Prefabricated wall panel manufacturing process and prefabricated wall panel

Abstract

The present invention discloses a prefabricated wall panel manufacturing process and prefabricated wall panels, belonging to the technical field of construction engineering wall panel production. The steps include a loading process, a turning process, a grouting process, a pre-curing process, and a unloading process. A turning machine is provided at the workstation of the turning process, and the turning machine includes a turning frame and a supporting frame that are perpendicular to each other. The turning process includes: step 1: the supporting frame of the turning machine is in a horizontal state, a conveyor vehicle is pre-transported thereon, and then the turning frame of the turning machine is turned to an inclined state; step 2: multiple panels are transferred to the turning frame of the turning machine, and the panels are assembled and gathered to form a prefabricated integrated wall panel; step 3: after the assembly is completed, the turning frame of the turning machine is turned vertically, so that the integrated wall panel is placed on the conveyor vehicle and transported to the next process. The present invention realizes the splicing of panels into integrated wall panels in a factory, reduces the turning stroke and time of the turning machine, integrates the turning process and the assembly process, improves production efficiency, and reduces construction waste.

Description

Technical Field

[0001] The present invention relates to the technical field of construction engineering wall panel production, and more particularly to a prefabricated wall panel production process and the prefabricated wall panel. Background Art

[0002] Wall panel installation is an essential step in the construction of building exterior walls. Integrated building installation is a development trend in the context of residential industrialization, which is specifically manifested in factory production and component standardization. With the acceleration of the country's promotion of integrated buildings, integrated buildings have become popular to a certain extent.

[0003] Currently, the production process for autoclaved aerated concrete panels requires post-processing before transporting them to the construction site, where they are assembled on the building frame and fastened to form the wall. Existing panel splicing and fastening are mostly done manually on-site, which delays construction schedules and reduces labor efficiency. Even for some integrated wall panels that are assembled and integrated in factories, the assembly and flipping processes are split into two steps, impacting production efficiency. Furthermore, the flipping process requires a long stroke, making it time-consuming and hindering efficiency and energy conservation.

[0004] After searching, Chinese patent CN114851396A discloses an integrated wall panel production system and process. The patent includes a splicing mechanism for splicing individual wall panels to be spliced ​​to form a large wall panel; a flipping mechanism for flipping the spliced ​​large wall panel, which includes a flipping frame and a first driving member. The large wall panel is placed horizontally on the flipping frame, and the first driving member drives the flipping frame to flip; a milling mechanism for milling and drilling the flipped large wall panel. In addition, it also includes a trolley and a ground rail for the movement of the trolley. The trolley is used to carry the wall panel and participate in the transportation between workstations; the flipping mechanism is provided with a rail, which is flipped and moved to dock with the ground rail. The flipping mechanism in this patent flips from horizontal to vertical, which is not conducive to the time-saving and labor-saving work of the flipping mechanism, and does not reflect the process of the wall panel circulation. Summary of the Invention

[0005] 1. Technical problem to be solved by the invention

[0006] The present invention provides a prefabricated wall panel manufacturing process and a prefabricated wall panel, wherein when the prefabricated wall panel is turned over, a turning frame is turned from vertical to inclined and then from inclined to vertical, thereby reducing the turning stroke and improving production efficiency.

[0007] 2. Technical solution

[0008] In order to achieve the above object, the technical solution provided by the present invention is:

[0009] A prefabricated wall panel manufacturing process, comprising a loading process, a turning process, a grouting process, a pre-curing process, and a unloading process. A turning machine is provided at the turning process station, and the turning machine comprises a turning frame and a supporting frame that are perpendicular to each other.

[0010] The flipping process comprises the following steps:

[0011] Step 1: The support frame of the turning machine is in a horizontal state, a conveyor vehicle is pre-transported thereon, and then the turning frame of the turning machine is turned to an inclined state;

[0012] Step 2: Transfer multiple panels from the loading process to the turning rack of the turning machine, and assemble and gather the panels to form prefabricated integrated wall panels;

[0013] Step 3: After the assembly is completed, the turning frame of the turning machine is turned vertically again, so that the integrated wall panel is placed on the conveyor vehicle and transported to the next process.

