CN212919859U - Nomadic three-dimensional production system of concrete prefabricated part - Google Patents
Nomadic three-dimensional production system of concrete prefabricated part Download PDFInfo
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- CN212919859U CN212919859U CN202020942413.2U CN202020942413U CN212919859U CN 212919859 U CN212919859 U CN 212919859U CN 202020942413 U CN202020942413 U CN 202020942413U CN 212919859 U CN212919859 U CN 212919859U
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 52
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- 238000012423 maintenance Methods 0.000 claims abstract description 40
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- 239000000047 product Substances 0.000 claims abstract description 20
- 239000010410 layer Substances 0.000 claims abstract description 13
- 239000002356 single layer Substances 0.000 claims abstract description 7
- 239000011178 precast concrete Substances 0.000 claims abstract description 4
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- 239000012530 fluid Substances 0.000 description 2
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- 229910001220 stainless steel Inorganic materials 0.000 description 2
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- 238000003306 harvesting Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
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Abstract
The utility model provides a three-dimensional production system of nomadism formula of precast concrete component, including the main part district that comprises component shaping district B and three-dimensional maintenance district A in the middle part of the production land, semi-manufactured goods transportation district D, vacant mould platform transport and stack district C and finished product shipment district E that lie in the main part district all around respectively, each district bears by detachable prefabricated basis, and carries out the material transportation through bridge crane or gantry crane and ferry vehicle between each district; a plurality of stations are respectively arranged in the area B and the area A, a single-layer or multi-layer mould table is respectively placed on each station in the area B, and a three-dimensional curing pile is respectively placed on each station in the area A and is formed by stacking a component semi-finished product poured and molded in the area B together with the corresponding mould table and a corresponding mould; and stacking racks are arranged in the area C close to the area A and used for stacking the empty die tables transferred from the area B, and the lower part of the stacking rack at the bottommost layer is empty and is used for the free passage of the ferry vehicle. The production system has high production efficiency and flexible production mode and can be repeatedly used.
Description
Technical Field
The utility model relates to an assembly type structure field, concretely relates to concrete prefabricated component's three-dimensional production system of nomadism formula, in particular to concrete prefabricated component's three-dimensional production system of reinforced concrete coincide floor, wallboard prefabrication.
Background
With the rapid development of the industrialized process of buildings in China, the demand of concrete prefabricated parts is increased year by year. The traditional production mode is 'fixed factory type' production, and the popularization process of the assembly type building is seriously hindered due to the limitation of the transportation distance. The traditional production process and equipment facilities of the concrete prefabricated part have the disadvantages of large early investment and high process requirement, or the production by a soil method has low efficiency and no quality guarantee. The method has the advantages that the territory of China is wide, the projects are scattered, the concrete prefabricated parts are produced in nomadic factories, the equipment is simple, the process is efficient, and considerable social and economic benefits are certainly brought to the development of assembly type buildings in China.
The fabricated building is produced by disassembling the traditional reinforced concrete building into various components (such as beams, plates, columns and the like) in a factory, and then transporting the components to a construction site for field assembly, wherein the main equipment facilities for manufacturing the concrete prefabricated components comprise:
1. a die table: the production platform is a production platform of the concrete prefabricated member, and the bottom surface of the member is ensured to be smooth and flat. The die table surface is typically made of a hard, smooth material such as steel plate.
2. A mould: the device is used for restraining the plane size and the side shape of a concrete prefabricated part and is generally processed by hard materials such as angle steel, C-shaped steel and the like. The mould is generally assembled and shaped on a mould table into a closed shape such as a rectangle, a triangle and the like according to the design requirements of components and is firmly connected with the mould table to prevent deformation and displacement in the concrete forming process.
3. Pouring equipment: the function is to convey the fluid concrete into the mould on the mould table, which is generally a distributing machine, a simple hopper and the like.
4. Concrete equipment of vibrating: generally, the concrete is a vibrating table or a vibrating rod, and the function of the concrete is to remove air bubbles through vibrating the fluid concrete, so as to ensure that the density and the strength of the concrete reach the standard.
5. Steam curing equipment: the device for increasing the concrete setting speed is generally a vertical kiln type or a shed type and is a closed space. High-temperature steam is introduced into the space, so that the hardening time of the concrete can be greatly reduced.
