Parallel PC component production system

Abstract

The present invention discloses a parallel PC component production system, characterized in that it includes a steel bar CNC processing station, a steel bar skeleton processing station and a plurality of prefabricated component production units arranged in parallel. Advantages: In the parallel PC component production system described in the present invention, each prefabricated component production unit is arranged in parallel without the need to set up a circular track, which effectively reduces the floor space and construction costs; multiple prefabricated component production units can produce multiple components at the same time, the production efficiency of each unit is not restricted by each other, the component production types are complete, the mold platform flow rhythm is not restricted by each other, the curing box is movable, and the small group mold platform component curing, demolding, and production can be independently operated at the same time, which improves the factory component production efficiency and reduces the component production cost; hot air curing replaces steam curing to avoid the problem of factory humidity caused by steam diffusion during the unpacking process.

Description

Technical field:

[0001] The invention relates to the technical field of PC component production, in particular to a parallel PC component production system. Background technology:

[0002] With the rapid development of prefabricated buildings in my country, the prefabricated concrete industry has developed rapidly in China, and major domestic assembly manufacturing companies have begun to enter the precast concrete (PC) industry. Among them, the PC component production line mainly provides customized PC components for prefabricated buildings.

[0003] At present, most PC component production lines follow the form of driving wheels and tugboats cooperating with mobile formwork platforms for assembly line operation. The entire factory formwork platform organizes large-scale circulation operations, that is, a circular track is set up, and steel bar processing area, casting area, maintenance area, spraying area, and finished product stacking area are set up on the outside of the track in sequence. During the production process, the mobile formwork platform moves along the track to the corresponding area and performs corresponding operations; this large-scale circulation operation system has the following problems: 1. This large-scale circulation operation system occupies a large area and has high construction costs; 2. In the actual production process, due to the diversity of prefabricated component types, the production rhythm of each station is different, resulting in the entire assembly line can only produce one component in a period of time, and assembly can only be carried out after all components are produced. This As a result, the production time of the entire component is relatively long, and the assembly and component production need to be carried out in different time periods, resulting in low overall production efficiency, high cost and low benefits; 3. Steam curing is generally used in the curing room. After the concrete components are cured, they will be taken out of the curing box. When the curing box is opened, a large amount of steam in the curing box will diffuse into the factory. In the long run, the working environment in the factory will become humid and unsuitable for workers to work for a long time; 4. After the concrete of the component is poured, the surface cannot be smoothed once, and a secondary surface treatment is required, that is, it needs to be sent to the curing box for pre-curing first, and then sent out of the curing box for smoothing after the pre-curing is completed. After smoothing, it is sent to the curing box again for curing. After the curing is completed, it can be demoulded. The pouring and curing process is cumbersome and inefficient. In general, the single type of components produced by the large-scale circulation production line of PC components and the diversified component types required for prefabricated buildings form a major contradiction, which to a certain extent restricts the development of prefabricated buildings in my country. The single type of components produced by the existing PC component production line has restricted the development of prefabricated buildings, so this problem urgently needs to be solved. Summary of the invention:

[0004] The object of the present invention is to provide a parallel PC component production system which can improve the overall production efficiency.

[0005] The present invention is implemented by the following technical scheme: a parallel PC component production system, which includes a steel bar CNC processing station, a steel bar skeleton processing station and a plurality of prefabricated component production units arranged in parallel, the prefabricated component production unit includes a mobile curing box and at least two groups of casting mold platform groups arranged in a straight line, each group of the casting mold platform groups includes at least two mold platforms, and the mobile curing box is movably arranged between each group of the casting mold platform groups; an AGV transport flat car for transporting materials is arranged between the steel bar CNC processing station, the steel bar skeleton processing station and the casting mold platform group; and overhead cranes corresponding to the steel bar CNC processing station, the steel bar skeleton processing station and the casting mold platform group are arranged in the factory area.