[0014] Furthermore, when the turning frame of the turning machine is turned to an inclined state in step 1, the turning frame forms an inclination angle with the vertical direction, and the inclination angle is 5° to 10°.

[0015] Furthermore, the loading process, flipping process, grouting process, pre-curing process and unloading process are connected in sequence through a traction conveyor line to form a product conveying loop; a crane is provided at the loading process station for transporting the panels to the flipping machine at the flipping station; the grouting process is used to insert reinforcing rods into the reinforcing rod holes of the integrated wall panels and grouting into the reinforcing rod holes; the pre-curing and unloading of the integrated wall panels are completed at the pre-curing process and unloading process stations.

[0016] Furthermore, the traction conveyor line includes a first traction machine and a second traction machine, the work station of the flipping process is set on the first traction machine track, the work station of the unloading process is set on the second traction machine track, and the work station of the unloading process is provided with a second transfer crane; one end of the first traction machine and the second traction machine extends to the pre-curing process, and the other end is connected to the transverse transfer vehicle, the work station of the pre-curing process is provided with a pre-curing room, and the pre-curing room is provided with a first transfer crane.

[0017] Furthermore, in the step 2, the turning frame of the turning machine faces the loading process, and the support frame is located on the first traction machine track when it is turned to a horizontal state.

[0018] Furthermore, a plurality of conveying vehicles are provided on the tracks of the first tractor and the second tractor for conveying integrated wall panels.

[0019] Furthermore, the first tractor and the second tractor tracks are parallel.

[0020] Furthermore, the transverse track of the transverse vehicle extends from the first tractor to the second tractor, and the transverse vehicle is used to transfer the returned empty transport vehicle from the second tractor track to the first tractor track.

[0021] Furthermore, before the plates are transferred to the workstation of the loading process, reinforcing rod holes are drilled on each plate.

[0022] The present invention also provides a prefabricated wall panel, which is manufactured using the prefabricated wall panel manufacturing process.

[0023] 3. Beneficial effects

[0024] Compared with the existing known technologies, the technical solution provided by the present invention has the following significant effects:

[0025] (1) A prefabricated wall panel manufacturing process of the present invention comprises a loading process, a turning process, a grouting process, a pre-curing process and a unloading process, wherein the turning machine in the turning process comprises a turning frame and a support frame perpendicular to each other. In the initial state, the turning frame is vertical, the conveyor vehicle is transported to the support frame, and then the turning frame is turned to an inclined state. The plates transported in the loading process are placed on the inclined turning frame, and then the plates are assembled. After the assembly is completed, the turning frame is turned back to a vertical state. The empty turning frame turns from vertical to inclined, and then from inclined to vertical after being loaded with assembled plates. It is not necessary to turn from vertical to horizontal in a conventional turning machine where the empty turning frame turns from vertical to horizontal and the turning frame loaded with plates turns from horizontal to vertical. In the present invention, the turning frame with full load turns from inclined to vertical, which makes it easier to turn the turning frame, thereby saving energy consumption during the turning process and saving energy. The travel of the turning frame from vertical to inclined and then from inclined to vertical is shorter than the travel from vertical to horizontal and then from horizontal to vertical, which reduces the time used in turning and improves production efficiency.

[0026] (2) The present invention provides a prefabricated wall panel manufacturing process, which includes a loading process, a turning process, a grouting process, a pre-curing process, and a unloading process. The panel assembly process is integrated into the turning process. In the turning process, the panels are transported to the turning rack and assembled by an assembly mechanism or manually. A separate panel assembly station is no longer required, saving production space. Each process is connected in sequence through a traction conveyor line to form a product conveying loop. A plurality of transport vehicles are provided on the traction conveyor line for transportation. After the prefabricated wall panel completes one process, it is automatically transported to the next process through the traction conveyor line, thereby improving production efficiency.

