An automated production line for sintered composite wall panels

Abstract

This application relates to an automated production line for sintered composite wall panels, comprising: a plastering unit for plastering the surface of a brick stack until the entire stack of wall panels is plastered and bonded; a grouting unit for injecting a predetermined amount of mortar into the rebar holes of the entire stack of wall panels; a straightening unit for straightening the rebar and threading it through the mortar-filled rebar holes from top to bottom; and a rebar shear for shearing the rebar after it reaches a preset position, completing the production of the sintered composite wall panels. This automated production line transforms bricks into sintered composite wall panels, ensuring stable production quality and improving production efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of composite wallboard production, and more particularly to an automated production line for sintering composite wallboards. Background Art

[0002] Existing wall panels, such as "ALC lightweight partition boards," are primarily made from fly ash (or silica sand), cement, and lime, and are cured using high-pressure steam. Partitions made with ALC lightweight partition boards are not moisture-resistant and have a high water absorption rate. When the air is humid, the walls absorb this moisture. Over time, the walls become damp, develop an odor, and may even become loose and collapse. Furthermore, ALC lightweight partition boards can deform due to temperature fluctuations, and they have low strength and poor impact resistance.

[0003] Compared to "ALC lightweight partition panels," the new sintered composite wall panels with structural columns offer superior performance, resisting cracking, moisture absorption, and delamination. They are also structurally safer, with built-in reinforcement ribs that significantly increase their overall strength, increasing their resistance to bending loads and seismic intensity. Furthermore, sintered composite wall panels offer greater construction flexibility, allowing for vertical installation of large panels or horizontal installation of shorter panels, effectively addressing the constraints of small construction spaces. However, the production of existing sintered composite wall panels with structural columns still relies heavily on manual labor, particularly in processes like plastering and reinforcing steel bars, resulting in inconsistent quality and low production efficiency. Summary of the Invention

[0004] The present invention provides an automated production line for sintering composite wall panels to solve the above technical problems.

[0005] An automated production line for sintered composite wall panels comprises: a plastering unit for plastering the surface of a brick stack until the entire stack of wall panels is plastered and bonded; a grouting unit for pouring a fixed amount of mortar into the steel bar holes of the entire stack of wall panels; a straightening unit for straightening the steel bars and passing them through the steel bar holes filled with mortar from top to bottom; and a steel bar shear for shearing the steel bars after they reach a preset position, thereby completing the production of the sintered composite wall panels.

[0006] In some embodiments, the plastering unit includes a mixer, a conveying pipe, a plastering robot and a plastering grouting nozzle, one end of the conveying pipe is connected to the mixer, the other end of the conveying pipe is connected to the plastering grouting nozzle, and the plastering grouting nozzle is connected to the plastering robot.

[0007] In some embodiments, the grouting nozzle includes a nozzle conduit portion and two liquid outlet pipes. The nozzle conduit portion has a guide cavity inside. One end of the guide cavity is provided with an internal thread connected to the conveying pipe, and the other end of the guide cavity is connected to the two liquid outlet pipes. The liquid outlet ends of the two liquid outlet pipes are vertically arranged; the outer edge of the nozzle conduit portion is connected to the grouting robot.

[0008] In some embodiments, the grouting unit includes a stirring device, a delivery hose, a grouting nozzle, a tee joint, a connecting seat unit, a connecting pipe and a grouting robot, one end of the delivery hose is connected to the stirring device, and the other end of the delivery hose is connected to the tee joint, the tee joint is arranged on the connecting seat unit, the other two ends of the tee joint are respectively connected to the connecting pipe, and the other end of the connecting pipe is connected to the grouting nozzle arranged on the connecting seat unit; the connecting seat unit is connected to the grouting robot.

[0009] In some embodiments, the connecting seat unit includes a connecting seat, a connecting plate, a pad and a U-shaped card. The connecting plate is bent, one end of the connecting plate is arranged at the lower part of the connecting seat, the grouting nozzle is fixed to the other end of the connecting plate through the U-shaped card, and the pad is arranged between the grouting nozzle and the connecting plate.

