Production system for concrete prefabricated elements for buildings

Abstract

The application discloses a production system for prefabricated concrete components in building, which comprises a raw material supply unit, a mold management unit, a feeding unit, a forming unit and a curing unit, characterized in that the raw material supply unit is provided with a plurality of storage bins for respectively storing water, cement, sand and gravel as main raw materials, and is equipped with a special additive storage tank area for storing water reducing agent, early strength agent, retarder and air entraining agent; an electronic metering device is installed at the output end of the storage bin to accurately control the discharging amount of the raw materials; the storage bin adopts a raw material conveying mode combining airtight belt conveyors and screw conveyors; through the realization of automatic control of each production link from raw materials to batching, then to discharging, forming and curing, manual intervention is reduced, production efficiency and quality stability are improved, mixed production of prefabricated components of different types is realized, and therefore the complexity of production of multiple production lines for assembled components is effectively solved, and the overall production process is more convenient and fast.

Description

Technical Field

[0001] This invention relates to the field of precast component production technology, and particularly to a production system for precast concrete components used in construction. Background Technology

[0002] With the acceleration of urbanization and the continuous expansion of building scale, the construction industry faces higher demands for construction speed, quality, and sustainability. Traditional on-site casting construction methods have many limitations, such as long construction cycles, significant susceptibility to weather conditions, high difficulty in quality control, and resource waste. Against this backdrop, prefabricated construction, with its unique advantages, has gradually become an important direction for the development of the construction industry. Prefabricated construction breaks down buildings into multiple prefabricated components, which are standardized and produced in factories, and then transported to the construction site for rapid assembly. This method significantly improves construction efficiency, shortens the construction cycle, and, due to the relatively stable factory production environment, better ensures component quality and reduces quality fluctuations caused by differences in on-site construction conditions.

[0003] Currently, the main production processes for precast components include fixed-mold production and assembly line production. Fixed-mold production involves fixing the mold table to the ground and placing the mold on the table for component production. Although this method requires less investment in molds and equipment and can adapt to the production of complex shapes and large-sized components, its production efficiency is low because each mold table is relatively independent and cannot form a continuous production process. Therefore, this solution proposes a production system for precast concrete components in construction to address this problem. Summary of the Invention

[0004] The purpose of this invention is to at least solve one of the technical problems existing in the prior art, and to provide a production system for precast concrete components in construction. By realizing automated control of each production link from raw materials to batching, feeding, molding and curing, manual intervention is reduced, production efficiency and quality stability are improved, and mixed production of different types of precast components is realized. This effectively solves the cumbersome production of multiple production lines for assembled components, and makes the overall production process more convenient and faster.

[0005] The present invention also provides 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. The raw material supply unit is characterized by having multiple storage silos for storing water, cement, sand, and gravel, and a dedicated additive storage tank area for storing water-reducing agents, early-strength agents, retarders, and air-entraining agents. The storage silos are designed to be closed, effectively preventing the raw materials from becoming damp or contaminated.

[0006] The output end of the storage bin is provided with an electronic metering device, which can accurately control the discharging amount of raw materials, the storage bin adopts a raw material conveying mode combining a closed belt conveyor and a screw conveyor; the adding time of additives in the concrete mixing process can also be accurately controlled through the control system to achieve the best use effect. The belt conveyor is responsible for conveying bulk raw materials from the storage bin to the temporary storage hopper near the mixing station, and the screw conveyor is used to accurately convey the raw materials in the temporary storage hopper into the mixer to ensure that the raw materials are not spilled or wasted during the conveying process.

[0007] The mold management unit is provided with a plurality of mold receiving and sending warehouses, all molds are classified and stored in the receiving and sending warehouses according to the size, shape and process requirements of different prefabricated components, the input and output ends of the receiving and sending warehouses are provided with drum 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 with the output end of the electronic metering device, the output end of the mold conveying device is opposite to the raw material feeding device, and the visual sampling device is arranged above the electronic metering device; the mold is analyzed by visual sampling, and the collected data is sent to the central database, a first conveying mechanism and a metering mechanism are arranged, various raw materials prepared in the raw material supply unit are matched, cement, water, sand and gravel are respectively conveyed into the mixer by the quantitative feeder for sufficient stirring, the uniformly stirred concrete slurry is uniformly conveyed into the storage hopper for centralized storage, the temperature and anti-caking stirring of the concrete slurry are effectively controlled during the storage process, and an additive supply module is arranged, various additives are added into the concrete by using an intelligent metering pump to accurately control the adding amount of the additives, the concrete is conveyed into the metering mechanism by the auger conveyor, the type of the mold is determined according to the visual sampling, the amount of the concrete is calculated, the concrete is quantitatively discharged through the feeding valve and introduced into the mold, and the concrete is continuously reciprocatingly conveyed by the first conveying mechanism,

