A large prefabricated component circulating flow production system

Abstract

The application discloses a large prefabricated component circulating flow production system, and relates to the field of large prefabricated component production. The system comprises a lower lying production line track, an upper bearing return track, a middle and side beam intelligent switching production system, a maintenance system, a hoisting and transporting system, two high-low track automatic transverse moving systems and a plurality of movable bottom molds. The lower lying production line track and the upper bearing return track are arranged side by side. A high-low track automatic transverse moving system is arranged at the starting point and the terminal point between the lower lying production line track and the upper bearing return track. The maintenance system is arranged on the lower lying production line track and located between the middle and side beam intelligent switching production system and the high-low track automatic transverse moving system at the terminal point. The hoisting and transporting system is arranged at the rear end of the high-low track automatic transverse moving system at the terminal point. The large prefabricated component circulating flow production system avoids the safety and quality hazards of high-altitude hoisting, improves the utilization rate of the production line and reduces the investment in the formwork and the production line.

Description

Technical Field

[0001] This invention relates to the field of large precast component production, and in particular to a large precast component circulating production system. Background Technology

[0002] In China, most large precast components are typically cast on-site on fixed concrete platforms using standardized steel formwork. This method is characterized by long construction cycles, low automation, large land area requirements, low construction efficiency, significant environmental pollution, high energy consumption, and major safety hazards.

[0003] With the development of technology, technologies such as movable bottom molds and hydraulic formwork have gradually emerged. To a certain extent, these technologies have solved the problems of low automation and large footprint, but they have also brought new challenges, such as the stability of hydraulic formwork and bottom molds for components with large height-to-width ratios, and the problem of cyclic return in grooved production lines. The former is generally solved by reducing the height of the production line, such as by setting up a grooved production line; the latter is generally solved by hoisting the bottom mold at height, but this method still has safety and quality risks associated with hoisting objects at height.

[0004] Large precast components for highway engineering are generally used in bridge construction. They are typically classified by cross-sectional shape as T-shaped or box-shaped, and by location as center beams and edge beams. The formwork for center beams and edge beams is not interchangeable. Furthermore, edge beams are further divided into left and right side beams, and the formwork for edge beams is also not interchangeable due to curved alignments and cross slopes. To manufacture these three different types of components, three sets of steel formwork and three production lines are usually required, resulting in significant space requirements and high costs for formwork and production lines, making it highly uneconomical. Summary of the Invention

[0005] To address the above technical problems, this invention provides a large-scale precast component circulating production system, which avoids safety and quality hazards associated with high-altitude lifting, improves production line utilization, and reduces investment in templates and production lines.

[0006] To achieve the above objectives, the present invention provides the following solution:

[0007] This invention provides a large-scale precast component circulating production system, including a horizontal production line track, an upper-bearing return track, a center-side beam intelligent switching production system, a curing system, a hoisting and transportation system, two high-low track automatic traversing systems, and multiple movable bottom molds. The horizontal production line track and the upper-bearing return track are arranged side by side. An automatic traversing system is located at both the starting point and the ending point between the horizontal production line track and the upper-bearing return track. The automatic traversing system at the ending point moves the movable bottom mold from the horizontal production line track to the upper-bearing return track, while the automatic traversing system at the starting point moves the movable bottom mold from the upper-bearing return track to the horizontal production line track. The center-side beam intelligent switching production system includes a longitudinal track, a first fixed hydraulic template, a second fixed hydraulic template, and a first movable hydraulic template. The system comprises a plate and a second movable hydraulic template. The first fixed hydraulic template and the second fixed hydraulic template are sequentially arranged along the length direction on one side of the horizontal production line track. The longitudinal track is arranged on the other side of the horizontal production line track. Both the first movable hydraulic template and the second movable hydraulic template can slide along the longitudinal track. The sides of the first fixed hydraulic template and the first movable hydraulic template near the horizontal production line track are planar structures. The sides of the second fixed hydraulic template and the second movable hydraulic template near the horizontal production line track are sequentially arranged along the length direction with multiple transverse partition grooves. The maintenance system is covered on the horizontal production line track and is located between the intelligent switching production system for the middle and side beams and the automatic transverse movement system for the high and low tracks at the end point. The hoisting and transportation system is located at the rear end of the automatic transverse movement system for the high and low tracks at the end point.

[0008] Preferably, the system further includes a bottom mold power supply system, which includes a sliding line and a movable power supply trolley. The horizontal production line track includes a groove and a production line track disposed on the bottom surface of the groove. One side wall of the groove is provided with a side receiving groove extending along the length direction. The sliding line is disposed in the side receiving groove and is used to supply power to the movable bottom mold. The movable power supply trolley is slidably mounted on the upper bearing return track and can be connected to the movable bottom mold to supply power to it.

[0009] Preferably, the high and low track automatic traverse system includes multiple traverse devices. Multiple connecting grooves are provided at the starting point and the ending point between the lower horizontal production line track and the upper bearing return track. Both ends of each connecting groove extend to the outer end face of the groove and the outer end face of the upper bearing return track, respectively. The bottom surface of each connecting groove is lower than the bottom surface of the groove. Each connecting groove is equipped with one of the traverse devices.

[0010] Preferably, the movable bottom mold includes a bottom mold body and a plurality of drive wheel sets arranged sequentially along the length direction at the bottom of the bottom mold body; the lateral movement device includes a support frame, a lifting drive mechanism, a support box, an intermediate track, a lateral drive mechanism, and two lateral slide rails. The lifting drive mechanism is disposed in the connecting groove, the support frame is disposed above the lifting drive mechanism, both lateral slide rails are disposed above the support frame, the support box is slidably mounted on the two lateral slide rails, the intermediate track is disposed above the support box, the lateral drive mechanism is used to drive the support box to reciprocate along the lateral slide rails, the intermediate track can dock with the production line track or the upper-bearing return track, and the drive wheel sets can be slidably mounted on the intermediate track.