6. Demolding equipment: after the concrete reaches a predetermined strength, the concrete is released from the mold base and the mold by a releasing device. The demolding equipment is generally a combined frame with a hook structure and is controlled by vertical transportation equipment.
7. Horizontal transportation equipment: the device is used for transporting raw materials, moulds, finished products and the like, and is generally a flat car, a trailer, a platform car and the like.
8. Vertical transportation equipment: the method is used for concrete distribution, die table (die) placement, component demoulding, finished product loading and the like. Typically a bridge crane or a gantry crane.
The necessary technical process comprises the following steps: the method comprises the steps of positioning a mold table, assembling a mold, placing steel bars and embedded parts, pouring concrete, maintaining a member (available steam), demoulding the member, hoisting and leaving a factory.
The current production system mode comprises a fixed factory building type and a flat die assembly line type, wherein,
the fixed factory building type mold table takes a foundation and the ground as supporting surfaces, has a single-layer structure and is permanently fixed. All production processes are carried out around a fixed die table, namely: and steel bar binding, concrete pouring and later maintenance are all completed around the fixed platform. The personnel and the materials move, and the mould table is not moved. This approach suffers mainly from the following drawbacks: the large floor space leads to large investment of basic construction; the production efficiency is low, and the personnel demand is large; single-layer plane maintenance and high energy consumption; the transportation of materials and finished products is difficult in the flat production; personnel, materials and equipment are mixed, and the potential safety hazard is large; is not easy to move; transportation limitation, and no long-distance project can be carried out; the method is not environment-friendly, each member factory needs to newly build a concrete mixing plant, and the existing commercial concrete supply system is not fully utilized.
The flat die assembly line needs to adopt complex mechanical and electric control equipment, and the component manufacturing process realizes the flow operation. In contrast to the fixed-table process, the flow-line process is a mold-table movement, with the operating stations being fixed. All the procedures are carried out according to a designed unique route in a flow process, including steel bar binding, concrete pouring and forming, later-stage maintenance and the like. This approach suffers mainly from the following drawbacks: the requirements of factory buildings and infrastructure are high, the investment is large, and the construction period is long; the production equipment investment is high, and the installation period is long; the electric control equipment is complex, and the requirement of operators is high; the occupied area of the production area is large; the maintenance of the components is seriously unreasonable: products produced in different periods are maintained in the same maintenance area, so that the energy consumption is high, and the product quality is not easy to guarantee; the mould table can only move in a plane and can only move in a specified route, so that the space is not reasonably utilized, and the production efficiency is low; single-line flow production, once any link goes wrong, the whole production line can form blockage; the material organization, the finished product transportation line is too long, the efficiency is low, and the waste is serious; cross working is not possible.
SUMMERY OF THE UTILITY MODEL
The utility model aims at overcoming prior art's weak point, providing a device is simple, convenient nimble concrete member three-dimensional production system, also can easily improve domestic current stock production facility simultaneously, really realizes social, the two harvest of economic benefits.
In order to achieve the above purpose, the utility model adopts the following technical scheme:
the utility model provides a three-dimensional production system of nomadism formula of precast concrete component, its characterized in that, including the main body district that comprises component shaping district B and three-dimensional maintenance district A in the middle part of the production land, semi-manufactured goods transshipment district D, vacant mould platform transship and stack district C and finished product shipment district E that lie in the main body district around respectively, each district is born by detachable prefabricated basis, and carry out the material transportation through bridge crane or gantry crane and ferry vehicle between each district; a plurality of stations are respectively arranged in the component forming area B and the three-dimensional curing area A, a single-layer or multi-layer mold table for component forming and pouring is respectively arranged on each station in the component forming area B, a three-dimensional curing pile is respectively arranged on each station in the three-dimensional curing area A, the three-dimensional curing pile is formed by overlapping a plurality of component semi-finished products which are poured and formed in the component forming area B together with the corresponding mold table and mold, and each three-dimensional curing pile is respectively wrapped by a curing cover; the empty die table transferring and stacking area C and the semi-finished product transferring area D are both provided with a transfer trolley, a stacking rack is arranged in the empty die table transferring and stacking area C in a range close to the component curing area A and used for stacking the empty die table transferred by the component forming area B, and the lower part of the stacking rack positioned at the bottommost layer is empty, so that a channel for the transfer trolley to freely pass is formed; the ferry vehicle in the semi-finished product transfer area D transports the semi-finished products of the prefabricated components loaded with the corresponding die tables and dies formed in the component forming area B to the component maintenance area A; and a transfer trolley is parked in the finished product delivery area E, and the transfer trolley is loaded with the finished prefabricated components in the component maintenance area A.