[0006] Furthermore, it also includes a component stacking area, a component painting station, a composite component processing station, and a finished product stacking area. AGV transport flat cars for transporting materials are arranged between the component stacking area, the component painting station, the composite component processing station, the finished product stacking area and the casting mold platform group; and overhead cranes corresponding to the component stacking area, the component painting station, the composite component processing station, and the finished product stacking area are arranged in the factory area.

[0007] Furthermore, each mold platform of each group of the casting mold platform groups is arranged in a straight line, and the mold platforms are flip-type mold platforms.

[0008] Furthermore, the mobile maintenance box includes a box body, which includes two oppositely arranged side panels and a top panel fixedly connected between the tops of the two side panels; door panels are installed at both ends of the box body, and the door panels are electric doors; electric drive wheels and a plurality of walking wheels are arranged at the bottom of both sides of the box body; a heating device is arranged on the top of the box body; and sealing structures are fixed to the inner bottom of the side panels and the inner bottom of the door panels.

[0009] Furthermore, tracks are arranged on both sides of the casting mold platform group, and the electric drive wheels and the walking wheels are arranged to roll along the corresponding tracks.

[0010] Furthermore, an insulation plate is arranged between the bottoms of the two side panels, and the casting mold platform group is arranged on the top of the insulation plate; a plurality of guide wheels are arranged to roll along the sides of the insulation plate for horizontal rotation on the inner side of the side panel, and the bottom end of the sealing structure is in active contact with the top of the insulation plate.

[0011] Furthermore, the insulation board includes two channel steels arranged relatively parallel to each other on the left and right sides and a insulation board body fixed between the insides of the two channel steels.

[0012] Furthermore, the sealing structure is a sealing airbag.

[0013] Furthermore, the heating device includes a hot air blower and an air supply pipe. The hot air blower is fixed on the outer wall of the box, and a plurality of air supply pipes connected to the hot air blower outlet are fixed inside the box; the air inlet of the hot air blower is connected to the interior of the box through a return air pipe.

[0014] Furthermore, a hollow cavity is arranged inside the mold platform, a plurality of ventilation holes connected with the hollow cavity are opened on the side of the mold platform, and the air outlet of the air supply pipe is arranged opposite to the ventilation holes.

[0015] Advantages of the present invention: In the parallel PC component production system described in the present invention, each prefabricated component production unit is arranged in parallel without the need to set up a circular track, which effectively reduces the floor space and reduces the construction cost; multiple prefabricated component production units can produce multiple components at the same time, the production efficiency of each unit is not restricted by each other, the component production types are complete, the mold table flow rhythm is not restricted by each other, the maintenance box is movable, and the maintenance, demolding and production of the small group mold table components can be independently operated at the same time, which improves the factory component production efficiency and reduces the component production cost; hot air maintenance replaces steam maintenance to avoid the problem of factory humidity caused by steam diffusion during the unpacking process; the use of a flip mold table and a covered mold in combination with casting can ensure the flatness of the surface of the cast component, and there is no need for pre-maintenance and smoothing treatment, and direct maintenance and demolding are sufficient, which is beneficial to improving production efficiency. Description of the drawings:

[0016] Figure 1 It is a schematic diagram of the overall structure of this embodiment.

[0017] Figure 2 This is a schematic diagram of the structure of the prefabricated component production unit.

[0018] Figure 3 A structural schematic diagram of a mobile curing box.

[0019] Figure 4 Another structural schematic diagram of a mobile curing box.