[0010] In some embodiments, the straightening unit includes a straightening robot, a support plate, a straightening wheel group and a traction wheel group. One end of the support plate is connected to the straightening robot, and the other end of the support plate is provided with a straightening wheel group and a traction wheel group in sequence from top to bottom.

[0011] In some embodiments, the straightening wheel assembly includes a first mounting base, a left straightening wheel unit, a right straightening wheel unit and a traction unit. The left straightening wheel unit is fixed on the first mounting base, and the right straightening wheel unit is slidably connected to the first mounting base through the traction unit. A gap is formed between the left straightening wheel unit and the right straightening wheel unit for straightening the steel bars.

[0012] In some embodiments, the left straightening wheel unit includes a left mounting bar and at least N left pulleys, wherein N≥4, the left mounting bar is fixedly mounted on the first mounting base plate, the N left pulleys are vertically arranged at equal intervals on the left mounting bar, and the axes of the N left pulleys are on the same straight line, the right straightening wheel unit includes a right mounting bar and N-1 right pulleys, the N-1 right pulleys are vertically arranged at equal intervals on the right mounting bar, and the axes of the N right pulleys are on the same straight line, and the right mounting bar is fixedly mounted on the traction unit.

[0013] In some embodiments, the traction unit includes a fixing rod, a screw rod and a spring. The fixing rod is fixed on the first mounting base plate. At least two of the screw rods are threaded through the fixing rod. The fixing rod is provided with a limiting hole opposite to the screw rod. The end of the screw rod is slidably set in the limiting hole. The two ends of the spring are respectively connected to the right mounting bar and the fixing rod.

[0014] In some embodiments, the traction unit includes a motor, a second mounting base, a driving wheel and a driven wheel. The motor is fixedly mounted on a support plate. The driving wheel is rotatably connected to the second mounting base, and the driving wheel is connected to the output end of the motor. The driven wheel is rotatably connected to the second mounting base, and a channel for pulling steel bars is formed between the driving wheel and the driven wheel. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] One or more embodiments are exemplarily illustrated by pictures in the corresponding drawings. These exemplifications do not constitute limitations on the embodiments. Elements with the same reference numerals in the drawings are represented as similar elements. Unless otherwise stated, the figures in the drawings do not constitute proportional limitations.

[0016] Figure 1 This is a schematic diagram of a plastering unit of an automated production line for sintered composite wall panels provided in one embodiment of the present application;

[0017] Figure 2 Schematic diagram of a plastering and grouting nozzle of a plastering unit provided in one embodiment of the present application;

[0018] Figure 3 Schematic diagram of a grouting unit of an automated production line for sintered composite wall panels provided in one embodiment of the present application;

[0019] Figure 4 is a schematic diagram of a connecting seat unit provided in one embodiment of the present application;

[0020] Figure 5 is a schematic diagram of a straightening unit provided in one embodiment of the present application;

[0021] Figure 6 is a schematic diagram of a straightening wheel assembly and a traction wheel assembly provided in one embodiment of the present application;

[0022] In the figure: 1- mixer, 2- conveying pipeline, 3- ash-making robot, 4- ash-making grouting nozzle, 5- nozzle conduit, 6- liquid outlet pipe, 7- stirring device, 8- conveying hose, 9- grouting robot, 10- connecting pipe, 11- three-way joint, 12- grouting nozzle, 13- connecting plate, 14- pad, 15- connecting seat, 16- U-shaped card, 17- straightening robot, 18- straightening wheel group, 19- supporting plate, 20- traction wheel group, 21- rebar shearing machine, 22- left pulley, 23- first mounting base plate, 24- right pulley, 25- screw, 26- second mounting base plate, 27- driving wheel, 28- guide hole, 29- left mounting bar, 30- right mounting bar, 31- spring, 32- fixing rod, 33- motor, 34- driven wheel. DETAILED DESCRIPTION

