Full-automatic command vehicle traction type intelligent beam factory production process

Abstract

The invention discloses a full-automatic command vehicle traction type intelligent beam factory production process. The production process comprises a steel bar machining station, a steel bar binding station, a ferry station, a command vehicle line changing first station, a pouring station, a core pulling mold station, a steam curing first station, a steam curing second station, a ferry tensioning second station and a concrete production station. The reinforcing steel bar raw materials are machined into semi-finished products at the reinforcing steel bar machining station, and the semi-finished products are machined into component reinforcing steel bars at the reinforcing steel bar binding station; ferrying the empty bottom die trolley back to a pouring line at a ferrying station; the field utilization rate is improved, potential risks such as cross operation and electric leakage are reduced, and the investment cost of the whole production line is reduced; the process of manually plugging and unplugging an aviation plug is omitted, and the automation degree is improved; the problem that a slide wire current collector is damaged due to a slide wire fracture is solved, and the running stability of a production line is improved; the whole production line is more flexible in arrangement, wider in control coverage, and simpler and more convenient in equipment installation.

Description

Technical Field

[0001] The present invention relates to the technical field of smart beam factory production technology, and in particular to a fully automatic command vehicle-pulled smart beam factory production technology. Background Art

[0002] In the current production process of smart beam factories, mobile bottom mold trolleys mostly use AC motors to drive self-propelled mechanisms. There are generally two ways of power supply, one is cable drum power supply, and the other is busbar power supply. Cable drum power supply is limited by the limited length of the cable reel, and workers must intervene to plug and unplug the power plug at each workstation. It cannot be automated and has low efficiency and high risks. Busbar power supply generally fixes the busbar at a height of less than half a meter from the ground, which requires occupying ground space, resulting in reduced ground space utilization and high leakage risk due to busbar damage. In addition, the busbar power collector is easily damaged at the busbar break, and the failure rate of production lines powered by busbars is also high.

[0003] For this purpose, it is necessary to provide a production process of a fully automatic command vehicle-traction smart beam factory. Summary of the invention

[0004] In view of the problems existing in the above-mentioned prior art, the present invention provides a smart beam factory production process pulled by a fully automatic command vehicle, aiming to realize a smart beam factory production process in which the command vehicle pulls the bottom mold trolley and conducts production scheduling and command of the entire production line.

[0005] In order to achieve the above-mentioned purpose, the present invention is implemented through the following technical scheme: a fully automatic command vehicle traction type smart beam factory production process, the production process includes a steel bar processing station, a steel bar binding station, a ferrying station, a command vehicle line changing station, a casting station, a core pulling mold station, a steaming station, a steaming station, a second steaming station, a ferrying tensioning station, and a concrete production station; the steel bar raw materials are processed into semi-finished products at the steel bar processing station, and the semi-finished products are processed into component steel bars at the steel bar binding station; the empty bottom mold trolley is ferried back to the casting line at the ferrying station; the command vehicle line changing station is completed at the command vehicle line changing station; the steel bar cage is put into the mold and the component is cast at the casting station; the core mold extraction action is completed at the core pulling mold station, the high temperature and high humidity steaming of the component is completed at the steaming station, the empty bottom mold trolley is ferried from the casting line to the return line at the ferrying tensioning station and the tensioning work of the component is completed, and the concrete production work is completed in the concrete production area.

[0006] The production line equipment in the production process includes steel bar processing equipment, command vehicle, concrete placing machine, feeder truck and its feeder truck track system, hydraulic formwork, curing kiln, bottom form trolley, mixer main unit and ancillary equipment, shuttle bus, track system and electronic control system. The steel bar processing equipment is used to process steel bar raw materials into semi-finished products. The command vehicle is used for towing the bottom form trolley and commanding the operation, debugging and operation of the entire production line equipment. The concrete placing machine is used to transfer and pour concrete from the feeder truck into the hydraulic formwork. The feeder truck and its feeder truck track system are used to transport concrete from the mixing station to the concrete placing machine. The hydraulic formwork is used for casting and forming components. The curing kiln is used for high-temperature heating and humidification curing of components. The bottom form trolley is used for casting components and transporting and circulating components. The mixer main unit and ancillary equipment are used for concrete production. The trolley track system is used to support the walking wheels of the bottom form trolley, concrete placing machine and shuttle bus. The electronic control system is used to power the entire production line equipment.

