Automatic wall-building machine using special wall bricks

Abstract

The present invention relates to the technical field of automation of construction engineering, and discloses an automatic bricklaying machine using special wall bricks. The special wall brick is a rectangular parallelepiped, with a concave top surface, a convex bottom surface, two long side surfaces being planes, and two wide side surfaces being concave. The wide side surface is provided with a grabbing groove of a mechanical claw of the automatic bricklaying machine. The fully automatic bricklaying machine comprises a bricklaying system, a brick supply system, a grouting system, a positioning and ranging system, a power supply system, and a PLC system. The PLC system moves the multi-section mechanical arm and the mechanical claw of the bricklaying system, and with the help of the positioning and ranging system, the mechanical claw extends into the grabbing groove, grabs the special wall bricks from the brick supply system, and then lays them on the wall. The PLC system starts the mortar pump of the grouting system, opens the electric valve at the nozzle outlet, and uses the mortar pipe to pour the mortar in the mortar storage tank into the concave part of the top surface of the special wall brick and the vertical gap at the horizontal connection of the special wall brick. The automatic bricklaying machine of the present invention has a high degree of automation and strong practicality.

Description

Technical Field

[0001] The invention relates to the technical field of construction engineering automation, and in particular to an automatic wall-building machine using special wall bricks. Background Art

[0002] At present, the labor cost of the construction industry in most countries is generally not too high, and the necessity of wall masonry automation is not very obvious. However, due to the high labor intensity of wall masonry, as labor costs increase, the use of automated equipment for wall masonry is bound to be a general trend.

[0003] The phenomenon of falling dust during wall construction has always been a difficulty in wall construction. It not only wastes building materials (water, sand and admixtures, etc.), increases construction costs, but also affects civilized production at the construction site. Summary of the invention

[0004] The technical problem to be solved by the present invention is to provide an automatic wall-building machine for building walls, especially load-bearing walls built with mortar.

[0005] To solve the above problems, the technical solution of the present invention is: an automatic wall-building machine using special wall bricks.

[0006] The special wall bricks used in the automatic wall-building machine of the present invention are rectangular parallelepiped (cube or heterocube). A mortar overflow baffle is provided on each of the two long edges (the edges where the length of the rectangular parallelepiped is located) of the top surface of the special wall brick; the top surface of the special wall brick is concave; the concave shape starts from the bottom inner edge line of the mortar overflow baffle and is gently recessed toward the middle part of the top surface. The bottom surface of the special wall brick is convex, starting from the same position of the bottom inner edge line of the top mortar overflow baffle on the bottom surface of the special wall brick, and is gently protruding toward the middle part of the bottom; the length and shape of the arc of the concave shape of the top surface of the special wall brick and the convex shape of the bottom surface of the special wall brick, as well as the central angle and radius are the same. The two long sides (the sides where the length of the rectangular parallelepiped is located) of the side surface of the special wall brick are planes. The two wide sides (referring to the sides where the width of the cuboid is located) of the side of the special wall brick are concave, and are both recessed toward the inside of the special wall brick; the two vertical edges of one wide side are provided with convex mortar flow blocks; the two corresponding vertical edges of the other wide side are provided with concave mortar flow blocks; the protruding part of the convex mortar flow block matches the concave part of the concave mortar flow block; when two special wall bricks are laid horizontally together, the protruding part of the rear wall brick is wedged into the concave part of the front special wall brick.

[0007] The size of the gap between the upper wall brick (layer) and the lower wall brick (layer), as well as the size of the gap between two wall bricks when laid horizontally together, are determined based on the designed mortar volume.

[0008] Special special wall bricks: The first layer of the wall is built with special special wall bricks (referred to as wall base bricks), and the upper and lower layers of wall bricks are staggered, which also requires special special wall bricks (referred to as staggered bricks). The bottom surface of the base wall brick is a plane; except for the bottom surface being a plane, the other technical features of the base wall brick are the same as the ordinary special wall bricks of the present invention. The length of the staggered brick is shorter than that of the ordinary special wall brick; except for the length being shorter than that of the ordinary special wall brick, the other technical features of the staggered brick are the same as the ordinary special wall bricks of the present invention.