[0011] Preferably, the lifting drive mechanism includes multiple vertical hydraulic cylinders, and the piston rods of each vertical hydraulic cylinder are connected to the support frame; the horizontal drive mechanism includes a horizontal hydraulic cylinder, a pulley mounting box, a first movable pulley, a second movable pulley, a first fixed pulley, a second fixed pulley, a first connecting rope, and a second connecting rope. The horizontal hydraulic cylinder is mounted on the support frame and located between two horizontal slide rails. The pulley mounting box is fixed to the end of the piston rod of the horizontal hydraulic cylinder. The first movable pulley and the second movable pulley are both mounted in the pulley mounting box. The first movable pulley is located between the piston rod of the horizontal hydraulic cylinder and the second movable pulley. The first fixed pulley and the second fixed pulley are respectively mounted at both ends of the support frame. The first fixed pulley is located at one end near the cylinder body of the horizontal hydraulic cylinder. The second fixed pulley is located at one end of the cylinder body away from the transverse hydraulic cylinder. One end of the first connecting rope is fixed to the cylinder body of the transverse hydraulic cylinder and is sequentially wound around the first movable pulley and the first fixed pulley. The other end of the first connecting rope is fixed to one end of the support box. One end of the second connecting rope is fixed to the support frame at one end away from the cylinder body of the transverse hydraulic cylinder and is sequentially wound around the second movable pulley and the second fixed pulley. The other end of the second connecting rope is fixed to the other end of the support box. The high and low track automatic transverse movement system also includes a hydraulic pump station, which is pre-embedded between the lower horizontal production line track and the upper bearing return track. All the transverse hydraulic cylinders and all the vertical hydraulic cylinders in each of the high and low track automatic transverse movement systems are connected to the hydraulic pump station.

[0012] Preferably, the first movable hydraulic template includes a first hydraulic template body and a plurality of first power wheel sets arranged sequentially along the length direction at the bottom of the first hydraulic template body, and the second movable hydraulic template includes a second hydraulic template body and a plurality of second power wheel sets arranged sequentially along the length direction at the bottom of the second hydraulic template body, wherein the first power wheel sets and the second power wheel sets are slidably mounted on the longitudinal track.

[0013] Preferably, the first fixed hydraulic template, the second fixed hydraulic template, the first hydraulic template body, and the second hydraulic template body are all hollow constant temperature hydraulic templates.

[0014] Preferably, the hollow thermostatic hydraulic template includes a hollow template, a heating pipe, an insulation layer, and multiple reinforcing beams. Multiple reinforcing beams are provided on the inner wall of the inner side of the hollow template, and the insulation layer is provided on the inner wall of the outer side of the hollow template. The heating pipe is located inside the hollow template and is used to introduce hot water or steam.

[0015] Preferably, the curing system includes a curing shed, a temperature sensor, a humidity sensor, multiple steam pipes, and multiple spray pipes. The curing shed is mounted on the track of the horizontal production line. Both ends of the curing shed are equipped with electrically controlled doors. The movable bottom mold can enter or leave the curing shed when the electrically controlled doors are opened. The temperature sensor, the humidity sensor, the multiple steam pipes, and the multiple spray pipes are all located on the inner wall of the curing shed.

[0016] Preferably, the hoisting and transportation system includes a gantry crane and two gantry crane tracks. The front end of one gantry crane track is located on the outer side of the rear end of the horizontal production line track, and the front end of the other gantry crane track is located on the outer side of the rear end of the vertical return track. The gantry crane is slidably mounted on the two gantry crane tracks.

[0017] The present invention achieves the following technical effects compared to the prior art:

[0018] The large-scale precast component circulating production system of this invention features an automatic high-low track traversing system at both the starting and ending points between the lower horizontal production line track and the upper bearing return track. This system enables the circulation of the movable bottom mold, thereby facilitating the cyclical production of large precast components. In other words, this invention achieves the circulation of the movable bottom mold on the ground, avoiding the safety and quality hazards associated with lifting objects at heights. The intelligent switching production system for the middle and side beams includes a longitudinal track, a first fixed hydraulic template, a second fixed hydraulic template, a first movable hydraulic template, and a second movable hydraulic template. This allows for the production of three types of components—left beam, right beam, and middle beam—using one production line and two sets of templates. This reduces the space required, improves production line utilization, and reduces investment in templates and the production line itself. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 Production flow diagram of the large prefabricated component circulating water production system provided by the present invention;

[0021] Figure 2 A schematic diagram showing the coordination between the horizontal production line track and the upward return track in the large prefabricated component circulating production system provided by the present invention.

[0022] Figure 3 A schematic diagram of the installation of the automatic transverse movement system of high and low tracks in the large prefabricated component circulating production system provided by the present invention.

[0023] Figure 4 A schematic diagram of the automatic transverse movement system of high and low tracks in the large prefabricated component circulating production system provided by the present invention;

[0024] Figure 5 A schematic diagram of the overall structure of the automatic transverse movement system of high and low tracks in the large prefabricated component circulating production system provided by the present invention;

[0025] Figure 6 A schematic diagram of the upper structure of the automatic transverse movement system of high and low tracks in the large prefabricated component circulating production system provided by the present invention.

[0026] Figure 7 A schematic diagram of the operation of the intelligent switching production system for middle and side beams in the large precast component circulating production system provided by the present invention during the production of side beams.

