A series of die tables device and production process for three-dimensional production of precast concrete slabs

Abstract

The present invention belongs to the technical field of prefabricated building engineering, and particularly relates to a series of formwork devices for three-dimensional production of precast concrete slabs and a production process. The device includes a formwork lifting tool and multiple groups of formwork components; the formwork components include a formwork and multiple support columns, and the multiple support columns are arranged circumferentially at the edge of the formwork; multiple groups of formwork components can be stacked for three-dimensional production of precast concrete slabs, and the support columns are used to support the upper formwork components; the formwork lifting tool is used for hoisting, translation and stacking of the formwork components. The present invention can achieve a production method of precast concrete components with low investment, high output, quick results, easy promotion and low energy consumption, such as the prefabrication of reinforced concrete composite floors and wall panels, which will surely have a huge impact on the popularization and application of prefabricated buildings in China, and at the same time achieve a double harvest of economic and social benefits.

Description

Technical Field

[0001] The present invention belongs to the technical field of prefabricated building engineering, and particularly relates to a series of die tables for three-dimensional production of precast concrete slabs and a production process. Background Art

[0002] Vigorously developing prefabricated buildings has become the basic direction of the upgrading of China's construction industry. The consumption of precast concrete components, especially floor slabs and wall panels, is increasing. The traditional production processes and methods not only involve large investments, low efficiency, and high energy consumption, but also the production capacity can no longer meet the market demand.

[0003] A die table is a production platform for precast concrete components, which consists of main die table beams, secondary die table beams, and a die table panel. The main die table beam is the main load-bearing member of the entire die table, responsible for ensuring the flatness and stability of the entire die table and transferring the load of the entire die table to the ground foundation. The secondary die table beams ensure the flatness and stability of the die table panel and transfer all the loads on the die table panel to the main die table beam. The die table panel is the operating surface for fabricating precast concrete components, generally made of hard and smooth materials such as steel plates to ensure the smoothness and flatness of the surface of precast concrete components.

[0004] Existing die table forms include: fixed die tables and assembly line die tables.

[0005] Fixed die tables are directly laid on the ground, that is, the main die table beams are in contact with the ground and remain stationary. Fixed die tables adopt flat production: the die tables are laid flat in the factory workshop and fixed. The basic process: after the formwork is assembled and poured, it is cured in place, and the finished products are hoisted in place one by one. Its defects are: the main die table beams are directly in contact with the ground foundation. If the ground is uneven, it is extremely easy to cause the main beams to twist, affecting the accuracy of the components; the die tables cannot be stacked: the main beams will deform when stacked layer by layer, and are more likely to twist and deform when in contact with the ground; it occupies a large area, requires a large basic investment, has low production efficiency, and requires a large number of personnel; single-layer flat curing has high energy consumption, flat production makes the transfer of materials and finished products difficult; the mixing of personnel, materials, and equipment poses a great safety hazard, and the factory space is not utilized at all.

[0006] The main girder of the table form of the production line is placed on the track and runs on the track through a movable pulley. Flat table form production line: Place the table form on the track, the production station personnel do not move, and the table form moves on the track and is lifted to the centralized curing point through extremely complex mechanical devices. Its defects are as follows: The table forms cannot be stacked. When curing centrally, the table forms are lifted by a bracket structure, that is, the upper and lower table forms do not touch, otherwise they will be deformed. High requirements for the factory building and infrastructure, large investment, long construction period, high investment in production equipment, long installation period, complex electric control equipment, high requirements for operators, large floor area of the production area; Component curing is seriously unreasonable: Products produced at different times are cured in the same curing area, not only with high energy consumption, but also the product quality is not easy to guarantee; The table form can only move horizontally and can only move along the specified route, failing to make reasonable use of space and resulting in low production efficiency; Single-line flow operation, once any link has a problem, the entire production line will be blocked, the material organization and the finished product transportation line are too long, with low efficiency, serious waste, and cannot carry out cross-operation. Summary of the Invention

[0007] Aiming at the above problems, the purpose of the present invention is to provide a series-connected table form device and production process for three-dimensional production of precast concrete slabs to overcome the deficiencies of the existing table form and production process.

