Modified polystyrene particle assembled floor support plate and modular production method thereof

Abstract

The application is suitable for the technical field of fabricated building, and provides a modified polystyrene particle fabricated floor support plate and a modular production method thereof, including the following steps: loading polystyrene particle raw materials and boiler biomass combustion materials; foaming the polystyrene particle raw materials into foam particles; making the modifier fully contact with the foam particles through a double-shaft double-spiral-blade self-control modification system to complete uniform modification; adding the modified foam particles into a full-automatic stirring system to prepare modified polystyrene particle concrete, and conveying the modified polystyrene particle concrete to a designated pouring position of a robot through a self-suction pump and a rubber hose; meanwhile, welding of truss reinforcement on a formwork is completed; formwork pouring and surface treatment are performed, and finally, a modified polystyrene particle fabricated floor support plate product is obtained. The application realizes uniform modification of the polystyrene particles, enhances the strength of the floor support plate, reduces the cost, improves the production and construction efficiency, and simultaneously has a significant heat preservation, sound insulation and noise reduction function.

Description

Technical Field

[0001] This invention belongs to the field of prefabricated building technology, and particularly relates to a modified polystyrene particle prefabricated floor deck and its modular production method. Background Technology

[0002] Green development is a major trend in my country's economic and social development and an important component of the new development philosophy. Prefabricated buildings, with their alignment with energy conservation, emission reduction, and environmental protection, are leading the development of green buildings. Prefabricated floor slabs, with their excellent integrity, formwork savings, high degree of industrialization, and efficient construction speed, occupy an important position in the prefabricated building field. However, traditional prefabricated floor slabs, due to their weight and thickness, bring many inconveniences to transportation, handling, and installation, and also increase costs. In recent years, modified polystyrene particle prefabricated floor slabs have gradually emerged in the construction industry due to their lightweight characteristics and good thermal insulation and sound insulation properties. Modified polystyrene particles are granular materials obtained by modifying polystyrene particles through a special process. Depending on different modification methods and additives, they can be divided into inorganic modified polystyrene particles, organic modified polystyrene particles, etc. This material not only has excellent thermal insulation performance, helping to reduce building energy consumption, but some modified polystyrene particles also have good fire resistance, meeting the fire protection requirements of buildings. Using modified polystyrene particle prefabricated floor decking can avoid the need to construct sound insulation and thermal insulation layers again after pouring the cast-in-place concrete, thereby improving construction efficiency and reducing the difficulty of on-site management.

[0003] However, some problems still exist in the current production process of modified polystyrene particle prefabricated floor decking. For example, the modification process of polystyrene particles is relatively complex, making prefabrication in the factory relatively difficult and hindering efficient assembly line production. Furthermore, the common method for modifying polystyrene particles during production involves adding them to a modification mother liquor for impregnation, stirring, and then drying. This can easily lead to residual mother liquor on the surface of the modified polystyrene particles, and the chemical components in the mother liquor (such as Cl) can become contaminated. - This can corrode the steel reinforcement inside the floor deck. Furthermore, existing modified polystyrene particle prefabricated floor decks typically consist of a precast concrete layer and a cast-in-place concrete layer. Although the precast concrete layer uses lightweight modified polystyrene particle concrete and incorporates wire mesh and truss reinforcement tied to the wire mesh, the bottom of the precast layer still requires pre-embedded mesh to enhance its forming strength and prevent cracking during transportation. This indicates a certain defect in using modified polystyrene particle concrete at the bottom of the precast layer. Additionally, the connection between precast layers via splicing reinforcement and the large-area on-site pouring of the cast-in-place layer necessitate improved construction efficiency (e.g., Chinese utility model patent CN220247340U, "A Modified Polystyrene Particle Insulated Composite Floor Slab and Its Precast Floor Slab").

[0004] To address the above problems, this invention proposes a modified polystyrene particle prefabricated floor decking and its modular production method. Summary of the Invention

[0005] The purpose of this invention is to provide a modified polystyrene particle prefabricated floor deck and its modular production method, aiming to solve the problems mentioned in the background art.

