Concrete prefabricated part flow production line and production process

Abstract

The invention relates to a concrete prefabricated part flow production line and a production process, and belongs to the technical field of concrete prefabricated part production. Comprising a main track, and feeding and distributing equipment, a plastering finishing area, a steam curing area, a demolding area and a mold cleaning and closing station which are arranged along the main track; the mold is arranged on the trolley and walks on the main track along with the trolley; the feeding and distributing equipment comprises a distributing rack and a distributing machine arranged on the distributing rack; the main track penetrates through the lower part of the material distributing rack; a demolding frame is arranged in the demolding area; the main track penetrates through the lower portion of the demolding frame. The steam-curing area is a closed space, a plurality of steam-curing area rails are arranged in the steam-curing area, and the steam-curing area rails are in butt joint with the main rail. According to the technical scheme, the feeding and distributing device, the plastering finishing area, the steam curing area, the demolding area and the mold cleaning and closing station are connected through the main track, then the trolley drives the mold to walk on the main track, assembly line work production of all processes of the concrete prefabricated part can be achieved, and therefore the working efficiency is improved.

Description

Technical Field

[0001] The invention relates to a concrete prefabricated part production line, in particular to a concrete prefabricated water channel production line, and belongs to the technical field of concrete prefabricated part production. Background Art

[0002] In construction, the use of precast concrete parts can improve the efficiency of construction. Precast concrete parts are concrete components that are prefabricated in a factory and then transported to the construction site for use.

[0003] In modern canal construction, prefabrication is gaining increasing popularity, particularly due to its significant technical advantages, including its unaffectedness from external factors such as site conditions and weather, high efficiency, rapid maintenance, and labor and cost savings. Prefabricating canals into standardized prefabricated components enables efficient canal construction.

[0004] Currently, there is no assembly line suitable for precast concrete parts. The production steps are not continuous, but are transferred between stations by manual labor and equipment. As a result, the production of precast concrete parts suffers from low production efficiency and unstable production quality. Summary of the Invention

[0005] The purpose of the present invention is to provide a prefabricated concrete production line to solve the above technical problems and realize the streamlined and efficient production of prefabricated water channels.

[0006] In order to achieve the above object, the technical solution adopted by the present invention is: A concrete precast part production line includes a main track and material feeding and distributing equipment, a finishing area, a steaming area, a demoulding area, and mold cleaning and closing stations arranged along the main track; the mold is set on a trolley and moves along the main track with the trolley; The material feeding and distributing equipment includes a distributing machine frame and a distributing machine arranged on the distributing machine frame; the main track passes through the bottom of the distributing machine frame; the material feeding machine feeds the material into the distributing machine; A demoulding frame is provided in the demoulding area, and an overhead crane for hoisting is provided on the demoulding frame; the main track passes under the demoulding frame; The steam curing area is a closed space, in which a number of steam curing area tracks are arranged, and the steam curing area tracks are connected to the main track; the steam curing area is divided into a temperature rising area, a constant temperature area and a temperature falling area.

[0007] A further improvement of the above technical solution of the present invention is that it also includes a concrete mixing station and a concrete tank truck for transporting concrete from the concrete mixing station to the loading and distributing equipment.

[0008] A further improvement of the above technical solution of the present invention is as follows: the material distributing machine includes a material distributing bin and a stirring member rotatably arranged in the material distributing bin; the lower end surface of the material distributing bin is a material discharging port; the material discharging port is controlled by a bin door driven by a telescopic rod.

[0009] A further improvement of the above technical solution of the present invention is as follows: a segmented track that is not integrated with the main track is set below the material placing machine; a vibration table is set below the segmented track; a lifting rod is set on the lower end surface of the segmented track; and the lifting rod drives the segmented track to move up and down.

[0010] A further improvement of the above technical solution of the present invention is that the stirring member is a spiral auger or a stirring shaft has a plurality of stirring blades fixedly arranged on its surface.

[0011] A further improvement of the above technical solution of the present invention is as follows: the mold includes a steel template and a bottom mold; the steel template forms a trapezoidal mold cavity structure, and the bottom mold is arranged in the mold cavity.