[0008] In order to achieve the above purpose, the present invention adopts the following technical solutions:

[0009] A series-connected table form device for three-dimensional production of precast concrete slabs, comprising: a table form lifting appliance and multiple groups of table form components;

[0010] The table form components include a table form and multiple support columns, and the multiple support columns are arranged circumferentially at the edge of the table form;

[0011] Multiple groups of table form components can be stacked for three-dimensional production of precast concrete slabs, and the support columns are used to support the upper table form components;

[0012] The table form lifting appliance is used for hoisting, translating and stacking of the table form components.

[0013] The upper end of the support column protrudes from the upper surface of the table form, and the height of the protruding part is greater than the thickness of the precast concrete slab;

[0014] The upper end surfaces of the multiple support columns are located on the same horizontal plane.

[0015] The table form is of a rectangular structure, and positioning angle plates are provided at the four corners, and the positioning angle plates are used for positioning with the table form lifting appliance.

[0016] The upper end surfaces of the positioning angle plates are located at the same height as the upper end surfaces of the support columns.

[0017] The table form lifting device includes a sling, a frame and a telescopic fixture. At least one set of relatively arranged telescopic fixtures is provided on the inner side of the frame, and the sling is connected to the frame for connecting with an external lifting device.

[0018] The frame is of a rectangular structure, and guiding mechanisms are provided at the four corners. The guiding mechanisms are used to cooperate with the alignment angle plates at the four corners of the table form to guide the frame to the outside of the table form.

[0019] The guiding mechanism includes a fixing plate, a telescopic rod and a diversion plate. The fixing plate is connected to the frame; the diversion plate is hinged to the lower end of the fixing plate and is inclined outward; the telescopic rod is arranged on the fixing plate, and the telescopic end is connected to the diversion plate.

[0020] A method for three-dimensional production of precast concrete slabs includes the series-connected table form device for three-dimensional production of precast concrete slabs as described in any one of the above. The method includes the following steps:

[0021] 1) Table form arrangement: Arranged in a flat-laying manner;

[0022] 2) Concrete pouring: Support the mold, bind the steel bars and fix the embedded parts on the arranged table form, and then pour the concrete;

[0023] 3) Lifting of the first table form: Align the table form lifting device and lower it to align the table form lifting device with the table form and clamp the table form;

[0024] 4) Table form displacement: The table form lifting device is connected to an external lifting device through the sling, and the table form is lifted and horizontally displaced;

[0025] 5) Stacking of table forms: Stack the table form above another table form;

[0026] 6) Multi-layer stacking, displacement and curing: After stacking the table forms to the designed number of layers, the whole stack of table forms is displaced to the curing station through the table form lifting device for three-dimensional curing;

[0027] 7) Displacement of finished products: After curing for a specified time, the concrete hardens and forms and reaches the form removal strength; at this time, the whole stack of table forms is displaced to the form removal station through the table form lifting device for demolding of the finished products;

[0028] 8) Cycle in sequence.

[0029] In step 3), the table form lifting device is aligned with the alignment angle plate on the table form through the diversion plate at the bottom, the frame is guided to the outside of the table form, and the telescopic fixture extends out and clamps the table form.

[0030] In step 5), the table form lifting device is aligned with the alignment angle plate on the table form through the diversion plate at the bottom, the frame is guided to the outside of the table form, and the telescopic fixture retracts to release the table form.

[0031] The advantages and beneficial effects of the present invention are as follows:

[0032] 1. The series formwork device and production process of the present invention give full play to the respective advantages of the traditional fixed formwork and assembly line processes (fixed formwork: more operation surfaces; assembly line: high efficiency), while abandoning the deficiencies of the two processes (fixed formwork: inflexible and low production capacity; assembly line: large investment and high energy consumption).

