Production device and method of concrete member

Abstract

The invention discloses a concrete member production device and method.The concrete member production device comprises a supporting assembly provided with a support and a supporting table, the supporting table is slidably connected with the support, a member mold is of a cubic structure and located on the supporting table, the member mold is formed by splicing a plurality of flexible mold units, and locking equipment is located on the supporting table; the locking device is used for fixing and limiting the position of the component mold, the control system is installed on the support, the bottom of the component mold is provided with an adjusting device, the adjusting device comprises a supporting air bag and a balance adjuster, and the inclination of the component mold is adjusted through the balance adjuster. According to the device, the component mold formed by splicing the multiple flexible mold units can adapt to different component shapes, so that the flexibility of the device is improved, meanwhile, under the mutual cooperation of the locking equipment and the adjusting device, the component mold can be stably kept at the needed fixing position, uniform pouring of concrete is effectively ensured, and the construction efficiency is improved. Therefore, the stability and the quality of the concrete member are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of concrete components, and in particular to a production device and method for concrete components. Background Art

[0002] Concrete components refer to structural parts made of steel bars and concrete as the main materials. They are widely used in various construction projects and infrastructure construction. Concrete components have the advantages of high strength, good durability, and strong plasticity. They can withstand various loads and transfer them to the foundation or other supporting structures. Common concrete components include beams, slabs, columns, walls, etc.

[0003] In the relevant technology, concrete components can be prefabricated, that is, they are pre-made outside the factory or construction site and then transported to the site for installation, or they can be cast on site, that is, the concrete is cast and formed directly at the construction site. In order to make concrete components better meet people's diverse needs, precast concrete is widely used, and concrete components are manufactured and produced according to needs using production equipment for subsequent installation and use.

[0004] However, it is difficult for existing concrete component production devices to accurately adjust the shape of the device to match the flow and filling characteristics of concrete, which can easily lead to local material shortages, dimensional deviations or uneven surfaces in the components. At the same time, it cannot meet the casting needs of concrete components with complex shapes, which can easily lead to uneven concrete distribution, voids or impacts on molds and steel bars. It is also unable to adapt to different climates, resulting in incomplete hydration and cracking of concrete components, thereby affecting the demolding and molding quality of the concrete components. Summary of the invention

[0005] In order to solve the problem that it is difficult to accurately adjust the shape of the device to match the flow and filling characteristics of concrete, which easily leads to local material shortage, size deviation or uneven surface of the component, and cannot meet the casting requirements of complex-shaped concrete components, easily leads to uneven concrete distribution, voids or impact on molds and steel bars, and cannot adapt to different climates, resulting in incomplete hydration and cracking of concrete components, thereby affecting the demoulding and molding quality of concrete components, the present invention provides a production device and method for concrete components, and the technical scheme adopted is as follows: According to a first aspect of the present application, the present application provides a production device for a concrete component, comprising: A support assembly, comprising a support and a support platform, wherein the support platform is slidably connected to the support; The component mold is in a cubic structure and is located on the support platform. The component mold is formed by splicing a plurality of flexible mold units, and two connected flexible mold units are connected by a hydraulic hinge; A locking device, located on the support platform, the locking device is used to fix and limit the position of the component mold; A control system, mounted on the bracket; The bottom of the component mold is provided with an adjustment device, which includes a supporting airbag and a balance adjuster installed on the supporting assembly, and the inclination of the component mold is adjusted by the balance adjuster.

[0006] Preferably, it also includes a pouring device installed on the bracket, the pouring device is located above the component mold, the pouring device includes a concrete box, a pouring pipe and a servo motor, the pouring pipe is connected to the concrete box through a five-axis robotic arm, the output end of the servo motor is connected to the five-axis robotic arm, and the servo motor is driven so that the five-axis robotic arm drives the pouring pipe to rotate at multiple angles.

[0007] Preferably, a high-precision flow sensor and a pressure sensor are installed on the pouring pipe, and the high-precision flow sensor and the pressure sensor are both electrically connected to the control system.

[0008] Preferably, a pressing plate is provided on one side of the casting equipment, the pressing plate is connected to the bracket via a telescopic cylinder, and the pressing plate matches the component mold; In the assembled state, the pressing plate is driven to approach or move away from the component mold along the height direction of the component mold, so that the concrete in the component mold is squeezed and released.