[0008] The forming unit is provided with a steel bar planting mechanism, a material distributing mechanism, a vibrating mechanism and a secondary conveying mechanism, the steel bar planting mechanism is arranged in the mold through a mechanical arm, the material distributing mechanism is provided with a conveyor belt, the secondary conveying mechanism is provided with a sorting drum conveyor, the vibrating mechanism is provided with a vibrating rod, the input end of the sorting drum conveyor is connected with the output end of the raw material feeding device, the vibrating mechanism is arranged at the upper end of the material distributing mechanism, the output end of the material distributing mechanism is connected with the input end of the secondary conveying mechanism, and the steel bar planting mechanism is arranged at the output end of the mold conveying device; the curing unit is provided with a plurality of large curing warehouses, the feeding end of the curing warehouse is connected with the output end of the sorting drum conveyor, and the curing warehouse is internally provided with a temperature control device.

[0009] The production system for prefabricated concrete components in construction provided by the application, the electronic metering device carries out metering control and quantitative discharge of cement, sand, stone, water and water-cement ratio according to the mixing ratio C:S:G=1:2.3:4.2, water-cement ratio W / C=0.6, adds water reducing agent according to 0.1% of the cement amount, adds reinforcing agent according to 1.5% of the cement amount, adds retarder according to 0.05% of the cement amount, and adds air entraining agent according to 0.015% of the cement amount.

[0010] The production system for prefabricated concrete components in construction provided by the application, the raw material feeding device uses a screw conveyor to convey raw materials, and the metering device uses a full-automatic electronic metering and batching bin, and the output end of the screw conveyor is connected with the full-automatic electronic metering and batching bin.

[0011] The production system for prefabricated concrete components in construction provided by the application, the visual sampling device extracts features of images through a pre-trained convolutional neural network (CNN), the image acquisition point of the visual sampling device is arranged in the effective output area of the full-automatic electronic metering and batching bin, the type of the mold is analyzed by analyzing the product line of the mold through visual sampling, and the collected data is sent to a central database to analyze the type of the mold, and the full-automatic electronic metering and batching bin realizes quantitative discharge according to the type of the mold. Through visual sampling analysis of the type of the mold, the discharge is effectively controlled, the mixed production of different types of prefabricated components is realized, and the problem that the assembled components are completed in the same production line is effectively solved.

[0012] The production system for prefabricated concrete components in construction provided by the application, the bar planting mechanism is arranged at the front end of the full-automatic electronic metering and batching bin, realizes arrangement of the reinforcing mesh before quantitative discharge, and the mechanical arm realizes quantitative discharge according to the type of the mold through the mold information collected by the visual sampling device.

[0013] The production system for prefabricated concrete components in construction provided by the application, the vibrating mechanism realizes uniform treatment of the concrete material in the mold through vibration generated by a vibrating rod, and the vibrating rod is movable through the connecting mechanical arm.

[0014] The production system for prefabricated concrete components in construction provided by the application, the sorting drum conveyor is provided with a plurality of output ends, each of the output ends is respectively provided with an automatic transfer vehicle, and the automatic transfer vehicle moves between the curing bin and the output end of the sorting drum conveyor according to a planned route.

[0015] Compared with the prior art, the production system of the prefabricated concrete component for building of the application realizes the automatic control of each production link from raw materials to batching, then to feeding and forming and curing, reduces the manual intervention, improves the production efficiency and quality stability, realizes the mixed production of different types of prefabricated components, thereby effectively solving the cumbersome of the multi-line production of the assembled components, and making the overall production process more convenient and fast. BRIEF DESCRIPTION OF DRAWINGS

[0016] The application will be further described below in combination with the drawings and embodiments.

[0017] Figure 1 The application is a production system of prefabricated concrete components for building. DETAILED DESCRIPTION

[0018] This part will describe the specific embodiments of the application in detail, the preferred embodiments of the application are shown in the drawings, the drawings serve to supplement the description of the text part of the description, so that people can intuitively and visually understand each technical feature and the overall technical scheme of the application, but it cannot be understood as a limitation on the protection scope of the application.

[0019] Referring to Figure 1 The production system of prefabricated concrete components for building of the embodiment of the application comprises a raw material supply unit, a mold management unit, a feeding unit, a forming unit and a curing unit, characterized in that the raw material supply unit is provided with a plurality of storage bins for respectively storing water, cement, sand and gravel as main raw materials, and is provided with a special additive storage tank area for storing water reducing agent, early strength agent, retarder and air entraining agent.