[0033] 2. The formwork of the present invention is easy to manufacture. Since the main beam becomes multi-point supported, its cross-section can be greatly reduced, and the original formwork is easy to transform, resulting in a reduced cost.

[0034] 3. The multi-process production of the present invention is compatible: it can be produced in the traditional flat-laying method or in a three-dimensional manner. For three-dimensional production, the factory building area is greatly reduced, making full use of space; three-dimensional zoning curing has low energy consumption and flexible operation; existing stock equipment is easy to transform, winning both social and economic benefits; formwork stacking, centralized vertical and horizontal transportation greatly improve production efficiency; cross-operation is possible; it is convenient for overall relocation and there is no construction waste during factory area migration; the project coverage is wide and the production capacity is large.

[0035] 4. The production method of the present invention is flexible: it can be produced in a nomadic manner at the construction site or in a fixed factory building. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] Figure 1 is a schematic structural diagram of the series formwork device for three-dimensional production of precast concrete slabs according to the present invention;

[0037] Figure 2 is a schematic structural diagram of the formwork in the present invention;

[0038] Figure 3 is Figure 2 a side view of;

[0039] Figure 4 is Figure 2 a top view of;

[0040] Figure 5 is a schematic structural diagram of the formwork body in the present invention;

[0041] Figure 6 is Figure 5 a side view of;

[0042] Figure 7 is a schematic structural diagram of the formwork lifting device in the present invention;

[0043] Figure 8 is Figure 7 a side view of;

[0044] Figure 9 is Figure 7 a top view of;

[0045] Figure 10 This is a schematic structural diagram of the guiding mechanism in the present invention;

[0046] Figure 11 This is a schematic diagram of the mold table hanger hoisting a single mold table in the present invention;

[0047] Figure 12 This is a schematic diagram of the mold table hanger hoisting a series of mold tables in the present invention.

[0048] In the figure: 1 is the mold table body, 101 is the main beam of the mold table, 102 is the secondary beam of the mold table, 103 is the mold table panel, 2 is the support column, 3 is the alignment angle plate, 4 is the mold table hanger, 401 is the suspension cable, 402 is the frame, 403 is the telescopic fixture, 404 is the guiding mechanism, 4041 is the fixing plate, 4042 is the telescopic rod, and 4043 is the flow guiding plate. Detailed implementation manners

[0049] In order to make the objectives, technical solutions, and advantages of the present invention clearer, the present invention will be described in detail below with reference to the accompanying drawings and specific embodiments.

[0050] As Figure 1 shown, a series of mold table devices for three-dimensional production of precast concrete slabs provided by the present invention include: a mold table hanger 4 and multiple groups of mold table components, wherein the mold table components include a mold table 1 and multiple support columns 2, and the multiple support columns 2 are arranged circumferentially at the edge of the mold table 1; multiple groups of mold table components can be stacked for three-dimensional production of precast concrete slabs, and the support columns 2 are used to support the upper-layer mold table components; the mold table hanger 4 is used for hoisting, translating, and stacking the mold table components.

[0051] As Figures 2 - 4 shown, in the embodiment of the present invention, the support column 2 is fixed at a position close to the edge of the mold table 1, and the lower end can be flush with or protrude from the bottom surface of the mold table 1; the upper end of the mold table 1 protrudes from the upper surface of the mold table 1, and the height of the protruding part is greater than the thickness of the precast concrete slab, so as to support the upper-layer mold table components. Preferably, for the stacked multiple groups of mold table components, the support columns 2 in each layer correspond one by one and are connected in series from bottom to top to ensure reliable support.

[0052] Furthermore, the upper end surfaces of the multiple support columns 2 at the edge of the mold table 1 are located on the same horizontal plane to ensure the horizontal position of the upper-layer mold table 1.

