A concrete prefabricated square pile manufacturing system and manufacturing process

Abstract

The present invention discloses a concrete prefabricated square pile manufacturing system and manufacturing process, the manufacturing system includes a crane and a work area located in a production workshop, a longitudinal pile outlet channel is provided in the middle area of ​​the work area, the crane includes a first crane and a second crane, a first steel cage processing area, a first steel cage stacking area, a first fixed mold platform area and a first pile storage area are provided in sequence in the area from one end of the work area in the transverse direction to the pile outlet channel, and a second steel cage processing area, a second steel cage stacking area, a second fixed mold platform area and a second pile storage area are provided in sequence in the area from the other end of the work area in the transverse direction to the pile outlet channel; a conveyor belt is provided on one side of the work area, and the conveyor belt is provided with a material distribution mechanism for distributing materials to a material distribution vehicle. The manufacturing system can operate efficiently, energy-saving, safely and time-saving, and can reduce the labor intensity and manufacturing cost of workers while ensuring product quality.

Description

Technical Field

[0001] The present invention relates to the technical field of precast concrete piles, and in particular to a manufacturing system for producing precast concrete square piles. The present invention also relates to a manufacturing method for producing precast concrete piles. Background Art

[0002] Precast piles used in the construction field mainly include two types of precast concrete piles and steel piles. Precast concrete piles are concrete piles with steel cages inside that are prefabricated in factories. They are characterized by being able to withstand large loads, being strong and durable, and having a fast construction speed.

[0003] Precast concrete piles are mostly processed and manufactured in the working area of ​​the factory. The production process usually includes preparing concrete materials, preparing steel cages, placing steel cages into molds, tensioning, injecting concrete materials into molds, steam curing, demoulding, stacking, etc. Since the entire production process is carried out in a factory with limited area and space, it is particularly important to reasonably arrange and control each production process.

[0004] Moreover, once the manufacturing system is put into use, it will be very difficult and costly to change it. Therefore, the scientific and reasonable design of the concrete precast pile manufacturing system and manufacturing process is the key scientific research direction of each manufacturer when building or upgrading a factory and before formal production.

[0005] For example, CN109676783A discloses a fixed formwork prestressed concrete square pile production line and production process, which is equipped with a mixing area, a distribution area, a cage weaving area and a molding area. The mixing area is provided with a cementitious material silo and a mixing tower. The distribution area is provided with a secondary material distribution hopper, a distribution hopper and a distribution vehicle. The cage weaving area is provided with a cage weaving machine and a steel cage stacking area. The molding area is provided with a tensioning machine, a tensioning machine track and a fixed formwork. The fixed formwork is provided with a tensioning longitudinal beam and a tensioning cross beam. A plurality of steam pipes are evenly arranged at the bottom of the fixed formwork, and the steam pipes are connected to the steam main pipe.

[0006] The mold of this production line is not easy to deform, which solves the technical problems of large mold size, back and forth movement affecting product quality, large steam consumption and high cost when entering the steam curing tank for curing. However, since it uses a crane to lift the material hopper for material distribution, and the location design of each processing area is not very reasonable, it does not have a very obvious advantage in production efficiency and manufacturing cost. Summary of the invention

[0007] The object of the present invention is to provide a concrete prefabricated square pile manufacturing system, which can operate efficiently, energy-saving, safely and time-saving, and can reduce the labor intensity of workers and manufacturing costs while ensuring product quality.

[0008] Another object of the present invention is to provide a process for manufacturing prefabricated concrete square piles.

[0009] To achieve the above-mentioned purpose, the present invention provides a concrete prefabricated square pile manufacturing system, comprising a crane and a work area located in a production workshop, a longitudinal pile-out channel being provided in the middle area of ​​the work area, the crane comprising a first crane located on one side of the pile-out channel and a second crane located on the other side of the pile-out channel, a first steel cage processing area, a first steel cage stacking area, a first fixed mold platform area and a first pile storage area being provided in sequence in an area from one end of the work area in the transverse direction to the pile-out channel, and a second steel cage processing area, a second steel cage stacking area, a second fixed mold platform area and a second pile storage area being provided in sequence in an area from the other end of the work area in the transverse direction to the pile-out channel. A pile storage area; a conveyor belt that circulates during operation to convey concrete materials is provided on one side of the working area, and the feeding line of the conveyor belt corresponds to the first fixed formwork area and the second fixed formwork area; the first fixed formwork area and the second fixed formwork area are respectively provided with a plurality of fixed formwork platforms, and a material distribution vehicle that can reciprocate along the length direction of the fixed formwork platform is provided above each of the fixed formwork platforms; the conveyor belt is provided with a material distribution mechanism, and the material distribution mechanism is used to transfer the concrete material on the conveyor belt to the material distribution vehicle of each of the fixed formwork platforms; a first tensioning operation area corresponding to the first fixed formwork area and a second tensioning operation area corresponding to the second fixed formwork area are provided on the other side of the working area.

[0010] Preferably, two material distributing vehicles are respectively arranged above each of the fixed mold platforms; when distributing materials, the two material distributing vehicles of each of the fixed mold platforms respectively run from both ends in the length direction to the middle after receiving the materials, and distributing materials during the operation, or, when distributing materials, the two material distributing vehicles respectively run in the same direction from one end and the middle part of the fixed mold platform to the other end after receiving the materials, and distributing materials during the operation.

[0011] Preferably, the fabric trolley is erected above the fixed mold platform through a transverse support beam mechanism, the fixed mold platform is provided with longitudinal tracks on both sides at the top, and the transverse support beam mechanism is configured to be able to run on the longitudinal tracks along the length direction of the fixed mold platform; the transverse support beam mechanism is provided with a transverse track, and the fabric trolley is configured to be able to run on the transverse track along the width direction of the fixed mold platform.

[0012] Preferably, the material placing vehicle is provided with a vibrating mechanism to vibrate the concrete material injected into the mold cavity; and a finishing mechanism is provided at the rear of the vibrating mechanism to finish the upper surface of the concrete material after vibration.