[0027] (3) A prefabricated wall panel manufacturing process of the present invention, wherein the loading process is used to transport the panels to the flipping process, the flipping process is used to complete the assembly and flipping of the panels, and the panels are transferred to a conveyor vehicle after flipping to enter the next process, the grouting process is used to grout the reinforcing rod holes of the prefabricated wall panels, the pre-curing process is used to pre-cured the prefabricated wall panels, and the unloading process is used to transfer the prefabricated integrated wall panels to a forklift station, and the processes of splicing, flipping, inserting reinforcing bars, grouting and pre-curing of the panels, etc., and the production links of each wall panel are completed in the factory, realizing factory customization of the wall panels, reducing the manual work on the construction site, avoiding low labor efficiency and thus delaying the construction period, and the quality of the manually spliced ​​walls on site is uneven and cannot be guaranteed, and a large amount of construction waste will be generated on the construction site.

[0028] (4) In a prefabricated wall panel manufacturing process of the present invention, a transverse moving machine and a first transfer crane are respectively arranged at the two ends of the first traction machine and the second traction machine track, so as to realize the transfer of the transport vehicle and the prefabricated integrated wall panels between the two traction tracks, thereby reducing the work of manual transfer. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 This is a structural diagram of the prefabricated wall panel manufacturing process system of the present invention;

[0030] Figure 2 This is a schematic diagram of the prefabricated wall panel of the present invention.

[0031] In the figure: 1. Conveyor; 2. Crane; 20. First crossbeam; 21. Second crossbeam; 3. Integrated wall panel; 31. Reinforcement rod hole; 4. Turning machine; 5. First tractor; 51. Second tractor; 6. First transfer crane; 61. Second transfer crane; 7. First forklift; 71. Second forklift; 8. Transverse transfer vehicle; 81. First cross rail; 82. Second cross rail; 9. Conveyor vehicle; 10. Handrail assembly; 11. Pre-curing room. DETAILED DESCRIPTION

[0032] In order to further understand the content of the present invention, the present invention is described in detail with reference to the accompanying drawings and embodiments.

[0033] like Figure 1As shown, a prefabricated wall panel manufacturing process includes a loading process, a turning process, a grouting process, a pre-curing process and a unloading process. Before the loading process, a reinforcing rod hole 31 is pre-drilled for each plate. A turning machine 4 is set at the work station of the turning process. The turning machine 4 includes a turning frame and a supporting frame perpendicular to each other. The specific production steps in the turning process are as follows: first, the supporting frame of the turning machine 4 is in a horizontal state, and a conveyor 9 is pre-conveyed on it, and then the turning frame of the turning machine 4 is turned to an inclined state; secondly, multiple plates are transferred from the loading process to the turning frame of the turning machine 4, and the plates are assembled and gathered to form a prefabricated integrated wall panel 3; finally, after the assembly is completed, the turning frame of the turning machine 4 is turned vertically again, so that the integrated wall panel 3 is located on the conveyor 9 and transported to the next process.

[0034] Compared to the traditional prefabricated integrated wallboard manufacturing process, in which the wallboard turning process involves the turning frame of the turning machine 4 first turning from a vertical position to a horizontal position and then from a horizontal position to a vertical position, in this embodiment, the turning frame of the turning machine 4 is first in a vertical position. The transport vehicle 9 is transported to the support frame of the turning machine 4. The turning frame then turns to an inclined position. The panels transferred during the loading process are placed on the inclined turning frame. The panels are then assembled. This assembly can be performed using an assembly mechanism or manually. After assembly is completed, the turning frame turns back to a vertical position. Specifically, the turning process of the unloaded turning frame is from vertical to inclined. After loading the assembled panels, it then turns from inclined to vertical. A fully loaded turning frame only turns from inclined to vertical. This makes turning the turning frame easier and more labor-saving, thereby saving energy during the turning process and conserving energy. In addition, because the turning frame's travel from vertical to inclined and then from inclined to vertical is shorter than its travel from vertical to horizontal and then from horizontal to vertical, the time used during the turning process is reduced, further improving production efficiency.