[0023] In order to make the purpose, technical solutions and advantages of the present application clearer, the technical solutions in the embodiments of the present application will be described in more detail below in conjunction with the drawings in the preferred embodiments of the present application. In the drawings, the same or similar reference numerals throughout represent the same or similar parts or parts with the same or similar functions. The described embodiments are part of the embodiments of the present application, not all of the embodiments. The embodiments described below with reference to the drawings are exemplary and are intended to be used to explain the present application, and should not be understood as limitations on the present application. Based on the embodiments in the present application, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of this application.

[0024] The embodiments of the present application are described in detail below with reference to the accompanying drawings.

[0025] The following will be combined with the drawings in the embodiments of this application to clearly and completely describe the technical solutions in the embodiments of this application. Obviously, the embodiments described are only part of the embodiments of this application, not all of the embodiments. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of this application.

[0026] The terms "first", "second" and "third" in this application are only used for descriptive purposes and cannot be understood as indicating or suggesting the quantity or order of the technical features indicated relative to importance or implicitly indicating the indicated technical features. In the embodiments of the present application, all directional indications (such as up, down, left, right, front, back ...) are only used to explain the relative position relationship or movement situation between the various components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication also changes accordingly. In addition, the terms "including" and "having" and any of their variations are intended to cover non-exclusive inclusions. For example, a process, method, system, product or equipment that includes a series of steps or units is not limited to the steps or units listed, but optionally also includes steps or units that are not listed, or optionally also includes other steps or units inherent to these processes, methods, products or equipment.

[0027] References herein to "embodiments" mean that a particular feature, structure, or characteristic described in connection with the embodiments may be included in at least one embodiment of the present application. The appearance of this phrase in various places in the specification does not necessarily refer to the same embodiment, nor does it constitute an independent or alternative embodiment that is mutually exclusive of other embodiments. It is understood, both explicitly and implicitly, by those skilled in the art that the embodiments described herein may be combined with other embodiments.

[0028] It should be noted that when an element is referred to as being "fixed to" another element, it may be directly attached to the other element or there may be an intermediate element. When an element is referred to as being "connected to" another element, it may be directly connected to the other element or there may be one or more intermediate elements therebetween. The terms "vertical," "horizontal," "left," "right," and similar expressions used herein are for illustrative purposes only and do not represent the only implementations.

[0029] The following will be combined Figure 1-6 , an automated production line for sintered composite wall panels according to an embodiment of the present application is described in detail. It should be noted that the following embodiments are only used to explain the present application and do not constitute a limitation of the present application.

[0030] In such Figure 1In the illustrated embodiment, an automated production line for sintered composite wall panels may include: a plastering unit, a grouting unit, a straightening unit, and a rebar shear 21. The plastering unit is used to plaster the surface of the brick stack until the entire stack of wall panels is plastered and bonded; the grouting unit is used to inject a predetermined amount of mortar into the rebar holes of the entire stack of wall panels; the straightening unit is used to straighten the rebar and pass it through the mortar-filled rebar holes from top to bottom; and the rebar shear 21 is used to shear the rebar after it reaches a preset position, completing the production of the sintered composite wall panels. The rebar shear 21 is a commercially available product and will not be described in detail here.

[0031] An embodiment of the present application provides an automated production line for sintered composite wall panels. The device can be used for the automated production of new sintered composite wall panels with structural columns. A robot is used to complete plastering, grouting and rebar planting to replace manual labor, thereby ensuring stable product quality and high production efficiency.

[0032] In some embodiments, the plastering unit includes a mixer 1, a conveying pipe 2, a plastering robot 3 and a plastering grouting nozzle 4, one end of the conveying pipe 2 is connected to the mixer 1, and the other end of the conveying pipe 2 is connected to the plastering grouting nozzle 4, and the plastering grouting nozzle 4 is connected to the plastering robot 3.