[0006] The objective of this invention is achieved through the following technical solution:

[0007] A modular production method for modified polystyrene particle prefabricated floor decking includes the following steps:

[0008] First, a feeding robot is used to automatically feed polystyrene granules and boiler biomass combustion materials. Then, the polystyrene granules are foamed into foam particles. Next, a dual-axis, dual-helix blade self-controlled modification system ensures that the modifier is in full contact with the foam particles, achieving uniform modification. The modified foam particles are then added to a fully automatic mixing system to prepare modified polystyrene granule concrete, which is then transported to the designated pouring position by the robot via a self-priming pump and rubber hose. Simultaneously, the truss reinforcement on the formwork is welded. Finally, the formwork is poured and the surface is treated to obtain the finished modified polystyrene granule prefabricated floor deck.

[0009] Furthermore, in the step of foaming polystyrene granular raw materials into foam particles, a fully automatic quantitative pre-expansion machine, a fluidized bed dryer, a horizontal steam generator, a permanent magnet variable frequency air compressor, and a steam storage tank are used for foaming the granular raw materials. The specific process is as follows:

[0010] The fully automatic quantitative pre-expansion machine automatically conveys polystyrene granules to the foaming tank via a screw feeder and accurately measures them using an electronic weighing device. Constant pressure foaming is performed in a fully enclosed stainless steel tank. During the foaming process, the steam pressure and temperature inside the tank remain stable, ensuring the foaming agent produces uniform bubbles. The fluidized bed dryer uses a drying medium that passes through the perforations under the grate, causing the granules to violently agitate and shift, forming a mixed bed of granules and gas. This achieves good gas-solid contact and dries the material. The fuel in the horizontal steam generator burns in the combustion chamber, releasing heat and heating the water in the horizontally arranged tube bundle, converting the water into steam. The generated steam is discharged from the steam outlet for use in the fully automatic quantitative pre-expansion machine. Excess steam is compressed into high-pressure gas by a permanent magnet variable frequency air compressor and stored in a steam storage tank.

[0011] Furthermore, the polystyrene granules are foamed to a diameter of 5 mm.

[0012] Furthermore, the biaxial double-helix blade self-controlled modification system employs a biaxial double-helix blade self-controlled modification machine. The inner wall of the modification cylinder of this machine is fully covered by a graphene heating film, creating a temperature self-control system. A temperature sensor monitors the temperature of the heating film in real time and feeds the temperature signal back to the controller, maintaining the temperature inside the cylinder between 50℃ and 85℃ to dilute the modifier. The flow rate of the liquefied modifier is identified by a core electronic level sensor, which transmits the flow rate value to the control panel. The control panel then adjusts the mist based on the flow rate value detected by the core electronic level sensor. The power and valve opening of the spray nozzle are regulated to ensure uniform spraying of the modifier. The electronically controlled suction system adjusts the fan power by identifying the flow rate and velocity of the foam particles in the transmission path. The fan generates negative pressure through rotating blades, drawing the foam particles into the modification cylinder and propelling them into a slow, suspended state within the cylinder. During this flow, the dual-axis, dual-helix blades propel and agitate the foam particles, ensuring that the atomized modifier evenly covers the surface of the foam particles at 360°. After modification, the electronically controlled suction system draws the modified polystyrene particles into an external storage chamber.

[0013] Furthermore, in the steps of casting the template and surface treatment, a casting robot and a surface treatment robot are used to perform the casting and surface treatment respectively, and both the casting robot and the surface treatment robot are equipped with ground rails.

[0014] The pouring robot is equipped with a gantry frame at its rear, and a slide rail is provided on the gantry frame. The pipeline is suspended on the gantry frame and moves smoothly left and right as the pouring robot moves.

[0015] The surface treatment robot is equipped with a quick-change tray robot at its end, which is used to install different tools; a tool rack for placing tools is provided on one side of the surface treatment robot.