[0013] Preferably, the material dividing mechanism includes a machine body and a circulating material dividing belt and a material dividing chute provided on the machine body, the circulating material dividing belt is obliquely arranged on the machine body, and its transport surface is arranged at an angle to the transport surface of the conveyor belt; the circulating material dividing belt has a working state and a non-working state, in the working state, its oblique downward end descends to the transport surface of the conveyor belt to transfer the concrete material on the conveyor belt to its own transport surface, in the non-working state, its oblique downward end is lifted to a height that is detached from the transport surface of the conveyor belt, and no concrete material is transported from the transport surface of the conveyor belt; the oblique upward end of the circulating material dividing belt corresponds to the feed port at the upper end of the material dividing chute, and the lower end of the material dividing chute extends obliquely downward to the bottom of one side of the conveyor belt and is provided with a discharge port.

[0014] Preferably, the conveyor belt is provided with a material dividing slide rail extending along its feeding direction, and the material dividing mechanism is reciprocatingly mounted on the material dividing slide rail.

[0015] Preferably, the fixed formworks of the first fixed formwork area and the second fixed formwork area are provided with at least one set of tensioning connectors in each mold cavity thereof, and the tensioning connectors divide the mold cavity in which they are located into at least two sub-mold cavities, and each of the sub-mold cavities is used to accommodate a steel cage that is located on the same axis and can be tensioned simultaneously after being placed therein, so as to produce at least two prefabricated concrete square piles using the same mold cavity.

[0016] Preferably, the first steel cage stacking area and the second steel cage stacking area are respectively divided into two stacking partitions along the length direction of the stacked steel cages, one of which is close to the conveyor belt, and the other of which is close to the tensioning operation area; the first pile storage area and the second pile storage area are respectively divided into two pile storage partitions along the length direction of the stored prefabricated concrete square piles, one of which is close to the conveyor belt, and the other of which is close to the tensioning operation area.

[0017] Preferably, each of the stacking partitions is provided with a fixed plate storage area at one end close to the conveyor belt, and a tensioning plate storage area at one end close to the tensioning operation area; each of the pile storage partitions is provided with a fixed plate collection area at one end close to the conveyor belt, and a tensioning plate collection area at one end close to the tensioning operation area.

[0018] Preferably, one stacking partition of the first steel cage stacking area corresponds to the cage unloading area of ​​the first steel cage processing area, and a first steel cage conveyor is provided between the two stacking partitions and the first fixed mold area to transport the steel cage from the stacking partition corresponding to the cage unloading area to another stacking partition; one stacking partition of the second steel cage stacking area corresponds to the cage unloading area of ​​the second steel cage processing area, and a second steel cage conveyor is provided between the two stacking partitions and the second fixed mold area to transport the steel cage from the stacking partition corresponding to the cage unloading area to another stacking partition.

[0019] Preferably, the device further comprises a concrete mixing mechanism which is arranged on the conveyor belt to supply materials to the conveyor belt.

[0020] To achieve the above another object, the present invention provides a process for manufacturing precast concrete square piles, which uses the above precast concrete square pile manufacturing system to produce precast concrete square piles, including:

[0021] Mixing and preparing concrete materials according to a formula, and supplying the prepared concrete materials to the conveyor belt, so that the conveyor belt transports the concrete materials along a conveying direction;

[0022] In the first steel cage processing area and the second steel cage processing area, a cage weaving machine is used to make steel cages, and the made steel cages are stored in the first steel cage stacking area and the second steel cage stacking area respectively;

[0023] The first crane and the second crane are used to hoist the steel cage into the mold cavity of the fixed mold platform of the first fixed mold platform area and the second fixed mold platform area, and the two ends of the steel cage are respectively connected to the tensioning mechanism;

[0024] In the first tensioning operation area and the second tensioning operation area, the steel cage is tensioned along the length direction of the steel cage by a tensioning machine, so that the steel cage has prestress;

[0025] Control the placing car to run to the material receiving position, and the material distribution mechanism distributes the concrete material on the conveyor belt to the placing car;

[0026] The placing vehicle runs along the length direction of the fixed formwork platform and injects concrete material into the mold cavity of the fixed formwork platform during the running process;

[0027] After resting, steam is introduced into the fixed mold platform for steam curing;

[0028] The prefabricated square concrete piles in the mold cavity are lifted by the first crane and the second crane to demould, and the prefabricated square concrete piles are stacked in the first pile storage area and the second pile storage area;

[0029] Transport the prefabricated concrete square piles from the pile outlet channel to outside the site.

[0030] Further, including:

[0031] For the same fixed formwork, when distributing materials, two distributing vehicles are controlled to run to the material receiving position, and the material distribution mechanism distributes the concrete materials on the conveyor belt to the two distributing vehicles in sequence. The distributing vehicle that receives the materials first runs to the end of the fixed formwork away from the conveyor belt after receiving the materials, and does not distribute the materials during the process of running to the end of the fixed formwork away from the conveyor belt. After the other distributing vehicle that receives the materials later receives the materials, the two distributing vehicles respectively run from the two ends of the fixed formwork to the middle in opposite directions, and distribute the materials during the operation;

[0032] Alternatively, for the same fixed formwork, when distributing materials, two distribution vehicles are controlled to run to the material receiving position, and the material distribution mechanism distributes the concrete materials on the conveyor belt to the two distribution vehicles in turn. The distribution vehicle that receives the materials first runs to the middle of the fixed formwork after receiving the materials, and does not distribute the materials during the process of running to the middle of the fixed formwork. After the other distribution vehicle that receives the materials later receives the materials, the two distribution vehicles respectively run in the same direction from one end and the middle of the fixed formwork to the other end, and distribute the materials during the operation.

[0033] Furthermore, the method includes: vibrating the concrete material injected into the mold cavity while spreading the material, and plastering the upper surface of the concrete material after the vibration.