[0035] In this embodiment, when the turning frame of the turning machine 4 is turned to an inclined state, an inclination angle will be formed between the plane where the turning frame is located and the vertical direction. Specifically, the inclination angle is set to 5°~10°. On the one hand, this inclination angle satisfies the requirement that after the plate is transported to the turning frame, the plate leans against the turning frame at an angle to prepare for the next step of assembly and folding, and can also reduce the turning stroke of the turning frame.

[0036] The loading process, flipping process, grouting process, pre-curing process and unloading process are connected in sequence through a traction conveyor line to form a product conveying loop; a crane 2 is provided at the loading process station to transport the plate to the flipping machine 4 at the flipping station, so the side of the flipping frame of the flipping machine 4 on which the plate is placed needs to face the loading direction of the crane 2. Since the plate has been pre-drilled with reinforcing rod holes 31, when the plate is placed on the flipping machine 4, it is necessary to note that the reinforcing rod holes 31 of each plate need to be aligned to prepare in advance for inserting the reinforcing rod into the reinforcing rod holes 31. The grouting process is used to insert the reinforcing rod into the reinforcing rod holes 31 of the integrated wall panel 3, and to grout into the reinforcing rod holes 31. The pre-curing and unloading of the integrated wall panel 3 are completed at the pre-curing process and unloading process stations.

[0037] The traction conveyor line connecting each process includes a first tractor 5 and a second tractor 51, wherein the flipping process, grouting process, and pre-curing process are arranged on the track of the first tractor 5, and the pre-curing process and unloading process are arranged on the track of the second tractor 51. The pre-curing process can connect the tracks of the first tractor 5 and the second tractor 51, and multiple conveying vehicles 9 are provided on the tracks of the first tractor 5 and the second tractor 51 for conveying the integrated wall panels 3.

[0038] A conveyor 1 is installed at the loading station. A first forklift 7 transfers concrete slabs onto conveyor 1, which then transfers them to the underside of crane 2. Crane 2 is mounted on a first beam 20 and a second beam 21 and can move along these beams. These beams extend from conveyor 1 to the turning station. Crane 2 transports concrete slabs from conveyor 1 to the turning rack of turning machine 4 for assembly and folding. After assembly and folding, the integrated wall panels 15 are transported to the next station.

[0039] The turning process station is located on the track of the first tractor 5 and at its starting point. It is important to note that the support frame, which is perpendicular to the turning frame, is located on the track of the first tractor 5 when horizontal. Before the panels are hoisted by the crane 2 to the turning machine 4, a transport vehicle 9 is pre-placed on the support frame to accommodate the integrated wall panels 3. In this embodiment, a separate assembly and collection process is no longer required; the panel assembly process is integrated into the turning process. During the turning process, after the panels are transported to the turning frame, they can be assembled using an assembly mechanism or manually, thus saving production space.

[0040] After the flipping process, the integrated wall panels 3 and the transport vehicle 9 are transported by the first tractor 5 to the grouting process, where reinforcing rods are inserted into the reinforcing rod holes 31 of the integrated wall panels 3 manually or robotically. Furthermore, the grouting process is provided with a grouting mechanism. After the reinforcing rods are inserted into the reinforcing rod holes 31, the grouting mechanism injects grout into the reinforcing rod holes 31, fastening the panels together via the reinforcing rods to form an integral structure. Afterwards, the integrated wall panels 3 and the transport vehicle 9 are transported by the first tractor 5 to the pre-curing process.