[0007] The production process steps are:

[0008] Step 1: The mixing station produces concrete, and the concrete is transported by a delivery truck to the discharge port;

[0009] Step 2: The feeding vehicle drives to the receiving position of the concrete placing machine and discharges the material to the concrete placing machine. After the concrete placing machine receives the material, it goes to the pouring station for pouring;

[0010] Step 3: After standing for a suitable time, open the side mold. If there are components such as box beams, the core mold must be pulled out first;

[0011] Step 4: The command vehicle pulls the bottom mold trolley to carry the components to the curing kiln for steam curing;

[0012] Step 5: After the curing process in the curing kiln is completed, the command vehicle pulls the bottom mold trolley to carry the components to the ferry tensioning station for tensioning;

[0013] Step 6: The beam-lifting gantry crane lifts the component to the beam storage area, and the shuttle bus shuttles the empty bottom mold trolley to the return line;

[0014] Step 7: The command vehicle pulls the empty bottom formwork trolley to the ferrying station, and the ferry vehicle ferries the empty bottom formwork trolley back to the casting line;

[0015] Step 8: The command vehicle pulls the empty bottom mold trolley to the pouring station, where the steel cage is placed into the mold and the mold is closed and waits for the next round of pouring.

[0016] In summary, the present invention provides a production process of a fully automatic command vehicle-driven smart beam factory, which has at least the following advantages:

[0017] 1. The mobile bottom mold trolley adopts a non-power source design, which eliminates the corresponding power supply part in the production line layout, reduces the amount of civil construction, and makes the on-site production line layout simpler, which improves the site utilization rate, reduces the dangers of cross-operation and leakage, and reduces the overall production line investment cost;

[0018] 2. The command vehicle is used to pull the mobile bottom mold trolley. Compared with the traditional mobile bottom mold trolley powered by cable reels, the process of manually plugging and unplugging aviation plugs is eliminated, which improves the degree of automation;

[0019] 3. The command vehicle is used to pull the mobile bottom mold trolley. Compared with the traditional mobile bottom mold trolley powered by the busbar, it completely solves the problem of busbar collector damage caused by busbar breakage and improves the stability of production line operation;

[0020] 4. Compared with the traditional wired communication between devices, the production mode using wireless linkage control of the command vehicle makes the entire production line more flexible, the control coverage is wider, and the equipment installation is simpler and more convenient. BRIEF DESCRIPTION OF THE DRAWINGS

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

[0022] Figure 2 It is a production line process flow chart of the production process of the present invention;

[0023] Figure 3 It is an electrical control logic flow chart of the production process of the present invention;

[0024] Figure 4 It is a main front view of the command vehicle traction of the production process of the present invention;

[0025] Figure 5 It is a traction side view of the command vehicle of the production process of the present invention;

[0026] Figure 6 It is a top view of the command vehicle traction of the production process of the present invention;

[0027] Figure 7 It is a front view of the command vehicle line change of the production process of the present invention;

[0028] Figure 8 It is a side view of the command vehicle line change of the production process of the present invention;

[0029] Fig. 9 It is a top view of the command vehicle line change in the production process of the present invention;

[0030] Fig.10 It is a hardware configuration diagram of the sensor of the command vehicle of the production process of the present invention;

[0031] Fig.11It is the sensor hardware distribution diagram of the command vehicle of the production process of the present invention;

[0032] Fig.12 It is a schematic diagram of the command vehicle software interface of the production process of the present invention;

[0033] Fig.13 It is a front view of the feeding car and track of the production process of the present invention;

[0034] Fig.14 It is a view of the material placing machine shaft of the production process of the present invention;

[0035] Fig.15 It is a view of the ferry axle of the production process of the present invention;

[0036] Fig.16 It is an axial view of the curing kiln of the production process of the present invention;

[0037] Fig.17 It is a view of the hydraulic die and bottom die trolley axis of the production process of the present invention;

[0038] Fig.18 It is a view of the axle of the movable bottom mold trolley of the production process of the present invention; DETAILED DESCRIPTION

[0039] The present invention will be further described below in conjunction with the accompanying drawings.