[0027] Figure 8 A schematic diagram of the operation of the intelligent switching production system for the middle and side beams in the large precast component circulating production system provided by the present invention during the production of the middle beam;

[0028] Figure 9 A schematic diagram of the hollow constant temperature hydraulic template in the large prefabricated component circulating production system provided by the present invention;

[0029] Figure 10 A schematic diagram of the installation of heating pipes in the large prefabricated component circulating water production system provided by the present invention;

[0030] Figure 11 A schematic diagram of the installation of horizontal pipes and fixing components in the large prefabricated component circulating water production system provided by the present invention;

[0031] Figure 12 A schematic diagram of the curing system in the large prefabricated component circulating water production system provided by the present invention;

[0032] Figure 13 This is a schematic diagram illustrating the coordination between the upper-bearing production line track and the upper-bearing return track in the existing technology.

[0033] Explanation of reference numerals in the attached drawings: 1. Lower horizontal production line track; 101. Groove; 102. Production line track; 103. Side receiving groove; 2. Upper bearing return track; 3. Movable bottom mold; 4. Movable power supply trolley; 5. Automatic horizontal movement system for high and low tracks; 51. Support frame; 52. Vertical hydraulic cylinder; 53. Horizontal slide rail; 54. Support box; 55. Middle track; 56. Horizontal hydraulic cylinder; 57. Pulley mounting box; 58. First movable pulley; 59. Second movable pulley; 510. First fixed pulley; 511. Second fixed pulley; 512. First connecting rope; 513. Second connecting rope; 514. Sliding wheel; 6. Intelligent switching production system for middle and side beams; 61. Longitudinal... 62. Track; 63. First fixed hydraulic template; 64. Second fixed hydraulic template; 65. First movable hydraulic template; 66. Second movable hydraulic template; 7. Curing system; 71. Hollow square steel pipe; 72. Double-layer polycarbonate sheet; 73. Steam pipe; 74. Spray pipe; 8. Gantry crane track; 9. Gantry crane; 10. Sliding line; 11. Hollow template; 12. Reinforcing beam; 13. Insulation layer; 14. Heating pipe; 141. Horizontal pipe; 142. Intermediate vertical pipe; 15. Fixture; 16. Main water inlet pipe; 17. Main water return pipe; 18. Support; 19. Platform; 20. Guardrail; 21. Upper tie rod; 22. Lower tie rod; 23. Upper-bearing production line track. Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] The purpose of this invention is to provide a large-scale precast component circulating production system that avoids safety and quality hazards caused by high-altitude lifting, improves production line utilization, and reduces investment in templates and production lines.

[0036] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments.

[0037] like Figures 1-12 As shown, this embodiment provides a large-scale precast component circulating production system, including a lower horizontal production line track 1, an upper bearing return track 2, a middle and side beam intelligent switching production system 6, a curing system 7, a hoisting and transportation system, two high and low track automatic traverse systems 5, and multiple movable bottom molds 3. The lower horizontal production line track 1 and the upper bearing return track 2 are arranged side by side. A high and low track automatic traverse system 5 is set at both the starting point and the ending point between the lower horizontal production line track 1 and the upper bearing return track 2. The high and low track automatic traverse system 5 at the ending point is used to move the movable bottom mold 3 from the lower horizontal production line track 1 to the upper bearing return track 2, and the high and low track automatic traverse system 5 at the starting point is used to move the movable bottom mold 3 from the upper bearing return track 2 to the lower horizontal production line track 1.

[0038] like Figure 13 As shown, when the upper-bearing production line track 23 and the upper-bearing return track 2 are combined, there are stability issues with the hydraulic template and bottom mold of the high aspect ratio component. For example... Figure 2 As shown, in this embodiment, by designing the production line as a groove type, and setting the movable bottom mold 3 as an upper-bearing return track 2 when returning unloaded, the overall construction height can be reduced, safety hazards can be eliminated, and stability and aesthetics can be improved, while not affecting the lateral passage of each functional area. In this embodiment, the circulation of the movable bottom mold 3 is realized through the high and low track automatic lateral movement system 5, thereby enabling the cyclical production of large precast components. That is, in this embodiment, the circulation of the movable bottom mold 3 is realized on the ground, avoiding the safety hazards and quality hazards of high-altitude lifting.

[0039] like Figure 7 and Figure 8As shown, the intelligent switching production system 6 for the middle and side beams includes a longitudinal track 61, a first fixed hydraulic template 62, a second fixed hydraulic template 63, a first movable hydraulic template 64, and a second movable hydraulic template 65. The first fixed hydraulic template 62 and the second fixed hydraulic template 63 are arranged sequentially along the length direction on one side of the horizontal production line track 1, and the longitudinal track 61 is arranged on the other side of the horizontal production line track 1. The first movable hydraulic template 64 and the second movable hydraulic template 65 can both slide along the longitudinal track 61. The sides of the first fixed hydraulic template 62 and the first movable hydraulic template 64 near the horizontal production line track 1 are both planar structures, that is, the sides of the first fixed hydraulic template 62 and the first movable hydraulic template 64 near the horizontal production line track 1 are not provided with transverse partition grooves. The sides of the second fixed hydraulic template 63 and the second movable hydraulic template 65 near the horizontal production line track 1 are each provided with multiple transverse partition grooves sequentially along the length direction. The intelligent switching production system 6 for the middle and side beams in this embodiment enables the production of three types of components—left beam, right beam, and middle beam—using one production line and two sets of templates. This reduces the space occupied, improves the utilization rate of the production line, and reduces the investment in templates and production lines.

[0040] The maintenance system 7 is installed on the lower horizontal production line track 1 and is located between the middle and side beam intelligent switching production system 6 and the high and low track automatic transverse movement system 5 at the end point. The hoisting and transportation system is located at the rear end of the high and low track automatic transverse movement system 5 at the end point.

