Intelligent manufacturing floor support plate production system and production method

Abstract

The invention discloses an intelligent manufacturing floor support plate production system and method. A forming conveying line body is sequentially provided with an upper mold station, a cleaning station, a mold oil spraying station, a gridding cloth arrangement station, a material distribution station, an automatic slicking station, a truss placement station, a vibration station, a stacking station, a gantry frame moving station and a conveying station in the conveying direction of the forming conveying line body. And bottom die feeding, cleaning, demolding oil spraying, gridding cloth arrangement, concrete distribution, concrete leveling, steel bar truss placement, bottom film vibration, bottom film stacking, bottom film maintenance and finished product conveying are sequentially carried out. The system can realize automatic processing of the steel bar truss floor support plate, has the characteristics of high automation and standardization, can greatly improve the production efficiency and the product quality stability, and reduces the labor cost and potential safety hazards in the production process.

Description

Technical Field

[0001] The present invention relates to the field of floor deck production, and in particular to an intelligent manufacturing floor deck production system and production method. Background Art

[0002] With the implementation of energy-saving and environmental protection policies, prefabricated buildings are being vigorously developed and promoted. This innovation is of great significance to protecting cultivated land, saving energy, improving the environment and implementing sustainable development strategies. As a key component of buildings, the traditional production method of floor decking is manual manufacturing on the construction site. This method not only has low production efficiency, but also has uneven production quality, making it difficult to ensure stable product quality. Therefore, it is imperative to optimize the production process of floor decking. Summary of the invention

[0003] The present invention aims to solve at least one of the technical problems existing in the prior art. To this end, one object of the present invention is to provide an intelligent manufacturing floor deck production system and production method.

[0004] The technical solution of the present invention is as follows: an intelligent manufacturing floor deck production system, characterized in that it includes:

[0005] Forming conveyor line body;

[0006] A bottom mold upper mold robot, wherein the bottom mold upper mold robot is used to convey the bottom mold to the molding conveyor line;

[0007] A cleaning device, the cleaning device is located at the downstream side of the bottom mold upper mold robot, and the cleaning device is used to clean the bottom mold;

[0008] A demoulding oil device, the demoulding oil device is located at the downstream side of the cleaning device, and the demoulding oil device is used to spread demoulding oil on the bottom mold;

[0009] A pouring device, the pouring device is located at the downstream side of the demoulding oil device, and the pouring device is used to pour the mesh cloth on the bottom mold and pour concrete;

[0010] A steel truss robot, the steel truss robot is located at the downstream side of the casting device, and the steel truss robot is used to place the steel truss on the bottom mold;

[0011] A vibration device, the vibration device is located at the downstream side of the steel truss robot, and the vibration device is used to fix the steel truss to the concrete bottom surface by vibration;

[0012] A maintenance device is located at the downstream side of the vibration device, and is used to maintain the produced steel truss floor deck.

[0013] A production method of the intelligent manufacturing floor deck production system according to claim 1, comprising the following steps:

[0014] S1. The bottom mold upper mold robot transports the bottom mold to the molding conveyor line, and the cleaning device cleans the bottom mold to ensure that there is no attachment on the bottom mold. Then, the bottom mold is transported to the demoulding oil device through the molding conveyor line to be coated with demoulding oil.

[0015] S2. The bottom mold is transported to the pouring device through the forming conveyor line to arrange the pouring mesh and pour the concrete. After the pouring is completed, the steel truss robot places the steel truss on the bottom mold, and then fixes the steel truss to the bottom surface of the concrete through the vibration device, completing the production of the steel truss floor deck;

[0016] S3. The steel truss floor decking is automatically released through the double-station ferry lifting device. After the release is completed, it is transported to the curing area and can be demoulded after 4-6 hours of curing. The bottom mold after demoulding can be recycled.

[0017] Compared with the prior art, the present invention has the following beneficial effects:

[0018] This system can realize the automated processing of steel truss floor decking, with the characteristics of high automation and standardization, which can greatly improve production efficiency and product quality stability, reduce labor costs and safety hazards in the production process.

[0019] Additional aspects and advantages of the present invention will be given in part in the following description and in part will be obvious from the following description, or will be learned through practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art are briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative work:

[0021] Figure 1 It is a schematic diagram of the production line layout of the present invention;

[0022] Figure 2 It is a process flow chart of the processing method of the present invention.

