CN211492145U - Automatic production line for Reactive Powder Concrete (RPC) prefabricated parts - Google Patents
Automatic production line for Reactive Powder Concrete (RPC) prefabricated parts Download PDFInfo
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- CN211492145U CN211492145U CN201921443336.XU CN201921443336U CN211492145U CN 211492145 U CN211492145 U CN 211492145U CN 201921443336 U CN201921443336 U CN 201921443336U CN 211492145 U CN211492145 U CN 211492145U
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Abstract
The utility model discloses an active powder concrete (RPC) prefabricated component automatic production line. Comprises an RPC stirring and conveying system, a production system and a steam curing system which are controlled by a central control room; wherein: the RPC stirring and conveying system comprises an RPC stirring station and RPC conveying equipment, and the production system comprises a die stripping production line, a die feeding production line and a transverse moving mechanism; the steam curing system comprises a steam curing kiln, a kiln inlet and outlet track and a primary and secondary vehicle. The production line of the utility model does not need to enter the steam curing kiln for operation, the residual temperature can be recycled, the steam curing quality is stable, and the requirements of the technical parameters of RPC steam curing such as heating rate, cooling rate, limit constant temperature, maximum temperature difference, air humidity and the like are met; the annular closed feeding, discharging and traversing mechanism is adopted, so that the moving and the placement of the mold are convenient, the mold and the component move on the steel rail in the steam curing kiln or move out of the kiln and enter the kiln along with a mother vehicle, and the movement and the transfer of two dimensions in the direction of a track of the feeding kiln and the direction of the discharging kiln and the direction vertical to the direction can be realized.
Description
Technical Field
The utility model belongs to the technical field of the continuous production line design, especially, belong to the design technical field of precast concrete pouring production line, in particular to Reactive Powder Concrete (RPC) prefabricated component's continuous production line.
Background
Reactive Powder Concrete (RPC) is ultrahigh-strength toughened Concrete produced by using active Powder materials such as cement and mineral admixture, fine aggregate, admixture, high-strength fine steel fiber and/or organic synthetic fiber, water and the like as raw materials. The concrete has the advantages of ultrahigh strength, high fire-proof grade, good durability, short maintenance period, small structural dead weight (under the same bearing capacity), convenient construction, less later maintenance and the like, and is developed greatly within 30 years of the short period.
At present, the main application direction of RPC in China is to gradually popularize and use RPC as a main material of a non-structural component in the field of prefabricated components such as cable trench cover plates, ditch cover plates, curbstones and subway evacuation platforms, for example: in 2007, the Ministry of railways and Ministry of construction stipulates that RPC cover plates are uniformly adopted for cover plates of passenger dedicated lines and intercity high-speed railways.
In the conventional production process of the RPC prefabricated part, because the unit weight of the RPC prefabricated part is small, for example, the average weight of an RPC cover plate of a high-speed railway is less than 20 KG/block, a complete production system which is originally produced in Germany and is formed by improving the RPC cover plate by a manufacturer is generally adopted. The system adopts manual and semi-automatic production line operation to sequentially realize mixing, transportation, material distribution and vibration forming of concrete until maintenance, demoulding and the like.
However, this system has the following problems:
1. the automation degree is low, the labor intensity is high, and the production efficiency is low. Except for mixing, conveying and distributing of RPC, all other procedures such as vibration forming, mold transferring, stacking, unstacking, demolding, mold cleaning and the like need to be achieved through manual operation.
2. The production process is suitable for manual carrying, mostly adopts a corrugated steel material die with light self weight, is complex to clean, needs acid washing, is dirty, messy and poor in operation site, and has high safety and civilized construction management and control difficulty and high occupational health risk.
3. The RPC prefabricated part can only be suitable for single RPC prefabricated parts within the range of manpower, and the production of the RPC prefabricated parts is developed in the direction of large-scale production, such as: the RPC evacuation platform plate adopted by a certain track traffic 18# line is divided into a standard block and an adjusting block, the sizes of the standard block and the adjusting block are 1800/1500x800x50 and 1800/1500x (518-753) x50 (unit: mm), the maximum single weight of the components is close to 180 KG/block, and the process of mass manual production cannot meet the requirements of the future market.
Disclosure of Invention
The utility model discloses a Reactive Powder Concrete (RPC) prefabricated component automation line is disclosed according to prior art's not enough. The utility model aims at providing a but continuous, loop operation's automatic Reactive Powder Concrete (RPC) prefabricated component production line.