[0020] Rebar CNC processing station 1, component painting station 2, composite component processing station 3, prefabricated component production unit 4, rebar skeleton processing station 4.1, casting mold platform group 4.2, mold platform 4.3, ventilation hole 4.4, mobile curing box 5, box body 5.1, hot air blower 5.2, air supply pipe 5.3, side panel 5.4, top plate 5.5, door panel 5.6, electric drive wheel 5.7, walking wheel 5.8, sealing structure 5.9, first transport channel 6, second transport channel 7, third transport channel 8, AGV transport flat car 9, ceiling crane 10, track 11, insulation board 12, channel steel 12.1, insulation board body 12.2, guide wheel 13, temperature sensor 15, controller 16, return air duct 17, component stacking area 18, finished product stacking area 19. Specific implementation method:

[0021] like Figure 1 and Figure 2 As shown, the parallel PC component production system includes a steel bar CNC processing station 1, a steel bar skeleton processing station 4.1, a component stacking area 18, a component coating station 2, a composite component processing station 3, a finished product stacking area 19 and a plurality of prefabricated component production units 4 arranged in parallel. The plurality of prefabricated component production units 4 are arranged in parallel. According to production needs, a plurality of prefabricated component production units 4 can be used to process different types of PC components at the same time. The processing of a plurality of PC components and the assembly of building components are carried out simultaneously, which greatly improves the processing efficiency. In addition, the parallel arrangement of a plurality of production lines and the large-circulation flow operation greatly reduce the plant area and construction costs.

[0022] The prefabricated component production unit 4 includes a mobile curing box 5 and at least two groups of casting mold platforms 4.2 in a straight line. Each group of casting mold platforms 4.2 includes at least two mold platforms 4.3. Each mold platform 4.3 of each group of casting mold platforms 4.2 is arranged in a straight line, and the mold platform 4.3 is a flip mold platform. A cover plate is set on the top of the mold of the PC component, and a casting hole is set on the cover plate. During the casting process, the mold is tilted by the mold platform 4.3, and the concrete can be filled in the mold while casting and vibrating, so as to ensure that the surface of the component is flat and free of air holes; A mobile curing box 5 is provided between the two groups of casting mold platforms 4.2 of the corresponding prefabricated component production unit 4. The casting mold platforms 4.2 are operated in parallel. When the components above one group of casting mold platforms 4.2 are being cured, the other group of casting mold platforms 4.2 can be used for the production of components, ensuring that the curing and casting are carried out at the same time, further improving the overall production efficiency.

[0023] The mobile maintenance box 5 includes a box body 5.1, which includes two side panels 5.4 arranged opposite to each other and a top panel 5.5 fixedly connected between the tops of the two side panels 5.4. The two side panels 5.4 are respectively located on both sides of the casting mold platform group 4.2; a sealing structure 5.9 is fixed to the inner bottom of the side panel 5.4 and the inner bottom of the door panel 5.6; the sealing structure 5.9 is a sealing airbag, or a sealing rubber. The sealing is performed by the sealing airbag, which is convenient for retraction and release, and can solve the problem of wear of the sealing structure 5.9 during movement.

[0024] Door panels 5.6 are installed at both ends of the box body 5.1. The door panels 5.6 are electric doors. In this embodiment, the electric doors are electric doors that can be opened and closed up and down. The door panels 5.6 can be opened and closed up and down to reduce the horizontal operation space and improve the utilization rate of the space.

[0025] A heating device is arranged on the top of the box 5.1; the heating device comprises a hot air blower 5.2 and an air supply pipe 5.3. The hot air blower 5.2 is fixed on the outer wall of the box 5.1, and a plurality of air supply pipes 5.3 connected to the outlet of the hot air blower 5.2 are fixed inside the box 5.1; the air inlet of the hot air blower 5.2 is connected to the inside of the box 5.1 through the return air pipe 17; the hot air blower 5.2 can heat the air to a set temperature and send it into the inside of the box 5.1 through the air supply pipe 5.3 to act on the PC components for maintenance, and the inside of the box 5.1 is connected to the hot air blower 5.2 through the return air pipe 17. 2, on the one hand, the air circulation inside the box body 5.1 can be accelerated by the hot air blower 5.2, and on the other hand, the hot air inside the box body 5.1 can be recycled to reduce the energy consumption of the hot air blower 5.2; of course, the heating device can also adopt the electric heating tube or steam heating tube commonly used in curing equipment; a temperature sensor 15 is arranged inside the box body 5.1, and the temperature sensor 15 is connected to the heater of the hot air blower 5.2 through the controller 16, and the curing temperature inside the box body 5.1 can be set through the controller 16, and the power of the heater of the hot air blower 5.2 can be controlled;