[0034] The concrete prefabricated square pile manufacturing system provided by the present invention divides the working area in the production workshop into two parts with the longitudinal pile outlet channel roughly located in the middle area as the center line, each part is provided with a reinforcement cage processing area, a reinforcement cage stacking area, a fixed mold platform area and a pile storage area, in these two areas, concrete prefabricated square piles can be produced relatively independently at the same time, the first crane and the second crane can operate relatively independently without affecting each other, reducing the waiting time of the cranes, and the two areas can share the same longitudinal pile outlet channel to output the concrete prefabricated square piles to the outside, each production area is reasonably arranged, the process is smooth, and the production efficiency can be significantly improved while saving area space.

[0035] In addition, the present invention also uses a conveyor belt to transport concrete materials, and distributes the concrete materials on the conveyor belt to the distribution vehicles of each fixed formwork platform through a material distribution mechanism, and then the distribution vehicle distributes the materials on the fixed formwork platform. There is no need to use a crane to lift the distribution vehicle for distribution, which reduces the operating frequency and distance of the crane, is beneficial to reduce energy consumption, and avoids the safety hazards caused by too frequent lifting operations. The time required for the distribution vehicle from receiving materials to completing distribution is relatively short, and the transportation distance and transportation time of the steel cage, tensioning components and prefabricated concrete square piles are also relatively short, which can speed up the production rhythm, improve production capacity, and reduce the labor intensity and manufacturing cost of workers while ensuring product quality.

[0036] The precast concrete square pile manufacturing process provided by the present invention applies the above-mentioned precast concrete square pile manufacturing system to produce precast concrete square piles. Since the above-mentioned precast concrete square pile manufacturing system has the above-mentioned technical effects, the precast concrete square pile manufacturing process should also have corresponding technical effects. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1 A plan layout diagram of a prefabricated concrete square pile manufacturing system disclosed in an embodiment of the present invention;

[0038] Figure 2 for Figure 1 A partial enlarged view of the middle A area;

[0039] Figure 3 for Figure 1 A partial enlarged view of the B area;

[0040] Figure 4 for Figure 1 The structural schematic diagram of the conveyor belt and material distribution mechanism of the concrete prefabricated square pile manufacturing system shown;

[0041] Figure 5 for Figure 4 The structural schematic diagram of the material distribution mechanism is shown in;

[0042] Figure 6 It is a structural schematic diagram of the fabric car;

[0043] Figure 7 It is a schematic diagram of the structure in which the material placing vehicle frame is arranged above the fixed die table;

[0044] Figure 8 It is a structural schematic diagram of another embodiment in which a material distributing vehicle frame is arranged above a fixed mold platform.

[0045] In the figure:

[0046] 1. First steel cage processing area 2. First steel cage stacking area 3. First fixed mold area 4. First pile storage area 5. Second steel cage processing area 6. Second steel cage stacking area 7. Second fixed mold area 8. Second pile storage area 9. Fixed mold 10. Pile channel 11. Tensioning longitudinal beam 12. Tensioning cross beam 13. Square pile mold 14. Tensioning wire rod 15. Steam pipeline 16. Steaming cover 17. Conveyor belt 18. Concrete mixing plant 19. Material distribution vehicle 20. Material distribution mechanism 201. Machine body 202. Material distribution chute 203. Roller 21. First tensioning operation area 22. Second tensioning operation area 23. Tensioning machine 24. First traveling crane 25. Second traveling crane 26. Tensioning connector 27. First steel cage conveyor 28. Second steel cage conveyor 29. Fixed plate storage area 30. Tensioning plate storage area 31. Fixed plate 32. Tensioning plate 33. Fixed plate collection area 34. Tensioning plate collection area 35. Material distribution slide 36. Transverse support beam mechanism 37. Longitudinal track 38. Transverse track 39. Vibration mechanism 40. Plastering mechanism DETAILED DESCRIPTION

[0047] In order to enable those skilled in the art to better understand the solution of the present invention, the present invention is further described in detail below in conjunction with the accompanying drawings and specific implementation methods.

[0048] In this article, the terms "upper, lower, inside, outside" and the like are established based on the positional relationships shown in the drawings. The corresponding positional relationships may also change depending on the drawings, and therefore cannot be understood as absolute limitations on the scope of protection; moreover, relational terms such as "first" and "second" and the like are merely used to distinguish one component from another with the same name, and do not necessarily require or imply any actual relationship or order between these components.

[0049] Please refer to Figure 1 , Figure 1 The present invention is a plan layout diagram of a system for manufacturing prefabricated concrete square piles disclosed in an embodiment of the present invention.

[0050] As shown in the figure, in a specific embodiment, the concrete precast square pile manufacturing system provided by the present invention is mainly composed of a crane and a work area located in a production workshop. The entire production workshop is generally rectangular in a top view, with a certain length and width, and the size can be determined according to the specific plan. Inside the production workshop, a crane for performing various lifting operations is erected in a horizontal manner in the upper area, and the work area based on the ground is divided into multiple work areas. The equipment in each work area respectively performs one or several links of the entire production process, and all equipment operates in an overall coordinated manner according to the set process to achieve orderly production of concrete precast square piles.

[0051] A longitudinal pile-out channel 10 is provided in the middle area of ​​the working area, and a first steel cage processing area 1, a first steel cage stacking area 2, a first fixed formwork area 3 and a first pile storage area 4 are provided in sequence in the area from one end of the working area in the transverse direction (i.e. the left end as shown in the figure) to the pile-out channel 10, and a second steel cage processing area 5, a second steel cage stacking area 6, a second fixed formwork area 7 and a second pile storage area 8 are provided in sequence in the area from the other end of the working area in the transverse direction (i.e. the right end as shown in the figure) to the pile-out channel 10.

[0052] Since the entire working area is in a bilaterally symmetrical layout with the longitudinal pile-exiting channel 10 as the center line, in order to save space, the following mainly introduces the working area on the left side of the pile-exiting channel 10 in detail, and the working area on the right side of the pile-exiting channel 10 is roughly the same in layout. The two do not need to be completely symmetrical. For example, the lengths and numbers of the fixed mold platforms can be inconsistent, etc. This non-completely symmetrical structure should not constitute an obstacle to an accurate understanding of the present invention.