The utility model discloses a following technical scheme realizes:
active powder concrete (RPC) prefabricated component automatic production line, its characterized in that: the production line comprises an RPC stirring and conveying system, a production system and a steam curing system which are controlled by a central control room;
RPC mixes system of making conveying includes: an RPC stirring station and RPC conveying equipment;
the production system comprises: a mold stripping production line, a mold feeding production line and a transverse moving mechanism;
the steam curing system comprises: steam curing kilns, kiln inlet and outlet tracks and primary and secondary vehicles;
the production line flow structure is as follows: the steam curing kiln is connected with a demolding production line through a kiln discharging track and a primary and secondary vehicle thereof, unstacking and transverse moving are completed through a demolding directional stacking unstacker, the cured RPC prefabricated part finished product is conveyed to the demolding production line, after a corresponding process is completed, the RPC prefabricated part mold is conveyed to a mold feeding production line through a transverse moving mechanism, after a set process is completed on the mold feeding production line, stacking and transverse moving are completed through the mold feeding directional stacking unstacker, finally, the RPC prefabricated part mold including the component is conveyed into the steam curing kiln through the kiln feeding track and the primary and secondary vehicles thereof for steam curing, and the RPC prefabricated part mold is discharged from the kiln after curing is completed.
The demolding production line comprises a unstacking transverse moving station, a unstacking conveying station, a finished product hoisting station, a mold cleaning station and a reinforcing mesh sheet mold entering station.
The mold feeding production line comprises stations of checking before pouring, pouring preparation, pouring forming, material clearing and supplementing, standing, fine plastering, stacking to be performed and stacking and transverse moving.
And the transverse moving mechanism is connected with the mold stripping production line and the mold feeding production line to complete the mold circulating transverse moving between the mold stripping production line and the mold feeding production line.
The steam curing kiln comprises a steam boiler, a closed loop steam conveying pipeline, a heat exchange system, a PLC automatic control program and auxiliary facilities.
The RPC prefabricated part mould is a steel structure mould.
The RPC stirring and conveying system is used for conveying RPC materials made by the RPC stirring station to an RPC prefabricated part mould of a mould-entering production line for pouring through RPC conveying equipment.
Compared with the prior art, the utility model discloses following beneficial effect has:
1. the problems that the manual and semi-automatic production process of the RPC prefabricated part is low in automation degree, high in labor intensity and low in production efficiency, and a large single RPC prefabricated part is difficult to produce in the prior art are solved.
2. When the RPC prefabricated part is produced, a steel die is preferred, a steel tray base can be adopted to be matched with a corrugated steel material die for production, the limitation of the types of the dies is avoided, and the adaptability is strong (the steel die is preferably selected by comprehensively considering high-efficiency production and safe and civilized construction management).
3. When the RPC prefabricated part is produced, the investment of the die is flexible, the investment number and the model number of the die can be adjusted at any time according to market requirements and production plans, and the investment and the configuration of the die are not limited by the number of production stations (but not exceeding the maximum die capacity of a production line).
4. The operation of operating personnel in the steam curing kiln is not needed, ventilation and heat exchange are not needed to be carried out on each steam curing kiln, after the RPC prefabricated part is taken out of the kiln, the residual temperature of the steam curing kiln can be continuously utilized in the next production cycle, the energy consumption is saved, and the production efficiency is higher because the temperature of the steam curing kiln is not needed to be reduced and raised.
5. The doors are respectively arranged at the inlet and the outlet of the steam curing kiln, so that the RPC prefabricated parts enter the kiln and leave the kiln firstly, secondly and then leave the kiln during steam curing, the steam curing time of the RPC prefabricated parts in the same kiln is ensured to be the same, each technical index of each RPC prefabricated part is the same during the leaving of the kiln, and the quality fluctuation caused by different steam curing time is eliminated.
6. In the steam curing kiln, the RPC prefabricated part mould is always in a static state in the steam curing process, so that the quality problem caused by irregular vibration of the mould in the steam curing process is avoided.
7. In the steam curing process of the RPC prefabricated part, a steam curing curve (time-temperature curve) is controlled by a PLC program of a heat exchange system and an upper computer, and the requirements of specifications on technical parameters such as the temperature rising rate, the temperature reduction rate, the ultimate constant temperature, the maximum temperature difference, the air humidity and the like of the RPC steam curing are met. The process adopts a steam boiler to supply heat in a centralized way, adopts a steam pipeline to guide heat and steam generated by the steam boiler into the steam curing kiln, and controls a steam curing curve (time-temperature curve) and air humidity requirements to meet the technical regulations of national specifications and industrial standards according to a PLC established program.