[0041] One end of the first tractor 5 and the second tractor 51 extends to the pre-curing process. Specifically, the end of the first tractor 5 and the starting end of the second tractor 51 are located at the pre-curing process. The workstation of the pre-curing process is provided with a pre-curing chamber 11. The pre-curing chamber 11 is provided with a first transfer crane 6. The first transfer crane 6 can transfer the integrated wall panels 3 to any pre-curing position in the pre-curing chamber 11 for pre-curing. In this embodiment, the integrated wall panels 3 and the conveyor trolley 9 are transported to the end of the first tractor 5. The first transfer crane 6 transfers the integrated wall panels 3 and the conveyor trolley 9 to an empty pre-curing position for pre-curing. After the integrated wall panels 3 are pre-cured in the pre-curing chamber 11 for several hours, the first transfer crane 6 lifts the pre-cured integrated wall panels 3 and the conveyor trolley 9 to the starting end of the second tractor 51. Thereafter, the integrated wall panels 3 are transported to the unloading process.

[0042] The unloading station is located on the track of the second tractor 51. A second transfer crane 61 is installed at the unloading station. The second transfer crane 61 lifts the integrated wall panels 3 from the conveyor vehicle 9. A second forklift 71 is installed below the second transfer crane 61 to transfer the lifted integrated wall panels 3 to the storage yard. The empty conveyor vehicle 9 continues to transport along the track of the second tractor 51.

[0043] The first tractor 5 and the second tractor 51 are connected to the transverse transfer vehicle 8 at one end away from the pre-curing chamber 11. In this embodiment, the tracks of the first tractor 5 and the second tractor 51 are parallel, and the transverse transfer vehicle 8 is set on the first transverse rail 81 and the second transverse rail 82. The transverse transfer vehicle 8 can move transversely on the first transverse rail 81 and the second transverse rail 82. The first transverse rail 81 and the second transverse rail 82 extend from the track of the first tractor 5 to the track of the second tractor 51. The transverse transfer vehicle 8 transports the returned empty conveyor vehicle 9 from the second tractor 51 to the work station of the flipping process of the first tractor 5.

[0044] Multiple conveyor vehicles 9 are provided on the tracks of the first tractor 5 and the second tractor 51 for conveying the integrated wall panels 3. The first forklift 7 transports the concrete slab to the conveyor 1 at the loading station. The crane 2 lifts the slab and moves along the first crossbeam 20 and the second crossbeam 21 to transport the slab from the conveyor 1 to the station for the turning process. Prior to this, the support frame of the turning machine 4 is in a horizontal state, and the transverse vehicle 8 transports the conveyor vehicle 9 to the support frame. The turning machine 4 flips, tilting the turning frame. The slab is placed on the turning frame for assembly and folding to form the integrated wall panels 3. The turning machine 4 flips in the opposite direction, turning the turning frame into a vertical state. At the same time, the integrated wall panels 3 are placed on the conveyor vehicle 9 and transported to the grouting process. The reinforcing rods are inserted into the reinforcing rod holes 31 and grouting is completed. After grouting, the integrated wall panels 3 are transported to the pre-curing room 11 for pre-curing. After several hours of pre-curing, the integrated wall panels 3 are transported to the yard, completing the production process of one integrated wall panel 3. Afterwards, the empty transport vehicle 9 continues to be pulled along the track of the second tractor 51 to one end close to the transverse vehicle 8. The transverse vehicle 8 moves transversely to a position that coincides with the extension line of the track of the second tractor 113. The transport vehicle 9 is transported to the transverse vehicle 8. Then the transverse vehicle 8 moves transversely to a position that coincides with the extension line of the track of the first tractor 5. The empty transport vehicle 9 is transported to the support frame of the turnover machine 4, completing a transport cycle of the transport vehicle 9.

[0045] In this embodiment, handrail assemblies 10 are provided along both sides of the track of the first traction machine 5 and on both sides of each pre-curing position, which effectively prevents the integrated wall panels 3 in a vertical state from tipping over.

[0046] like Figure 2 , this embodiment also provides a prefabricated wall panel, which is manufactured using a prefabricated wall panel manufacturing process.

[0047] This embodiment can realize the processes of splicing panels into integrated wall panels, assembling and closing, inserting reinforcing rods, grouting, and pre-curing in the factory, which can realize factory customization of integrated panels, and reduce the turning stroke and time of the turning machine, integrate the turning process and the assembly process, improve production efficiency, and reduce construction waste.