[0026] A hollow cavity is arranged inside the mold platform 4.3, and a plurality of ventilation holes 4.4 connected to the hollow cavity are opened on the side of the mold platform 4.3. The air outlet of the air supply pipe 5.3 is arranged opposite to the ventilation hole 4.4, and the air supply pipe 5.3 is evenly arranged on both sides of the mold platform 4.3; the hot air sent by the air supply pipe 5.3 enters the hollow cavity of the mold platform 4.3 through the ventilation hole 4.4, and acts on the bottom of the PC component through the top of the hollow cavity, and then is dissipated through other ventilation holes 4.4 to act on the top and surroundings of the PC component, so that the uniformity of maintenance can be ensured and the maintenance effect can be improved;

[0027] Electric drive wheels 5.7 and a plurality of running wheels 5.8 are arranged at the bottom of both sides of the box body 5.1. A plurality of electric drive wheels 5.7 can be arranged, and the box body 5.1 can be moved back and forth between the two corresponding casting mold platform groups 4.2 by means of the electric drive wheels 5.7.

[0028] In order to prevent the box 5.1 from deflecting when moving, a guide structure is provided. Figure 3 As shown, tracks 11 are arranged on both sides of the casting mold platform group 4.2, and the electric drive wheel 5.7 and the running wheel 5.8 are arranged to roll along the corresponding tracks 11, and the electric drive wheel 5.7 drives the mold platform 4.3 to move back and forth along the tracks 11;

[0029] or Figure 4As shown, an insulation board 12 is arranged between the bottoms of the two side panels 5.4, and the casting mold platform group 4.2 is arranged on the top of the insulation board 12. The insulation board 12 can prevent heat from being dissipated from the bottom of the box body 5.1, thereby improving the utilization rate of heat energy; a plurality of guide wheels 13 are arranged to roll along the side edges of the insulation board 12 for horizontal rotation on the inner side of the side panel 5.4, and the guide wheels 13 can play a guiding role in preventing the box body 5.1 from moving when the electric drive wheel 5.7 drives the box body 5.1 to move; the bottom end of the sealing structure 5.9 is in active contact with the top of the insulation board 12 to enhance the sealing performance and prevent heat loss; the insulation board 12 includes two channel steels 12.1 arranged relatively parallel to each other on the left and right and an insulation board body 12.2 fixed between the insides of the two channel steels 12.1, and the channel steels 12.1 on both sides are arranged to move along the sides of the insulation board 12. The insulation board body 12.2 can be protected, and the guide wheel 13 rolls along the channel steel 12.1, which can prevent the insulation board from being worn due to direct contact between the guide wheel 13 and the insulation board body 12.2, thereby ensuring the normal operation of the equipment;

[0030] Rebar CNC processing station 1 arranges corresponding rebar machinery and equipment according to the rebar processing form required by the type of factory component production, including: rebar CNC hoop bending machine, rebar bar processing production line, rebar mesh production line, etc., to meet the supply of finished rebars for the factory's PC component production;

[0031] An AGV transport flat car 9 for transporting materials is arranged between the steel bar CNC processing station 1, the steel bar skeleton processing station 4.1, the component stacking area 18, the component coating station 2, the composite component processing station 3, the finished product stacking area 19 and the casting mold platform group 4.2. Specifically, a first transport channel 6 is arranged between the steel bar CNC processing station 1 and the steel bar skeleton processing station 4.1, a second transport channel 7 is arranged between the steel bar skeleton processing station 4.1 and the casting mold platform group 4.2, and a third transport channel 8 is arranged between the casting mold platform group 4.2 and the component stacking area 18, the component coating station 2, the composite component processing station 3, and the finished product stacking area 19, and an AGV transport flat car 9 is arranged in the first transport channel 6, the second transport channel 7 and the third transport channel 8;