8. The traversing system (the mold discharging production line completes the traversing of the mold towards the mold entering production line) adopts a circulating chain traversing mechanism, a small amount of molds can be temporarily stored on the circulating chain traversing mechanism, the swinging back and forth is not needed, the molds only need to be rotated towards the direction of a target production line (the mold entering production line) through a circulating chain, and the molds are conveyed to a target station under the control of an automatic control program or manual operation.
9. The PLC program and the upper computer are adopted to realize full-automatic production, and the forward, backward, stop and other control actions of the production line can be realized under the remote control of an operator by a centralized control platform of a central control room and a monitoring system.
10. The secondary car and the primary car are used as a mould transfer tool, the secondary car has a mould jacking function, is convenient for moving and placing the mould, and can move on the steel rail in the steam curing kiln or move on the steel rail out of the kiln and in the kiln along with the primary car. The primary vehicle and the secondary vehicle form a linkage mechanism to realize the movement and transfer of the mold in the kiln inlet and outlet track direction and two dimensions vertical to the direction (X direction and Y direction).
11. And a finished product conveying line is arranged on one side of a demolding production line of the production system, and the RPC prefabricated part after demolding is transferred to a product stacking area through a finished product conveying roller way.
12. The top surface of the steam curing kiln is connected with the terrace by a steel ladder, and can be used as a steel bar welding and steel bar semi-finished product stacking area when the area of a factory is in shortage.
Drawings
FIG. 1 is a schematic plan view of the process of the present invention;
fig. 2 is a plan view of the RPC mixing and conveying system of the present invention.
In the figure, 1 is a demoulding carrier, 2 is a demoulding directional code unstacker, 3 is a mould rollgang, 4 is a special bridge machine for demoulding, 5 is a finished product rollgang, 6 is a transverse moving mechanism, 7 is a central control room, 8 is a vibration rollgang, 9 is a spreader, 10 is an RPC conveying hopper, 11 is an RPC stirring station, 12 is a mould entering directional code unstacker, 13 is a mould entering carrier, 14 is a steam curing kiln, 15 is a kiln exiting track (primary car), 16 is a kiln entering track (primary car), and 17 is an in-kiln track (secondary car).
Detailed Description
The present invention will be further described with reference to the following embodiments, which are intended to illustrate the principles of the present invention without limiting the present invention in any way, and the present invention is not beyond the scope of the present invention.
With reference to the attached drawings.
The automatic production line of the Reactive Powder Concrete (RPC) prefabricated parts comprises a central control room for controlling the operation: RPC mixes system of transferring, production system and steam curing system.
RPC mixes system of making conveying includes: an RPC stirring station 11 and an RPC conveying device; the RPC conveying equipment comprises an RPC conveying hopper 10 that can run on rails or by hoisting.
The production system comprises: a mold stripping production line, a mold feeding production line and a transverse moving mechanism.
The steam curing system comprises: steam curing kiln, kiln inlet and outlet tracks and primary and secondary vehicles.
The production line steam curing kiln is connected with a demolding production line through a kiln outlet rail and a primary and secondary vehicle thereof, unstacking and transverse moving are completed through a directional stacker crane, a cured RPC prefabricated part finished product is conveyed to the demolding production line, after a corresponding process is completed, a mold is conveyed to a mold inlet production line through a transverse moving mechanism, stacking and transverse moving are completed through the directional stacker crane after a set process is completed on the mold inlet production line, finally, the RPC prefabricated part is conveyed into the steam curing kiln through the kiln inlet rail and the primary and secondary vehicles thereof for steam curing, and the kiln outlet is completed after curing is completed, so that a production cycle is completed.
The automatic production line adopts a PLC control program and an upper computer to realize automatic production, and meanwhile, semi-automatic remote control production can be realized in a central control room by a monitoring system according to requirements.
The demolding production line comprises a unstacking transverse moving part, a unstacking conveying part, a finished product hoisting conveying part, a mold cleaning part and a reinforcing mesh sheet mold entering station.
The mold entering production line comprises a station for checking before pouring, pouring preparation, pouring forming, material clearing and supplementing, standing, fine plastering, waiting for stacking and transverse moving.
The transverse moving mechanism completes the circular transverse moving of the mold between the mold stripping production line and the mold feeding production line.
The two directional stacking machines comprise an ejection directional stacking unstacker 2 and an injection directional stacking unstacker 12 which are respectively arranged at the connection part of the injection production line and the kiln inlet track and the connection part of the ejection track and the ejection production line.
The steam curing kiln is integrated with a steam boiler, a closed loop steam conveying pipeline, a heat exchange system, a PLC automatic control program and auxiliary facilities.
The kiln inlet track, the kiln outlet track and the corresponding matched primary and secondary vehicles finish the carrying operation of the mold in and out of the kiln. The utility model discloses RPC prefabricated component mould first-selected steel mould.
