Production system for precast concrete components in buildings

Abstract

The invention discloses a production system for precast concrete components in buildings, which comprises a raw material supply unit, a mold management unit, a feeding unit, a forming unit and a curing unit, and is characterized in that the raw material supply unit is provided with a plurality of storage bins for respectively storing main raw materials such as water, cement, sand and stones, and is provided with a special additive storage tank area; storing a water reducing agent, an early strength agent, a retarder and an air entraining agent; an electronic metering device is installed at the output end of the storage bin, the discharging amount of raw materials can be accurately controlled, and the storage bin adopts a raw material conveying mode that a closed belt conveyor and a spiral conveyor are combined; through automatic control of production links from raw materials to burdening to blanking as well as forming and maintenance, manual intervention is reduced, production efficiency and quality stability are improved, and mixed production of prefabricated components of different models is realized, so that the problem of production complexity of multiple production lines for assembling the components is effectively solved, and the production cost is reduced. And the whole production process is more convenient and quicker.

Description

Technical Field

[0001] The invention relates to the technical field of prefabricated component production, in particular to a production system of prefabricated concrete components used in buildings. Background Art

[0002] With the acceleration of urbanization and the continuous expansion of construction scale, the construction industry is facing higher requirements for construction speed, quality and sustainability. The traditional cast-in-place construction method has many limitations, such as long construction period, great influence of weather, high difficulty in quality control and waste of resources. In this context, prefabricated buildings have gradually become an important direction for the development of the construction industry with their unique advantages. Prefabricated buildings break down buildings into multiple prefabricated components, carry out standardized production in factories, and then transport them to the construction site for rapid assembly. This method significantly improves the construction efficiency of buildings and shortens the construction period. At the same time, due to the relatively stable factory production environment, it can better guarantee the quality of components and reduce quality fluctuations caused by differences in on-site construction conditions.

[0003] At present, the production process of prefabricated components mainly includes fixed formwork production and assembly line production. Fixed formwork production is to fix the formwork on the ground and place the mold on the formwork to produce components. Although this method requires small investment in molds and equipment and can adapt to the production of complex shapes and large-sized components, the production efficiency is low because each formwork is relatively independent and cannot form a continuous production process. Therefore, in order to solve this problem, this solution proposes a production system for concrete prefabricated components in construction. Summary of the invention

[0004] The purpose of the present invention is to solve at least one of the technical problems existing in the prior art and to provide a production system for precast concrete components for construction. By realizing automated control of each production link from raw materials to batching to unloading, molding and curing, manual intervention can be reduced, production efficiency and quality stability can be improved, and mixed production of precast components of different models can be realized, thereby effectively solving the cumbersomeness of production of multiple production lines for assembling components and making the overall production process more convenient and quick.