[0009] Preferably, a vibration system is provided at the bottom of the support platform, and the vibration system includes a vibrator and a plurality of telescopic springs. An output end of the vibrator is connected to the support platform, and the other end is connected to the bracket. Each telescopic spring is installed at the corner where the support platform is connected to the bracket.

[0010] Preferably, the locking device includes an electric slide rail, a mechanical gripper and a hydraulic locking mechanism. The electric slide rail is installed on the top surface of the support table. One end of the mechanical gripper is connected to the electric slide rail, and the other end is connected to the hydraulic locking mechanism. The mechanical gripper is driven to move along the extension direction of the electric slide rail to drive the hydraulic locking mechanism to fix and connect the component mold.

[0011] Preferably, the component mold has a heating wire and a cooling water pipe inside, and a temperature sensor and a humidity sensor are installed around the component mold, and the temperature sensor and the humidity sensor are both electrically connected to the control system; The control system sends a control signal to the heating wire or the cooling water pipe according to preset concrete pouring and curing conditions and sensor data to automatically control the temperature and humidity environment.

[0012] Preferably, a sealing rubber ring or a metal sealing gasket is provided at the connection of the component mold.

[0013] According to a second aspect of the present application, the present application provides a method for producing a concrete component, comprising: Mold preparation: Select flexible mold units according to the shape and size of the component, assemble them into a component mold through hydraulic hinges and place them on the support table. Use a balance adjustment device to adjust the inclination of the support table and the component mold, and drive the mechanical gripper and hydraulic locking mechanism of the locking device to lock the component mold; Concrete pouring: Move the support platform to the bottom of the pouring equipment, turn on the pouring equipment to allow the concrete to flow into the component mold through the pouring pipe, and put in steel bars to complete the prefabrication of the concrete; Vibration: After pouring, the support platform is slid to the bottom of the pressing plate, and the pressing plate is driven to move closer to or away from the component mold. Then, the vibrator is started to evenly place the concrete in the component mold and reduce bubbles in the concrete.

[0014] Preferably, the method further includes curing: during and after pouring, the control system controls the heating wire or the cooling water pipe through the sensor data in the component mold so that the concrete is at a suitable temperature and humidity.

[0015] Compared with the prior art, the present invention has the following technical advances: The component mold formed by splicing multiple flexible mold units in the present invention can adapt to different component shapes, thereby improving the flexibility of the device. At the same time, with the cooperation of the locking device and the adjusting device, the component mold can be stably maintained in the required fixed position, effectively ensuring uniform pouring of concrete, thereby improving the stability and quality of the concrete component. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The accompanying drawings are used to provide further understanding of the present invention and constitute a part of the specification. They are used to explain the present invention together with the embodiments of the present invention and do not constitute a limitation of the present invention.

[0017] In the attached picture: Figure 1 It is a structural schematic diagram of a production device for concrete components of the present invention; Figure 2 A schematic diagram of a production device for a concrete member according to the present invention; Figure 3 A structural diagram of a production device for a concrete member of the present invention; Figure 4 It is a three-dimensional diagram of the production device of the concrete component of the present invention.

[0018] In the figure: 1. Support assembly; 11. Bracket; 12. Support table; 13. Slide; 2. Component mold; 21. Flexible mold unit; 22. Seal; 3. Locking device; 31. Electric slide rail; 32. Mechanical gripper; 33. Hydraulic locking mechanism; 4. Control system; 5. Adjustment device; 51. Support airbag; 52. Balance regulator; 6. Pouring equipment; 61. Concrete box; 62. Pouring pipe; 63. Servo motor; 7. Sensor; 8. Press plate; 9. Telescopic cylinder; 10. Vibration system; 101. Vibrator; 102. Telescopic spring. DETAILED DESCRIPTION

[0019] The following specific embodiments may be combined with each other, and the same or similar concepts or processes may not be described in detail in some embodiments. The embodiments of the present invention will be described below in conjunction with the accompanying drawings.