Compared with the prior art, the utility model has the following characteristics and beneficial effect:
the nomadic three-dimensional production system of the concrete prefabricated part has low requirement on required basic construction, can be used for open-air production, and can also be used for producing standardized temporary plants; due to the adoption of the prefabricated foundation, the whole body is convenient to move, no construction waste is generated during the factory transportation, and the energy is saved and the environment is protected; the required equipment is simple, and the existing stock equipment is easy to transform; the space can be fully utilized; the semi-finished product of the prefabricated part is maintained in a three-dimensional partition mode, so that the energy consumption is low and the operation is flexible; the vertical and horizontal transportation distances are shortened and the cross operation can be realized by reasonably partitioning the production field, so that the production efficiency is greatly improved; under the same productivity condition, the occupied area is about 15% of that of the traditional factory, and the construction period is about 10% of that of the traditional factory building; the production mode is flexible, and the production can be performed in a nomadic mode on a construction site and in a fixed factory house mode.
Drawings
Fig. 1 is a schematic view of a partition of a nomadic three-dimensional production system according to an embodiment of the present invention.
Fig. 2 is a schematic diagram of the layout of the internal mold table in the three-dimensional curing area a or the component forming area B in the nomadic three-dimensional production system.
Fig. 3 is a schematic diagram of the layout of the hollow mold placing table in the nomadic three-dimensional production system for transferring and stacking the hollow mold placing table in the C region.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more clearly understood, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the detailed description and specific examples, while indicating the scope of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
In order to understand the utility model discloses, the following detailed description the utility model provides a concrete prefabricated component's three-dimensional production system's of nomadic formula application example.
Referring to fig. 1, the nomadic three-dimensional production system of the precast concrete component of the embodiment comprises a main body area, a semi-finished product transfer area D, an empty mold table transfer and stacking area C and two finished product delivery areas E, wherein the main body area is located in the middle of a production site and consists of a component forming area B and two three-dimensional curing areas a located on the east and west sides of the component forming area B; a plurality of stations are respectively arranged in the component forming area B and each three-dimensional curing area A. A single-layer or multi-layer mold table is respectively arranged on each station M2 in the member forming area B and is used for member forming and pouring, and a three-dimensional curing pile formed by overlapping a plurality of member semi-finished products which are poured and formed in the member forming area B together with the mold table and a mold is respectively arranged on each station M1 in each three-dimensional curing area A. The material is transported between the areas through a bridge crane or a portal crane and a ferry vehicle, in the embodiment, the bridge crane Q is adopted above the three-dimensional maintenance area A, and the portal crane H is adopted above the component forming area B.
The specific implementation and functions of each component in this embodiment are described as follows:
and arranging a component forming area B and a component maintenance area A according to the design requirement of capacity, and arranging stations in the component forming area B and the component maintenance area A. In order to facilitate transportation and storage of the formed components after maintenance, the component forming areas B are arranged in the center of the production site, the component maintenance areas a are respectively arranged on the east and west sides of the component forming areas B, and the finished product discharge areas E are respectively arranged on the east and west sides of the two component maintenance areas a, so that subsequent finished prefabricated components can be conveniently transported to a construction site. The stations M1 and M2 in the component forming area B and each three-dimensional curing area A are arranged in a 3X 3 array form, the station arrangement form is not limited to the above, the station arrangement form is set according to the capacity design requirement, and the station size is set according to the size of the prefabricated component. Respectively arranging a semi-finished product transfer area D and an empty mold platform transfer and stacking area C at the north and south sides of a component forming area B and a component maintenance area A, hoisting a cast semi-finished product of a prefabricated component together with a mold platform and a mold on a station M2 of the component forming area B to a shuttle S2 in the semi-finished product transfer area D through a gantry crane H above the component forming area B, moving the shuttle S2 to the working range of a bridge crane Q above the component maintenance area A, and hoisting the semi-finished product of the prefabricated component on the shuttle S2 together with the mold platform and the mold to a corresponding station M1 in the component maintenance area A by the bridge crane Q. The empty mold tables in the component molding area B and the component maintenance area a are transported to a designated position in the empty mold table transferring and stacking area C by a bridge crane or a gantry crane and a ferry vehicle S1 in the empty mold table transferring and stacking area C.