[0023] Figure 3 It is a schematic diagram of applying mold release oil of the present invention;

[0024] Figure 4 is a schematic diagram of a glass hanging mesh cloth of the present invention;

[0025] Figure 5is a schematic diagram of the fabric of the present invention;

[0026] Figure 6 is a schematic diagram of an upper steel bar truss of the present invention;

[0027] Figure 7 It is a vibration schematic diagram of the present invention;

[0028] Figure 8 This is a schematic diagram of kiln curing of the present invention;

[0029] Fig. 9 It is a finished product schematic diagram of the present invention. DETAILED DESCRIPTION

[0030] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0031] Embodiments of the present invention are described in detail below, and examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. In the description of the present invention, it should be understood that the orientations or positional relationships indicated by the terms "upper", "lower", "front", "rear", "left", "right", "inner", "outer", "vertical", "circumferential", etc. are based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0032] In the prior art, a type of floor slab used in prefabricated buildings is a PC laminated slab, which is composed of a prefabricated concrete base plate and a concrete layer poured on site. The following pain points exist in the actual construction and use of ordinary PC laminated slabs:

[0033] 1. High assembly investment cost

[0034] The investment in an assembly plant can cost tens of millions or even hundreds of millions. The investment cost needs to be spread over the product components, which results in the high price of PC laminated boards (60mm).

[0035] 2. Low production efficiency

[0036] The four-way reinforcement of the truss steel composite plate has extremely low production efficiency and a large mold amortization

[0037] 3. Difficult transportation

[0038] PC laminated boards are difficult to transport and are prone to cracking

[0039] 4. Inconvenient installation

[0040] A 300-wide post-casting strip is left between the boards, which is prone to water seepage, increasing the workload of template installation. In addition, due to the reinforcement of the composite board in four directions, the installation is inconvenient and unsafe. If there is a little wind or heavy rain, the work can only be stopped. The PC board needs a full-house bracket during installation.

[0041] 5. Complex construction process

[0042] Install the PC board first and then tie the beam reinforcement. When tying the beam reinforcement, the composite board has reinforcement in four directions. The reinforcement between the plates makes it very difficult to tie the beam reinforcement. To tie the beam reinforcement properly, you can only do it in a rough way, which greatly increases the cost of PC assembly.

[0043] The assembled truss reinforced composite slab adopts the design of 60+70 or 60+80. Among them, 60 is prefabricated and 70 is cast-in-place concrete. It is difficult to install 3 ∮25 wire tubes + ∮8 steel bars for 70mm cast-in-place, and at least 80mm cast-in-place is required. The formed thickness of the floor slab reaches more than 140mm, which increases the amount of cast-in-place concrete.

[0044] Based on the shortcomings of this PC composite board, floor decking has begun to be used in floor construction. In order to optimize the production and processing process of floor decking, this application scheme provides the following Figure 1-Figure 9 An intelligent manufacturing floor deck production system shown includes: a concrete mixing station, a forming conveyor line and a curing kiln.

[0045] The molding conveyor line is provided with a mold upper station, a cleaning station, a demoulding oil spraying station, a mesh cloth arrangement station, a material distribution station, an automatic scraping station, a truss placement station, a vibration station, a stacking station, a gantry shifting station and a conveying station in sequence along its conveying direction;

[0046] The loading station is provided with a bottom mold upper mold robot, and the bottom mold upper mold robot is used to transport the bottom mold to the molding conveyor line body;

[0047] The cleaning station is provided with a cleaning device, and the cleaning device is used to clean the bottom mold;

[0048] The demoulding oil spraying station is provided with a demoulding oil device, and the demoulding oil device is used to spray demoulding oil onto the bottom mold;

[0049] The mesh cloth arrangement station is provided with a mesh cloth arrangement device, and the mesh cloth arrangement device is used to arrange the mesh cloth on the bottom mold;

[0050] The material distribution station is provided with a pouring device, and the pouring device is used to pour concrete into the bottom mold;

[0051] The automatic scraping station is provided with a scraping device, which is used to scrape the poured concrete flat;

[0052] A steel truss robot is provided at the truss placement station, and the steel truss robot is used to place the steel truss on the bottom mold;

[0053] The vibration station is provided with a vibration device, and the vibration device is used to compact the bottom mold with the steel bar truss by vibration;

[0054] A palletizing robot is provided at the palletizing station, and the palletizing robot is used to batch palletize the bottom molds with steel bar trusses;

[0055] A frame transfer robot is provided at the gantry frame transfer station, and the frame transfer robot is used to send the bottom mold with the steel bar truss to the curing kiln for rapid steam curing, and to remove the cured truss plate;

[0056] A conveying device is provided at the conveying station, and the conveying device is used to convey the truss plate.

[0057] The specific method of producing steel truss floor decking in this system is as follows:

[0058] S1. The bottom mold upper mold robot transports the bottom mold to the molding conveyor line, the cleaning device cleans the bottom mold to ensure that there is no attachment on the bottom mold, and then the demoulding oil device sprays demoulding oil on the bottom mold;

[0059] S2, the mesh cloth arrangement device arranges the mesh cloth on the bottom mold, the pouring device pours concrete on the bottom mold, and then the leveling device levels the poured concrete, the steel truss robot places the steel truss on the bottom mold, and then vibrates it through the vibration device;

[0060] S3. After the stacking robot stacks the bottom molds with steel trusses in batches, the rack transfer robot will then send them to the curing kiln for rapid steaming. After curing for 4-6 hours, they can be demoulded. The cured truss plates are then removed and transported outward. The demoulded bottom molds are recycled.