[0040] Equipment Introduction:

[0041] (I) Process electrical configuration

[0042] The production line is equipped with three battery-driven intelligent command vehicles. The wireless network covers the entire workshop. The host computer in the central control room issues tasks, and the intelligent command vehicles perform the tasks of pushing and pulling the trolleys according to the tasks, thus achieving automation.

[0043] (ii) Command vehicle

[0044] The command vehicle plays the following roles in the production line process:

[0045] 1. To pull and push the mobile bottom mold trolley to achieve the action of switching the mobile bottom mold trolley; 2. Record and manage the position of the mobile bottom mold trolley of the entire production line system; 3. Command and dispatch the coordination of various equipment in the entire production line, and record and output production data;

[0046] Introduction to the mechanical structure of the command vehicle: The command vehicle has two sets of mutually perpendicular wheel drive systems, one of which can be raised and lowered to achieve the positive and negative height difference between the wheel treads of the two drive systems. By switching the positive and negative height difference, the two sets of drive systems can be put on the ground, thereby realizing the functions of the command vehicle towing and changing lines. The command vehicle is designed with a tow hook assembly, which is divided into two parts, one part is installed at both ends of the command vehicle body, and the other part is installed at both ends of the mobile bottom mold trolley. The two parts of the tow hook assembly cooperate to complete the automatic connection and separation of the command vehicle and the mobile bottom mold trolley. The command vehicle is powered by lithium batteries, and charging piles are designed at appropriate workstations. When the command vehicle detects the charging signal, it will automatically return to the charging pile for charging at the appropriate time.

[0047] Electrical configuration of command vehicle: encoder, AGV card reader, laser ranging sensor, proximity sensor, travel switch, QR code reader, wireless CV, remote control, tablet computer, programmable logic controller, columnar alarm.

[0048] 1. Command vehicle automation technology: using advanced automated control systems, intelligent sensors, etc., to enable production equipment to automatically complete more production processes;

[0049] 2. Internet of Things technology: Through the Internet of Things technology, the interconnection between devices can be realized, the equipment status can be remotely monitored in real time, and the production process can be optimized;

[0050] 3. Wireless communication technology: Use mature industrial 5G wireless communication technology to achieve full wireless network coverage of the entire workshop, effectively solve the data transmission between rail cars, and upload data to the host computer control system;

[0051] 4. Laser detection: The intelligent command vehicle is equipped with a laser ranging sensor to ensure smooth docking between the intelligent command vehicle and the trolley, and to identify obstacles;

[0052] 5. Scan code detection: The intelligent command vehicle is equipped with a QR code or barcode scanner, and the trolley is installed with stainless steel to make a QR code or barcode, which can ensure the accuracy of trolley identification;

[0053] 6. Coordinates: The intelligent command vehicle is equipped with an AGV card reader to read the ground magnetic card, which effectively solves the position detection of the intelligent command vehicle after the track change and realizes the accuracy of the vehicle's position record;

[0054] 7. Record query: record the pouring start and end time (can be entered manually), curing temperature and time curve

[0055] , record the start and end time of tensioning (can be entered manually), and historical data can be queried;

[0056] 8. Battery power detection: read battery power information in real time to ensure the safe operation of the intelligent command vehicle;

[0057] Feeder and track: The feeder track can be a straight track or a circulating track according to the process requirements. The feeder moves along the feeder track and can automatically transport concrete from the mixing plant to the receiving point of the concrete placing machine.

[0058] Concrete placing machine: Concrete placing machine evenly pours the concrete transported by the feeder truck into the hydraulic formwork. The concrete placing machine is divided into two parts: the concrete placing machine bucket and the concrete placing machine trolley. The two parts can move in two horizontal directions perpendicular to each other to cover all positions of the hydraulic formwork.