[0053] In the embodiment of the present invention, the mold table 1 is of a rectangular structure, and alignment angle plates 3 are provided at the four corners. The alignment angle plates 3 are used for alignment with the mold table hanger 4. Preferably, the upper end surfaces of the alignment angle plates 3 and the support columns 2 are at the same height, which ensures the smooth alignment of the mold table hanger 4 and the alignment angle plates 3, and at the same time does not interfere with the support of the upper-layer mold table 1 by the support columns 2.

[0054] As Figures 5 - 6 shown, in the embodiment of the present invention, the mold table 1 includes a main mold table beam 101, a secondary mold table beam 102 and a mold table panel 103. A plurality of mutually parallel secondary mold table beams 102 are connected between the two main mold table beams 101 to form a mold table support, and the mold table panel 103 is arranged on the mold table support.

[0055] As Figures 7 - 9 shown, in the embodiment of the present invention, the mold table lifting device 4 includes a sling 401, a frame 402 and a telescopic fixture 403. At least one set of oppositely arranged telescopic fixtures 403 is provided inside the frame 402, and the sling 401 is connected to the frame 402 for connecting with an external hoisting device.

[0056] The frame 402 is of a rectangular structure, and guiding mechanisms 404 are provided at the four corners. The guiding mechanisms 404 are used to cooperate with the alignment angle plates 3 at the four corners of the mold table 1 to guide the frame 402 to the outside of the mold table 1. In this embodiment, two sets of oppositely arranged telescopic fixtures 403 are provided on the inner four frames of the frame 402. By extending or retracting the telescopic fixtures 403, clamping or releasing of the mold table 1 is achieved.

[0057] Specifically, the sling 401 is made of a flexible material, and specifically, high-strength steel cables or ropes can be used, and it moves up and down synchronously through a pulley block. The frame 402 is a high-rigidity and high-strength hollow frame structure, the inner frame is slightly larger than the outer contour of the series-connected mold tables, and a hydraulic and electric control system is built-in. The telescopic fixture 403 is placed inside the frame 402 and can be clamped to the outside of the main mold table beam 101 when extended. In the embodiment of the present invention, the telescopic fixture 403 is a prior art and will not be elaborated here.

[0058] As Figure 10 shown, in the embodiment of the present invention, the guiding mechanisms 404 are placed at the four corners of the inner frame of the frame 402, and include a fixing plate 4041, a telescopic rod 4042 and a deflector plate 4043. The fixing plate 4041 is connected to the frame 402; the deflector plate is hinged to the lower end of the fixing plate 4041 and is inclined outward; the telescopic rod 4042 is arranged on the fixing plate 4041, and the telescopic end is connected to the deflector plate 4043. The telescopic rod 4042 drives the deflector plate 4043 to rotate, thereby adjusting the inclination angle of the deflector plate 4043. In the non-working state, the deflector plate 4043 is driven by the telescopic rod 4042 to rotate to the horizontal position and fit under the frame 402, which is convenient for storage.

[0059] When the mold table lifting device 4 approaches the mold table 1, the four deflector plates 4043 are driven by the telescopic rods 4042 to open, roughly align with the alignment angle plates 3 and then close. The sling 401 will swing slightly for position adjustment. After the four corners are aligned, the telescopic fixtures 403 extend to clamp the mold table 1, and the deflector plates 4043 are driven by the telescopic rods 4042 to open for the second time, and the mold table lifting device 4 is in place.

[0060] A method for three-dimensional production of precast concrete slabs, including the tandem mold table device for three-dimensional production of precast concrete slabs as described in any one of the above embodiments, the method comprising the following steps:

[0061] 1) Mold table arrangement: laid-out arrangement;

[0062] 2) Concrete pouring: Support the mold on the arranged mold table 1, bind the steel bars, fix the embedded parts, and then pour the concrete;

[0063] 3) Lifting of the first mold table: Align the mold table lifting tool 4 with the mold table 1 and lower it, so that the mold table lifting tool 4 is aligned with the mold table 1 and clamps the mold table 1;