[0033] The mixer 1 is a screw pump 25 that completes the mortar mixing work and cooperates with the robot's program control to apply mortar to the outline of each block, achieving bonding between adjacent blocks through the applied mortar, and achieving the required mortar dosage during the application. The delivery pipe 2 is a hose used to realize the mortar delivery action.

[0034] In some embodiments, the grouting nozzle 4 includes a nozzle conduit 5 and two liquid outlet pipes 6. The nozzle conduit 5 has a diversion chamber, one end of which is provided with an internal thread connected to the delivery pipe 2, and the other end of which is connected to the two liquid outlet pipes 6. The liquid outlet ends of the two liquid outlet pipes 6 are arranged vertically. The outer edge of the nozzle conduit 5 is connected to the grouting robot 3. The width of the two liquid outlet pipes 6 is exactly the width of the composite wallboard. Preferably, the two liquid outlet pipes 6 can be equipped with valves to independently control the liquid discharge. The provision of two liquid outlet pipes 6 in the grouting nozzle 4 can improve grouting efficiency, especially when the composite wallboard is very long, where the efficiency improvement is more significant.

[0035] In some embodiments, the grouting unit includes a stirring device 7, a delivery hose 8, a grouting nozzle 12, a tee joint 11, a connecting seat 15 unit, a connecting pipe 10 and a grouting robot 9, one end of the delivery hose 8 is connected to the stirring device 7, and the other end of the delivery hose 8 is connected to the tee joint 11, the tee joint 11 is arranged on the connecting seat 15 unit, and the other two ends of the tee joint 11 are respectively connected to the connecting pipe 10, and the other end of the connecting pipe 10 is connected to the grouting nozzle 12 arranged on the connecting seat 15 unit; the connecting seat 15 unit is connected to the grouting robot 9.

[0036] The stirring device 7 utilizes a secondary pump to thoroughly stir the mortar and deliver the measured, pressurized mortar to the grouting nozzle 12 for grouting. The mortar is delivered to the tee 11 via a delivery hose 8, where it is then diverted to the connecting pipes 10 on either side before being injected into the rebar holes through the grouting nozzle 12. During injection, the mortar should not be completely filled; allowance should be made for the upward displacement of the mortar after the rebar is inserted. This means the reserved volume should be sufficient to accommodate the insertion volume of the rebar.

[0037] In some embodiments, the connecting seat 15 unit includes a connecting seat 15, a connecting plate 13, a pad 14 and a U-shaped card 16. The connecting plate 13 is bent, and one end of the connecting plate 13 is arranged at the lower part of the connecting seat 15. The connecting seat 15 is connected to the grouting robot 9. The grouting nozzle 12 is fixed to the other end of the connecting plate 13 by the U-shaped card 16. The pad 14 is arranged between the grouting nozzle 12 and the connecting plate 13. The connecting seat 15 unit can realize the centralized assembly of multiple components. The connecting plate 13 is bent to facilitate the grouting nozzle 12 to be placed in the front and to the bottom. It is convenient to pour mortar into the steel bar hole. At the same time, there is a pad 14 between the grouting nozzle 12 and the connecting plate 13, which can play a buffering role and facilitate the grouting nozzle 12 to be fixed firmly.

[0038] In some embodiments, the straightening unit includes a straightening robot 17, a support plate 19, a straightening wheel group 18 and a traction wheel group 20. One end of the support plate 19 is connected to the straightening robot 17, and the other end of the support plate 19 is provided with a straightening wheel group 18 and a traction wheel group 20 in sequence from top to bottom. The front end drives the traction wheel through the traction wheel group 20 to pull the steel bars, and the straightening wheel group 18 is used to straighten the steel bars. The straightened steel bars are inserted into the steel bar holes filled with mortar, and the production of sintered composite wall panels is completed after solidification. The plastering robot 3, grouting robot 9 and straightening robot 17 provided in this embodiment are all 6-axis industrial robots.