[0041] In this embodiment, the large precast component circulating production system consists of, from front to back, a rebar binding area, a concrete pouring area, a steam curing area, an initial tensioning and lifting area, and a beam storage area. Specifically, the area corresponding to the automatic high-low track traversing system 5 at the starting point is the rebar binding area; the area corresponding to the intelligent switching production system 6 for the middle and side beams is the concrete pouring area; the area corresponding to the curing system 7 is the steam curing area; the area corresponding to the automatic high-low track traversing system 5 at the end point and the area at the front end of the hoisting and transportation system are the initial tensioning and lifting area; and the area at the rear end of the hoisting and transportation system is the beam storage area.

[0042] This embodiment adopts a general approach of fixed side molds and sliding bottom molds. It utilizes a horizontal production line track 1 in conjunction with an upper-bearing return track 2, and an automatic lateral movement system 5 to achieve the circulation of the movable bottom mold 3. This enables the cyclical production of large precast components, upgrading the traditional concrete fixed bottom mold and assembled side mold production system to an industrialized cyclical production system. The site is divided into longitudinal functional areas according to the precast component construction sequence. The movable bottom mold 3 moves along the production line, completing the corresponding process in each functional area. At the start and end points of the production line, technical measures are used to complete the lateral movement and circulation of the movable bottom mold 3, achieving assembly line production, standardized operation, and intelligent management of precast components.

[0043] Compared to the traditional fixed concrete formwork production process, the time occupied by a single formwork is reduced to 40 hours. The production efficiency of precast components under the same number of concrete formwork is increased by 150%, and the production efficiency of precast components is increased by 50% under the same floor space. The self-designed high and low track automatic lateral movement system 5 realizes the lateral circulation between the lower horizontal production line track 1 and the upper bearing return track 2. Compared with the conventional gantry crane high-altitude hoisting circulation method, the safety is greatly improved, and the deflection impact of the double lifting point hoisting of the formwork is reduced, thereby improving the quality of the finished precast components. It also achieves the effects of shortening the construction cycle, reducing the floor space, and increasing construction efficiency.

[0044] like Figure 2 and Figure 3 As shown, this embodiment also includes a bottom mold power supply system, which includes a sliding line 10 and a movable power supply trolley 4. The horizontal production line track 1 includes a groove 101 and a production line track 102 disposed on the bottom surface of the groove 101. One side wall of the groove 101 is provided with a side receiving groove 103 extending along the length direction. The sliding line 10 is disposed in the side receiving groove 103 and is used to supply power to the movable bottom mold 3. In this embodiment, the sliding line 10 adopts a slot contact type, which can conceal the wires. The design of the side receiving groove 103 greatly reduces the risk of water accumulation, dust accumulation, and electric shock. The movable power supply trolley 4 is slidably installed on the upper-bearing return track 2. The movable power supply trolley 4 can be connected to the movable bottom mold 3 to supply power to the movable bottom mold 3. In this embodiment, the bottom mold power supply system adopts two different power supply methods according to the actual situation of the horizontal production line track 1 and the upper-bearing return track 2, which improves the safety, aesthetics, and practicality of the bottom mold power supply system.

[0045] Specifically, the mobile power supply trolley 4 consists of twenty-six 1.4KW lead-acid batteries, equipped with a transformer, a controller, and a retractable power supply plug. The retractable power supply plug can supply power to the mobile base mold 3 after being connected to it. The entire machine is powered by four motors with a total of 3KW, and can operate independently, moving along the upper-bearing return track 2. After connecting to the mobile base mold 3, the power of the mobile power supply trolley 4 is turned off, and the mobile base mold 3 drives it to move. When it is necessary to separate the mobile power supply trolley 4 from the mobile base mold 3, the retractable power supply plug can be separated from the mobile base mold 3.

[0046] Specifically, the production line track 102 is laid out with P75 steel rails, reinforced with grouting at the bottom, and the groove 101 has a reserved cross slope for water collection and a longitudinal slope for drainage in the middle, and a reserved side receiving groove 103 on the side wall.

[0047] This embodiment also includes a smart beam yard management platform. The intelligent switching production system 6 for the middle and side beams, the maintenance system 7, the hoisting and transportation system, the bottom formwork power supply system, the two high and low track automatic lateral movement systems 5, and multiple movable bottom forms 3 are all connected to the smart beam yard management platform.

[0048] Specifically, both the sliding line 10 and the movable power supply trolley 4 are connected to the intelligent beam yard management platform. The first fixed hydraulic formwork 62, the second fixed hydraulic formwork 63, the first movable hydraulic formwork 64, and the second movable hydraulic formwork 65 are all connected to the intelligent beam yard management platform.

[0049] The high and low track automatic traverse system 5 includes multiple traverse devices. Multiple connecting grooves are provided at the starting point and the ending point between the lower horizontal production line track 1 and the upper bearing return track 2. The two ends of each connecting groove extend to the outer end face of the groove 101 and the outer end face of the upper bearing return track 2, respectively. The bottom surface of each connecting groove is lower than the bottom surface of the groove 101. A traverse device is installed in each connecting groove.

[0050] The movable bottom mold 3 includes a bottom mold body and multiple active wheel sets arranged sequentially along the length direction at the bottom of the bottom mold body. The active wheel sets are connected to the intelligent beam yard management platform. The active wheel sets can move along the production line track 102 or the upper-bearing return track 2. The active wheel sets are powered by the sliding line 10 or the movable power supply trolley 4.

[0051] In this embodiment, the bottom mold body adopts a steel platform with a length of 41m and a width of 1m. Each large precast component circulating production system is equipped with four movable bottom molds 3, which can be moved along the production line track 102 or the upper-bearing return track 2 with beams or no load after power supply.