[0053] The steel cage is mainly composed of main bars distributed in a rectangular array and spiral bars wrapped and welded on the outer periphery of the main bars. Both ends of the main bars are usually provided with piers and sleeve nuts that are locked in the opposite direction to the piers. Therefore, the first steel cage processing area 1 can be subdivided into a main bar processing area (including straightening, truncation, nut installation, piers, etc.), a spiral bar processing area, and a cage weaving area where the main bars and spiral bars are welded into a steel cage using a cage weaving machine. The steel cages manufactured in the first steel cage processing area 1 can be unloaded to the first steel cage stacking area 2 for standby use, so as to store a sufficient number of steel cages to meet the needs of subsequent processes for steel cages.

[0054] The right side of the first steel cage stacking area 2 is the first fixed mold area 3, and the first fixed mold area 3 is provided with a plurality of fixed molds 9 (five in the figure), each fixed mold 9 is respectively provided with a tensioning longitudinal beam 11, a tensioning cross beam 12, and a square pile mold 13 located inside, and the tensioning cross beams 12 at both ends are respectively provided with a tensioning mechanism including a tensioning wire rod 14. When the steel cage is tensioned, the tensioning longitudinal beam 11 and the tensioning cross beam 12 bear the tensioning force, and the square pile mold 13 does not bear the tensioning force, so the square pile mold 13 can be made of thinner steel. The square pile mold 13 is mainly composed of a bottom mold and a plurality of U-shaped mold cavities above the bottom mold with openings facing upward, so that a plurality of square piles can be produced at one time. The tensioning longitudinal beams 11 and the tensioning cross beams 12 form a long strip space which is closed in the circumferential direction, and a steam pipe 15 is provided at the bottom thereof. The steam pipe 15 is connected to the steam main pipe, and steam can be introduced into the fixed mold platform 9 through the steam pipe 15 for steam curing. When steam curing is performed, a steaming cover 16 can be provided on the top of the fixed mold platform 9 or covered with canvas to prevent steam leakage and ensure the steaming effect.

[0055] The right side of the first fixed formwork area 3 is the first pile storage area 4. Since the demoulding precast concrete piles may not be transported out in time at the first time, they can be temporarily stored in the first pile storage area 4 to provide enough buffer time.

[0056] A conveyor belt 17 is provided on one side of the working area (the upper side as shown in the figure). The conveyor belt 17 is arranged horizontally in a direction perpendicular to the fixed formwork platform 9. It circulates continuously during operation to continuously convey concrete materials to the positions of the first fixed formwork platform area 3 and the second fixed formwork platform area 7 so as to supply materials to the first fixed formwork platform area 3 and the second fixed formwork platform area 7. That is to say, the length of the conveyor belt 17 should cover the first fixed formwork platform area 3 and the second fixed formwork platform area 7 in the horizontal direction. The concrete mixing plant 18 is located at one end of the conveyor belt 17 (the right end as shown in the figure), which is used to mix and prepare concrete materials according to the formula and supply the mixed concrete materials to the conveyor belt 17.

[0057] Taking the first fixed formwork area 3 as an example, a material distribution vehicle 19 capable of reciprocating along the length direction thereof is provided above each fixed formwork platform 9 of the first fixed formwork area 3, and a material distribution mechanism 20 is provided at a position corresponding to each fixed formwork platform 9 of the conveyor belt 17. The material distribution mechanism 20 can transfer the concrete material on the conveyor belt 17 to the material distribution vehicle 19 of each fixed formwork platform 9, and then the material distribution vehicle 19 runs along the length direction of the fixed formwork platform 9, and distributes the material during the running process to inject the concrete material into the mold cavity of the fixed formwork platform 9.

[0058] The other side of the working area (the lower side in the figure) is provided with a first tensioning operation area 21 corresponding to the first fixed die table area 3 and a second tensioning operation area 22 corresponding to the second fixed die table area 7. The end of each die cavity of the fixed die table 9 is provided with a tensioning mechanism including a tensioning screw 14 (see Figure 2 ) is used to tension the steel cage placed in the fixed formwork platform 9 through a tensioning machine 23, so that the steel cage has prestress.

[0059] Since the steel bar cage weaving machine, the laying machine 23, the concrete mixing plant 18 and other equipment can be realized by using existing technologies, these equipments will not be described in detail in this article.

[0060] The "in sequence" mentioned above mainly refers to the general arrangement order of the first steel cage processing area 1, the first steel cage stacking area 2, the first fixed mold platform area 3 and the first pile storage area 4, and does not exclude that other functional areas may be set between these areas.

[0061] The cranes include a first crane 24 located on one side of the pile-exiting channel and a second crane 25 located on the other side of the pile-exiting channel. Two first cranes 24 can be set, and their operating areas cover the first steel cage processing area 1, the first steel cage stacking area 2, the first fixed mold platform area 3 and the first pile storage area 4 to meet the needs of actual production. For example, when one of the first cranes 24 performs the task of lifting the steel cage and placing it into the fixed mold platform 9 on the left, the other first crane 24 can simultaneously perform the task of lifting the prefabricated concrete square piles from the fixed mold platform 9 on the right for demolding, and so on, thereby ensuring that each production process can be connected in an orderly manner to avoid time-consuming waiting due to insufficient cranes. Similarly, two second cranes 25 can also be set.

[0062] The working area in the production workshop is divided into two parts, each of which is provided with a reinforcement cage processing area, a reinforcement cage stacking area, a fixed mold platform area and a pile storage area. In these two areas, precast concrete square piles can be produced relatively independently at the same time. The first crane 24 and the second crane 25 can operate relatively independently without affecting each other, thereby reducing the waiting time for the cranes. Moreover, the two areas can share the same longitudinal pile outlet channel 10 to output precast concrete square piles. Each production area is reasonably arranged, the process is smooth, and the production efficiency can be significantly improved while saving area space.