[0032] The factory area is provided with ceiling cranes 10 corresponding to the component stacking area 18, the component painting station 2, the composite component processing station 3, the finished product stacking area 19, the steel bar CNC processing station 1, the steel bar skeleton processing station 4.1 and the casting mold platform group 4.2. The steel bars or components on the corresponding stations can be moved to the AGV transport flat car 9 through the ceiling crane 10. The steel bars between the steel bar CNC processing station 1 and the steel bar skeleton processing station 4.1, the steel bar skeleton between the steel bar skeleton processing station 4.1 and the casting mold platform group 4.2, and the PC components between the casting mold platform group 4.2 and the component painting station 2 or the composite component processing station 3 can be transported.

[0033] Preferably, the component stacking area 18 and the finished product stacking area 19 are respectively arranged on both sides of the composite component processing station 3, and the component stacking area 18, the component coating station 2, the composite component processing station 3, and the finished product stacking area 19 are all arranged on the side of the casting mold platform group 4.2 away from the steel bar CNC processing station 1;

[0034] Instructions for use: First, use the corresponding steel bar machinery to process the steel bars into steel mesh, threaded steel bars, finished stirrups and other semi-finished steel bars at the steel bar CNC processing station 1; then, use the overhead crane to move the semi-finished steel bars at the steel bar CNC processing station 1 to the AGV transport flat car 9, and transport them to the steel bar skeleton processing station 4.1 of the corresponding prefabricated component production unit 4 through the first transport channel 6, and manually process the semi-finished steel bars to form a steel bar skeleton; then, the AGV transport flat car 9 moves the steel bar skeleton to the casting mold group 4.2, and the manual assisted overhead crane 10 completes the assembly of the steel bar skeleton and the mold. The AGV transport flat car 9 carries concrete to the casting mold group 4.2, and the overhead crane 10 lifts the ash hopper to cast concrete to complete the casting of component concrete. During the casting process, the casting mold group 4.2 is controlled to tilt 60° to complete the concrete grouting, and then the mold is restored to a horizontal state; after all the components on a group of casting mold groups 4.2 are cast, the mobile curing box 5 is moved to Above the casting mold platform group 4.2, fill the sealed airbag with air until its bottom contacts the ground or the insulation board 12, then close the door panels 5.6 on both sides, start the hot air blower 5.2 to maintain the casting mold platform group 4.2, and control the overall flow beat of the group to be less than or equal to the component maintenance time beat to achieve efficient factory production. The mold platform components on the casting mold platform group 4.2 that have been maintained are demolded and manufactured during the maintenance time of another casting mold platform group 4.2; after demolding, the AGV transport flat car 9 The demoulding components are transported to the component stacking area 18 (components that do not require painting, such as floor slabs, interior wall panels, etc.) or the composite component processing station 3 (components that require painting, such as exterior wall components) according to their types. At the composite component processing station 3, the PC components that form the shear wall exterior are completed and then transported by the AGV transport flat car 9 to the component painting station 2 to complete the window installation and exterior wall decoration of the components. The finished components are hoisted into the finished product stacking area 19. The factory has a 24-hour circulation production line, realizing the group production of multiple types of component production lines.

[0035] The present invention provides a planar layout of a parallel fixed-die PC component production line. This solution is applied to the production of prefabricated components for assembled buildings, improves the component production process layout, produces a full range of component types, and the flow rhythms between die platforms are not restricted to each other. The maintenance of small group die platforms is independently operated, which improves the factory component production efficiency, reduces the component production cost, and has good economy and practicality.