[0052] like Figure 5 As shown, the lateral movement device includes a support frame 51, a lifting drive mechanism, a support box 54, a middle track 55, a lateral drive mechanism, and two lateral slide rails 53. The lifting drive mechanism is disposed in the connecting groove, the support frame 51 is disposed on the upper part of the lifting drive mechanism, and the two lateral slide rails 53 are both disposed on the upper part of the support frame 51. The support box 54 is slidably mounted on the two lateral slide rails 53. In this embodiment, the support box 54 is slidably mounted on the two lateral slide rails 53 through the sliding wheel 514 at the bottom. The middle track 55 is disposed on the upper part of the support box 54. The lateral drive mechanism is used to drive the support box 54 to reciprocate along the lateral slide rails 53. In this embodiment, the production line track 102 and the upper-bearing return track 2 are disconnected at the location of the connecting groove. The middle track 55 can dock with the production line track 102 or the upper-bearing return track 2. That is, the connecting groove in this embodiment can accommodate the support frame 51 and make the middle track 55 flush with the production track. The drive wheel set can be slidably mounted on the middle track 55. The lifting drive mechanism and the lateral drive mechanism are both connected to the intelligent beam yard management platform.

[0053] like Figure 4As shown, by controlling the lateral drive mechanism at the endpoint, the support box 54 and the intermediate track 55 are positioned on the side corresponding to the production line track 102. The lifting drive mechanism is controlled to lower the support frame 51, making the intermediate track 55 flush with the production line track 102. At this time, the intermediate track 55 and the production line track 102 are connected, allowing the active wheel set of the movable bottom mold 3 to move onto the intermediate track 55. Then, the lateral drive mechanism drives the support box 54 and the intermediate track 55 to move towards the upper-bearing return track 2. The lifting drive mechanism is controlled to raise the support frame 51, making the intermediate track 55 flush with the upper-bearing return track 2. At this time, the intermediate track 55 and the upper-bearing return track 2 are connected, allowing the active wheel set of the movable bottom mold 3 to move onto the upper-bearing return track 2 and return to the starting point. Specifically, after the movable bottom mold 3 moves to the upper-bearing return track 2, the movable power supply trolley 4 connects with the movable bottom mold 3 to supply power. Correspondingly, at the starting point, by controlling the lateral drive mechanism and the lifting drive mechanism at the starting point, the movable bottom mold 3 can be moved from the upper bearing return track 2 to the production line track 102, thereby completing the cyclic movement of the movable bottom mold 3.

[0054] The lifting drive mechanism includes multiple vertical hydraulic cylinders 52, and the piston rod of each vertical hydraulic cylinder 52 is connected to the support frame 51. The lifting and lowering of the support frame 51 is achieved by the extension and retraction of the piston rod of the vertical hydraulic cylinder 52.

[0055] like Figure 6 As shown, the lateral drive mechanism includes a lateral hydraulic cylinder 56, a pulley mounting box 57, a first movable pulley 58, a second movable pulley 59, a first fixed pulley 510, a second fixed pulley 511, a first connecting rope 512, and a second connecting rope 513. The lateral hydraulic cylinder 56 is mounted on the support frame 51 and located between two lateral slide rails 53. The pulley mounting box 57 is fixed to the end of the piston rod of the lateral hydraulic cylinder 56. The first movable pulley 58 and the second movable pulley 59 are both mounted in the pulley mounting box 57. The first movable pulley 58 is located between the piston rod of the lateral hydraulic cylinder 56 and the second movable pulley 59. The first fixed pulley 510 and the second fixed pulley 511 are respectively mounted on the support frame 51. At both ends of the support frame 51, the first fixed pulley 510 is located at one end of the cylinder body near the transverse hydraulic cylinder 56, and the second fixed pulley 511 is located at one end of the cylinder body away from the transverse hydraulic cylinder 56. One end of the first connecting rope 512 is fixed to the cylinder body of the transverse hydraulic cylinder 56 and is wound around the first movable pulley 58 and the first fixed pulley 510 in sequence. The other end of the first connecting rope 512 is fixed to one end of the support box 54. One end of the second connecting rope 513 is fixed to the end of the support frame 51 away from the cylinder body of the transverse hydraulic cylinder 56 and is wound around the second movable pulley 59 and the second fixed pulley 511 in sequence. The other end of the second connecting rope 513 is fixed to the other end of the support box 54.

[0056] In this embodiment, the transverse hydraulic cylinder 56 is installed on the support frame 51 at one end corresponding to the production line track 102. When working, the piston rod of the transverse hydraulic cylinder 56 extends, and the support box 54 and the intermediate track 55 move toward the side closer to the production line track 102; when the piston rod of the transverse hydraulic cylinder 56 retracts, the support box 54 and the intermediate track 55 move toward the side closer to the upper bearing return track 2.

[0057] In this specific embodiment, the transverse slide rail 53 is a steel rail, the first connecting rope 512 is a first steel wire rope, and the second connecting rope 513 is a second steel wire rope.

[0058] The automatic lateral movement system 5 for high and low tracks also includes a hydraulic pump station, which is pre-embedded between the lower horizontal production line track 1 and the upper bearing return track 2. All horizontal hydraulic cylinders 56 and all vertical hydraulic cylinders 52 in each automatic lateral movement system 5 are connected to the hydraulic pump station. Furthermore, the horizontal hydraulic cylinders 56, vertical hydraulic cylinders 52, and the hydraulic pump station are all connected to the intelligent beam yard management platform. After installation, the strokes of the horizontal hydraulic cylinders 56 and vertical hydraulic cylinders 52 are precisely adjusted. The intelligent beam yard management platform records and records data, and after debugging, no further adjustments are required. The horizontal hydraulic cylinders 56 and vertical hydraulic cylinders 52 in each automatic lateral movement system 5 share a single hydraulic pump station, achieving synchronous lifting and lateral movement.