[0009] One or more semi-square (semi-circular or special-shaped) grooves are respectively arranged at the corresponding positions of the two wide sides of the special wall bricks, which are the grooves for the mechanical claws of the automatic wall-building machine to grab the special wall bricks, and the outer dimensions of the grooves are the same. By changing the design of the mechanical claws, it is also possible not to set the gripping grooves of the mechanical claws on the wide sides of the special wall bricks.

[0010] The automatic wall-building machine of the present invention comprises a wall-building system, a brick supply system, a grouting system, a positioning and distance measuring system, a power supply system and a PLC system.

[0011] The automatic bricklayer is a mobile device with 4 support feet on its base. The level of the entire bricklayer can be corrected by automatically or manually adjusting the support feet.

[0012] The wall-building system includes a multi-section robot arm and a mechanical claw. The multi-section robot arm is arranged on the base of the automatic wall-building machine body. The multi-section robot arm is connected to the PLC system for communication, and the start, stop, operation and protection of the multi-section robot arm are executed by the PLC system. The multi-section robot arm can rotate left and right, rise and fall, or extend and retract forward and backward. The front end of the multi-section robot arm is equipped with a mechanical claw, which can rotate itself. The mechanical claw is connected to the PLC system for communication, and the start, stop, operation and protection of the mechanical claw are executed by the PLC system.

[0013] The brick supply system includes multiple brick storage frames. The brick storage frames are movable devices, divided into ordinary brick storage frames and special brick storage frames. Ordinary brick storage frames are suitable for special wall bricks, and special brick storage frames are suitable for special wall bricks. The automatic wall-building machine has reserved positions for ordinary brick storage frames and special brick storage frames, and brick storage frame sensors are also set.

[0014] The same model of ordinary brick storage frames have the same external dimensions, and the same model of ordinary brick storage frames can accommodate the same total number of special wall bricks, the number of layers, and the number of special wall bricks per layer. When special wall bricks are loaded into ordinary brick storage frames, the top surface of the special wall bricks faces upward; for the same model of brick storage frames, the convex mortar baffles or concave mortar baffles of the special wall bricks are placed in the same fixed direction.

[0015] The same model of special brick storage frames have the same external dimensions. Different models of special brick storage frames are used for different special wall bricks. The same model of special brick storage frames can accommodate the same total number of special wall bricks, the number of layers, and the number of special wall bricks per layer. When the special wall bricks are loaded into the special brick storage frame, the top surface of the special wall brick faces upward, and the convex mortar baffle or concave mortar baffle of the special wall brick is placed in the same fixed direction.

[0016] The grouting system includes a mortar supply device, a mortar pipe and a nozzle. The mortar pipe connects the nozzle and the mortar supply device. The mortar supply device is external and may not be connected to the automatic wall-building machine. The mortar pipe is attached to a multi-section mechanical arm, which moves the nozzle to the concave part of the top surface of the special wall brick or the special wall brick and the vertical gap between the front and rear special wall bricks or the special wall bricks. The nozzle is provided with an electric valve. The opening and protection of the nozzle electric valve are executed by the PLC system.

[0017] The slurry supply device includes a slurry tank, an agitator, a mortar pump and a mortar position sensor. The slurry tank is used to store mortar. The agitator is located in the slurry tank and is used to stir the mortar in the slurry tank. The mortar pipe is connected to the slurry tank through the mortar pump. The mortar position sensor is connected to the PLC system for communication, and transmits the quantity information of the mortar in the slurry tank to the PLC system. The mortar pump and the agitator are connected to the PLC system for communication, and the start, stop, operation and protection of the mortar pump and the agitator motor are executed by the PLC system. The mortar of the slurry supply device can be provided by the mixing station or mixed on site by the slurry supply device.