[0016] A modified polystyrene particle prefabricated floor deck produced according to the above-described modular production method includes a ready-mixed concrete layer, a modified concrete layer, a steel mesh frame, transverse steel bars, grid steel bars, and two pre-embedded bolt holes. The ready-mixed concrete layer is a commercially cast concrete layer. The modified concrete layer is cast above the ready-mixed concrete layer. The steel mesh frame is prefabricated and placed within the ready-mixed concrete layer. The truss steel bars include grid steel bars and transverse steel bars. The transverse steel bars are located within the modified concrete layer. The bottom surface of the grid steel bars is approximately 50 mm higher than the surface of the cast ready-mixed concrete layer. The grid steel bars are tied and fixed to the steel mesh frame. Two pre-embedded bolt holes are provided on both the ready-mixed concrete layer and the modified concrete layer.

[0017] Furthermore, the connection between the floor decking slabs adopts a point-like semi-flexible connection; the overlap length on both sides of the floor decking slab is 100mm, and the overlap between the slabs is bolted together through the first pre-embedded bolt hole, with a spacing of 500mm between the first pre-embedded bolt holes on both sides; the floor decking slab is connected to the beam through the second pre-embedded bolt hole; the connection between the floor decking slab and the concrete beam adopts chemical anchor bolts; the connection between the floor decking slab and the steel structure beam adopts shear studs, with a pre-embedded shear stud hole diameter of 50mm.

[0018] Compared with the prior art, the beneficial effects of the present invention are:

[0019] 1. Uniform Modification of Polystyrene Particles: A JX-1 biaxial, double-helix blade self-controlled modifier is used. A high-temperature system atomizes the modifier and sprays it uniformly onto the surface of the polystyrene particles, ensuring full contact between the modifier and the particles. This modification method not only improves the modification effect but also avoids the corrosive effect of concentrated modifiers on steel reinforcement, ensuring the durability and safety of the material.

[0020] 2. Improved strength of modified polystyrene particle prefabricated floor decking: The floor decking has a ready-mixed concrete layer at the bottom and a modified concrete layer at the top. The reinforcing steel mesh is placed within the ready-mixed concrete layer, which is superior to wire mesh, giving the floor decking higher strength. Furthermore, the point-like semi-flexible connection method has a certain energy dissipation effect under horizontal loads, further enhancing the structure's seismic performance.

[0021] 3. Reduced Costs: Lightweight prefabricated floor decking facilitates transportation, handling, and installation, reducing the costs associated with manual and mechanical handling. Furthermore, the lighter weight of the floor decking reduces the amount of cement or steel used in the main beams and columns, thereby lowering overall construction costs.

[0022] 4. Improved Production and Construction Efficiency: The production process is highly automated, employing a modular production method that effectively improves production efficiency. The modified polystyrene particle prefabricated floor decking is entirely prefabricated in the factory, eliminating the need for separate prefabricated and cast-in-place layers, as well as additional sound insulation and thermal insulation layers. Point-based semi-flexible connections are used on-site, facilitating convenient and quick installation, effectively shortening the construction period and improving construction efficiency.

[0023] 5. Excellent thermal insulation, sound insulation, and noise reduction functions: Modified polystyrene particles have excellent thermal insulation, sound insulation, and noise reduction functions, effectively insulating heat, especially suitable for northern regions, reducing geothermal heat loss. The modified polystyrene particles are evenly distributed in concrete, achieving sound insulation standards without the need for additional sound insulation or thermal insulation layers. Attached Figure Description

[0024] Figure 1 This is a flowchart of the method of the present invention.

[0025] Figure 2This is a physical image of the loading robot used in this invention.

[0026] Figure 3 This is a model diagram of the fully automatic quantitative pre-dispensing machine in this invention.

[0027] Figure 4 This is a model diagram of the fluidized bed in this invention.

[0028] Figure 5 This is a physical image of the horizontal steam generator in this invention.

[0029] Figure 6 This is a model diagram of the permanent magnet variable frequency air compressor in this invention.

[0030] Figure 7 This is a model diagram of the steam storage tank in this invention.

[0031] Figure 8 This is a physical image of the biaxial double-helix blade self-controlled modification machine of the present invention.

[0032] Figure 9 This is a physical image of the fully automatic mixer used in this invention.

[0033] Figure 10 This is a physical image of the welding robot used in this invention.

[0034] Figure 11 This is a site layout diagram for the template casting and surface treatment steps of this invention.

[0035] Figure 12 This is a schematic diagram of the surface treatment robot in this invention.