The foundation of the bottom of each area in the nomadic three-dimensional production system can adopt a prefabricated foundation, wherein each station in the component forming area B and the component maintenance area A can adopt a prefabricated and on-site assembled concrete or stainless steel plate type foundation, and the load of the concrete or stainless steel plate type foundation is designed according to the load capacity designed on the station. The bridge crane or the gantry crane adopts a prefabricated and on-site assembled independent foundation, and the load of the independent foundation is designed according to the maximum use load of the crane.
And (3) pouring the prefabricated part in the component forming area B, referring to fig. 2, flatly laying or stacking the mould tables 3 on each station M2 in the component forming area B, wherein each mould table 3 consists of a mould table panel 3-1, a mould table supporting leg 3-2 and a hanging ring 3-3 positioned at two sides of the mould table panel 3-1. In the component forming area B, the mould table 3 is first laid flat on each station M2 in the component forming area B by means of the gantry crane H, and then each team member works on the corresponding mould table in the following sequence: supporting a mould, binding reinforcing steel bars, placing embedded parts and pouring concrete; and forming a semi-finished product of the prefabricated part. The prefabricated part semi-finished product 4 together with the die table 3 and the die are vertically hoisted and translated by a gantry crane H to a ferry vehicle S2 in the semi-finished product transfer area D.
And (3) performing maintenance on the prefabricated parts in the part maintenance area A, transporting the prefabricated part semi-finished products 4 and the die platforms 3 on the prefabricated part semi-finished products to the working range of a bridge crane Q above the part maintenance area A by a ferry vehicle S2 in the semi-finished product transfer area D, vertically hoisting the prefabricated part semi-finished products 4 and the die platforms 3 on the translational ferry vehicle S2 by the bridge crane Q to a working position M1, and stacking to form a three-dimensional maintenance pile, which is shown in figure 2. Each three-dimensional curing pile is respectively wrapped by a curing cover, when the temperature is lower, high-temperature steam is introduced into the curing cover, the high-temperature steam can be obtained by a steam generator or waste heat steam of a power plant and the like, and a temperature control device is installed when the steam is used; when the temperature is higher, high-temperature steam does not need to be introduced into the maintenance cover; the maintenance cover has the function of moisturizing, cold-proof, makes the prefabricated component semi-manufactured goods that stack be located the enclosure space, the full play of high temperature steam of being convenient for, and maintenance cover adopts the canvas covering or awning on a car, boat, etc. to protect in this embodiment, and the maintenance cover can be the maintenance of single-deck mould platform, also can the maintenance of multilayer mould platform in the lump. And when the semi-finished prefabricated part 4 reaches the demolding condition through maintenance, removing the mold at a corresponding station in the part maintenance area A by each team and using a bridge crane Q to vertically hoist and translate the finished prefabricated part to a finished product delivery area E.
A stacking rack is arranged in the empty mould station transfer and stacking area C close to the component maintenance area a for stacking empty mould stations 3, see fig. 3. The stacking rack consists of a panel 5-1, a column foot 5-2 and lifting rings 5-3 positioned on two sides of the panel 5-1, and is positioned below the stacking rack at the bottommost layer in a vacant mode to form a channel 5-4 for the free passage of the ferry vehicle S1. The empty die table 3 for finished product shipment of the prefabricated part is completed in the part maintenance area A, and is vertically lifted and translated to the stacking rack through the bridge crane Q, and at the moment, the die table 3 is light and can be stacked in multiple layers. The lifting height of the stacking rack and the multiple layers of empty mold platforms 3 stacked above the stacking rack are lifted by the ferry S1 to be conveyed to the vicinity of the component forming area B for the next casting of the prefabricated components.