[0018] The positioning and ranging system uses a laser or infrared rangefinder to communicate with the PLC system. The positioning and ranging system can measure the foundation and range of the wall, locate the special wall bricks in the ordinary brick storage frame and the special brick storage frame and their mechanical claw grasping grooves, monitor the quality of wall masonry (whether the special wall bricks are laid correctly, whether the wall surface is flowing, etc.), and monitor the working conditions of the multi-section robotic arm and mechanical claw.

[0019] The power supply system comes from the construction power of the construction site, and you can also use a self-provided power supply. The power supply system provides power for all systems of the automatic wall-building machine. The electrical control and protection of the power supply system are performed by PLC. The automatic wall-building machine is equipped with a manual emergency stop button.

[0020] The PLC system is connected to the wall-building system, the brick supply system, the grouting system, the positioning and ranging system and the power supply system to control and protect the various devices of the automatic wall-building machine of the present invention and obtain information such as the working status of each device. The PLC system is installed with automatic wall-building program software. The PLC system receives the design drawing data of the brick wall by wire or wireless means. The PLC system is provided with an alarm function (including voice and light alarm).

[0021] Control method of automatic bricklaying machine: open the PLC system and input the data of brick wall design drawing.

[0022] Start the positioning and distance measuring system to measure and locate the wall foundation and the entire wall surface.

[0023] According to the design requirements, select special wall bricks and special wall bricks. Push the brick storage frame into the reserved position of the automatic wall machine and trigger the brick storage frame sensor.

[0024] Connect the mortar pipe of the grouting system to the mortar supply device. The PLC system starts the agitator of the mortar supply device, and the mortar position sensor returns the amount of mortar in the mortar storage tank.

[0025] The PLC system controls the multi-section robotic arms and mechanical claws. The mechanical claws extend into the grabbing grooves of the special wall bricks or special wall bricks, firmly clamp the special wall bricks or special wall bricks, grab one or more special wall bricks or special wall bricks from the brick storage frame, and lay them on the wall.

[0026] The PLC system controls the multi-section robotic arm to move the nozzle of the grouting system to the top of the dedicated wall bricks or special wall bricks that have been built. The PLC system starts the mortar pump, opens the nozzle electric valve, and pours the required mortar volume into the concave top surface of the dedicated wall bricks or special wall bricks and the vertical gap at the horizontal connection of the dedicated wall bricks or special wall bricks. After completion, the PLC system closes the mortar pump and the nozzle electric valve.

[0027] Furthermore, each time before pushing the ordinary brick storage frame into the reserved position of the automatic wall-building machine, the ordinary brick storage frame must be filled with special wall bricks. When the special wall bricks in the ordinary brick storage frame are used up, the automatic wall-building machine stops running and emits an audible and visual alarm. After replacing a new ordinary brick storage frame, manually press the "resume" button, and the automatic wall-building machine continues to run.

[0028] After pushing the special brick storage frame into the reserved position of the automatic wall-building machine, the quantity, placement direction and position information of the special wall bricks (wall base bricks, staggered bricks, etc.) in the special brick storage frame need to be input into the PLC system.

[0029] When the mortar in the mortar storage tank drops to the designed lowest position, the automatic wall-building machine stops running and sounds an audible and visual alarm. After the mortar is added to the mortar storage tank, the "resume" button is manually pressed and the automatic wall-building machine continues to run.

[0030] At the positions of tie bars, embedded parts and lintels, the automatic wall-building machine stops running and sounds an audible and visual alarm. After the on-site personnel complete the work of tie bars, embedded parts and lintels, they manually press the "resume" button and the automatic wall-building machine continues to run.

[0031] During operation, if an unexpected emergency occurs, you can press the manual emergency stop button. After the accident is handled, press the "resume" button manually and the automatic wall-building machine will continue to run.

[0032] During operation, the PLC system monitors the number of special wall bricks remaining in the brick storage frame, the amount of mortar in the mortar storage tank, the quality of wall construction (whether the special wall bricks are laid in place, or whether the wall surface is slurry flowing), and the operation of each device. If an abnormality is found, the automatic wall-building machine stops running and sounds an audible and visual alarm. After the on-site personnel have finished handling, they manually press the "resume" button and the automatic wall-building machine continues to run.