[0020] An electronic metering device is installed at the output end of the storage bin, which can accurately control the discharging amount of the raw materials, and the storage bin adopts a raw material conveying mode combining airtight belt conveyors and screw conveyors; the mold management unit is provided with a plurality of mold receiving and sending bins, all molds are classified and stored in the receiving and sending bins according to the size, shape and process requirements of different prefabricated components, and a roller conveyor is arranged at the input and output ends of the receiving and sending bins.

[0021] The feeding unit comprises 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 with the output end of the electronic metering device, the output end of the mold conveying device is connected with the raw material feeding device, and the visual sampling device is arranged above the electronic metering device.

[0022] The forming unit is provided with a steel bar planting mechanism, a material distributing mechanism, a vibrating mechanism and a secondary conveying mechanism. The steel bar planting mechanism is used to place a steel bar mesh into a mold through a mechanical arm. The material distributing mechanism is provided with a conveyor belt. The secondary conveying mechanism is provided with a sorting drum conveyor. The vibrating mechanism is provided with a vibrating rod. The input end of the sorting drum conveyor is connected with the output end of the raw material feeding device. The vibrating mechanism is arranged at the upper end of the material distributing mechanism. The output end of the material distributing mechanism is connected with the input end of the secondary conveying mechanism. The steel bar planting mechanism is arranged at the output end of the mold conveying device. The curing unit is provided with a plurality of large curing bins. The feeding end of the curing bin is connected with the output end of the sorting drum conveyor. The curing bin is internally provided with a temperature control device.

[0023] The electronic metering device controls and quantitatively discharges cement, sand, stone, water and water-cement according to the mixing ratio C:S:G=1:2.3:4.2 and the water-cement ratio W / C=0.6. The water-reducing agent is added according to 0.1% of the cement dosage. The reinforcing agent is added according to 1.5% of the cement dosage. The retarder is added according to 0.05% of the cement dosage. The air entraining agent is added according to 0.015% of the cement dosage.

[0024] The raw material feeding device adopts a screw conveyor to convey raw materials. The metering device adopts a full-automatic electronic metering batching bin. The output end of the screw conveyor is connected with the full-automatic electronic metering batching bin. The screw conveyor is made of high-strength alloy steel. The shell is cylindrical. The inner wall is subjected to special wear-resistant treatment to cope with friction in the long-term raw material conveying process. The screw blade is made of high-quality steel with good toughness and wear resistance. The pitch of the screw blade is accurately designed according to the characteristics and conveying efficiency requirements of the raw materials. A high-performance motor is provided as a power source. The power of the motor is selected according to the raw material conveying capacity requirements of the entire production system. The motor is connected with the screw shaft through a speed reducer. The speed reducer can accurately adjust the rotating speed of the screw shaft. At the same time, a torque sensor is installed in the driving system to monitor the torque change of the screw conveyor in real time. When the torque abnormally increases, it indicates that there may be problems such as raw material blockage. The system will immediately issue an alarm and automatically stop running to avoid equipment damage. The feeding port is located at one end of the screw conveyor. A raw material flow monitoring sensor is also installed at the feeding port to measure the raw material flow entering the screw conveyor in real time and transmit the data to the control system.

[0025] The full-automatic electronic metering and batching bin is based on a PLC programmable logic controller and can receive data from weighing sensors, level sensors and screw conveyor flow monitoring sensors. According to the preset raw material formula and production task, the control system accurately calculates the batching amount of each raw material and controls the running state of the screw conveyor in real time to realize accurate adjustment of the raw material conveying amount. In addition, the control system also has data storage and analysis functions, which can record each batching data for production management and quality traceability. At the same time, through the connection with the upper computer monitoring system, the operator can remotely monitor the running state and batching condition of the bin in the central control room.

[0026] 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 located in the effective output area of the full-automatic electronic metering and batching bin. The mold type is analyzed by the visual sampling device and the collected data is sent to the central database. The full-automatic electronic metering and batching bin realizes quantitative feeding 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 performs deep analysis on the mold features in the image and extracts key feature information such as the outline, texture and identification of the mold. 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 discriminability for the mold type.

[0027] The visual sampling device sends the analyzed feature vector to the central database through a safe 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 the data. After receiving the visual sampling data, a special analysis module in the database further processes the data and compares the received feature vector with the pre-stored feature templates of various mold types in the database.

[0028] The comparison algorithm in the database is based on advanced pattern recognition techniques such as nearest neighbor algorithm based on distance metric or Bayesian classification algorithm based on probability model. Through these algorithms, the type of the mold is accurately determined, and the recognition result is fed back to the control system of the full-automatic electronic metering and batching bin and the control system of the steel bar planting mechanism.

[0029] The steel bar planting mechanism is located at the front end of the full-automatic electronic metering and batching bin and realizes the arrangement of the steel bar mesh before quantitative feeding. According to the mold information collected by the visual sampling device, the mechanical arm realizes quantitative feeding according to the mold type.