And the finished product delivery area E can stop a transfer trolley, and the finished prefabricated part in the part maintenance area A is directly placed on the transfer trolley for direct delivery through a bridge crane Q.
The ferry cars S1 and S2 are standard lifting ferry cars which can bear the weight of a stacking rack and a plurality of vacant die tables 3 and can bear the weight of a semi-finished product of a prefabricated part which is just cast and molded and is provided with the die tables and a die. Can run on a track and also can run on flat ground. The top plates of the ferry vehicles S1 and S2 can be lifted and lowered and can be controlled manually or electrically. When the top of the ferry vehicle is not lifted, the ferry vehicle can freely enter and exit in the lower channel 5-4 of the stacking rack. When the top of the ferry vehicle is lifted, the stacking rack and the multi-layer empty mold platforms 3 stacked above the stacking rack can be lifted to walk.
The bridge crane or the gantry crane is used for vertically lifting a die table, materials and the like, and can be horizontally transported in a small range after being vertically lifted. If a bridge crane is adopted, arranging a crane beam on a standard factory building column; if a portal crane is adopted, an assembled track and a track foundation need to be arranged on the ground.
The installation and production process of the production system of the embodiment is as follows:
1) basic construction: and leveling the land of the plant area, installing a prefabricated foundation of the plant, and installing an upper structure of the plant.
2) Station arrangement: and arranging the stations in the component forming area B and the component maintenance area A according to the design requirement of capacity, wherein 9 stations are respectively arranged. The station foundation is a prefabricated concrete plate foundation which can be spliced on site. The size of the station is determined by the size of the standard die table designed. The base load of the station M1 of the die table in the component curing area A is determined according to the designed stacking layer number of the die table. The prefabricated station foundations of all the die tables can be conveniently disassembled and reused, and are generally made of concrete slabs or thick steel plates.
3) Arranging a mould platform: and hoisting the empty die table in the empty die table transferring and stacking area C to each station in the component forming area B by using a bridge crane or a gantry crane, wherein the die table can be in a single-layer state or a multi-layer stacking state.
4) Forming a member: in the component forming zone B and on the mould table of each station M2 in the zone-the crew members work on the mould table in the following sequence: supporting a mould, binding reinforcing steel bars, placing embedded parts and pouring concrete; forming a semi-finished component (i.e., a component that has just been cast in a mold).
5) And (3) transporting the semi-finished product: in the semi-finished product transfer area D, the component semi-finished products of the component forming area B together with the mold table) are vertically lifted by a bridge crane or a gantry crane and placed on a shuttle S2 in the semi-finished product transfer area D, and the shuttle S2 lifts the component semi-finished products together with the mold table to the component curing area a.
6) The maintenance area is in place: in the component curing area A, the component semi-finished products of the shuttle S1 together with the die table are vertically lifted by a bridge crane or a gantry crane and placed at the corresponding stations of the component curing area A.
7) And (3) maintenance in different areas: and (4) stacking the semi-finished products of the prefabricated components and the die table in the component curing area A to the designed layer number to form a three-dimensional curing pile, installing a curing awning, and introducing steam for curing in due time.
8) Demoulding of a finished product: and (3) in the component curing area A, curing the semi-finished prefabricated components to a certain time (for example, curing for 8 hours at 60 ℃ by steam) according to the design requirements to achieve the condition of demolding, wherein the semi-finished prefabricated components are finished products, removing the side molds, and then lifting and translating the finished prefabricated components to the finished product delivery area E by using a demolding lifting appliance.
9) And (3) empty die table transfer: after the finished component is removed, the mold table in the component curing area a is an empty mold table, and the component forming area B needs to be removed again for work. At the moment, the transfer is started, the transfer is carried out in the empty module platform transferring and stacking area C, and the empty module platform is horizontally transferred to a ferry vehicle S1 in the empty module platform transferring and stacking area C through a bridge crane or a gantry crane; to improve the efficiency of the dumping, the ferry vehicle S1 may utilize the empty mold station stacks to transport multiple empty mold stations, such as 5 or more layers at a time (where the mold stations are light).