[0061] This intelligent manufacturing floor deck production system has the following advantages:

[0062] 1. The single-line output of the intelligent manufacturing floor decking production system can reach 2,500 square meters, and one board can be produced in 30 seconds;

[0063] 2. Convenient and fast construction, four-way reinforcement-free dense connection, and no post-casting strip;

[0064] 3. It is also suitable for areas that are easy to cut, open holes, and have special-shaped panels. The bottom plate does not require formwork, and pipeline penetration is convenient;

[0065] 4. The deadweight is only one-third of the weight of the PC truss reinforced concrete composite plate, which saves labor and materials, thus greatly reducing the cost of components in various links such as manufacturing, storage, transportation and installation;

[0066] 5. The transportation efficiency is more than 3 times that of ordinary laminated panels;

[0067] To sum up, the overall cost is about 200 yuan / ㎡ lower than that of traditional PC (60mm) boards.

[0068] Manufacturing advantages:

[0069] 1. Small equipment investment and low amortization cost;

[0070] 2. The production line has a high degree of automation;

[0071] 3. The side mold is fixed and no reinforcement is produced;

[0072] 4. The base plate is thin and the production speed is fast; the daily output of a single line can reach 2500 square meters, and one plate can be produced in 30 seconds;

[0073] 5. Small storage space is occupied, and zero inventory can be achieved;

[0074] 6. The production efficiency is five times that of concrete composite slabs.

[0075] Installation and transportation advantages:

[0076] 1. The formwork for the cast-in-place joints of the 60mm thick composite slab is cancelled, the bottom slab reinforcement is not cut off, the force is better, and the support is supported at a large spacing, reducing the support workload;

[0077] 2. The inorganic composite floor decking is installed closely and quickly;

[0078] 3. High transportation efficiency, more than three times that of ordinary laminated panels. It is hoisted in bundles and has no special requirements for tower cranes.

[0079] 4. The base plate has good adhesion to the wall, and the putty has good effect and will not fall off.

[0080] In summary, this system can realize the automated processing of steel truss floor decking, has the characteristics of high automation and standardization, can greatly improve production efficiency and product quality stability, reduce labor costs and safety hazards in the production process.

[0081] Although a portion of the embodiments of the present invention have been shown and described, those skilled in the art will appreciate that various changes, modifications, substitutions and variations to these embodiments are within the scope of protection of the claims of the present invention without departing from the principles and purpose of the present invention.

Claims

1. An intelligent manufacturing floor deck production system, characterized in that: include: Concrete mixing plants, forming conveyor lines and curing kilns; The molding conveyor line is provided with a mold upper station, a cleaning station, a demoulding oil spraying station, a mesh cloth arrangement station, a material distribution station, an automatic scraping station, a truss placement station, a vibration station, a stacking station, a gantry shifting station and a conveying station in sequence along its conveying direction; The loading station is provided with a bottom mold upper mold robot, and the bottom mold upper mold robot is used to transport the bottom mold to the molding conveyor line body; The cleaning station is provided with a cleaning device, and the cleaning device is used to clean the bottom mold; The demoulding oil spraying station is provided with a demoulding oil device, and the demoulding oil device is used to spray demoulding oil onto the bottom mold; The mesh cloth arrangement station is provided with a mesh cloth arrangement device, and the mesh cloth arrangement device is used to arrange the mesh cloth on the bottom mold; The material distribution station is provided with a pouring device, and the pouring device is used to pour concrete into the bottom mold; The automatic scraping station is provided with a scraping device, which is used to scrape the poured concrete flat; A steel truss robot is provided at the truss placement station, and the steel truss robot is used to place the steel truss on the bottom mold; The vibration station is provided with a vibration device, and the vibration device is used to compact the bottom mold with the steel bar truss by vibration; A palletizing robot is provided at the palletizing station, and the palletizing robot is used to batch palletize the bottom molds with steel bar trusses; A frame transfer robot is provided at the gantry frame transfer station, and the frame transfer robot is used to send the bottom mold with the steel bar truss to the curing kiln for rapid steam curing, and to remove the cured truss plate; A conveying device is provided at the conveying station, and the conveying device is used to convey the truss plate.

2. A production method of the intelligent manufacturing floor deck production system according to claim 1, characterized in that: The following steps are involved: S1. The bottom mold upper mold robot transports the bottom mold to the molding conveyor line, the cleaning device cleans the bottom mold to ensure that there is no attachment on the bottom mold, and then the demoulding oil device sprays demoulding oil on the bottom mold; S2, the mesh cloth arrangement device arranges the mesh cloth on the bottom mold, the pouring device pours concrete on the bottom mold, and then the leveling device levels the poured concrete, the steel truss robot places the steel truss on the bottom mold, and then vibrates it through the vibration device; S3. After the stacking robot stacks the bottom molds with steel trusses in batches, the rack transfer robot will then send them to the curing kiln for rapid steaming. After curing for 4-6 hours, they can be demoulded. The cured truss plates are then removed and transported outward. The demoulded bottom molds are recycled.

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