[0059] Shuttle car: The shuttle car includes a shuttle car track, a shuttle car body, and a lifting mechanism. The shuttle car track is perpendicular to the mobile bottom mold trolley track. The lifting mechanism can lift the empty mobile bottom mold trolley to separate it from its own track, and then the shuttle car body moves horizontally along the shuttle car track. When it reaches the expected track, the lifting mechanism falls and places the mobile bottom mold trolley on the new track to complete the line-changing ferrying function of the empty mobile bottom mold trolley;

[0060] Curing kiln: The curing kiln can be designed with heating and humidification pipelines. Under the control of the command vehicle, it can automatically complete the high-temperature and high-humidity curing of components, realize automatic adjustment of temperature and humidity, and record and output of steam curing data. The curing kiln consists of an insulated kiln body, an automatic opening and closing door, and heating and humidification pipelines;

[0061] Hydraulic mold: Hydraulic mold is an important equipment to complete the curing and forming of components. It is mainly composed of mold side mold, bottom mold, core mold (some components have), accessories, opening and closing drive cylinder, vibration system and control system. After the concrete is poured into the mold, the mold's own vibration system and manual auxiliary vibration operation can quickly achieve the exhaust and compaction effect. After the component strength reaches the requirement, the hydraulic mold is opened to open the side mold (the core mold with a core mold will be removed earlier than the side mold);

[0062] Mobile bottom mold trolley: The mobile bottom mold trolley plays two roles in the production line process: 1. Acting as the supporting structure of the bottom mold, sealing with the outer mold to form the casting cavity required for the component; 2. Carrying the component to each workstation after demolding; The mobile bottom mold trolley mainly includes the load-bearing vehicle body, the walking wheel box, the bottom mold and the towing hook assembly at both ends. Two ends of the mobile bottom mold trolley are designed with QR codes containing identity information. When the mobile bottom mold trolley is combined with the command vehicle, the command vehicle can identify the relevant information of the current bottom mold trolley. The mobile bottom mold trolley adopts a non-powered design, and its displacement is completed by towing or pushing by the command vehicle.

[0063] like Figures 1 to 18 As shown:

[0064] The present invention discloses a fully automatic command vehicle traction type intelligent beam factory production process, including a steel bar processing station, a steel bar binding station, a ferry station, a command vehicle line change station 1, a pouring station, a core-pulling mold station, a steaming station 1, a steaming station 2, a ferry tensioning station 2, and a concrete production station;

[0065] The production line equipment in the production process includes steel bar processing equipment, command vehicle, placing machine, feeder vehicle and its feeder vehicle track system, hydraulic formwork, curing kiln, bottom form trolley, mixing main machine and auxiliary equipment, shuttle vehicle, track system and electronic control system.

[0066] The present invention is further described below in conjunction with the flow process of the entire production line. After the concrete is mixed at the mixing station, it is transported to the placing machine by the feeder along the feeder track. The placing machine assists the traveling mechanism on the placing trolley and the placing bucket to achieve full coverage pouring of the hydraulic mold. The vibration system on the hydraulic mold assists in the rapid compaction of the concrete. When the component reaches the mold opening time, the hydraulic mold opens, and the mobile bottom mold trolley enters the curing station under the traction of the command vehicle. The curing kiln automatically performs high temperature and high humidity curing on the component. After the curing is completed, the command vehicle tractions the mobile bottom mold trolley into the ferrying and tensioning station. After tensioning, the component is transferred to the beam storage area, and the ferry ferry the empty mobile bottom mold trolley to the return line. The command vehicle automatically changes the line to the return line to traction the empty mobile bottom mold trolley and ferry it to the casting station end. The ferry ferry the empty bottom mold trolley back to the casting line, and the command vehicle tractions the empty bottom mold trolley to the casting work and waits for the next round of casting work to begin. In the above production process, the command vehicle can record its own position in real time. When it is connected to the empty mobile bottom mold trolley, it can read the relevant identity information of the mobile bottom mold trolley through the QR code reader and record its position and status information. In addition, the shuttle bus, feeder truck, material placing machine, hydraulic template, curing kiln and other equipment can automatically feedback the position and status to the command vehicle, and the command vehicle will automatically process and record the relevant data and coordinate the production line equipment to cooperate with each other to achieve fully automatic production of the production line. The command vehicle can also record and output relevant process data generated during the production process, such as the maintenance temperature rise curve of the component, the real-time position of the mobile bottom mold trolley and feeder truck and other equipment.