[0005] The present invention also provides a production system of the above-mentioned precast concrete components for construction, comprising a raw material supply unit, a mold management unit, a feeding unit, a molding unit, and a curing unit, characterized in that the raw material supply unit is provided with a plurality of storage bins for storing the main raw materials of water, cement, sand, and gravel respectively, and is equipped with a special additive storage tank area for storing water reducing agent, early strength agent, retarder, and air entraining agent; the storage bin adopts a closed design to effectively prevent the raw materials from being damp and contaminated; The output end of the storage silo is equipped with an electronic metering device that can accurately control the discharge volume of raw materials. The storage silo adopts a raw material transportation method that combines a closed belt conveyor and a screw conveyor. The timing of adding additives during the concrete mixing process can also be accurately controlled by the control system to achieve the best use effect. The belt conveyor is responsible for transporting bulk raw materials from the storage silo to the temporary storage hopper near the mixing station, and the screw conveyor is used to accurately transport the raw materials in the temporary storage hopper to the mixer to ensure that the raw materials are not spilled or lost during the transportation process. The mold management unit is provided with a plurality of mold receiving and dispatching bins. All molds are classified and stored inside the receiving and dispatching bins according to the sizes, shapes and process requirements of different prefabricated components. The input and output ends of the receiving and dispatching bins are provided with roller conveyors. The feeding unit includes a raw material feeding device, a mold conveying device and a visual sampling device. The input end of the raw material feeding device is connected to the output end of the electronic metering device, and the output end of the mold conveying device is connected to the raw material feeding device. The visual sampling device is arranged directly above the electronic metering device. The mold series are analyzed through visual sampling, and the collected data are sent to the central database. It is equipped with a primary conveying mechanism and a metering mechanism. The various raw materials prepared in the raw material supply unit are proportioned, and cement, water, sand and gravel are respectively transported to the mixer by quantitative feeders for full mixing. The concrete slurry after uniform mixing is uniformly transported to the storage tank for centralized storage and standby. During the storage process, it is effectively temperature-controlled and anti-caking stirred. In addition, an additive supply module is provided. Various additives are added to the concrete by intelligent metering pumps to accurately control the amount of additives. The concrete is transported to the metering mechanism by an auger conveyor. The mold type is determined according to visual sampling, and the amount of concrete is calculated. After quantitative determination, the material is discharged through the feeding valve and introduced into the mold, and it is continuously transported back and forth by the primary conveying mechanism. The forming unit is provided with a reinforcement mechanism, a material dividing mechanism, a vibrating mechanism and a secondary conveying mechanism. The reinforcement mechanism arranges the steel mesh in the mold through a mechanical arm, the material dividing mechanism is provided with a conveyor belt, the secondary conveying mechanism is provided with a sorting roller conveyor, the vibrating mechanism is provided with a vibrating rod, the input end of the sorting roller conveyor is connected to the output end of the raw material feeding device, the vibrating mechanism is arranged at the upper end of the material dividing mechanism, the output end of the material dividing mechanism is connected to the input end of the secondary conveying mechanism, and the reinforcement mechanism is arranged at the output end of the mold conveying device; the curing unit is equipped with a plurality of large curing bins, the feeding end of the curing bin is connected to the output end of the sorting roller conveyor, and a temperature control device is arranged inside the curing bin.

[0006] According to the production system of precast concrete components for construction provided by the present invention, the electronic metering device implements cement, sand, stone, water and water-cement metering control and quantitative discharge according to the mix ratio C:S:G=1:2.3:4.2 and the water-cement ratio W / C=0.6, adds a water reducer according to 0.1% of the cement dosage, adds a strengthening agent according to 1.5% of the cement dosage, adds a retarder according to 0.05% of the cement dosage, and adds an air entraining agent according to 0.015% of the cement dosage.

[0007] According to the production system of precast concrete components for construction provided by the present invention, the raw material feeding device uses a screw conveyor to convey the raw materials, the metering device uses a fully automatic electronic metering batching bin, and the output end of the screw conveyor is connected to the fully automatic electronic metering batching bin.

[0008] According to the production system of precast concrete components for construction provided by the present invention, the visual sampling device extracts the features of the image through a pre-trained convolutional neural network CNN, the image acquisition point of the visual sampling device is set in the effective output area of ​​the fully automatic electronic metering batching bin, the mold type is analyzed through visual sampling, and the collected data is sent to the central database to analyze the mold type, and the fully automatic electronic metering batching bin realizes quantitative discharge according to the mold type. The type of mold is analyzed through visual sampling to effectively control the unloading of materials, and the mixed production of different types of precast components is realized, thereby effectively solving the problem of assembling components to complete the production and production on the same production line.

[0009] According to the production system of precast concrete components for construction provided by the present invention, the rebar embedding mechanism is arranged at the front end of the fully automatic electronic metering and batching bin, and the steel mesh is arranged before quantitative material discharge. The mold information is collected by the visual sampling device, and the mechanical arm realizes quantitative material distribution according to the mold type.

[0010] According to the production system of precast concrete components for construction provided by the present invention, the vibrating mechanism vibrates the concrete material in the mold evenly by means of vibration generated by a vibrating rod, and the vibrating rod is movable by being connected to a mechanical arm.

[0011] According to the production system of precast concrete components for construction provided by the present invention, the sorting roller conveyor is provided with a plurality of output ends, each of which is respectively equipped with an automatic transfer vehicle, and the automatic transfer vehicle moves between the curing bin and the output end of the sorting roller conveyor according to a planned route.