[0036] Figure 13 This is a side view of the floor decking in this invention.

[0037] Figure 14 This is a top view of the floor decking in this invention.

[0038] In the diagram: 1. Commercial concrete layer; 2. Modified concrete layer; 3. Steel mesh frame; 4. Horizontal steel reinforcement; 5. Grid steel reinforcement; 6. Pre-embedded bolt hole 1; 7. Pre-embedded bolt hole 2; 8. Pouring robot; 9. Surface treatment robot; 10. Ground rail; 11. Gantry frame; 12. Pipeline; 13. Quick-change plate robot; 14. Tool rack. Detailed Implementation

[0039] In order to provide a clearer understanding of the technical features, objectives and beneficial effects of the present invention, the technical solution of the present invention will now be described in detail below, but it should not be construed as limiting the scope of implementation of the present invention.

[0040] The specific implementation of the present invention will be described in detail below with reference to specific embodiments.

[0041] like Figures 1-12 One embodiment of the present invention provides a modular production method for modified polystyrene particle prefabricated floor decking, the flowchart of which is shown below. Figure 1 As shown, the method includes the following steps:

[0042] First, a feeding robot is used to automatically feed polystyrene granules and biomass combustion materials for the boiler. Then, the polystyrene granules are foamed into foam particles. Next, a dual-axis, dual-helix blade self-controlled modification system ensures that the modifier is in full contact with the foam particles, achieving uniform modification. The modified foam particles are then added to a fully automatic mixing system to prepare modified polystyrene granule concrete, which is then transported to the designated pouring position by the robot via a self-priming pump and rubber hose. Simultaneously, the truss reinforcement on the formwork is welded. Finally, the formwork is poured and surface treatment is performed to obtain the finished modified polystyrene granule prefabricated floor deck.

[0043] The feeding process utilizes a six-degree-of-freedom robot, model BRTIRUS3511A. This robot automatically feeds and unloads the granular raw materials and boiler biomass combustion materials. After unloading, it stacks the packaging bags in designated locations and is capable of handling heavy loads. This equipment ensures thorough preparation for the polystyrene granule foaming process. Figure 2 As shown.

[0044] Granular raw material foaming: XL-PSD1600 fully automatic quantitative pre-expansion machine (e.g.) Figure 3 (as shown), fluidized bed XL-LH1400 (such as) Figure 4 As shown), horizontal steam generator LHS0.7-0.09-Y(Q) type (such as...) Figure 5 As shown), permanent magnet variable frequency air compressor QF-22G model (such as...) Figure 6 (as shown) and steam storage tank type R22048 (such as) Figure 7 (As shown) the granular raw material is foamed.

[0045] The fully automatic quantitative pre-expansion machine automatically conveys polystyrene (EPS) granules to the foaming tank via a screw feeder and accurately measures the amount of raw material using an electronic weighing device to ensure that the amount of raw material input meets the set requirements. A fully enclosed stainless steel tank is used for constant pressure foaming. During the foaming process, the steam pressure and temperature inside the tank remain stable, causing the foaming agent to generate uniform bubbles, resulting in high thermal efficiency, strong penetration, and uniform particle density. A PLC programmable controller and touch screen are used to achieve automatic cyclic operation of the entire process, including feeding, steam supply, temperature control, foaming, and discharging. Each stage of operation can be precisely controlled according to preset programs and parameters, ensuring stable and efficient operation. Operators can also intuitively set parameters and monitor the equipment's operating status through the touch screen. The fluidized bed dryer uses a drying medium that passes through the perforations under the grate at a certain speed, slightly exceeding the critical fluidization velocity. This causes the granular raw material in the bed to violently agitate and displace, forming a mixed bed of granular raw material and gas. This achieves good gas-solid two-phase contact, enhances heat and mass transfer, and achieves the drying purpose. In the horizontal steam generator, fuel is burned in the combustion chamber, releasing heat energy to heat water in the horizontally arranged tube bundle, converting the water into steam. The generated steam is discharged from the steam outlet for use in the fully automatic quantitative pre-generator. Excess steam is compressed into high-pressure gas by a permanent magnet variable frequency air compressor and stored in a steam storage tank. This process can foam polystyrene granules to a diameter of about 5mm, which are then placed in the granule storage silo to prepare for the next process.