Referring to fig. 1 and 2, the utility model discloses a RPC mixes system of transferring, production system and steam curing system.
As shown in fig. 2, the RPC blending conveying system is composed of an RPC stirring station 11, an RPC conveying hopper 10 and a spreader 9.
As shown in fig. 1, the production system comprises an ejection line, a traverse mechanism, an insertion line, and a central control room, wherein: the demolding production line consists of a demolding directional stacking unstacker 2, a mold conveying roller table 3, a demolding special bridge machine 4 and a finished product conveying roller table 5; the transverse moving mechanism 6 adopts a circulating chain transverse moving mechanism; the mold entering production line consists of a vibration conveying roller way 8, a mold conveying roller way 3 and a mold entering directional stacking unstacker 12; the central control room 7 is independently arranged and provided with a centralized control platform, a CCTV system and other supporting facilities, so that the automation/semi-automation control, monitoring and security of the whole production process are realized.
The steam curing system comprises a mold entering carrier 13, a steam curing kiln 14, a kiln entering track (primary vehicle) 16, a kiln inner track (secondary vehicle) 17, a kiln discharging track (primary vehicle) 15, a mold discharging carrier 1 and a steam boiler matched with the mold discharging carrier, a steam conveying pipeline (closed loop), a heat exchange system, a PLC automatic control program, auxiliary facilities and the like.
The RPC mixing and conveying system is arranged on the plane as shown in figure 2, so that the RPC is continuously produced and continuously supplied by the RPC conveying hopper 10.
The RPC that the hopper 10 was transported is evenly spread in waiting to pour RPC prefabricated component mould according to design engineering volume above the shaping station is pour to cloth machine 9.
The demolding production line comprises work stations such as unstacking and transverse moving, unstacking and conveying, finished product hoisting and conveying, mold cleaning (coating release agent), reinforcing mesh sheet mold entering and the like.
The transverse moving mechanism 6 adopts a circulating chain transverse moving mechanism, and a small amount of moulds can be temporarily stored on the circulating chain as required.
The mold entering production line comprises stations of inspection before casting, casting preparation, casting forming, material cleaning and supplementing, standing, fine plastering, stacking waiting, stacking and transverse moving and the like.
Under the working conditions shown in fig. 1, a production cycle of the present invention is as follows (the beginning of a new production cycle is counted by the end of the previous production cycle, i.e. by the draw meter):
the demolding truck 1 transports the RPC prefabricated part subjected to steaming in the previous production cycle to a directional stacker crane (unstacking) 2 through an in-kiln track (subsidiary car) 17 and an out-kiln track (main car) 15 in a steam curing kiln 14, unstacking and transverse moving are completed by the directional stacker crane, the cured RPC prefabricated part finished product is transported to a mold conveying roller table 3 of a demolding production line and enters a finished product hoisting station through the unstacking conveying station, demolding is completed by a clamp or a vacuum chuck on a special demolding bridge machine 4, the demolded steel mold continues to move to a mold cleaning station (coating demolding agent) on the mold conveying roller table 3, and the demolded RPC prefabricated part is transported to a product stacking area through a finished product conveying roller table 5 to be stacked.
The cleaned steel mould continuously moves on a mould conveying roller 3 of a demoulding production line to a reinforcing mesh sheet mould-entering station, after a reinforcing mesh sheet mould-entering process is completed, the mould with the reinforcing mesh sheet placed therein is transferred into the mould production line by a traversing mechanism 6, pouring forming of RPC prefabricated components is completed on a vibration conveying roller 8, the formed mould enters a stacking and traversing station by the mould conveying roller 3 of the mould-entering production line after being sequentially subjected to standing, fine surface cleaning and stacking stations, stacking and traversing are completed by a directional stacker (stacking) 12, finally, the RPC prefabricated components enter a steam curing kiln 14 for steam curing by a kiln-entering rail (mother vehicle) 16 and a kiln inner rail (son vehicle) 17 through a kiln-entering rail (mother vehicle) 16, and the RPC prefabricated components exit from the kiln after the steam curing is completed, and a production cycle is completed.
Under the working condition shown in figure 1, 0-140 molds can be flexibly put into the mold, under the condition that 4 steam-curing kilns are fully opened, 5 stacks of steel molds can be cured by each steam-curing kiln, the stack height is 6 layers, the total number of 120 steel molds can be cured by a single production cycle, each steel mold can mold 3 RPC prefabricated parts with the maximum size of 1800x1000x50mm, and 360 RPC prefabricated parts can be produced by a single production cycle at most.