[0033] Furthermore, brick wall design needs to consider the size of professional wall bricks (especially the design of wall height).

[0034] Furthermore, based on the effects of the mortar flow baffle and the mortar overflow baffle (the effect of the mortar flow baffle is to prevent the mortar in the vertical gap at the horizontal connection between the front and rear wall bricks from flowing out along the vertical edges of the wide side surfaces of the wall bricks. The effect of the mortar overflow baffle is to prevent the mortar on the concave top surface of the lower wall bricks from overflowing when the upper and lower wall bricks are laid together), the use of the special wall bricks of the present invention in artificial wall construction can completely avoid the dust falling phenomenon caused by the use of traditional wall bricks on construction sites. When the special wall bricks of the present invention are used in artificial wall construction, there is no need to process the gripping grooves of the mechanical claws when producing the special wall bricks.

[0035] In summary, the present invention has the following beneficial effects:

[0036] 1. Technical evaluation of the present invention

[0037] 1. Due to the design of professional wall tiles, the technical solution of the present invention is novel.

[0038] 2. The technical solution of the present invention is feasible, reliable and practical.

[0039] 2. Beneficial Effects of the Invention

[0040] 1. The present invention can provide bricks that meet the requirements of the process flow of an automatic wall-building machine.

[0041] 2. The present invention can well realize the automation of mechanical wall construction and can greatly improve work efficiency.

[0042] 3. The present invention can not only reduce construction costs, but also prevent dust from falling during wall construction, which is beneficial to civilized production at the construction site. The economic and social benefits of the present invention are significant. BRIEF DESCRIPTION OF THE DRAWINGS

[0043] Figure 1 It is a top view of the special wall brick of the present invention, Figure 2It is a side view (wide side) of the special wall brick of the present invention.

[0044] Description of codes in the figure:

[0045] 1: Concave top surface of wall brick; 2: Sand overflow block; 3: Mechanical claw grab groove; 4: Wide side surface of wall brick; 5: Convex flow block; 6: Concave flow block; 7: Convex bottom surface of wall brick; 8: Inner edge of bottom of sand overflow block DETAILED DESCRIPTION

[0046] The present invention is implemented in the following manner:

[0047] 1. Move the automatic bricklaying machine to a suitable position close to the brick wall, adjust the supporting feet of the automatic bricklaying machine, and calibrate the level of the automatic bricklaying machine;

[0048] 2. Open the PLC system and input the design drawing data of the brick wall;

[0049] 3. Turn on the power supply;

[0050] 4. Start the positioning and ranging system to measure and locate the wall foundation and the entire wall surface;

[0051] 5. According to the design requirements, push the ordinary brick storage frame into the reserved position of the automatic wall-building machine in the set direction and trigger the brick storage frame sensor;

[0052] 6. According to the design requirements, push the special brick storage frame into the reserved position of the automatic bricklaying machine in the set direction and trigger the brick storage frame sensor;

[0053] 7. Input the quantity, position and placement direction information of special wall bricks (wall base bricks, staggered bricks, etc.) in the special brick storage frame into the PLC system;

[0054] 8. Connect the mortar pipe of the grouting system to the slurry supply device;

[0055] 9. The PLC system starts the agitator of the slurry supply device, and the mortar position sensor sends back the amount of mortar in the slurry storage tank;

[0056] 10. Check the fluidity (sinking degree) of the mortar to see if it meets the design requirements for special wall tiles;

[0057] 11. The PLC system moves the nozzle of the grouting system above the wall foundation by controlling the multi-section robotic arm;

[0058] 12. The PLC system starts the mortar pump, opens the nozzle electric valve, controls the output of the mortar pump and the movement speed of the nozzle, and pours the required mortar volume on the wall foundation. After completion, the PLC system closes the mortar pump and the nozzle electric valve;

[0059] 13. The PLC system controls the multi-section robotic arms and mechanical claws. The mechanical claws extend into the grabbing grooves of the wall base bricks, firmly clamp the wall base bricks, grab one or more wall base bricks from the special brick storage box, and lay them on the wall foundation. The first layer of wall masonry is completed;