[0020] like Figures 1 to 4 As shown, the present invention discloses a production device for concrete components, including a support assembly 1, a component mold 2, a locking device 3 and a control system 4, wherein the support assembly 1 includes a bracket 11 and a support platform 12 slidably connected to the bracket 11, so that the support platform 12 can be moved to a required area according to the steps required by the operator during use, thereby improving the consistency and efficiency of the production process. In an example, as shown in Figure 4 As shown, a slide groove 13 is arranged on the bracket 11, and the support platform 12 is slidably connected to the bracket 11 through the slide groove, so that the support platform 12 can be slid to the required area for the production of concrete components. The component mold 2 is a cubic structure and is located on the support platform 12. The component mold 2 is spliced ​​by a plurality of flexible mold units 21, and the two connected flexible mold units 21 are connected by a hydraulic hinge. The operator only needs to adjust the shape of the component mold 2 according to the concrete components of different shapes and sizes by controlling the extension and rotation of the hydraulic hinge, so as to facilitate the production of the required concrete components, thereby improving the versatility and adaptability of the component mold 2 and shortening the production preparation time. The locking device 3 is located on the support platform 12, and the locking device 3 is used to fix and limit the position of the component mold 2 to ensure the stability of the component mold 2 in subsequent operations. The control system 4 is installed on the bracket 11, and can control the locking device 3 and the support platform 12 for easy operation. In one example (not shown in the drawings), a handle is further provided on the component mold, so that the operator can hold the handle to place the component mold on the support table. After completing the production of the concrete component, the operator holds the handle again to place the component mold with the concrete component in a drying area for subsequent processing operations.

[0021] The bottom of the component mold 2 is provided with an adjustment device 5, which includes a support airbag 51 and a balance regulator 52 installed on the bracket 11. The support airbag 51 is located between the support platform 12 and the component mold 2. The balance regulator 52 can adjust the inclination of the component mold 2. The support airbag 51 is used to support concrete and the component mold 2, and the surface of the support airbag 51 is a smooth surface that directly contacts the concrete, which is convenient for subsequent demoulding of concrete components to avoid adhesion that affects the quality of the concrete components. During the use of the device, the operator places the component mold 2 on the support platform 12 and adjusts the balance regulator 52. 2 adjusts the parallelism between the component mold 2 and the ground so that the component mold 2 is in a horizontal state. When pouring concrete in the component mold 2, the horizontality can be adjusted at any time to ensure the flatness of the subsequent concrete component surface and the quality of the entire product. When the component mold 2 with an inclination is to be produced, the operator adjusts it through the balance regulator 52 so that the support platform 12 drives the inside of the support airbag 51 to tilt to one side, and the bottom surface of the component mold 2 has an inclination angle with the ground, so as to produce an inclined concrete component, thereby improving the molding accuracy of the concrete component and reducing the defective rate caused by the position deviation of the component mold 2.

[0022] Preferably, continue to refer to Figure 1 and Figure 4 The production device of the concrete component also includes a pouring device 6 installed on the bracket 11. The pouring device 6 is located above the component mold 2 and is responsible for pouring concrete evenly into the component mold 2. The pouring device 6 includes a concrete box 61, a pouring pipe 62 and a servo motor 63. The concrete box 61 and the servo motor 63 are installed on the top of the bracket 11. One end of the pouring pipe 62 is connected to the concrete box 61, and the other end is arranged on the top of the component mold 2. Among them, the concrete box 61 is used to store and supply concrete to ensure that the concrete can be continuously supplied during the production process to avoid insufficient or interrupted conditions during the pouring process. The pouring pipe 62 is used to transport concrete from the concrete box 61 to the component mold 2 to avoid blockage or uneven distribution. The pouring pipe 62 is connected to the concrete box 61 through a five-axis robot arm. The concrete box 61 is connected so that the layout and pouring process of the pouring pipe 62 can be flexibly adjusted. The five-axis robotic arm allows the pouring pipe 62 to be precisely operated at multiple angles and directions through its multi-degree-of-freedom movement ability. The five-axis robotic arm can accurately control the pouring direction and flow rate of concrete according to the shape and requirements of different component molds 2, ensure that the concrete is evenly distributed, and avoid the occurrence of bubbles, gaps or excessive concentration. The output end of the servo motor 63 is connected to the five-axis robotic arm, and the servo motor 63 is driven to enable the five-axis robotic arm to drive the pouring pipe to rotate at multiple angles. Through the cooperation of the five-axis robotic arm and the servo motor 63, the pouring pipe 62 can be rotated at multiple angles and precisely controlled to ensure that the concrete is evenly poured in the component mold 2, avoiding deviations or unevenness that may occur in traditional pouring methods.