[0063] In addition, a conveyor belt 17 is used to transport concrete materials, and the concrete materials on the conveyor belt 17 are distributed to the distribution vehicles 19 of each fixed formwork platform 9 through the material distribution mechanism 20, and then the distribution vehicle 19 distributes the materials on the fixed formwork platform 9. There is no need to use a crane to lift the distribution vehicle 19 for distribution, which reduces the operating frequency and distance of the crane, is beneficial to reduce energy consumption, and avoids the safety hazards caused by too frequent lifting operations. The time required for the distribution vehicle from receiving materials to completing distribution is short, and the transportation distance and time of the steel cage, tensioning components and prefabricated concrete piles are also relatively short, which can speed up the production rhythm, improve production capacity, and reduce the labor intensity and manufacturing cost of workers while ensuring product quality.

[0064] like Figure 3 As shown, in some other embodiments, the fixed formwork 9 of the first fixed formwork area 3 and the second fixed formwork area 7 is provided with a group of tensioning connectors 26 in each mold cavity thereof, and the tensioning connector 26 divides the mold cavity where it is located into two sub-mold cavities, each sub-mold cavity is used to accommodate a steel cage that is located on the same axis and can be tensioned at the same time after being inserted, so as to produce two prefabricated concrete square piles using the same mold cavity.

[0065] In the industry, a production workshop in which the mold cavity of the fixed mold table 9 can only accommodate one standard length steel cage at a time in the length direction is usually called a one-span workshop. The mold cavity of the fixed mold table 9 shown in the figure can accommodate two standard length steel cages at a time in the length direction, so it can be called a two-span workshop.

[0066] It can be understood that two or three groups of tensioning connectors 26 can be provided in the mold cavity of the fixed mold platform 9. When it is provided with two groups of tensioning connectors 26, three precast concrete square piles of the same or different lengths can be produced at one time. When it is provided with three groups of tensioning connectors 26, four precast concrete square piles of the same or different lengths can be produced at one time.

[0067] Although all the fixed mold platforms 9 shown in the figure are provided with a set of tension connection components 26, and the tension connection components 26 are located in the middle position, in actual production, tension connection components 26 with different positions and quantities can be set in different fixed mold platforms 9 as needed, or tension connection components 26 with different positions and quantities can be set in different mold cavities of the same fixed mold platform 9.

[0068] In this embodiment, since the fixed mold platform 9 is a two-span mold platform, the first steel cage stacking area 2 is divided into two stacking partitions along the length direction of the stacked steel cages. One of the stacking partitions is close to the conveyor belt 17 to supply the steel cages to the first span mold cavity on the upper side. During the lifting operation, it can be avoided that the vehicle runs longitudinally from the second span to the first span. The other stacking partition is close to the first tensioning operation area 21 to supply the steel cages to the second span mold cavity on the lower side.

[0069] In order to facilitate the transportation of the steel cage from the second span to the first span, a first steel cage conveyor 27 is provided between the two stacking sections of the first steel cage stacking area 2 and the first fixed mold platform area 3. The first steel cage conveyor 27 can transport the steel cage from the stacking section corresponding to the cage weaving machine's cage outgoing area to another stacking section.

[0070] The first pile storage area 4 is divided into two pile storage partitions along the length direction of the stored precast concrete square piles. One of the pile storage partitions is close to the conveyor belt 17 and is used to store the square piles produced by the first span mold cavity on the upper side. During the lifting operation, it can avoid the vehicle running longitudinally from the second span to the first span. The other pile storage partition is close to the first tensioning operation area 21 and is used to store the square piles produced by the second span mold cavity.

[0071] Each reinforcement cage stacking partition is provided with a fixed plate storage area 29 at one end close to the conveyor belt 17, and a tensioning plate storage area 30 at one end close to the tensioning operation area, so as to facilitate the assembly of fixed plates 31 and tensioning plates 32 on the reinforcement cage; each square pile storage partition is provided with a fixed plate collection area 33 at one end close to the conveyor belt 17, and a tensioning plate collection area 34 at one end close to the tensioning operation area, so as to store the fixed plates 31 and tensioning plates 32 removed after demoulding.

[0072] Moreover, since the first steel cage conveyor 27 can run between the first span and the second span, the first steel cage conveyor 27 can also be used to transport the fixed plate 31 and the tension plate 32 between the first span and the second span. The first steel cage conveyor 27 can be a circulating belt conveyor, a chain conveyor, or a reciprocating vehicle with a track.

[0073] Please refer to Figure 4 , Figure 5 , Figure 4 for Figure 1 The structural schematic diagram of the conveyor belt and material distribution mechanism of the concrete prefabricated square pile manufacturing system shown; Figure 5 for Figure 4 The structural schematic diagram of the material distribution mechanism is shown in .

[0074] As shown in the figure, the material dividing mechanism 20 includes a machine body 201 and a circulating material dividing belt (not shown) and a material dividing chute 202 arranged on the machine body 201. The circulating material dividing belt is driven by multiple groups of rollers 203 arranged on the machine body 201. The circulating material dividing belt is arranged obliquely on the machine body 201, and its material transporting surface is arranged at an angle to the material transporting surface of the conveyor belt 17.

[0075] The circulating material distribution belt has a working state and a non-working state. In the working state, its oblique downward end descends to the transport surface of the conveyor belt 17 to transfer the concrete material on the conveyor belt 17 to its own transport surface. In the non-working state, its oblique downward end is lifted to a height away from the transport surface of the conveyor belt 17, and does not transport concrete materials from the transport surface of the conveyor belt 17; the oblique upward end of the circulating material distribution belt corresponds to the feed port at the upper end of the distribution chute 202, and the lower end of the distribution chute 202 extends obliquely downward to the bottom of one side of the conveyor belt 17 and is provided with a discharge port. When distributing materials, the distribution vehicle 19 runs to below the discharge port of the distribution mechanism 20, and the distribution mechanism 20 can transport the concrete material from the discharge port to the hopper of the distribution vehicle 19.