[0046] Biaxial double-helix blade self-controlled modification system: Employs a biaxial double-helix blade self-controlled modification machine (such as...) Figure 8 As shown in the image, compared to traditional turbine-type liquid delivery control systems, this equipment offers significant advantages in liquid transfer rate, stability, and spray adhesion area. The system is no longer limited by transfer rate fluctuations caused by voltage fluctuations and equipment wear. Specifically, the dual-shaft, dual-helix blade self-controlled modifier is equipped with a core electronic level sensor. This high-precision component ensures accurate control of the modifier flow rate, thereby achieving high stability and data adjustability during the production process.

[0047] Furthermore, the inner wall of the modified cylinder of the dual-axis, dual-helix blade self-controlled modifying machine is covered by a graphene heating film temperature control system. A temperature sensor monitors the temperature of the heating film in real time and feeds the temperature signal back to the controller. When the temperature reaches the set upper limit, the controller automatically adjusts the current passing through the heating film to reduce heat generation; when the temperature falls below the set lower limit, the current is increased to raise the temperature. This system effectively controls the temperature between 50℃ and 85℃, allowing the originally viscous modifier to be completely diluted at the critical temperature required for liquefaction, changing it from viscous to thin, which is beneficial for the flow of the modifier. The liquefied modifier is precisely regulated by an electronic flow control system. The flow rate of the liquefied modifier is identified by a core electronic level sensor, which transmits the flow value to the control panel. The control panel precisely regulates the power of the mist ejector and the valve opening based on the flow value detected by the core electronic level sensor. Eight mist ejectors are set along the edge of the transmission path, each positioned at a 45° angle to the inner wall of the modified cylinder, ensuring that the mist modifier evenly covers the surface of the foam particles. Under the action of the electronically controlled automatic suction system, the flow rate and velocity of the foam particles within the transmission path are identified to adjust the fan power. The fan generates negative pressure through rotating blades, allowing the suction port to draw in the foam particles, propelling them into a slow, suspended state within the modified cylinder. During this flow, the dual-axis, dual-helix blades not only propel the foam particles but also continuously agitate them, ensuring that the atomized modifier uniformly covers the surface of the foam particles at 360°.

[0048] After modification, an electronically controlled suction system draws the modified polystyrene particles into an external storage chamber. The entire process is automated through an electronically controlled control panel. Atomizers arranged around the entire transport path ensure that the modifier is evenly coated on the surface of each polystyrene particle, achieving excellent homogeneity. In summary, the dual-axis, dual-helix blade self-controlled modification machine demonstrates significant innovation and practicality in both design and function.

[0049] Fully Automatic Mixing System: Utilizing a JX-3 fully automatic mixer with built-in weighing functions for cement, polystyrene granules, and water, effectively ensuring the required mix proportions during mixing. Internally, it features upper and lower agitators for double mixing, ensuring uniform distribution of the modified polystyrene granules and guaranteeing the performance of the resulting lightweight concrete. Simultaneously, the machine automatically feeds, unloads, and pumps the modified polystyrene granule concrete, delivering it to the designated pouring location via a self-priming pump and rubber hoses. Equipment as follows... Figure 9 As shown.

[0050] Formwork reinforcement welding: The reinforcement is welded automatically by a robot, using a six-degree-of-freedom robot, model BRTIRUS3511A (e.g.) Figure 10As shown in the figure, precise product fixtures are selected based on specific steel reinforcement frames to ensure the welding position and welding quality of the robot. On-site manual welding is no longer required, thereby reducing the labor intensity of workers and improving welding quality. Overtime work can be carried out at any time without restrictions.

[0051] Formwork casting and surface treatment: A six-degree-of-freedom robot, model BRTIRUS3511A, was used. The site layout is as follows: Figure 11 As shown. There is one casting robot 8 and one surface treatment robot 9, and both casting robot 8 and surface treatment robot 9 are equipped with ground rails 10.