[0023] Preferably, Figure 4 As shown, a sensor 7 is installed on the pouring pipe 62. The sensor 7 monitors and accurately controls the concrete in real time. The sensor 7 can be a high-precision flow sensor and a pressure sensor. The high-precision flow sensor is used to accurately measure the flow rate of concrete in the pouring pipe. By monitoring, it can be ensured that the concrete flows into the component mold 2 evenly and stably. The pressure sensor is used to detect the pressure of the concrete in the pouring pipe 62 to ensure that the concrete maintains an appropriate pressure level during the entire pouring process. Too high pressure may cause the pouring pipe 62 to rupture or uneven distribution of concrete, while too low pressure may cause incomplete or uneven pouring. The high-precision flow sensor and the pressure sensor are both electrically connected to the control system 4, ensuring real-time transmission and processing of sensor data, and the operator can make timely adjustments based on the data.

[0024] Preferably, Figures 1 to 4 As shown, a pressure plate 8 is provided on one side of the pouring equipment 6. The pressure plate 8 is used to apply pressure to the concrete in the component mold 2 during the concrete pouring process to help the concrete evenly fill the component mold 2 and eliminate bubbles or gaps therein. The pressure plate 8 is connected to the bracket 11 through the telescopic cylinder 9, and the pressure plate 8 matches the component mold 2.

[0025] In the assembled state, the pressing plate 8 is driven close to or away from the component mold 2 along the height direction of the component mold 2 to squeeze and release the concrete in the component mold 2. When the pressing plate 8 is close to the component mold 2, the concrete in the component mold 2 can be squeezed to help the concrete better fill various parts of the component mold 2, and remove the bubbles or gaps therein, thereby enhancing the density and stability of the concrete. After the extrusion is completed, the pressing plate 8 is driven away from the component mold 2, so that the concrete in the component mold 2 forms a prototype, and the concrete is placed in a drying area for solidification and hardening.

[0026] Preferably, Figures 1 to 4 As shown, a vibration system 10 is arranged at the bottom of the support platform 12, and the vibration system 10 includes a vibrator 101 and a plurality of telescopic springs 102. The output end of the vibrator 101 is connected to the support platform 12. When the vibrator 101 is turned on, the vibration effect generated by the support platform 12 helps to distribute the concrete more evenly in the component mold 2 and remove the bubbles in the concrete, thereby ensuring the density and strength of the concrete component. Four telescopic springs 102 are arranged, and each telescopic spring 102 is installed at the corner where the support platform 12 is connected to the bracket 11. The telescopic spring 102 has a certain elasticity, which can effectively absorb and disperse the mechanical impact generated by the vibrator 101, and prevent the structural damage or instability of the support platform 12 and the bracket 11 caused by excessive vibration.

[0027] Preferably, continue to refer to Figures 1 to 4There are four locking devices 3, which are respectively located on the four sides of the component mold 2. The locking devices 3 include an electric slide rail 31, a mechanical gripper 32 and a hydraulic locking mechanism 33. The electric slide rail 31 is installed on the top surface of the support platform 12. The extension direction of the electric slide rail 31 is parallel to the edge of the support platform 12. One end of the mechanical gripper 32 is connected to the electric slide rail 31, and the other end is connected to the hydraulic locking mechanism 33. The mechanical gripper 32 is driven to move along the extension direction of the electric slide rail 31 to drive the hydraulic locking mechanism 33 to fix and connect the component mold 2. During the working process, when it is necessary to fix the component mold 2, the electric slide rail 31 drives the mechanical gripper 32 to move along the extension direction of the electric slide rail 31 and approach the component mold 2, and accurately locates the hydraulic locking mechanism 33 to the side wall of the component mold 2. At this time, the hydraulic locking mechanism 33 clamps and locks the component mold 2 by applying hydraulic pressure, ensuring that the component mold 2 remains stable and does not move during the entire production process, avoiding errors caused by manual operation, and effectively ensuring the quality of concrete components.