[0076] The conveyor belt 17 is provided with a material distribution slide rail 35 extending along the feeding direction thereof, and a running roller is provided at the bottom of the material distribution mechanism 20, which can reciprocate on the material distribution slide rail 35. In this way, the material distribution mechanism 20 can run horizontally and stay at positions corresponding to different fixed die tables 9. Only one material distribution mechanism 20 is required for the first fixed die table area 3 to meet the material needs of all the fixed die tables 9.

[0077] Please refer to Figure 6 , Figure 7 , Figure 6 It is a structural schematic diagram of the fabric car; Figure 7 It is a structural schematic diagram of a fabric carriage mounted above a fixed mold platform.

[0078] As shown in the figure, in a preferred embodiment, two cloth-distributing carts 19 are respectively provided above each fixed mold platform 9, and each cloth-distributing cart 19 is erected above the fixed mold platform 9 through a transverse support beam mechanism 36. The fixed mold platform 9 is provided with longitudinal rails 37 on both sides at the top, and the transverse support beam mechanism 36 is configured to be able to run on the longitudinal rails 37 along the length direction of the fixed mold platform 9; the transverse support beam mechanism 36 is provided with a transverse rail 38, and the cloth-distributing cart 19 is configured to be able to run on the transverse rail 38 along the width direction of the fixed mold platform 9.

[0079] A vibrating mechanism 39 is provided at the rear of the material placing vehicle 19 to vibrate the concrete material injected into the mold cavity; a finishing mechanism 40 is provided at the rear of the vibrating mechanism 39 to finish the upper surface of the concrete material after vibration.

[0080] When laying materials, the two laying vehicles 19 of each fixed mold platform 9 respectively run from both ends in the length direction to the middle after receiving the materials, and lay the materials during the operation, or, when laying materials, the two laying vehicles 19 respectively run from one end and the middle to the other end of the fixed mold platform 9 in the same direction after receiving the materials, and lay the materials during the operation.

[0081] In this way, on the one hand, after the first fabric distribution vehicle 19 receives the materials, the running time of the first fabric distribution vehicle 19 can be used to transfer the materials to the second fabric distribution vehicle 19, thereby shortening the time for transferring the materials from the conveyor belt 17 to the fabric distribution vehicle 19; on the other hand, the first fabric distribution vehicle 19 distributes the materials to the mold cavity in one span, and the second fabric distribution vehicle 19 distributes the materials to the mold cavity in the other span. The two fabric distribution vehicles 19 are operated in opposite or opposite directions to distribute the materials at the same time, which can significantly save the distribution time and improve the production efficiency.

[0082] Please refer to Figure 8 , Figure 8 It is a structural schematic diagram of another embodiment in which a material distributing vehicle frame is arranged above a fixed mold platform.

[0083] As shown in the figure, in some other embodiments, by properly processing the tensioning longitudinal beams 11 and the tensioning transverse beams 12 of the fixed mold platform 9, two layers of square pile molds 13 can be set inside the same fixed mold platform 9. During production, the first layer of square pile molds 13 are first injected, and then the second layer of square pile molds 13 are stacked on the first layer of square pile molds 13, and then the second layer of square pile molds 13 are injected. The first layer of square pile molds 13 and the second layer of square pile molds 13 can be separated by a certain distance through a pad to prevent the bottom of the second layer of square pile molds 13 from affecting the normal molding of the upper surface of the first layer of square piles.

[0084] In this way, the space above the fixed formwork platform 9 can be fully utilized. Under the condition of the same floor area, the number of square piles that can be produced by the same fixed formwork platform 9 is twice that of a single-layer fixed formwork platform 9. If multiple layers are stacked, the number can be several times, which helps to further improve production capacity.

[0085] The above embodiments are only preferred solutions of the present invention, and are not limited thereto. On this basis, targeted adjustments can be made according to actual needs to obtain different implementation methods. For example, other equipment such as a discharger is used as a material distribution mechanism 20 to distribute materials from the conveyor belt 17 to the material distribution vehicle 19, or a circulating transmission chain mechanism is used to transport the fixed plate 31 and the tensioning plate 32 between different production areas, etc. Since there are many possible implementation methods, they will not be described one by one here.

[0086] In addition, the technical solutions between the embodiments can be combined with each other, but it should be based on the fact that ordinary technicians in the field can implement it. If the combination of technical solutions is contradictory or cannot be implemented, it should be considered that such combination of technical solutions does not exist and is not within the scope of protection required by the present invention.

[0087] In addition to the above-mentioned precast concrete square pile manufacturing system, the present invention also provides a precast concrete square pile manufacturing process, which uses the above-mentioned precast concrete square pile manufacturing system to produce precast concrete square piles, mainly comprising the following steps:

[0088] Mixing concrete materials in a concrete mixing plant 18 according to the formula, and supplying the prepared concrete materials to a conveyor belt 17, which transports the concrete materials along a conveying direction;

[0089] In the first reinforcement cage processing area 1 and the second reinforcement cage processing area 5, a cage weaving machine is used to make reinforcement cages, and the made reinforcement cages are stored in the first reinforcement cage stacking area 2 and the second reinforcement cage stacking area 6 respectively;

[0090] The first trolley 24 and the second trolley 25 hoist the steel cage into the mold cavity of the fixed mold platform 9 of the first fixed mold platform area 3 and the second fixed mold platform area 7, and connect the two ends of the steel cage to the fixed plate 31 and the tensioning plate 32 of the tensioning mechanism respectively;

[0091] In the first tensioning operation area 21 and the second tensioning operation area 22, the steel cage is tensioned along the length direction of the steel cage by a tensioning machine 23, so that the steel cage has prestress;

[0092] The material distribution vehicle 19 is controlled to move to the material receiving position, and the material distribution mechanism 20 distributes the concrete material on the conveyor belt 17 to the material distribution vehicle 19;

[0093] The material placing vehicle 19 runs along the length direction of the fixed mold platform 9 and injects concrete material into the mold cavity of the fixed mold platform 9 during the running process;

[0094] After resting, steam is introduced into the fixed die table 9 for steam curing for several hours;

[0095] The first crane 23 and the second crane 25 lift the prefabricated concrete square piles in the mold cavity to demould, and stack the prefabricated concrete square piles in the first pile storage area 4 and the second pile storage area 8;

[0096] The prefabricated concrete square piles are transported from the pile delivery channel 10 to outside the site.