[0039] In some embodiments, the straightening wheel group 18 includes a first mounting base plate 23, a left straightening wheel unit, a right straightening wheel unit and a traction unit. The left straightening wheel unit is fixed on the first mounting base plate 23, and the right straightening wheel unit is slidably connected to the first mounting base plate 23 through the traction unit. A gap for straightening the steel bars is formed between the left straightening wheel unit and the right straightening wheel unit.

[0040] The left straightening wheel unit includes a left mounting bar 29 and at least N left pulleys 22, where N≥4. The left mounting bar 29 is fixedly mounted on the first mounting base plate 23. The N left pulleys 22 are vertically arranged at equal intervals on the left mounting bar 29, and the axes of the N left pulleys 22 are on the same straight line. The right straightening wheel unit includes a right mounting bar 30 and N-1 right pulleys 24. The N-1 right pulleys 24 are vertically arranged at equal intervals on the right mounting bar 30, and the axes of the N right pulleys 24 are on the same straight line. The right mounting bar 30 is fixedly mounted on the traction unit.

[0041] There can be four left pulleys 22 and three right pulleys 24, with the left and right pulleys 22 and 24 arranged in an interlaced manner. The rebar passes through the gap between the left and right pulleys 22, 24 to complete the straightening process. To facilitate the passage of the rebar between the left and right pulleys 22, 24, guide holes 28 can be provided in the first mounting base plate 23.

[0042] In some embodiments, the traction unit includes a fixing rod 32, a screw rod 25, and a spring 31. The fixing rod 32 is fixed to the first mounting base plate 23. At least two screw rods 25 are threaded through the fixing rod 32. The fixing rod 32 is provided with a limiting hole opposite to the screw rod 25. The end of the screw rod 25 is slidably disposed in the limiting hole. The two ends of the spring 31 are respectively connected to the right mounting bar 30 and the fixing rod 32. The screw rod 25 causes the right mounting bar 30 to keep the spring 31 in a stretched state.

[0043] The right straightening wheel unit is slidably connected to the first mounting base plate 23 via a traction unit, enabling straightening of rebars of varying diameters. A screw 25 tensions a spring 31 on the right mounting bar 30. By rotating the screw 25 relative to the fixed rod 32, the tensile strength of the spring 31 is adjusted, thereby adjusting the gap between the left and right pulleys 22 and 24 to accommodate the straightening of rebars of varying diameters. Both pulleys 22 and 24 are equipped with arcuate grooves that mate with the outer edges of the rebars.

[0044] In some embodiments, the traction unit includes a motor 33, a second mounting base 26, a driving pulley 27, and a driven pulley 34. The motor 33 is fixedly mounted on the support plate 19. The driving pulley 27 is rotatably connected to the second mounting base 26 and is connected to the output end of the motor 33. The driven pulley is rotatably connected to the second mounting base 26. A channel for pulling rebar is formed between the driving pulley 27 and the driven pulley. The motor 33 drives the driving pulley 27 through gear rotation, and the rebar is then pulled into the rebar hole between the driving pulley 27 and the driven pulley. A pair of driven pulleys can also be provided below the driving pulley 27 and the driven pulley to assist in conveying the rebar.

[0045] The automated production line for sintered composite wall panels provided in this embodiment has the following beneficial effects compared to the prior art:

[0046] 1. The automated combination of building blocks into sintered composite wall panels is realized, which stabilizes the production quality and improves the production efficiency.

[0047] 2. Reinforced structural columns are formed inside, which greatly improves the overall strength of the wall panels and increases the compressive strength to 12MPa.

[0048] 3. The production process of sintered wall panels has been standardized and stabilized.