[0028] Preferably, in one example (not shown in the attached drawings), the component mold has a heating wire and a cooling water pipe inside, and a temperature sensor and a humidity sensor are installed around the component mold. The temperature sensor and the humidity sensor are electrically connected to the control system. The main function of the heating wire is to increase the temperature inside the component mold to meet the temperature requirements during the concrete solidification process. In a low temperature environment, the cement hydration reaction of the concrete is slow, which affects the strength development of the concrete. The heating wire provides a uniform temperature through electric heating to promote the hardening of the concrete. The control system adjusts the heating intensity of the heating wire according to the real-time temperature data provided by the temperature sensor to keep the temperature inside the component mold within the required range. The cooling water pipe is used to reduce the temperature inside the component mold by circulating cooling water. When the ambient temperature is too high or too much heat is generated during the concrete curing process, the cooling water pipe can effectively take away the excessive heat to avoid the high temperature affecting the quality of the concrete. The cooling system accurately controls the temperature inside the mold by controlling the water flow and water temperature to ensure that the concrete will not produce cracks or other structural problems due to excessive temperature during the curing process.

[0029] Preferably, a seal 22 is provided at the connection of the component mold 2, and the seal 22 can fill the gap at the connection of the component mold 2 to prevent the concrete from flowing out and affecting the quality of the concrete component. In one example, the seal 22 is a sealing rubber ring, which has good elasticity and compressibility, and can automatically adapt to different surface shapes when the component mold 2 is assembled, ensuring that the connection of the component mold 2 is completely sealed. When the component mold 2 is tightly connected, the sealing rubber ring will be compressed to form an effective sealing layer to prevent the concrete from overflowing or leaking from the connection during the pouring process. In another example, the seal 22 is a metal sealing gasket, which is made of a high temperature resistant and corrosion resistant metal material and can provide a more solid and durable sealing effect.

[0030] The present application provides a method for producing a concrete component, comprising: Mould preparation: Select flexible mould units 21 according to the shape and size of the concrete component, assemble them into a component mould 2 through hydraulic hinges and place them on the support platform 12. Use the balance regulator 51 to adjust the inclination of the support platform 12 and the component mould 2, so as to effectively prevent the deviation or uneven distribution of concrete during the pouring process, thereby affecting the quality of subsequent concrete components. Then drive the mechanical gripper 32 and the hydraulic locking mechanism 33 of the locking device 3 to lock the component mould 2, so as to limit the position of the component mould 2 and avoid displacement in subsequent operations.

[0031] Concrete pouring: After placing the component mold 2, move the support platform 12 and drive the component mold 2 to the bottom of the pouring equipment 6, turn on the pouring equipment 6 to allow the concrete to flow into the component mold 2 through the pouring pipe 62, and adjust the flow rate of the concrete according to the sensor (high-precision flow sensor and pressure sensor) to ensure that the concrete can completely fill every corner of the component mold 2 to form a uniform concrete layer. At the same time, put in steel bars to complete the prefabrication of the concrete.

[0032] Vibration: After pouring, slide the support platform 12 to the bottom of the pressing plate 8, drive the pressing plate 8 close to the component mold 2 and apply appropriate pressure to ensure that the concrete is within the required range. At the same time, start the vibrator 101 to evenly place the concrete in the component mold 2, thereby improving the fluidity of the concrete and making the concrete density uniform, reducing bubbles in the concrete, and avoiding the occurrence of defects such as cracks and voids in the later stage.

[0033] Maintenance: During and after pouring, the control system 4 obtains data through the temperature sensor and humidity sensor in the component mold 2 and adjusts the heating wire or cooling water pipe according to the data feedback to ensure that the concrete is in the most suitable temperature and humidity environment. The heating wire is heated by electric energy to increase the internal temperature of the component mold 2, especially in a low temperature environment, which helps to accelerate the hydration reaction of the concrete and prevent the insufficient strength or crack formation of the concrete caused by low temperature. When the ambient temperature is high or the concrete generates too much heat, the cooling water pipe takes away excess heat through the circulation of cooling water to keep the temperature inside the component mold 2 stable and avoid concrete structural defects caused by overheating, thereby improving the strength and durability of the concrete.