[0064] Specifically, when the mold table lifting tool 4 is lowered, the mold table lifting tool 4 is aligned with the alignment angle plate 3 on the mold table 1 through the flow guide plate 4043 at the bottom. Because the flow guide plate 4043 is inclined outwards and has a wider opening, it can contain the mold table 1 within it. Adjust the position of the frame 402 through the flow guide plates 4043 at the four corners, and smoothly introduce the frame 402 to the outside of the mold table 1. The two sets of telescopic clamps 403 extend and clamp the mold table 1, or can also clamp the support column 2, as Figure 1 shown;

[0065] 4) Mold table displacement: The mold table lifting tool 4 is connected to an external hoisting device through the sling 401, and the mold table 1 is lifted and horizontally displaced;

[0066] 5) Stacking of mold tables: Stack the mold table 1 above another mold table 1 through the mold table lifting tool 4;

[0067] Specifically, when the mold table lifting tool 4 hoists the mold table 1 above another mold table 1, the mold table lifting tool 4 is aligned with the four alignment angle plates 3 on another mold table 1 through the four flow guide plates 4043 at the bottom, smoothly introduce the frame 402 to the outside of another mold table 1, the upper mold table 1 and the lower mold table 1 complete the docking and positioning, and the telescopic clamp 403 retracts to release the mold table 1, as Figure 11 shown;

[0068] 6) Multi-layer stacking, displacement and curing: After stacking the mold tables 1 to the designed number of layers, the whole stack is displaced to the curing station through the mold table lifting tool 4 for three-dimensional curing, as Figure 12 shown;

[0069] 7) Finished product displacement: After curing for the specified time, the concrete hardens and forms, and reaches the form removal strength; at this time, the whole stack is displaced to the form removal station through the mold table lifting tool 4 for finished product demolding;

[0070] 8) Cycle in sequence.

[0071] In the embodiments of the present invention, the support column 2 is a high-strength load-bearing body, which is connected to the main girder 101 of the formwork. All the weight of the formwork is transmitted layer by layer to the ground foundation through the support column 2. The bottom surface of the support column 2 is flush with or protrudes from the bottom surface of the main girder of the formwork. The upper surface of the support column 2 supports the bottom surface of the support column of the upper layer of the formwork, so that the upper and lower formworks are in a series connection state, that is: the formwork 1 forms a stacked state through the support column 2. The force transmission path of the series-connected formwork is clear and definite: concrete component → formwork panel → secondary beam of the formwork → main beam of the formwork → formwork support column → ground foundation. The support column 2 can also protrude from the lower part of the formwork, so that the top surface of the column is flush with the formwork panel. In this example, the support column protrudes from the upper part of the formwork, which can avoid pouring components or setting up molds at the column, otherwise it will affect the alignment of the upper and lower series-connected formworks. The top end of the support column can be designed in a conical shape. At this time, the bottom surface of the support column needs to be designed with alignment holes to facilitate upper and lower alignment, forming a corner alignment device similar to that of a container.

[0072] In the embodiments of the present invention, the alignment angle plates 3 are embedded at the four corners of the formwork 1 and are flush with the support columns 2 at the four corners. When the upper and lower formworks are stacked and aligned, the flow guide plate 4043 of the lifting device can easily come into contact and alignment with them, so that the four sides of the upper and lower formworks are flush and consistent. The formwork lifting device 4 can also be of single-sided opening or double-sided opening for lateral alignment. The formwork lifting device 4 is connected to the lifting equipment through the lifting cable 401 for operation. Lifting equipment such as gantry crane, bridge crane, gantry crane, mobile gantry, tower crane, etc. can all be used.

[0073] The present invention can realize a production method of precast concrete components with low investment, high output, quick results, easy promotion and low energy consumption, such as the precast of reinforced concrete composite floor slabs and wall panels, which will surely have a huge impact on the popularization and application of prefabricated buildings in our country, and at the same time achieve a double harvest of economic and social benefits.