[0049] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. An automated production line for sintering composite wall panels, characterized in that: include: A plastering unit, which is used to apply plaster to the surface of the brick stack until the entire stack of wall panels is plastered and bonded; A grouting unit, which is used to pour a fixed amount of mortar into the steel bar holes of the entire stack of wall panels; A straightening unit, which is used to straighten the steel bars and pass them through the steel bar holes filled with mortar from top to bottom; The steel bar shear is used to cut the steel bars after they reach the preset position, and the sintered composite wall panels are completed; The mortar unit includes a mixer, a conveying pipe, a mortar robot and a mortar grouting nozzle. One end of the conveying pipe is connected to the mixer, and the other end of the conveying pipe is connected to the mortar grouting nozzle. The mortar grouting nozzle is connected to the mortar robot. The straightening unit includes a straightening robot, a support plate, a straightening wheel group and a traction wheel group, one end of the support plate is connected to the straightening robot, and the other end of the support plate is provided with a straightening wheel group and a traction wheel group in sequence from top to bottom; The straightening wheel assembly includes a first mounting base, a left straightening wheel unit, a right straightening wheel unit and a traction unit. The left straightening wheel unit is fixed on the first mounting base, and the right straightening wheel unit is slidably connected to the first mounting base via the traction unit. A gap is formed between the left straightening wheel unit and the right straightening wheel unit for straightening the steel bars. The left straightening wheel unit includes a left mounting bar and at least N left pulleys, wherein N ≥ 4, the left mounting bar is fixedly mounted on the first mounting base plate, the N left pulleys are arranged vertically on the left mounting bar at equal intervals, and the axes of the N left pulleys are on the same straight line; the right straightening wheel unit includes a right mounting bar and N-1 right pulleys, the N-1 right pulleys are arranged vertically on the right mounting bar at equal intervals, and the axes of the N right pulleys are on the same straight line, and the right mounting bar is fixedly mounted on the traction unit; The traction unit includes a fixing rod, a screw rod and a spring. The fixing rod is fixed on the first mounting base plate. At least two of the screw rods are threaded through the fixing rod. The fixing rod is provided with a limiting hole opposite to the screw rod. The end of the screw rod is slidably arranged in the limiting hole. The two ends of the spring are respectively connected to the right mounting bar and the fixing rod.

2. The automated production line for sintered composite wall panels according to claim 1, characterized in that: The grouting nozzle includes a nozzle conduit portion and two liquid outlet pipes. The nozzle conduit portion has a guide cavity inside. One end of the guide cavity is provided with an internal thread connected to the conveying pipe, and the other end of the guide cavity is connected to the two liquid outlet pipes. The liquid outlet ends of the two liquid outlet pipes are vertically arranged; the outer edge of the nozzle conduit portion is connected to the grouting robot.

3. The automated production line for sintered composite wall panels according to claim 1, characterized in that: The grouting unit includes a stirring device, a delivery hose, a grouting nozzle, a tee joint, a connecting seat unit, a connecting pipe and a grouting robot. One end of the delivery hose is connected to the stirring device, and the other end of the delivery hose is connected to the tee joint. The tee joint is arranged on the connecting seat unit, and the other two ends of the tee joint are respectively connected to the connecting pipe, and the other end of the connecting pipe is connected to the grouting nozzle arranged on the connecting seat unit; the connecting seat unit is connected to the grouting robot.

4. The automated production line for sintered composite wall panels according to claim 3, characterized in that: The connecting seat unit includes a connecting seat, a connecting plate, a pad and a U-shaped card. The connecting plate is bent, one end of the connecting plate is arranged at the lower part of the connecting seat, the grouting nozzle is fixed to the other end of the connecting plate through the U-shaped card, and the pad is arranged between the grouting nozzle and the connecting plate.

5. The automated production line for sintered composite wall panels according to claim 1, characterized in that: The traction unit includes a motor, a second mounting base, a driving wheel and a driven wheel. The motor is fixedly mounted on the support plate. The driving wheel is rotatably connected to the second mounting base and is connected to the output end of the motor. The driven wheel is rotatably connected to the second mounting base. A channel for traction of steel bars is formed between the driving wheel and the driven wheel.

Images