[0060] 14. The PLC system controls the multi-section robotic arm to move the nozzle of the grouting system to the top of the first layer of the wall that has been built;

[0061] 15. The PLC system starts the mortar pump, opens the nozzle electric valve, controls the output of the mortar pump and the moving speed of the nozzle, and pours the required mortar volume into the vertical gap between the concave top surface of the wall base brick and the horizontal connection of the wall base brick. After completion, the PLC system closes the mortar pump and the nozzle electric valve;

[0062] 16. The PLC system controls the multi-section robot arm and robot claw. The robot claw first extends into the grabbing groove of the staggered brick, firmly clamps the staggered brick, grabs a staggered brick from the special brick storage frame, and lays it at the beginning of the second layer of the wall; then the robot claw extends into the grabbing groove of the special wall brick, firmly clamps the special wall brick, grabs one or more special wall bricks from the ordinary brick storage frame, and lays them on the first layer of the wall in sequence. The second layer of wall masonry is completed;

[0063] 17. The PLC system controls the multi-section robotic arm to move the nozzle of the grouting system to the top of the second layer of the wall that has been built;

[0064] 18. The PLC system starts the mortar pump, opens the nozzle electric valve, controls the output of the mortar pump and the moving speed of the nozzle, and pours the required mortar volume into the concave top surface of the staggered bricks and special wall bricks and the vertical gaps at the horizontal connection of the staggered bricks and special wall bricks. After completion, the PLC system closes the mortar pump and the nozzle electric valve;

[0065] 19. Repeat this cycle to complete the construction of the entire wall.

[0066] The above describes the basic principles and main features of the present invention. The description in the specification only illustrates the principles of the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, and these changes and improvements all fall within the scope of the present invention claimed for protection.

Claims

1. An automatic wall-building machine using special wall bricks, characterized in that: The automatic wall-building machine is a movable device, including a wall-building system, a brick supply system, a grouting system, a positioning and distance measurement system, a power supply system and a PLC system; The wall-building system of the automatic wall-building machine includes a multi-section mechanical arm and a mechanical claw; the multi-section mechanical arm is arranged on the base of the automatic wall-building machine body; the multi-section mechanical arm can rotate left and right, rise and fall, or extend and retract forward and backward; the front end of the multi-section mechanical arm is provided with a mechanical claw, and the mechanical claw itself can rotate; the mechanical claw is connected to the PLC system for communication, and the start, stop, operation and protection of the mechanical claw are executed by the PLC system; The positioning and distance measuring system of the automatic wall-building machine uses a laser or infrared distance meter to communicate with the PLC system; the positioning and distance measuring system measures the foundation and range of the wall, locates the special wall bricks and special wall bricks in the ordinary brick storage frame and the special brick storage frame and the gripping grooves of the mechanical claws, monitors the quality of wall masonry, and monitors the working conditions of the multi-section mechanical arms and mechanical claws; The power supply system provides power for all systems of the automatic bricklaying machine; the electrical control and protection of the power supply system are performed by PLC; The PLC system of the automatic bricklaying machine communicates with the bricklaying system, brick supply system, grouting system, positioning and distance measurement system and power supply system, and has the functions of controlling and protecting each device of the automatic bricklaying machine and obtaining the working status information of each device; the PLC system is installed with automatic bricklaying program software; the PLC system receives the design drawing data of the brick wall through wired or wireless means; the PLC system is equipped with voice and light alarm functions; The special wall bricks used by the automatic wall-building machine are rectangular, cube or heterocubic; a mortar overflow barrier is provided on each of the two long edges on the top surface of the special wall brick; the top surface of the special wall brick is concave, and is concave toward the inside of the special wall brick; the bottom surface of the special wall brick is convex, and is convex toward the outside of the special wall brick; the concave shape of the top surface of the special wall brick is similar to the convex shape of the bottom surface of the special wall brick; the two long sides of the side surface of the special wall brick are flat; the two wide sides of the side surface of the special wall brick are concave, and are both concave toward the inside of the special wall brick. ; The two vertical edges of one wide side are provided with convex mortar flow blocks; the two corresponding vertical edges of the other wide side are provided with concave mortar flow blocks; the protruding part of the convex mortar flow block matches the concave part of the concave mortar flow block, and when two special wall bricks are laid horizontally, the protruding part of the rear wall brick can be wedged into the concave part of the front special wall brick; the two wide side surfaces of the special wall brick are each provided with one or more semi-square or semi-circular or special-shaped grooves, which are the grooves for the mechanical claws of the automatic wall-building machine to grab the special wall bricks.