[0012] Compared with the prior art, the production system of precast concrete components for construction of the present invention reduces manual intervention, improves production efficiency and quality stability, and realizes mixed production of precast components of different models by realizing automated control of each production link from raw materials to batching, unloading, molding and maintenance, thereby effectively solving the cumbersomeness of production of multiple production lines for assembling components and making the overall production process more convenient and quick. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The present invention is further described below in conjunction with the accompanying drawings and embodiments; Figure 1 The present invention is a structural diagram of a production system for precast concrete components used in buildings. DETAILED DESCRIPTION

[0014] This section will describe in detail the specific embodiments of the present invention. The preferred embodiments of the present invention are shown in the accompanying drawings. The purpose of the accompanying drawings is to supplement the description of the text part of the specification with graphics, so that people can intuitively and vividly understand each technical feature and the overall technical solution of the present invention, but it cannot be understood as a limitation on the scope of protection of the present invention.

[0015] Reference Figure 1 The embodiment of the present invention is used for a production system of precast concrete components in a building, which includes a raw material supply unit, a mold management unit, a feeding unit, a molding unit, and a curing unit. The raw material supply unit is characterized in that a plurality of storage bins are provided to store the main raw materials of water, cement, sand, and gravel respectively, and a special additive storage tank area is provided to store water reducing agent, early strength agent, retarder, and air entraining agent; The output end of the storage bin is equipped with an electronic metering device, which can accurately control the discharge amount of raw materials. The storage bin adopts a raw material conveying method that combines a closed belt conveyor and a screw conveyor. The mold management unit is equipped with multiple mold receiving and dispatching bins. According to the size, shape and process requirements of different prefabricated components, all molds are classified and stored inside the receiving and dispatching bins. Roller conveyors are installed at the input and output ends of the receiving and dispatching bins. The feeding unit includes a raw material feeding device, a mold conveying device and a visual sampling device. The input end of the raw material feeding device is connected to the output end of the electronic metering device, the output end of the mold conveying device and the raw material feeding device are connected to each other, and the visual sampling device is arranged directly above the electronic metering device; The molding unit is provided with a reinforcement mechanism, a material dividing mechanism, a vibrating mechanism and a secondary conveying mechanism. The reinforcement mechanism arranges the steel mesh in the mold through a mechanical arm, the material dividing mechanism is provided with a conveyor belt, the secondary conveying mechanism is provided with a sorting roller conveyor, the vibrating mechanism is provided with a vibrating rod, the input end of the sorting roller conveyor is connected with the output end of the raw material feeding device, the vibrating mechanism is provided at the upper end of the material dividing mechanism, the output end of the material dividing mechanism is connected with the input end of the secondary conveying mechanism, the reinforcement mechanism is provided at the output end of the mold conveying device, the curing unit is equipped with multiple large curing bins, the feeding end of the curing bin is connected with the output end of the sorting roller conveyor, and a temperature control device is provided inside the curing bin.

[0016] The electronic metering device implements cement, sand, stone, water and water-cement metering control and quantitative discharge according to the mix ratio C:S:G=1:2.3:4.2 and the water-cement ratio W / C=0.6. Water reducer is added according to 0.1% of the cement dosage, fortifier is added according to 1.5% of the cement dosage, retarder is added according to 0.05% of the cement dosage, and air entraining agent is added according to 0.015% of the cement dosage.

[0017] The raw material feeding device uses a screw conveyor to convey the raw materials, and the metering device uses a fully automatic electronic metering batching bin. The output end of the screw conveyor is connected to the fully automatic electronic metering batching bin. The screw conveyor is made of high-strength alloy steel as a whole, and the outer shell is cylindrical. Its inner wall has undergone special wear-resistant treatment to cope with the friction during long-term raw material transportation. The spiral blades are made of high-quality steel with good toughness and wear resistance. The pitch of the spiral blades is precisely designed according to the characteristics of the raw materials and the requirements of conveying efficiency. It is equipped with a high-performance motor as the power source, and the power of the motor is selected according to the raw material conveying volume requirements of the entire production system. The motor and the screw shaft are connected through a reducer, and the reducer can accurately adjust the speed of the screw shaft. At the same time, a torque sensor is installed in the drive system to monitor the torque changes of the screw conveyor in real time during operation. When the torque increases abnormally, it indicates that there may be problems such as raw material blockage. The system will immediately sound an alarm and automatically stop running to avoid equipment damage. The feed port is located at one end of the screw conveyor. A raw material flow monitoring sensor is also installed at the feed port, which can measure the raw material flow entering the screw conveyor in real time and transmit the data to the control system.