[0067] The embodiments of the present invention are only used to illustrate the present invention and do not constitute a limitation on the scope of the claims. Other substantially equivalent substitutes that can be thought of by those skilled in the art are all within the protection scope of the present invention.

Claims

1. A production process of a fully automatic command vehicle traction type smart beam factory, characterized in that: The production process includes steel bar processing station, steel bar binding station, ferrying station, command vehicle line changing station 1, casting station, core pulling mold station, steaming curing station 1, steaming curing station 2, ferrying and tensioning station 2, and concrete production station; the steel bar raw materials are processed into semi-finished products at the steel bar processing station, and the semi-finished products are processed into component steel bars at the steel bar binding station; the empty bottom mold trolley is ferried back to the casting line at the ferrying station; the command vehicle line changing and translational action is completed at the command vehicle line changing station 1; the steel bar cage is placed in the mold and the component is cast at the casting station; the core mold extraction action is completed at the core pulling mold station, the high temperature and high humidity steaming of the component is completed at the steaming station, the empty bottom mold trolley is ferried from the casting line to the return line at the ferrying and tensioning station and the tensioning of the component is completed, and the concrete production work is completed in the concrete production area.

2. According to claim 1, a production process of a fully automatic command vehicle traction type smart beam factory is characterized in that: The production line equipment in the production process includes steel bar processing equipment, command vehicle, concrete placing machine, feeder truck and its feeder truck track system, hydraulic formwork, curing kiln, bottom form trolley, mixer main unit and ancillary equipment, shuttle bus, track system and electronic control system. The steel bar processing equipment is used to process steel bar raw materials into semi-finished products. The command vehicle is used for towing the bottom form trolley and commanding the operation, debugging and operation of the entire production line equipment. The concrete placing machine is used to transfer and pour concrete from the feeder truck into the hydraulic formwork. The feeder truck and its feeder truck track system are used to transport concrete from the mixing station to the concrete placing machine. The hydraulic formwork is used for casting and forming components. The curing kiln is used for high-temperature heating and humidification curing of components. The bottom form trolley is used for casting components and transporting and circulating components. The mixer main unit and ancillary equipment are used for concrete production. The trolley track system is used to support the walking wheels of the bottom form trolley, concrete placing machine and shuttle bus. The electronic control system is used to power the entire production line equipment.

3. According to claim 1, a fully automatic command vehicle traction type smart beam factory production process is characterized in that: The production process steps are: Step 1: The mixing station produces concrete, and the concrete is transported by a delivery truck to the discharge port; Step 2: The feeding vehicle drives to the receiving position of the concrete placing machine and discharges the material to the concrete placing machine. After the concrete placing machine receives the material, it goes to the pouring station for pouring; Step 3: After standing for a suitable time, open the side mold. If there are components such as box beams, the core mold must be pulled out first; Step 4: The command vehicle pulls the bottom mold trolley to carry the components to the curing kiln for steam curing; Step 5: After the curing process in the curing kiln is completed, the command vehicle pulls the bottom mold trolley to carry the components to the ferry tensioning station for tensioning; Step 6: The beam-lifting gantry crane lifts the component to the beam storage area, and the shuttle bus shuttles the empty bottom mold trolley to the return line; Step 7: The command vehicle pulls the empty bottom formwork trolley to the ferrying station, and the ferry vehicle ferries the empty bottom formwork trolley back to the casting line; Step 8: The command vehicle pulls the empty bottom mold trolley to the pouring station, where the steel cage is placed into the mold and the mold is closed and waits for the next round of pouring.

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