2. An automatic wall-building machine using special wall bricks as claimed in claim 1, characterized in that: The brick supply system of the automatic wall-building machine includes multiple brick storage frames. The brick storage frames are movable devices, which are divided into ordinary brick storage frames and special brick storage frames. The ordinary brick storage frames are suitable for special wall bricks, and the special brick storage frames are suitable for special wall bricks. The automatic wall-building machine has reserved positions for ordinary brick storage frames and special brick storage frames, and is equipped with brick storage frame sensors. Ordinary brick storage frames of the same model have the same overall dimensions, and the total number of special wall bricks, the number of layers, and the number of special wall bricks per layer are the same. Different special wall bricks use different models of special brick storage frames. Special brick storage frames of the same model have the same overall dimensions, and the total number of special wall bricks, the number of layers, and the number of special wall bricks per layer are the same.

3. An automatic wall-building machine using special wall bricks as claimed in claim 1 or 2, characterized in that: The grouting system of the automatic wall-building machine includes a slurry supply device, a mortar pipe and a nozzle; the slurry supply device includes a slurry tank, a stirrer, a mortar pump and a mortar position sensor; the slurry tank is used to store mortar; the stirrer is located in the slurry tank and is used to stir the mortar in the slurry tank; the mortar pipe is connected to the slurry tank at one end through the mortar pump and is connected to the nozzle at the other end; the PLC system is communicated with the mortar position sensor to obtain the quantity information of the mortar in the slurry tank; the mortar pump and the stirrer are communicated with the PLC system, and the start, stop, operation and protection of the mortar pump and stirrer motors are executed by the PLC system; the mortar pipe is attached to a multi-section robotic arm, and the multi-section robotic arm moves the nozzle to the top of the concave surface of the special wall brick or the special wall brick and above the vertical gap at the connection of the special wall brick or the special wall brick; the nozzle is provided with an electric valve, and the opening and protection of the nozzle electric valve are executed by the PLC system.

4. A control method for an automatic wall-building machine using special wall bricks as claimed in claim 1, 2 or 3, characterized in that: The automatic bricklaying machine is in place; the PLC system is turned on and the data of the brick wall design drawings are input; the automatic bricklaying machine is powered on; the positioning and distance measuring system is started to measure and locate the wall foundation and the entire wall surface; special wall bricks and special wall bricks are selected according to the design requirements; the brick storage frame is pushed into the reserved position of the automatic bricklaying machine and the brick storage frame sensor is triggered; the number, placement direction and position information of the special wall bricks in the special brick storage frame are input into the PLC system; the mortar pipe of the grouting system is connected to the mortar supply device; the PLC system starts the agitator of the mortar supply device, and the mortar position sensor sends back the amount of mortar in the mortar storage tank; the PLC The system controls the mechanical claw, which extends into the grabbing groove of the special wall brick or the special wall brick, clamps the special wall brick or the special wall brick, grabs one or more special wall bricks or the special wall brick from the brick storage frame, and lays them on the wall; the PLC system controls the multi-section mechanical arm to move the nozzle of the grouting system to the top of the completed wall; the PLC system starts the mortar pump, opens the nozzle electric valve, and pours the required mortar amount into the concave top surface of the special wall brick or the special wall brick and the vertical gap at the horizontal connection of the special wall brick or the special wall brick; after completion, the PLC system closes the mortar pump and the nozzle electric valve.

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