[0018] The fully automatic electronic metering batching silo is based on a PLC programmable logic controller and can receive data from weighing sensors, material level sensors, and screw conveyor flow monitoring sensors. According to the preset raw material formula and production tasks, the control system accurately calculates the batching amount of each raw material, and controls the operating status of the screw conveyor in real time to achieve precise adjustment of the raw material delivery amount. In addition, the control system also has data storage and analysis functions, which can record each batching data to facilitate production management and quality traceability. At the same time, through the connection with the host computer monitoring system, the operator can remotely monitor the operating status and batching situation of the batching silo in the central control room.

[0019] The visual sampling device extracts the features of the image through the pre-trained convolutional neural network CNN. The image acquisition point of the visual sampling device is set in the effective output area of ​​the fully automatic electronic metering batching bin. The mold type is analyzed through visual sampling, and the collected data is sent to the central database to analyze the mold type. The fully automatic electronic metering batching bin realizes quantitative discharge according to the mold type. The pre-processed image data of the visual sampling device is input into the pre-trained CNN model. The model deeply analyzes the mold features in the image and extracts key feature information such as the mold contour, texture, and logo. These feature information is continuously abstracted and fused in the multi-layer network structure of the model, and finally forms a feature vector with high discriminative power for the mold type.

[0020] The visual sampling device sends the analyzed feature vectors to the central database through a secure and stable network communication protocol. The central database is the data hub of the entire production system and has powerful data storage and processing capabilities. It adopts a distributed storage architecture to ensure high reliability and scalability of data. After receiving the visual sampling data, the special analysis module in the database further processes the data and compares the received feature vectors with the feature templates of various mold types pre-stored in the database.

[0021] The comparison algorithm in the database is based on advanced pattern recognition technology, such as the nearest neighbor algorithm based on distance measurement or the Bayesian classification algorithm based on probability model. These algorithms can accurately determine the type of mold and feed back the recognition results to the control system of the fully automatic electronic metering batching bin and the control system of the reinforcing bar implant mechanism.

[0022] The rebar embedding mechanism is located at the front end of the fully automatic electronic metering and batching bin to realize the arrangement of the steel mesh before quantitative material discharge. The mechanical arm realizes quantitative material distribution according to the mold type based on the mold information collected by the visual sampling device.

[0023] The vibrating mechanism vibrates the concrete in the mold evenly through the vibration generated by the vibrating rod, and the vibrating rod is moved by connecting the mechanical arm. The sorting roller conveyor is equipped with multiple output ends, each of which is equipped with an automatic transfer vehicle. The automatic transfer vehicle moves between the curing bin and the output end of the sorting roller conveyor according to the proposed route. The sorting roller conveyor is equipped with intelligent sensors at key positions of the conveyor. These sensors include photoelectric sensors, proximity sensors and other types. Photoelectric sensors are used to detect the position and shape of prefabricated components, and proximity sensors are used to determine whether the components have reached the sorting point. When the sensor detects specific information about the prefabricated components, the control system activates the corresponding sorting mechanism. The sorting mechanism consists of electrically controllable baffles, guide plates and branch rollers. The baffles and guide plates can flexibly change their positions according to instructions to guide the prefabricated components into the designated output end, and the branch rollers provide auxiliary conveying power during the sorting process to ensure that the components enter the target output end smoothly.

[0024] The automatic transfer vehicle is connected to the central control system of the entire production system through a wireless communication module. The central control system sends the transport task instructions to the transfer vehicle, including the specific output end of the sorting roller conveyor and the designated location of the maintenance bin and the driving route. During the driving process, the transfer vehicle will feed back its own status information, such as position, speed, power, etc. to the central control system in real time. At the same time, the control system of the transfer vehicle itself can automatically adjust the driving speed and steering angle according to the real-time road conditions and task requirements to ensure the safe and efficient completion of the transfer task.