[0034] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or replace some of the technical features therein with equivalents. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the scope of protection of the claims of the present invention.

Claims

1. A production device for concrete components, characterized in that: include: A support assembly, comprising a support and a support platform, wherein the support platform is slidably connected to the support; The component mold is in a cubic structure and is located on the support platform. The component mold is formed by splicing a plurality of flexible mold units, and two connected flexible mold units are connected by a hydraulic hinge; A locking device, located on the support platform, the locking device is used to fix and limit the position of the component mold; A control system, mounted on the bracket; The bottom of the component mold is provided with an adjustment device, which includes a supporting airbag and a balance adjuster installed on the supporting assembly, and the inclination of the component mold is adjusted by the balance adjuster.

2. A production device for concrete components according to claim 1, characterized in that: It also includes a pouring device installed on the bracket, the pouring device is located above the component mold, the pouring device includes a concrete box, a pouring pipe and a servo motor, the pouring pipe is connected to the concrete box through a five-axis robotic arm, the output end of the servo motor is connected to the five-axis robotic arm, and the servo motor is driven so that the five-axis robotic arm drives the pouring pipe to rotate at multiple angles.

3. A production device for concrete components according to claim 2, characterized in that: A high-precision flow sensor and a pressure sensor are installed on the pouring pipeline, and both the high-precision flow sensor and the pressure sensor are electrically connected to the control system.

4. A production device for concrete components according to claim 3, characterized in that: A pressing plate is provided on one side of the casting equipment, the pressing plate is connected to the bracket through a telescopic cylinder, and the pressing plate matches the component mold; In the assembled state, the pressing plate is driven to approach or move away from the component mold along the height direction of the component mold, so that the concrete in the component mold is squeezed and released.

5. The production device of a concrete component according to claim 2, characterized in that: A vibration system is arranged at the bottom of the support platform, and the vibration system includes a vibrator and a plurality of telescopic springs. An output end of the vibrator is connected to the support platform, and the other end is connected to the bracket. Each telescopic spring is installed at the corner where the support platform is connected to the bracket.

6. A production device for concrete components according to claim 5, characterized in that: The locking device includes an electric slide rail, a mechanical gripper and a hydraulic locking mechanism. The electric slide rail is installed on the top surface of the support table. One end of the mechanical gripper is connected to the electric slide rail, and the other end is connected to the hydraulic locking mechanism. The mechanical gripper is driven to move along the extension direction of the electric slide rail to drive the hydraulic locking mechanism to fix and connect the component mold.

7. The production device of a concrete component according to claim 1, characterized in that: The component mold has a heating wire and a cooling water pipe inside, and a temperature sensor and a humidity sensor are installed around the component mold, and the temperature sensor and the humidity sensor are both electrically connected to the control system; The control system sends a control signal to the heating wire or the cooling water pipe according to preset concrete pouring and curing conditions and sensor data to automatically control the temperature and humidity environment.

8. The production device of a concrete component according to claim 7, characterized in that: The connection of the component mold is provided with a sealing rubber ring or a metal sealing gasket for sealing.

9. A method for producing a concrete component, characterized in that: include: Mold preparation: Select flexible mold units according to the shape and size of the component, assemble them into a component mold through hydraulic hinges and place them on the support table. Use a balance adjustment device to adjust the inclination of the support table and the component mold, and drive the mechanical gripper and hydraulic locking mechanism of the locking device to lock the component mold; Concrete pouring: Move the support platform to the bottom of the pouring equipment, turn on the pouring equipment to allow the concrete to flow into the component mold through the pouring pipe, and put in steel bars to complete the prefabrication of the concrete; Vibration: After pouring, the support platform is slid to the bottom of the pressing plate, and the pressing plate is driven to move closer to or away from the component mold. Then, the vibrator is started to evenly place the concrete in the component mold and reduce bubbles in the concrete.

10. A method for producing a concrete component according to claim 9, characterized in that: The maintenance is also included: during and after pouring, the control system controls the heating wire or the cooling water pipe through the sensor data in the component mold so that the concrete is at a suitable temperature and humidity.

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