[0052] A gantry frame 11 is located behind the pouring robot 8. A slide rail is installed on the gantry frame 11, and the pipe 12 is suspended from it. The pipe 12 moves smoothly left and right with the pouring robot 8, ensuring consistent material output. Flow detection is added to ensure consistent pouring volume each time. The pouring pipe on the pouring robot 8 and the pipe 12 on the gantry frame 11, in conjunction with the ground rail 10, complete the pouring of cement up to 6 meters × 3 meters in size. The surface treatment robot 9 is responsible for tasks other than pouring, such as scraping, shoveling, and smoothing. The surface treatment robot 9 has a quick-change disc robot 13 at its end, which can be equipped with different tools for rapid tool changes. A tool rack 14 is located on one side of the surface treatment robot 9. Tools are placed on the tool rack 14, and the surface treatment robot 9 automatically changes tools on the tool rack 14 without human intervention. Figure 12 As shown in the figure. Finally, the modified polystyrene particle prefabricated floor decking is produced.

[0053] like Figure 13 and Figure 14 As shown, one embodiment of the present invention provides a modified polystyrene particle prefabricated floor deck, including a commercial concrete layer 1, a modified concrete layer 2, a steel mesh 3, transverse steel bars 4, lattice steel bars 5, pre-embedded bolt holes 6 and 7. The commercial concrete layer 1 is a commercial concrete pouring layer, and the appropriate strength grade of commercial concrete can be selected according to the actual project needs. The modified concrete layer 2 is directly poured on top of the commercial concrete layer 1 in the factory. The steel mesh 3 is prefabricated and placed within the commercial concrete layer 1. The truss steel bars include lattice steel bars 5 and transverse steel bars 4. The transverse steel bars 4 are located within the modified concrete layer 2. The bottom surface of the lattice steel bars 5 is approximately 50mm higher than the pouring surface of the commercial concrete layer 1. The lattice steel bars 5 are tied and fixed to the steel mesh 3. Pre-embedded bolt holes 6 and 7 are provided on both the commercial concrete layer 1 and the modified concrete layer 2.

[0054] The floor decking is connected using a point-type semi-flexible connection. The overlap length on both sides of the floor decking is 100mm. The overlap between the deckings is bolted through pre-embedded bolt holes 6, with a spacing of 500mm between the pre-embedded bolt holes 6 on both sides. The floor decking is connected to the beam through pre-embedded bolt holes 7, with the hole spacing determined by the decking width. Chemical anchors are used to connect the floor decking to the concrete beam. Shear studs are used to connect the floor decking to the steel structure beam. The shear stud holes are pre-drilled on parallel lines 50mm from the edges on both longitudinal sides and at two transverse ends of the floor decking, with a hole diameter interval of 500mm.

[0055] In this embodiment of the invention, the precast concrete layer 1 of the modified polystyrene particle precast floor deck is set as the bottom of the floor deck, and the modified concrete layer 2 is set as the top of the floor deck. A steel mesh 3 is installed within the precast concrete layer 1, which, unlike wire mesh, gives the floor deck both high strength and thermal and sound insulation functions. Placing the precast concrete layer 1 at the bottom also ensures the bottom forming strength and prevents cracking during transportation, eliminating the need for pre-embedded mesh fabric at the bottom. Furthermore, the entire modified polystyrene particle precast floor deck proposed in this invention is prefabricated in the factory. The bottom precast concrete layer 1 and the top modified concrete layer 2 are poured sequentially and naturally cured. The atomized modified polystyrene particles can bond well with the concrete, and the upper and lower parts of the floor deck naturally bond after curing. The bottom surface of the grid-like steel reinforcement 5 is 50mm higher than the pouring surface of the precast concrete layer 1, and the installation of bolts also effectively improves the overall integrity of the slab structure.

[0056] Existing modified polystyrene particle prefabricated floor decking typically places the modified polystyrene particle layer at the bottom, with the upper part cast-in-place on-site. Connections between decks and between decks and beams are achieved using cast-in-place reinforced steel. This invention, however, employs a point-based semi-flexible connection method. Deck layers overlap and are connected by bolts, with pre-embedded bolt holes. On-site installation only requires bolt installation and filling of the bolt holes, ensuring connection stability. Chemical anchors are used to connect decks to concrete beams, while shear studs are used to connect them to steel beams. This method facilitates installation and transportation, effectively improving construction efficiency and reducing the construction period. Furthermore, the point-based semi-flexible connection method allows the overall structure to absorb energy under horizontal loads.