10) Stacking empty die tables: the transfer and stacking is carried out in an empty mold table transferring and stacking area C, and the empty mold table is stacked beside an area B by using a stacking rack for standby.
10) And continuously repeating the steps until the production of the component is finished.
Finally, it should be noted that: the above embodiments are only used to illustrate the technical solution of the present invention, and not to limit it; although the present invention has been described in detail with reference to the foregoing embodiments, it should be understood by those skilled in the art that: the technical solutions described in the foregoing embodiments may still be modified, or some technical features may be equivalently replaced; such modifications and substitutions do not depart from the spirit and scope of the present invention in its corresponding aspects.
Claims (4)
1. A nomadic three-dimensional production system of precast concrete components is characterized by comprising a main body area, a semi-finished product transferring area D, an empty mold table transferring and stacking area C and a finished product discharging area E, wherein the main body area is positioned in the middle of a production site and consists of a component forming area B and a three-dimensional curing area A; a plurality of stations are respectively arranged in the component forming area B and the three-dimensional curing area A, a single-layer or multi-layer mold table for component forming and pouring is respectively arranged on each station in the component forming area B, a three-dimensional curing pile is respectively arranged on each station in the three-dimensional curing area A, the three-dimensional curing pile is formed by overlapping a plurality of component semi-finished products which are poured and formed in the component forming area B together with the corresponding mold table and mold, and each three-dimensional curing pile is respectively wrapped by a curing cover; the empty die table transferring and stacking area C and the semi-finished product transferring area D are both provided with a transfer trolley, a stacking rack is arranged in the empty die table transferring and stacking area C in a range close to the component curing area A and used for stacking the empty die table transferred by the component forming area B, and the lower part of the stacking rack positioned at the bottommost layer is empty, so that a channel for the transfer trolley to freely pass is formed; the ferry vehicle in the semi-finished product transfer area D transports the semi-finished products of the prefabricated components loaded with the corresponding die tables and dies formed in the component forming area B to the component maintenance area A; and a transfer trolley is parked in the finished product delivery area E, and the transfer trolley is loaded with the finished prefabricated components in the component maintenance area A.
2. The nomadic three-dimensional production system according to claim 1, wherein two three-dimensional curing areas A are provided, one on each east-west side of the component molding area B; the semi-finished product transferring area D and the empty mould platform transferring and stacking area C are respectively positioned on the north and south sides of the main body area; and two finished product delivery areas E are arranged and are respectively positioned on the east and west sides of the main body area.
3. The nomadic three-dimensional production system according to claim 1, wherein the ferry vehicle is a lifting ferry vehicle, and a top plate of the ferry vehicle can be lifted.
4. The nomadic three-dimensional production system according to claim 1, wherein the mould table and the piling bin are both provided with lifting rings.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN113696323A (en) * | 2021-07-27 | 2021-11-26 | 江苏中江装配式建筑科技股份有限公司 | Prefabricated pulsating 5G automatic assembly line for assembly type building special-shaped components |
| CN114012883A (en) * | 2021-11-25 | 2022-02-08 | 上海建工建材科技集团股份有限公司 | Three-dimensional mobile PC component digital production system and production method |
| CN114932612A (en) * | 2022-07-04 | 2022-08-23 | 南京平达绿色建材科技有限公司 | Production process of high-efficiency energy-saving prefabricated laminated slab |
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2020
- 2020-05-29 CN CN202020942413.2U patent/CN212919859U/en active Active
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN113696323A (en) * | 2021-07-27 | 2021-11-26 | 江苏中江装配式建筑科技股份有限公司 | Prefabricated pulsating 5G automatic assembly line for assembly type building special-shaped components |
| CN114012883A (en) * | 2021-11-25 | 2022-02-08 | 上海建工建材科技集团股份有限公司 | Three-dimensional mobile PC component digital production system and production method |
| CN114012883B (en) * | 2021-11-25 | 2023-03-07 | 上海建工建材科技集团股份有限公司 | Three-dimensional mobile PC component digital production system and production method |
| CN114932612A (en) * | 2022-07-04 | 2022-08-23 | 南京平达绿色建材科技有限公司 | Production process of high-efficiency energy-saving prefabricated laminated slab |
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