[0030] The vibrating mechanism generates vibrations to the concrete in the mold through the vibrating rod, and the vibrating rod is movable through the connecting mechanical arm. The sorting drum conveyor is provided with multiple output ends, each of which is equipped with an automatic transfer vehicle. The automatic transfer vehicle moves between the curing warehouse and the output end of the sorting drum conveyor according to the planned route. The sorting drum conveyor is provided with intelligent sensors at key positions of the conveyor, including photoelectric sensors, proximity sensors and other types. The photoelectric sensor is used to detect the position and shape of the precast component, and the proximity sensor is used to determine whether the component reaches the sorting point. When the sensor detects specific information of the precast component, the control system will activate the corresponding sorting mechanism. The sorting mechanism is composed of electrically controllable baffles, guide plates and branch drums. The baffles and guide plates can change positions flexibly according to instructions, guide the precast component into the designated output end, and the branch drum provides auxiliary conveying power during the sorting process to ensure that the component smoothly enters the target output end.

[0031] 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 transportation task instructions to the transfer vehicle, including information such as specific output ends of the sorting drum conveyor, designated positions of the curing warehouse and driving routes. During driving, the transfer vehicle will feed back its state information such as position, speed, power and the like to the central control system in real time. At the same time, the control system of the transfer vehicle can automatically adjust the driving speed and steering angle according to the real-time road conditions and task requirements to ensure safe and efficient completion of the transfer task.

[0032] The above describes the embodiments of the present application in detail in combination with the drawings, but the present application is not limited to the above embodiments, and various changes can be made within the knowledge of those skilled in the art without departing from the purpose of the present application.

Claims

1. A production system for precast concrete elements for use in construction, comprising a raw material supply unit, a mould management unit, a feeding unit, a forming unit, a curing unit, characterised in that, The raw material supply unit is provided with a plurality of storage bins for storing water, cement, sand and gravel, and a special additive storage tank area for storing water reducing agent, early strength agent, retarder and air entraining agent; The output end of the storage bin is provided with an electronic metering device, which can accurately control the discharge amount of raw materials. The storage bin adopts a raw material conveying mode combining a closed belt conveyor and a screw conveyor. The mold management unit is provided with a plurality of mold receiving and sending bins. According to the size, shape and process requirements of different prefabricated components, all molds are classified and stored in the receiving and sending bins. The input and output ends of the receiving and sending bins are provided with drum 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 with the output end of the electronic metering device. The output end of the mold conveying device is connected with the raw material feeding device. The visual sampling device is arranged above the electronic metering device. The forming unit is provided with a steel bar planting mechanism, a material distribution mechanism, a vibrating mechanism and a secondary conveying mechanism. The steel bar planting mechanism is arranged in the mold through a mechanical arm. The material distribution mechanism is provided with a conveyor belt. The secondary conveying mechanism is provided with a sorting drum conveyor. The vibrating mechanism is provided with a vibrating rod. The input end of the sorting drum conveyor is connected with the output end of the raw material feeding device. The vibrating mechanism is arranged at the upper end of the material distribution mechanism. The output end of the material distribution mechanism is connected with the input end of the secondary conveying mechanism. The steel bar planting mechanism is arranged at the output end of the mold conveying device. The curing unit is provided with a plurality of large curing bins. The feeding end of the curing bin is connected with the output end of the sorting drum conveyor. The curing bin is provided with a temperature control device inside. 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 arranged in the effective output area of the full-automatic electronic metering and batching bin. The mold type is analyzed by analyzing the product list of the mold through visual sampling and sending the collected data to the central database. The full-automatic electronic metering and batching bin realizes quantitative discharge according to the mold type.

2. The production system for concrete precast elements for use in construction according to claim 1, characterized in that, The electronic metering device controls and quantitatively discharges cement, sand, gravel, water and water-cement according to the mixing ratio C:S:G=1:2.3:4.2 and water-cement ratio W / C=0.

6. The water reducing agent is added according to 0.1% of the cement dosage. The strengthening agent is added according to 1.5% of the cement dosage. The retarder is added according to 0.05% of the cement dosage. The air entraining agent is added according to 0.015% of the cement dosage.

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

4. The production system for concrete precast elements in construction according to claim 1, characterized in that, The steel bar planting mechanism is arranged at the front end of the full-automatic electronic metering and batching bin to realize the arrangement of the steel bar mesh before quantitative discharge. The mold information collected by the visual sampling device is used to realize quantitative distribution according to the mold type.

5. The production system for concrete precast elements in construction according to claim 1, characterized in that, The vibrating mechanism vibrates the concrete in the mold through the vibrating rod. The vibrating rod is movable through the connecting mechanical arm.

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

Images