[0036] Taking the production of a 100-square-meter villa as an example, it requires 16 shear walls, 10 floor slabs, 4 beams, and 2 stairs;

[0037] If the traditional large-scale water circulation operation is adopted, the water flow rhythm must be calculated according to the maximum water flow rhythm, that is, 0.75 hours for the shear wall. Each component needs to go through five construction processes: steel bar binding, embedded parts installation, concrete pouring, pre-curing, and secondary plastering. The total time is: 0.75*5*(16+10+4+2) / 16=7.5 working hours;

[0038] If the parallel PC component production system disclosed in the present invention is used for production operations, each station is in production and construction at the same time, and the flow beat is not restricted by each other, then the flow beat is calculated according to the average flow beat, that is, the average beat is 0.5 hours. Each component needs to go through three construction processes: steel bar binding, embedded parts installation, concrete pouring, and the total time is: 0.5*3* (16+10+4+2) / 16=3 working hours;

[0039] It can be seen from this that the parallel PC component production system disclosed in the present invention can greatly save operation time and improve production efficiency compared with traditional large-scale flow circulation operations. The production efficiency is increased by 60%, while reducing labor cost input, which is beneficial to improving the overall economic benefits of the factory.

[0040] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principle of the present invention should be included in the protection scope of the present invention.

Claims

1. Parallel PC component production system, characterized in that: It includes a steel bar CNC processing station, a steel bar skeleton processing station and a plurality of prefabricated component production units arranged in parallel, wherein the prefabricated component production unit includes a mobile curing box and at least two groups of casting mold platform groups arranged in a straight line, each group of the casting mold platform groups includes at least two mold platforms, and the mobile curing box is movably arranged between each group of the casting mold platform groups; an AGV transport flat car for transporting materials is arranged between the steel bar CNC processing station, the steel bar skeleton processing station and the casting mold platform group; and a AGV transport flat car connected to the steel bar CNC processing station and the casting mold platform group is arranged in the factory area. The mobile maintenance box comprises a box body, and the box body comprises two oppositely arranged side panels and a top panel fixedly connected between the tops of the two side panels; door panels are installed at both ends of the box body, and the door panels are electric doors; electric drive wheels and a plurality of walking wheels are arranged at the bottom of both sides of the box body; a heating device is arranged on the top of the box body; sealing structures are fixed on the inner bottom of the side panels and the inner bottom of the door panels; and the formwork platform is a flip formwork platform.

2. The parallel PC component production system according to claim 1, characterized in that: It also includes a component stacking area, a component painting station, a composite component processing station, and a finished product stacking area. AGV transport flat cars for transporting materials are arranged between the component stacking area, the component painting station, the composite component processing station, the finished product stacking area and the casting mold platform group; and overhead cranes corresponding to the component stacking area, the component painting station, the composite component processing station, and the finished product stacking area are arranged in the factory area.

3. The parallel PC component production system according to claim 1, characterized in that: Tracks are arranged on both sides of the casting mold platform group, and the electric drive wheels and the walking wheels are arranged to roll along the corresponding tracks.

4. The parallel PC component production system according to claim 1, characterized in that: An insulation board is arranged between the bottoms of the two side panels, and the casting mold platform group is arranged on the top of the insulation board; a plurality of guide wheels are arranged to roll along the sides of the insulation board for horizontal rotation on the inner side of the side panel, and the bottom end of the sealing structure is in active contact with the top of the insulation board.

5. The parallel PC component production system according to claim 4, characterized in that: The heat preservation board comprises two channel steels which are arranged relatively parallel to each other on the left and right sides and a heat preservation board body which is fixed between the insides of the two channel steels.

6. The parallel PC component production system according to claim 1, characterized in that: The sealing structure is a sealing airbag.

7. The parallel PC component production system according to claim 1, characterized in that: The heating device includes a hot air blower and an air supply pipe. The hot air blower is fixed on the outer wall of the box, and a plurality of air supply pipes connected to the hot air blower outlet are fixed inside the box; the air inlet of the hot air blower is connected to the inside of the box through a return air pipe.

8. The parallel PC component production system according to claim 7, characterized in that: A hollow cavity is arranged inside the mold platform, a plurality of ventilation holes connected with the hollow cavity are opened on the side of the mold platform, and the air outlet of the air supply pipe is arranged opposite to the ventilation holes.

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