[0074] The above description is only the implementation mode of the present invention and is not used to limit the protection scope of the present invention. Any modification, equivalent replacement, improvement, expansion, etc. made within the spirit and principle of the present invention are all included in the protection scope of the present invention.

Claims

1. A tandem mold table device for three - dimensional production of precast concrete slabs, characterized in that, it includes: a mold table sling (4) and multiple groups of mold table components; The mold table components include a mold table (1) and multiple support columns (2). The multiple support columns (2) are arranged circumferentially at the edge of the mold table (1); Multiple groups of mold table components can be stacked for three - dimensional production of precast concrete slabs. The support columns (2) are used to support the upper - layer mold table components; The mold table sling (4) is used for hoisting, translation and stacking of the mold table components; The upper end of the support column (2) protrudes above the upper surface of the mold table (1), and the height of the protruding part is greater than the thickness of the precast concrete slab; the upper end faces of the multiple support columns (2) are on the same horizontal plane; The mold table (1) is of a rectangular structure, and positioning angle plates (3) are provided at the four corners. The positioning angle plates (3) are used for positioning with the mold table sling (4); The mold table sling (4) includes a suspension cable (401), a frame (402) and a telescopic fixture (403). At least one set of oppositely - arranged telescopic fixtures (403) is provided inside the frame (402). The suspension cable (401) is connected to the frame (402) and is used for connecting with an external hoisting device; The frame (402) is of a rectangular structure, and guiding mechanisms (404) are provided at the four corners. The guiding mechanisms (404) are used to cooperate with the positioning angle plates (3) at the four corners of the mold table (1) to guide the frame (402) to the outside of the mold table (1); The guiding mechanism (404) includes a fixing plate (4041), a telescopic rod (4042) and a guiding plate (4043). The fixing plate (4041) is connected to the frame (402); the guiding plate is hinged at the lower end of the fixing plate (4041) and is inclined outward; the telescopic rod (4042) is arranged on the fixing plate (4041), and its telescopic end is connected to the guiding plate (4043).

2. The tandem mold table device for three - dimensional production of precast concrete slabs according to claim 1, characterized in that, the upper end face of the positioning angle plate (3) is at the same height as the upper end face of the support column (2).

3. A method for three - dimensional production of precast concrete slabs, characterized in that, it includes the tandem mold table device for three - dimensional production of precast concrete slabs according to any one of claims 1 - 2. The method includes the following steps: 1) Mold table arrangement: flat - laying arrangement; 2) Concrete pouring: Support the mold on the arranged mold table (1), bind the steel bars, fix the embedded parts, and then pour the concrete; 3) Hoisting of the first mold table: Align the mold table sling (4) with the mold table (1) and lower it so that the mold table sling (4) is positioned with the mold table (1) and clamps the mold table (1); 4) Mold table displacement: The mold table sling (4) is connected to an external hoisting device through the suspension cable (401), and the mold table (1) is hoisted and horizontally displaced; 5) Mold table stacking: Stack the mold table (1) above another mold table (1); 6) Multi - layer stacking, displacement and curing: After stacking the mold tables (1) to the designed number of layers, the entire stack is displaced to the curing station through the mold table sling (4) for three - dimensional curing; 7) Finished product shifting: After curing for the specified time, the concrete hardens and forms, and reaches the form removal strength; at this time, the whole stack is shifted to the form removal station through the table lifter (4) for demolding the finished product; 8) Cycle in sequence; In step 3), the table lifter (4) is aligned with the alignment angle plate (3) on the table (1) through the flow guide plate (4043) at the bottom, and the frame (402) is introduced to the outside of the table (1), and the telescopic fixture (403) extends and clamps the table (1).

4. The method according to claim 3, characterized in that In step 5), the table lifter (4) is aligned with the alignment angle plate (3) on the table (1) through the flow guide plate (4043) at the bottom, and the frame (402) is introduced to the outside of the table (1), and the telescopic fixture (403) retracts to release the table (1).

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