[0057] The above are merely preferred embodiments of the present invention. It should be noted that those skilled in the art can make several modifications and improvements without departing from the concept of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the present invention.

Claims

1. A modular production method for modified polystyrene particle prefabricated floor decking, characterized in that... This includes the following steps: First, a feeding robot is used to automatically feed polystyrene granules and boiler biomass combustion materials. Then, the polystyrene granules are foamed into foam particles. Next, a dual-axis, dual-helix blade self-controlled modification system ensures that the modifier is in full contact with the foam particles, achieving uniform modification. The modified foam particles are then added to a fully automatic mixing system to prepare modified polystyrene granule concrete, which is then transported to the designated pouring position by the robot via a self-priming pump and rubber hose. Simultaneously, the truss reinforcement on the formwork is welded. Finally, the formwork is poured and the surface is treated to obtain the finished modified polystyrene granule prefabricated floor deck. The biaxial double-helix blade self-controlled modification system employs a biaxial double-helix blade modifyer. The modification cylinder wall of the biaxial double-helix blade modifyer utilizes a graphene heating film-covered temperature self-control system. A temperature sensor monitors the temperature of the heating film in real time and feeds the temperature signal back to the controller, maintaining the temperature inside the cylinder between 50℃ and 85℃ to dilute the modifier. After liquefaction, the flow rate of the modifier is identified by a core electronic level sensor, transmitting the flow value to the control panel. The control panel adjusts the power of the mist sprayer and the valve opening based on the flow value detected by the core electronic level sensor, ensuring uniform spraying of the modifier. The electronic self-controlled air suction system adjusts the fan power by identifying the flow rate and velocity of the foam particles within the transmission path. The fan generates negative pressure through rotating blades, drawing the foam particles into the modification cylinder and propelling them into a slow, suspended state within the cylinder. During this flow, the biaxial double-helix blades propel and agitate the foam particles, ensuring the mist modifier evenly covers the surface of the foam particles at 360°.

2. The modular production method according to claim 1, characterized in that... In the step of foaming polystyrene granules into foam particles, a fully automatic quantitative pre-expansion machine, a fluidized bed dryer, a horizontal steam generator, a permanent magnet variable frequency air compressor, and a steam storage tank are used for foaming the granular raw materials. The specific process is as follows: The fully automatic quantitative pre-expansion machine automatically conveys polystyrene granules to the foaming tank via a screw feeder and accurately measures them using an electronic weighing device. Constant pressure foaming is performed in a fully enclosed stainless steel tank. During the foaming process, the steam pressure and temperature inside the tank remain stable, ensuring the foaming agent produces uniform bubbles. The fluidized bed dryer uses a drying medium that passes through the perforations under the grate, causing the granules to violently agitate and shift, forming a mixed bed of granules and gas. This achieves good gas-solid contact and dries the material. The fuel in the horizontal steam generator burns in the combustion chamber, releasing heat and heating the water in the horizontally arranged tube bundle, converting the water into steam. The generated steam is discharged from the steam outlet for use by the fully automatic quantitative pre-expansion machine. Excess steam is compressed into high-pressure gas by a permanent magnet variable frequency air compressor and stored in a steam storage tank.

3. The modular production method according to claim 1, characterized in that... The polystyrene granules are foamed to a diameter of 5 mm.

4. The modular production method according to claim 1, characterized in that... In the steps of template casting and surface treatment, a casting robot and a surface treatment robot are used to perform template casting and surface treatment respectively, and both the casting robot and the surface treatment robot are equipped with ground rails. The pouring robot is equipped with a gantry frame at its rear, and a slide rail is provided on the gantry frame. The pipeline is suspended on the gantry frame and moves smoothly left and right as the pouring robot moves. The surface treatment robot is equipped with a quick-change tray robot at its end, which is used to install different tools; a tool rack for placing tools is provided on one side of the surface treatment robot.

Images