[0059] In this specific embodiment, the high and low track automatic traverse system 5 includes three traverse devices. Three connecting slots are provided at both the starting point and the ending point between the lower horizontal production line track 1 and the upper supporting return track 2. The three traverse devices are respectively located below the three drive wheel sets of the movable bottom mold 3, and the distance between two adjacent traverse devices is ten meters.

[0060] In this specific embodiment, the hydraulic pump station has a width of 2m, a length of 2m, and a height of 2m, with reinforced concrete sidewalls around it. The transverse movement device has a length of 3.75m, a width of 0.6m, and a height of 1.5m, and is equipped with two vertical hydraulic cylinders 52, each with a stroke of 0.6m. The intermediate track 55 has a length of 0.6m.

[0061] The first movable hydraulic formwork 64 includes a first hydraulic formwork body and multiple first power wheel sets sequentially arranged along the length direction at the bottom of the first hydraulic formwork body. The second movable hydraulic formwork 65 includes a second hydraulic formwork body and multiple second power wheel sets sequentially arranged along the length direction at the bottom of the second hydraulic formwork body. Both the first and second power wheel sets are slidably mounted on the longitudinal track 61. The first hydraulic formwork body, the first power wheel sets, the second hydraulic formwork body, and the second power wheel sets are all connected to the intelligent beam yard management platform. By controlling the first and second power wheel sets, the first movable hydraulic formwork 64 and the second movable hydraulic formwork 65 can move along the longitudinal track 61.

[0062] During operation, by moving the first movable hydraulic template 64 and the second movable hydraulic template 65 on the longitudinal track 61, when the first fixed hydraulic template 62 and the second movable hydraulic template 65 are positioned correspondingly, one type of side beam can be produced; when the second fixed hydraulic template 63 and the first movable hydraulic template 64 are positioned correspondingly, another type of side beam can be produced, with multiple transverse diaphragms arranged sequentially along the length direction on one side of the produced side beam; when the second fixed hydraulic template 63 and the second movable hydraulic template 65 are positioned correspondingly, a middle beam can be produced, with multiple transverse diaphragms arranged sequentially along the length direction on both sides of the produced middle beam. Therefore, in this embodiment, by adjusting the positions of the first movable hydraulic template 64 and the second movable hydraulic template 65, the production of three types of components—left side beam, right side beam, and middle beam—can be achieved.

[0063] In this specific embodiment, the second fixed hydraulic template 63 is disposed at the front end of the first fixed hydraulic template 62, and the first movable hydraulic template 64 is disposed at the front end of the second movable hydraulic template 65. When the positions of the first fixed hydraulic template 62 and the second movable hydraulic template 65 are corresponding, the positions of the second fixed hydraulic template 63 and the first movable hydraulic template 64 are also corresponding, so that the production of the two types of side beams can be completed respectively.

[0064] In this specific embodiment, the first fixed hydraulic template 62 is the first fixed high-side hydraulic template, the second fixed hydraulic template 63 is the second fixed high-side hydraulic template, the first movable hydraulic template 64 is the first movable low-side hydraulic template, and the second movable hydraulic template 65 is the second movable low-side hydraulic template.

[0065] The first fixed hydraulic template 62, the second fixed hydraulic template 63, the first hydraulic template body, and the second hydraulic template body are all hollow constant temperature hydraulic templates. In this embodiment, the hollow constant temperature hydraulic template adopts an integral stainless steel hydraulic template and is connected to the intelligent beam yard management platform. It can be opened and closed as a whole with one click, that is, the hollow constant temperature hydraulic template can move laterally in the opening and closing direction using hydraulic devices.

[0066] like Figure 9 As shown, in this embodiment, a support 18 is provided on the outer side of the hollow thermostatic hydraulic template, a platform 19 is provided on the outer side of the upper part of the support 18, and a guardrail 20 is provided around the platform 19. It also includes an upper pull rod 21 and a lower pull rod 22, which are used to connect the upper and lower parts of the supports 18 of two corresponding hollow thermostatic hydraulic templates, respectively.

[0067] Addressing the challenges of large diurnal temperature variations and low temperatures in spring and autumn in mountainous areas, the hollow thermostatic hydraulic formwork comprises a hollow formwork 11, heating pipes 14, an insulation layer 13, and multiple reinforcing beams 12. Multiple reinforcing beams 12 are installed on the inner wall of the hollow formwork 11, while the insulation layer 13 is installed on the inner wall of the outer side of the hollow formwork 11 to reduce heat loss. The heating pipes 14 are located inside the hollow formwork 11 and are used to circulate hot water or steam. The hot water or steam heats the hollow formwork 11, maintaining a constant temperature, reducing the diurnal temperature variation, and minimizing the impact of temperature differences on the quality of finished components. This ensures high-quality, consistent finished products, particularly improving edge chipping and corner breakage, resulting in a better appearance and ensuring efficient production cycle.

[0068] The hollow formwork 11 is made of stainless steel panel. Five reinforcing beams 12 are set on the inner wall of the stainless steel panel inside the hollow formwork 11. Four of them are set on the rib plate and one is set at the bottom of the wing plate to enhance the rigidity of the stainless steel panel.

[0069] like Figure 10 As shown, the heating tube 14 includes a central vertical tube 142 and multiple horizontal tubes 141. The multiple horizontal tubes 141 are arranged sequentially from top to bottom within the hollow template 11. Multiple fasteners 15 are installed along the length of each horizontal tube 141, and these fasteners 15 are welded to the inner wall of the hollow template 11 to secure the horizontal tubes 141 and prevent displacement that could affect the temperature control. The central vertical tube 142 is connected to the middle of the multiple horizontal tubes 141. A water tap is installed at the lower end of the central vertical tube 142, and the tap extends from an outlet on the side wall of the hollow template 11 to the outside. The tap is turned on periodically to prevent condensate or gas inside the hollow template 11 from clogging the heating tube 14.