[0025] The embodiments of the present invention are described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Various changes can be made within the knowledge scope of ordinary technicians in the technical field without departing from the purpose of the present invention.

Claims

1. A production system for precast concrete components used in construction, comprising a raw material supply unit, a mold management unit, a feeding unit, a molding unit, and a curing unit, characterized in that: The raw material supply unit is equipped with multiple storage silos to store the main raw materials of water, cement, sand and gravel respectively, and is equipped with a special additive storage tank area to store water reducing agent, early strength agent, retarder and air entraining agent; The output end of the storage bin is equipped with an electronic metering device, which can accurately control the discharge amount of raw materials. The storage bin adopts a raw material conveying method combining a closed belt conveyor and a screw conveyor; The mold management unit is provided with a plurality of mold receiving and dispatching bins. All molds are classified and stored inside the receiving and dispatching bins according to the sizes, shapes and process requirements of different prefabricated components. The input and output ends of the receiving and dispatching bins are both provided with roller conveyors. The feeding unit includes a raw material feeding device, a mold conveying device and a visual sampling device, the input end of the raw material feeding device is connected to the output end of the electronic metering device, the output end of the mold conveying device and the raw material feeding device are connected to each other, and the visual sampling device is arranged directly above the electronic metering device; The forming unit is provided with a reinforcement mechanism, a material dividing mechanism, a vibrating mechanism and a secondary conveying mechanism. The reinforcement mechanism arranges the steel mesh in the mold through a mechanical arm, the material dividing mechanism is provided with a conveyor belt, the secondary conveying mechanism is provided with a sorting roller conveyor, the vibrating mechanism is provided with a vibrating rod, the input end of the sorting roller conveyor is connected to the output end of the raw material feeding device, the vibrating mechanism is arranged at the upper end of the material dividing mechanism, the output end of the material dividing mechanism is connected to the input end of the secondary conveying mechanism, the reinforcement mechanism is arranged at the output end of the mold conveying device, the curing unit is equipped with a plurality of large curing bins, the feeding end of the curing bin is connected to the output end of the sorting roller conveyor, and a temperature control device is arranged inside the curing bin.

2. The production system of precast concrete components for construction according to claim 1, characterized in that: The electronic metering device implements cement, sand, stone, water and water-cement metering control and quantitative discharge according to the mix ratio C:S:G=1:2.3:4.2 and the water-cement ratio W / C=0.6, adds a water reducer according to 0.1% of the cement dosage, a fortifier according to 1.5% of the cement dosage, a retarder according to 0.05% of the cement dosage, and an air entraining agent according to 0.015% of the cement dosage.

3. The production system of precast concrete components for construction according to claim 1, characterized in that: The raw material feeding device uses a screw conveyor to convey the raw materials, and the metering device uses a fully automatic electronic metering batching bin, and the output end of the screw conveyor is connected to the fully automatic electronic metering batching bin.

4. The production system of precast concrete components for construction according to claim 1, characterized in that: The visual sampling device extracts image features through a pre-trained convolutional neural network (CNN). The image acquisition point of the visual sampling device is set in the effective output area of ​​the full-automatic electronic metering and batching bin. The mold series is analyzed through visual sampling, and the collected data is sent to the central database to analyze the mold type. The full-automatic electronic metering and batching bin realizes quantitative discharging according to the mold type.

5. The production system of precast concrete components for construction according to claim 1, characterized in that: The rebar embedding mechanism is arranged at the front end of the fully automatic electronic metering batching bin to realize the arrangement of the steel mesh before quantitative discharging. The mold information is collected by the visual sampling device, and the mechanical arm realizes quantitative discharging according to the mold type.

6. The production system of precast concrete components for construction according to claim 1, characterized in that: The vibrating mechanism vibrates the concrete material in the mold evenly through the vibration generated by the vibrating rod, and the vibrating rod is movable by connecting to the mechanical arm.

7. The production system of precast concrete components for construction according to claim 1, characterized in that: The sorting roller conveyor is provided with a plurality of output ends, each of which is respectively equipped with an automatic transfer vehicle, and the automatic transfer vehicle moves between the curing bin and the output end of the sorting roller conveyor according to a planned route.

Images