. The automated production line of prefabricated pier caps of claim 1, wherein:
the production line also comprises a steel reinforcement cage die-entering station (1);
the bidirectional rail-mounted logistics master-slave vehicle group (13) carries a pier cap reverse pouring special-shaped mold (9) to enter the steel reinforcement cage mold entering station (1) before entering the pouring vibrating station (2), and a pier cap steel reinforcement framework is hoisted into the pier cap reverse pouring special-shaped mold (9) by an in-site gantry crane.
3. The automated production line of prefabricated pier caps of claim 2, wherein:
the production line also comprises a mould cleaning station (6);
and the bidirectional rail-mounted logistics master-slave vehicle set (13) carries the pier cap reverse pouring special-shaped mold (9), leaves the demolding station (4), and then enters the mold cleaning station (6).
4. The automated production line of prefabricated pier caps of claim 3, wherein:
the production line also comprises a release agent spraying station (7);
and the bidirectional rail-mounted logistics master-slave vehicle set (13) carries the pier cap reverse pouring special-shaped mold (9), leaves the mold cleaning station (6), and then enters the release agent spraying station (7).
5. The automated production line of prefabricated pier caps of claim 4, wherein:
the pouring vibration station (2), the steam curing station (3), the demolding station (4) and the overturning station (5) are arranged on one logistics master-slave vehicle group running line (8), the reinforcement cage mold entering station (1), the mold cleaning station (6) and the demolding agent spraying station (7) are arranged on the other logistics master-slave vehicle group running line (8), and the two logistics master-slave vehicle group running lines (8) are parallel to each other;
a transverse channel (12) is arranged between the material flow primary-secondary vehicle group running line (8) between the steam curing station (3) and the demolding station (4) and the other material flow primary-secondary vehicle group running line (8); and another transverse channel (12) is arranged between the logistics master-slave vehicle set running line (8) in front of the pouring vibrating station (2) and the other logistics master-slave vehicle set running line (8).
6. The automated production line of prefabricated pier caps of claim 5, wherein:
the bidirectional rail-mounted logistics primary and secondary vehicle group (13) comprises a heavy-load primary vehicle (1301), a heavy-load secondary vehicle (1302) and a light-load primary vehicle (1303);
the bottom of the heavy-load mother vehicle (1301) is provided with a transversely moving walking wheel; a longitudinal first heavy-load sub-vehicle walking guide rail (1306) for supporting the heavy-load sub-vehicle (1301) is arranged at the top of the heavy-load mother vehicle (1301);
the bottom of the heavy-duty sub-vehicle (1302) is provided with a traveling wheel which moves longitudinally; a heavy-duty sub-vehicle lifting oil cylinder (1304) is arranged at the top of the heavy-duty sub-vehicle (1302);
the bottom of the light-load mother vehicle (1303) is provided with a transversely moving walking wheel; and the top of the light-load mother vehicle (1303) is provided with a longitudinal second heavy-load sub-vehicle traveling guide rail (1307) for supporting the heavy-load sub-vehicle (1302) and a light-load mother vehicle lifting oil cylinder (1308).
7. The automated production line of prefabricated pier caps of claim 6, wherein:
a transfer bearing platform (16) is arranged on each station, and the bidirectional rail-mounted logistics master-slave vehicle group (13) completes the position conversion of the mold on the transfer bearing platform (16);
the transfer bearing platform (16) comprises a light-load bus position (1601) and a heavy-load bus position (1602) which are separated by a transverse boss (1603), and a walking guide rail (1604) is arranged on the transverse boss (1603).
8. The method for producing an automated production line of prefabricated pier caps according to claim 7, wherein the method comprises the following steps:
the method comprises the following steps:
the bidirectional rail-mounted logistics master-slave vehicle group (13) carries the pier cap reverse pouring special-shaped mold (9) to enter the pouring vibration station (2), concrete is poured by using a distributor, and the concrete is vibrated during pouring;
after the pouring vibration is finished, the bidirectional rail-mounted logistics master-slave vehicle set (13) carries the pier cap reverse pouring special-shaped mold (9), leaves the pouring vibration station (2), enters the steam curing station (3) for steam curing, and performs anchor bolt loosening on the bottom of the pier cap reverse pouring special-shaped mold (9) after the steam curing is finished;
after the anchor bolts are loosened, the bidirectional rail-mounted logistics master-slave vehicle set (13) carries the pier cap reverse pouring special-shaped mold (9), leaves the steam curing station (3), enters the demolding station (4), and lifts the finished pier cap in the pier cap reverse pouring special-shaped mold (9) for demolding;
after demolding is finished, the finished pier caps are hoisted to the overturning station (5) from the demolding station (4) by using an in-site gantry crane, and after the finished pier caps are overturned for 180 degrees, the finished pier caps are hoisted to the pier cap storage area by using the in-site gantry crane.
9. The production method of the automatic production line of the assembled prefabricated pier caps according to claim 8, wherein the production method comprises the following steps:
the method further comprises the following steps:
the bidirectional rail-mounted logistics master-slave vehicle group (13) carries the pier cap reverse pouring special-shaped mold (9) to firstly enter the steel reinforcement cage mold entering station (1), an in-site gantry crane is used for hoisting and conveying a pier cap steel reinforcement framework into the pier cap reverse pouring special-shaped mold (9), and then the bidirectional rail-mounted logistics master-slave vehicle group (13) conveys the pier cap reverse pouring special-shaped mold (9) to the pouring vibration station (2).
10. The production method of the automatic production line for the prefabricated assembled pier caps according to claim 9, wherein the production method comprises the following steps:
the method further comprises the following steps:
after demoulding is carried out at the demoulding station (4) and finished product pier caps are hung and moved, the bidirectional rail-mounted logistics master-slave vehicle set (13) carries the pier cap reverse pouring special-shaped mold (9) to enter the mold cleaning station (6), and the pier cap reverse pouring special-shaped mold (9) is opened for cleaning;
after cleaning, the bidirectional rail-mounted logistics master-slave vehicle set (13) carries the pier cap reverse pouring special-shaped mold (9) to enter the mold release agent spraying station (7) for mold release agent spraying.
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