[0070] like Figure 11 As shown, a fixing member 15 is installed every 2m along the length of the horizontal pipe 141. The fixing member 15 is a steel ring made of φ8mm steel bars, which wraps around the horizontal pipe 141. The end of the steel ring extends outward and is then welded to the hollow template 11. In this embodiment, the horizontal pipe 141 is a galvanized pipe and is wrapped with thermal insulation asbestos.

[0071] The two ends of the horizontal pipe 141 are connected to the inlet main pipe 16 and the return main pipe 17, respectively. Both the inlet main pipe 16 and the return main pipe 17 are pre-embedded underground in the prefabrication site. During construction in low-temperature and cold weather, the inlet main pipe 16 and the return main pipe 17 are connected to the boiler. The boiler provides heating, allowing hot water or steam to flow through the pipes to achieve a constant temperature. The hot water or steam is supplied by the inlet main pipe 16 to each horizontal pipe 141 of the formwork through pressure, and then flows out through the return main pipe 17 on the other side, forming a loop.

[0072] like Figure 12 As shown, the curing system 7 includes a curing shed, a temperature sensor, a humidity sensor, multiple steam pipes 73 and multiple spray pipes 74. The curing shed is mounted on the horizontal production line track 1. Both ends of the curing shed are equipped with electrically controlled doors. The movable bottom mold 3 can enter or leave the curing shed when the electrically controlled doors are opened. The temperature sensor, humidity sensor, multiple steam pipes 73 and multiple spray pipes 74 are all installed on the inner wall of the curing shed.

[0073] In this embodiment, multiple steam pipes 73 are connected to a steam supply pipe, and a flow valve is installed on the steam supply pipe. Multiple spray pipes 74 are connected to a spray supply pipe, and a switch is installed on the spray supply pipe. The temperature sensor, humidity sensor, flow valve, and switch are all connected to the smart beam yard management platform.

[0074] Twelve hours after concrete pouring, the movable bottom formwork 3, carrying the components, is moved to the curing shed. Temperature and humidity sensors pre-installed within the shed monitor the temperature and humidity, uploading the data to the smart beam yard management platform. The platform intelligently adjusts the steam flux and spraying frequency based on the temperature and humidity data, saving energy and water while ensuring a smooth transition in temperature and humidity. In this embodiment, the curing system 7 employs a fully enclosed steam spraying curing method. After 24 hours of constant temperature and humidity curing, it switches to conventional spraying curing to enhance the curing effect and ensure efficient cycle operation.

[0075] The curing shed is constructed using double-layer polycarbonate panels 72 and hollow square steel pipes 71 with sides of 30mm. Five steam pipes 73 are installed circumferentially on the inner wall of the shed, and three spray pipes 74 are installed on the top, left, and right sides. The double-layer polycarbonate panels 72 can quickly raise the temperature inside the curing shed during periods of ample sunlight in summer, eliminating the need for a steam boiler to supply steam for curing; spray curing is sufficient. This method offers low construction costs, energy savings, and high durability.

[0076] The curing system 7 utilizes innovative methods such as high-precision sensors to control temperature and humidity, ensuring a smooth transition in temperature and humidity within the shed. This guarantees rapid improvement in concrete strength and accelerates the production efficiency of the recycling system. Traditional recycling precast component processes have high requirements for concrete curing and ambient temperature. The innovatively designed hollow constant-temperature hydraulic formwork and double-layer steam spray curing have enabled the successful application of the recycling precast process in mountainous areas of northern China with large diurnal temperature differences, greatly expanding the applicability of the recycling precast component process.

[0077] The hoisting and transportation system includes a gantry crane 9 and two gantry crane tracks 8. The front end of one gantry crane track 8 is located on the outer side of the rear end of the horizontal production line track 1, and the front end of the other gantry crane track 8 is located on the outer side of the rear end of the upper-bearing return track 2. The gantry crane 9 is slidably installed on the two gantry crane tracks 8. The gantry crane 9 is connected to the intelligent beam yard management platform. The gantry crane 9 is used to hoist and transport finished components to the beam storage area.

[0078] This specification uses specific examples to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. Furthermore, those skilled in the art will recognize that, based on the ideas of the present invention, there will be changes in the specific implementation methods and application scope. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A large-scale prefabricated component circulating production system, characterized in that, The system includes a horizontal production line track, an upper-bearing return track, a center-side beam intelligent switching production system, a maintenance system, a hoisting and transportation system, two high-low track automatic traversing systems, and multiple movable bottom molds. The horizontal production line track and the upper-bearing return track are arranged side by side. An automatic traversing system is located at both the starting and ending points between the horizontal production line track and the upper-bearing return track. The automatic traversing system at the ending point moves the movable bottom mold from the horizontal production line track to the upper-bearing return track, while the automatic traversing system at the starting point moves the movable bottom mold from the upper-bearing return track to the horizontal production line track. The center-side beam intelligent switching production system includes a longitudinal track, a first fixed hydraulic template, a second fixed hydraulic template, a first movable hydraulic template, and a second movable hydraulic template. The first fixed hydraulic template and the second fixed hydraulic template are sequentially arranged along the length direction on one side of the horizontal production line track, and the longitudinal track is arranged on the other side of the horizontal production line track. The first movable hydraulic template and the second movable hydraulic template can both slide along the longitudinal track. The sides of the first fixed hydraulic template and the first movable hydraulic template near the horizontal production line track are both planar structures. The sides of the second fixed hydraulic template and the second movable hydraulic template near the horizontal production line track are each sequentially arranged along the length direction with multiple transverse partition grooves. The maintenance system is covered on the horizontal production line track and is located between the intelligent switching production system for the middle and side beams and the automatic transverse movement system for the high and low tracks at the end point. The hoisting and transportation system is located at the rear end of the automatic transverse movement system for the high and low tracks at the end point.