As shown in fig. 1, under the condition that the height of the steam curing kiln is allowed and the stacking height is subjected to stress and stability calculation, the stacking height can be increased properly, and more RPC prefabricated components 60 can be produced in a single production cycle when one stacking height is increased; likewise, each time the stack height is reduced, a single production cycle produces fewer pieces of RPC prefabricated components 60. The number of the moulds put into the whole production process is also adjusted.
The automatic production line is mainly used for producing RPC plate type prefabricated parts, particularly subway evacuation platforms, ditch cover plates, cable ditch cover plates and the like, and can produce any type of RPC prefabricated parts as required by adjusting the die.
Claims (7)
1. The utility model provides an active powder concrete (RPC) prefabricated component automatic production line which characterized in that: the production line comprises an RPC stirring and conveying system, a production system and a steam curing system which are controlled by a central control room;
RPC mixes system of making conveying includes: an RPC stirring station and RPC conveying equipment;
the production system comprises: a mold stripping production line, a mold feeding production line and a transverse moving mechanism; the stacking unstacking machine is used for stacking and unstacking RPC prefabricated part molds or finished products among the demolding production line, the mold feeding production line and the transverse moving mechanism;
the steam curing system comprises: steam curing kilns, kiln inlet and outlet tracks and primary and secondary vehicles; the steam curing kiln is connected with a demolding production line through a kiln discharging track and a primary and secondary vehicle thereof.
2. The automatic production line of Reactive Powder Concrete (RPC) prefabricated parts according to claim 1, characterized in that: the demolding production line comprises a unstacking transverse moving station, a unstacking conveying station, a finished product hoisting station, a mold cleaning station and a reinforcing mesh sheet mold entering station.
3. The automatic production line of Reactive Powder Concrete (RPC) prefabricated parts according to claim 1, characterized in that: the mold feeding production line comprises stations of checking before pouring, pouring preparation, pouring forming, material clearing and supplementing, standing, fine plastering, stacking to be performed and stacking and transverse moving.
4. The automatic production line of Reactive Powder Concrete (RPC) prefabricated parts according to claim 1, characterized in that: and the transverse moving mechanism is connected with the mold stripping production line and the mold feeding production line to complete the mold circulating transverse moving between the mold stripping production line and the mold feeding production line.
5. The automatic production line of Reactive Powder Concrete (RPC) prefabricated parts according to claim 1, characterized in that: the steam curing kiln comprises a steam boiler, a closed loop steam conveying pipeline, a heat exchange system, a PLC automatic control program and auxiliary facilities.
6. The automatic production line of Reactive Powder Concrete (RPC) prefabricated parts according to claim 1, characterized in that: the RPC prefabricated part mould is a steel structure mould.
7. The automatic production line of Reactive Powder Concrete (RPC) prefabricated parts according to claim 1, characterized in that: the RPC stirring and conveying system is used for conveying RPC materials made by the RPC stirring station to an RPC prefabricated part mould of a mould-entering production line for pouring through RPC conveying equipment.
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114633358A (en) * | 2022-04-22 | 2022-06-17 | 德州海天机电科技有限公司 | Operation control method and system for central ferry vehicle and storage medium |
| CN114919051A (en) * | 2021-10-15 | 2022-08-19 | 江西龙正科技发展有限公司 | Full-automatic equipment for producing RPC cover plate |
| CN115157427A (en) * | 2022-08-04 | 2022-10-11 | 湖南三一快而居住宅工业有限公司 | Aerated concrete production line and aerated concrete production method |
| CN115256620A (en) * | 2022-06-16 | 2022-11-01 | 佛山市慧达智能科技有限公司 | Multi-mould grouting circulation production line |
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2019
- 2019-09-02 CN CN201921443336.XU patent/CN211492145U/en active Active
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN114919051A (en) * | 2021-10-15 | 2022-08-19 | 江西龙正科技发展有限公司 | Full-automatic equipment for producing RPC cover plate |
| CN114633358A (en) * | 2022-04-22 | 2022-06-17 | 德州海天机电科技有限公司 | Operation control method and system for central ferry vehicle and storage medium |
| CN115256620A (en) * | 2022-06-16 | 2022-11-01 | 佛山市慧达智能科技有限公司 | Multi-mould grouting circulation production line |
| CN115256620B (en) * | 2022-06-16 | 2024-05-03 | 佛山市慧达智能科技有限公司 | Multi-mold grouting circulation production line |
| CN115157427A (en) * | 2022-08-04 | 2022-10-11 | 湖南三一快而居住宅工业有限公司 | Aerated concrete production line and aerated concrete production method |
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