[0097] Depending on the mold used, the square piles produced can be conventional square piles, variable-section square piles, bamboo piles, octagonal piles and other square piles.

[0098] In another embodiment, for the same fixed formwork platform 9, when distributing materials, two distribution vehicles 19 are controlled to run to the material receiving position, and the material distribution mechanism 20 distributes the concrete material on the conveyor belt 17 to the two distribution vehicles 19 in turn. Among them, the distribution vehicle 19 that receives the materials first runs to the end of the fixed formwork platform 9 away from the conveyor belt 17 after receiving the materials, and does not distribute materials in the process of running to the end of the fixed formwork platform 9 away from the conveyor belt 17. After the other distribution vehicle 19 that receives the materials later receives the materials, the two distribution vehicles 19 respectively run from the two ends of the fixed formwork platform 9 to the middle in opposite directions, and distribute materials during the operation.

[0099] Alternatively, for the same fixed formwork platform 9, when distributing materials, two distribution vehicles 19 are controlled to run to the material receiving position, and the material distribution mechanism 20 distributes the concrete material on the conveyor belt 17 to the two distribution vehicles 19 in turn. The distribution vehicle 19 that receives the materials first runs to the middle of the fixed formwork platform 9 after receiving the materials, and does not distribute the materials during the process of running to the middle of the fixed formwork platform 9. After the other distribution vehicle 19 that receives the materials later receives the materials, the two distribution vehicles 19 respectively run in the same direction from one end and the middle to the other end of the fixed formwork platform 9, and distribute the materials during the operation.

[0100] In other embodiments, while laying the material, the concrete material injected into the mold cavity can be vibrated by a vibrating mechanism 39 to increase the density of the concrete material, discharge the mixed gas, and avoid the appearance of internal voids in the square piles. After vibration, the upper surface of the concrete material can be smoothed by a smoothing mechanism 40 to improve the quality of the non-mold surface of the square piles.

[0101] The above is a detailed introduction to the concrete prefabricated square pile manufacturing system and manufacturing process provided by the present invention. This article uses specific examples to illustrate the principles and implementation methods of the present invention. The description of the above embodiments is only used to help understand the core idea of ​​the present invention. It should be pointed out that for ordinary technicians in this technical field, without departing from the principle of the present invention, several improvements and modifications can be made to the present invention, and these improvements and modifications also fall within the scope of protection of the claims of the present invention.

Claims

1. A system for manufacturing prefabricated concrete square piles, characterized in that: It includes a crane and a work area in a production workshop, a longitudinal pile-out channel is provided in the middle area of ​​the work area, the crane includes a first crane located on one side of the pile-out channel and a second crane located on the other side of the pile-out channel, a first steel cage processing area, a first steel cage stacking area, a first fixed mold platform area and a first pile storage area are arranged in sequence in the area from one end of the work area in the transverse direction to the pile-out channel, and a second steel cage processing area, a second steel cage stacking area, a second fixed mold platform area and a second pile storage area are arranged in sequence in the area from the other end of the work area in the transverse direction to the pile-out channel; a conveyor belt is provided on one side of the work area for circulating during operation to transport concrete materials, and the feeding line of the conveyor belt corresponds to the first fixed mold platform area and the second fixed mold platform area; the first fixed mold platform area and the second fixed mold platform area A plurality of fixed formwork tables are respectively provided in each stage area, and a material distribution vehicle capable of reciprocating along the length direction of each fixed formwork table is respectively provided above each fixed formwork table, and two material distribution vehicles are respectively provided above each fixed formwork table; the conveyor belt is provided with a material distribution mechanism, and the material distribution mechanism is used to transfer the concrete material on the conveyor belt to the material distribution vehicle of each fixed formwork table; a first tensioning operation area corresponding to the first fixed formwork table area and a second tensioning operation area corresponding to the second fixed formwork table area are provided on the other side of the working area; the material distribution vehicle is provided with a vibrating mechanism to vibrate the concrete material injected into the mold cavity of the fixed formwork table; the material distribution mechanism comprises a machine body and a circulating material distribution belt and a material distribution chute arranged on the machine body, the circulating material distribution belt is arranged obliquely to the machine body, and the material transporting surface of the circulating material distribution belt is arranged at an angle to the material transporting surface of the conveyor belt.

2. The prefabricated concrete square pile manufacturing system according to claim 1, characterized in that: When laying materials, the two laying vehicles of each fixed mold platform respectively run from the two ends of the fixed mold platform in the length direction to the middle after receiving the materials, and lay the materials during the operation, or, when laying materials, the two laying vehicles respectively run in the same direction from one end and the middle of the fixed mold platform to the other end after receiving the materials, and lay the materials during the operation.

3. The prefabricated concrete square pile manufacturing system according to claim 2, characterized in that: The fabric distribution vehicle is erected above the fixed mold platform through a transverse support beam mechanism. The fixed mold platform is provided with longitudinal tracks on both sides at the top. The transverse support beam mechanism is configured to be able to run on the longitudinal tracks along the length direction of the fixed mold platform; the transverse support beam mechanism is provided with a transverse track, and the fabric distribution vehicle is configured to be able to run on the transverse track along the width direction of the fixed mold platform.

4. The prefabricated concrete square pile manufacturing system according to claim 1, characterized in that: A finishing mechanism is arranged at the rear of the vibrating mechanism to finish the upper surface of the concrete material after vibrating.