2. The large-scale prefabricated component circulating production system according to claim 1, characterized in that, It also includes a bottom mold power supply system, which includes a sliding line and a movable power supply trolley. The horizontal production line track includes a groove and a production line track disposed on the bottom surface of the groove. One side wall of the groove is provided with a side receiving groove extending along the length direction. The sliding line is disposed in the side receiving groove and is used to supply power to the movable bottom mold. The movable power supply trolley is slidably mounted on the upper bearing return track. The movable power supply trolley can be connected to the movable bottom mold to supply power to the movable bottom mold.

3. The large-scale prefabricated component circulating production system according to claim 2, characterized in that, The high and low track automatic traverse system includes multiple traverse devices. Multiple connecting slots are provided at the starting point and the ending point between the lower horizontal production line track and the upper bearing return track. Both ends of each connecting slot extend to the outer end face of the groove and the outer end face of the upper bearing return track, respectively. The bottom surface of each connecting slot is lower than the bottom surface of the groove. Each connecting slot is equipped with one of the traverse devices.

4. The large-scale prefabricated component circulating production system according to claim 3, characterized in that, The movable bottom mold includes a bottom mold body and multiple drive wheel sets arranged sequentially along the length direction at the bottom of the bottom mold body; the lateral movement device includes a support frame, a lifting drive mechanism, a support box, an intermediate track, a lateral drive mechanism, and two lateral slide rails. The lifting drive mechanism is disposed in the connecting groove, the support frame is disposed above the lifting drive mechanism, both lateral slide rails are disposed above the support frame, the support box is slidably mounted on the two lateral slide rails, the intermediate track is disposed above the support box, the lateral drive mechanism is used to drive the support box to reciprocate along the lateral slide rails, the intermediate track can dock with the production line track or the upper-bearing return track, and the drive wheel sets can be slidably mounted on the intermediate track.

5. The large-scale prefabricated component circulating production system according to claim 4, characterized in that, The lifting drive mechanism includes multiple vertical hydraulic cylinders, and the piston rods of each vertical hydraulic cylinder are connected to the support frame. The horizontal drive mechanism includes a horizontal hydraulic cylinder, a pulley mounting box, a first movable pulley, a second movable pulley, a first fixed pulley, a second fixed pulley, a first connecting rope, and a second connecting rope. The horizontal hydraulic cylinder is mounted on the support frame and located between two horizontal slide rails. The pulley mounting box is fixed to the end of the piston rod of the horizontal hydraulic cylinder. The first movable pulley and the second movable pulley are both mounted in the pulley mounting box. The first movable pulley is located between the piston rod of the horizontal hydraulic cylinder and the second movable pulley. The first fixed pulley and the second fixed pulley are respectively mounted at both ends of the support frame. The first fixed pulley is located at one end near the cylinder body of the horizontal hydraulic cylinder. The second fixed pulley is located at one end of the cylinder body away from the transverse hydraulic cylinder. One end of the first connecting rope is fixed to the cylinder body of the transverse hydraulic cylinder and is sequentially wound around the first movable pulley and the first fixed pulley. The other end of the first connecting rope is fixed to one end of the support box. One end of the second connecting rope is fixed to the support frame at one end away from the cylinder body of the transverse hydraulic cylinder and is sequentially wound around the second movable pulley and the second fixed pulley. The other end of the second connecting rope is fixed to the other end of the support box. The high and low track automatic transverse movement system also includes a hydraulic pump station, which is pre-embedded between the lower horizontal production line track and the upper bearing return track. All the transverse hydraulic cylinders and all the vertical hydraulic cylinders in each of the high and low track automatic transverse movement systems are connected to the hydraulic pump station.

6. The large-scale prefabricated component circulating production system according to claim 1, characterized in that, The first movable hydraulic template includes a first hydraulic template body and a plurality of first power wheel sets arranged sequentially along the length direction at the bottom of the first hydraulic template body. The second movable hydraulic template includes a second hydraulic template body and a plurality of second power wheel sets arranged sequentially along the length direction at the bottom of the second hydraulic template body. Both the first power wheel sets and the second power wheel sets are slidably mounted on the longitudinal track.

7. The large-scale prefabricated component circulating production system according to claim 6, characterized in that, The first fixed hydraulic template, the second fixed hydraulic template, the first hydraulic template body, and the second hydraulic template body are all hollow constant temperature hydraulic templates.

8. The large-scale prefabricated component circulating production system according to claim 7, characterized in that, The hollow thermostatic hydraulic template includes a hollow template, a heating pipe, an insulation layer, and multiple reinforcing beams. Multiple reinforcing beams are provided on the inner wall of the inner side of the hollow template, and the insulation layer is provided on the inner wall of the outer side of the hollow template. The heating pipe is located inside the hollow template and is used to introduce hot water or steam.

9. The large-scale prefabricated component circulating production system according to claim 1, characterized in that, The curing system includes a curing shed, a temperature sensor, a humidity sensor, multiple steam pipes, and multiple spray pipes. The curing shed is mounted on the track of the horizontal production line. Both ends of the curing shed are equipped with electrically controlled doors. The movable bottom mold can enter or leave the curing shed when the electrically controlled doors are opened. The temperature sensor, the humidity sensor, the multiple steam pipes, and the multiple spray pipes are all located on the inner wall of the curing shed.

10. The large-scale prefabricated component circulating production system according to claim 1, characterized in that, The hoisting and transportation system includes a gantry crane and two gantry crane tracks. The front end of one gantry crane track is located on the outer side of the rear end of the horizontal production line track, and the front end of the other gantry crane track is located on the outer side of the rear end of the vertical return track. The gantry crane is slidably installed on the two gantry crane tracks.

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