[0048] The above is a schematic description of the present invention and its embodiments, which is not restrictive. The drawings show only one embodiment of the present invention, and the actual structure is not limited thereto. Therefore, if a person skilled in the art is inspired by this and, without departing from the purpose of the present invention, designs a structure and embodiment similar to this technical solution without inventiveness, they shall fall within the scope of protection of the present invention.

Claims

1. A prefabricated wall panel production process, comprising a loading process, a turning process, a grouting process, a pre-curing process and a blanking process, characterized in that: The loading process, the turning process, the grouting process, the pre-curing process and the unloading process are sequentially connected through a traction conveyor line to form a product conveying loop; a turning machine (4) is provided at the work station of the turning process, and the turning machine (4) includes a turning frame and a supporting frame perpendicular to each other; The flipping process comprises the following steps: Step 1: The support frame of the turning machine (4) is in a horizontal state, a transport vehicle (9) is pre-transported thereon, and then the turning frame of the turning machine (4) is turned to an inclined state, wherein the turning frame forms an inclination angle with the vertical direction, and the inclination angle is 5° to 10°; Step 2: Before the panels are transferred to the loading station, a reinforcing rod hole (31) is drilled in each panel, and multiple panels are transferred from the loading station to the turning rack of the turning machine (4), and the panels are assembled and gathered to form a prefabricated integrated wall panel (3); Step 3: After the assembly is completed, the turning frame of the turning machine (4) is turned vertically again, so that the integrated wall panel (3) is placed on the conveying vehicle (9) and transported to the next process, and then goes through the grouting process, the pre-curing process and the unloading process in sequence. The conveying vehicle (9) is connected in sequence through the traction conveyor line to form a product conveying loop and is then conveyed to the turning machine (4) again, completing a conveying cycle.

2. The prefabricated wall panel production process according to claim 1, characterized in that: A crane (2) is provided at the loading process station for transporting the panels to a turning machine (4) at the turning process station. The grouting process is used to insert reinforcing rods into the reinforcing rod holes (31) of the integrated wall panels (3) and to grout the reinforcing rod holes (31). Pre-curing and unloading of the integrated wall panels (3) are completed at the pre-curing process and unloading process stations.

3. The prefabricated wall panel production process according to claim 2, characterized in that: The traction conveyor line includes a first traction machine (5) and a second traction machine (51), the station of the flipping process is set on the track of the first traction machine (5), the station of the unloading process is set on the track of the second traction machine (51), and the station of the unloading process is provided with a second transfer crane (61); one end of the first traction machine (5) and the second traction machine (51) extends to the pre-curing process, and the other end is connected to the transverse transfer vehicle (8), the station of the pre-curing process is provided with a pre-curing room (11), and the first transfer crane (6) is provided in the pre-curing room (11).

4. The prefabricated wall panel production process according to claim 3, characterized in that: In the second step, the turning frame of the turning machine (4) faces the loading process, and the support frame is located on the track of the first traction machine (5) when it is turned to a horizontal state.

5. The prefabricated wall panel production process according to claim 3, characterized in that: A plurality of conveying vehicles (9) are provided on the tracks of the first traction machine (5) and the second traction machine (51) for conveying the integrated wall panels (3).

6. The process for producing prefabricated wall panels according to claim 5, characterized in that: The tracks of the first traction machine (5) and the second traction machine (51) are parallel.

7. The prefabricated wall panel manufacturing process according to claim 3, characterized in that: The transverse track of the transverse vehicle (8) extends from the first tractor (5) to the second tractor (51), and the transverse vehicle (8) is used to transfer the returned empty transport vehicle (9) from the track of the second tractor (51) to the track of the first tractor (5).

8. A prefabricated wall panel, characterized in that: The prefabricated wall panel is manufactured using the prefabricated wall panel manufacturing process described in any one of claims 1 to 7.

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