5. The prefabricated concrete square pile manufacturing system according to claim 1, characterized in that: The circulating material dividing belt has a working state and a non-working state. In the working state, the oblique downward end of the circulating material dividing belt descends to the material transporting surface of the conveyor belt to transfer the concrete material on the conveyor belt to its own material transporting surface. In the non-working state, the oblique downward end of the circulating material dividing belt is lifted to a height away from the material transporting surface of the conveyor belt, and the concrete material is not transported from the material transporting surface of the conveyor belt; the oblique upward end of the circulating material dividing belt corresponds to the feed port at the upper end of the material dividing chute, and the lower end of the material dividing chute extends obliquely downward to the bottom of one side of the conveyor belt and is provided with a discharge port.

6. The prefabricated concrete square pile manufacturing system according to claim 1, characterized in that: The conveyor belt is equipped with a material dividing slide rail extending along its feeding direction, and the material dividing mechanism is reciprocatingly mounted on the material dividing slide rail.

7. The prefabricated concrete square pile manufacturing system according to claim 1, characterized in that: The fixed formworks of the first fixed formwork area and the second fixed formwork area are provided with at least one group of tensioning connectors in each mold cavity thereof, and the tensioning connectors divide the mold cavity where the tensioning connectors are located into at least two sub-mold cavities, and each of the sub-mold cavities is used to accommodate a steel cage that is located on the same axis after being placed therein and can be tensioned simultaneously, so as to produce at least two prefabricated concrete square piles using the same mold cavity.

8. The prefabricated concrete square pile manufacturing system according to claim 7, characterized in that: The first steel cage stacking area and the second steel cage stacking area are respectively divided into two stacking partitions along the length direction of the stacked steel cages, one of which is close to the conveyor belt, and the other of which is close to the first tensioning operation area and the second tensioning operation area; the first pile storage area and the second pile storage area are respectively divided into two pile storage partitions along the length direction of the stored prefabricated concrete square piles, one of which is close to the conveyor belt, and the other of which is close to the first tensioning operation area and the second tensioning operation area.

9. The prefabricated concrete square pile manufacturing system according to claim 8, characterized in that: Each of the stacking partitions is provided with a fixed plate storage area at one end close to the conveyor belt, and a tensioning plate storage area at one end close to the first tensioning operation area and the second tensioning operation area; each of the pile storage partitions is provided with a fixed plate collection area at one end close to the conveyor belt, and a tensioning plate collection area at one end close to the first tensioning operation area and the second tensioning operation area.

10. The prefabricated concrete square pile manufacturing system according to claim 9, characterized in that: One stacking partition of the first steel cage stacking area corresponds to the cage unloading area of ​​the first steel cage processing area, and a first steel cage conveyor is provided between the two stacking partitions and the first fixed mold area to transport the steel cage from the stacking partition corresponding to the cage unloading area to another stacking partition; one stacking partition of the second steel cage stacking area corresponds to the cage unloading area of ​​the second steel cage processing area, and a second steel cage conveyor is provided between the two stacking partitions and the second fixed mold area to transport the steel cage from the stacking partition corresponding to the cage unloading area to another stacking partition.

11. The prefabricated concrete square pile manufacturing system according to any one of claims 1 to 10, characterized in that: The invention further comprises a concrete mixing mechanism which is arranged on the conveyor belt to supply materials to the conveyor belt.

12. A process for manufacturing precast concrete square piles, using the precast concrete square pile manufacturing system according to any one of claims 1 to 11 to produce precast concrete square piles, comprising: Mixing and preparing concrete materials according to a formula, and supplying the prepared concrete materials to the conveyor belt, so that the conveyor belt transports the concrete materials along a conveying direction; In the first steel cage processing area and the second steel cage processing area, a cage weaving machine is used to make steel cages, and the made steel cages are stored in the first steel cage stacking area and the second steel cage stacking area respectively; The first crane and the second crane are used to hoist the steel cage into the mold cavity of the fixed mold platform of the first fixed mold platform area and the second fixed mold platform area, and the two ends of the steel cage are respectively connected to the tensioning connectors; In the first tensioning operation area and the second tensioning operation area, the steel cage is tensioned along the length direction of the steel cage by a tensioning machine, so that the steel cage has prestress; Control the placing car to run to the material receiving position, and the material distribution mechanism distributes the concrete material on the conveyor belt to the placing car; The placing vehicle runs along the length direction of the fixed formwork platform and injects concrete material into the mold cavity of the fixed formwork platform during the running process; After resting, steam is introduced into the fixed mold platform for steam curing; The prefabricated square concrete piles in the mold cavity are lifted by the first crane and the second crane to demould, and the prefabricated square concrete piles are stacked in the first pile storage area and the second pile storage area; Transport the prefabricated concrete square piles from the pile outlet channel to outside the site.

13. The manufacturing process of prefabricated concrete square piles according to claim 12, characterized in that: Further including: For the same fixed formwork, when distributing materials, two distributing vehicles are controlled to run to the material receiving position, and the material distribution mechanism distributes the concrete materials on the conveyor belt to the two distributing vehicles in sequence. The distributing vehicle that receives the materials first runs to the end of the fixed formwork away from the conveyor belt after receiving the materials, and does not distribute the materials during the process of running to the end of the fixed formwork away from the conveyor belt. After the other distributing vehicle that receives the materials later receives the materials, the two distributing vehicles respectively run from the two ends of the fixed formwork to the middle in opposite directions, and distribute the materials during the operation; Alternatively, for the same fixed formwork, when distributing materials, two distribution vehicles are controlled to run to the material receiving position, and the material distribution mechanism distributes the concrete materials on the conveyor belt to the two distribution vehicles in turn. The distribution vehicle that receives the materials first runs to the middle of the fixed formwork after receiving the materials, and does not distribute the materials during the process of running to the middle of the fixed formwork. After the other distribution vehicle that receives the materials later receives the materials, the two distribution vehicles respectively run in the same direction from one end and the middle of the fixed formwork to the other end, and distribute the materials during the operation.

14. The manufacturing process of prefabricated concrete square piles according to claim 12, characterized in that: Further including: While spreading the material, the concrete material injected into the mold cavity is vibrated, and the upper surface of the concrete material is plastered after vibration.

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