[0012] The above technical solution of the present invention is further improved as follows: a mold base is fixedly arranged on the trolley; the steel template includes two end templates and two side templates; the end templates and the side templates are hingedly connected to the mold base; and the joints of the end templates and the side templates are connected with bolts.

[0013] A further improvement of the above technical solution of the present invention is that the staff in the finishing area holds the finishing tools to perform finishing; the staff in the mold cleaning and closing station holds the cleaning tools to perform cleaning and close the mold.

[0014] A concrete precast part production process, using a concrete precast part production line, comprises the following steps: 1) Transport the prepared concrete to the concrete placing machine through the loader; 2) The concrete placing boom injects concrete into the mold. After the concrete is poured into the mold, the lifting rod descends, causing the mold to fall onto the vibrating table. The trolley and segmented tracks follow the lifting cylinder and descend. Both ends of the mold are placed on the vibrating table and separated from the trolley. The vibrating table vibrates. After the vibration is completed, the lifting rod rises until the segmented tracks are aligned with the main track. The trolley moves forward along the main track. After the next mold is moved into place, the concrete placing boom pours concrete into the mold again. 3) After the concrete is poured into the mold, it moves to the finishing area, where the staff will use hand-held tools to finish the finishing. After the finishing is completed, the trolley continues to move forward along the main track; 4) The trolley moves with the mold to the steaming area, where it is steamed for a period of time. The trolley moves forward intermittently in the steaming area. 5) After steaming is completed, the trolley carries the mold along the main track to the demoulding area. After the staff opens the mold, the formed channel prefabricated part is hoisted out using an overhead crane; 6) The trolley carries the demoulded mold to the cleaning and mold closing station, where the staff cleans the inner surface of the mold and closes the mold. Then, the trolley carries the mold to the position of the loading and distributing equipment to start the next work cycle.

[0015] A further improvement to the technical solution of the above process of the present invention is as follows: in step 4, the carriage and the mold move from entering the steaming zone to exiting the steaming zone for a total of 5 hours; the carriage advances once every 3 minutes; and every 3 minutes, a group of carriages moves out of the exit of the steaming zone and then a group of carriages moves into the entrance of the steaming zone.

[0016] Due to the adoption of the above technical solution, the technical effects achieved by the present invention are as follows: The precast concrete production line in this technical solution utilizes a main track to allow a trolley to travel with the molds. Loading and distributing equipment, a finishing area, a steaming and curing area, a demolding area, and mold cleaning and closing stations are sequentially arranged along the main track. The main track connects these various work areas, and the trolley, which carries the molds, travels along the main track, enabling assembly line production of precast concrete parts, thereby improving work efficiency.

[0017] In this technical solution, multiple steaming area tracks are set in the steaming area. The trolley moves intermittently in the steaming area to achieve assembly line steaming of multiple or multiple groups of trolley molds, thereby improving the steaming work efficiency.

[0018] This technical solution sets a vibration table below the loading and distributing equipment. Through the split setting and lifting setting of the segmented track, the mold can fall onto the vibration table. By vibrating the mold, the density of the concrete in the mold is improved, thereby improving the quality of the concrete prefabricated product.

[0019] In this technical solution, the movement frequency of the trolley is set to advance one position every 3 minutes, which can make the trolley stay in the heating zone, constant temperature zone and cooling zone for a reasonable time, and can achieve good heating effect, constant temperature maintenance effect and cooling effect.

[0020] In this technical solution, by setting a mold, the mold has a mold cavity and a bottom mold, which can realize the production of concrete prefabricated parts of various shapes. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 The present invention is the production line layout Figure 1 ; Figure 2 The present invention is the production line layout Figure 2 ; Figure 3 Schematic diagram of the demoulding area of ​​the present invention; Figure 4Schematic diagram of four states of the mold of the present invention; Figure 5 This is a schematic diagram of the mold opening state of the present invention; Figure 6 This is a schematic diagram of the mold closing state of the present invention; Figure 7 Schematic diagram of the steaming area of ​​the present invention; Figure 8 This is a schematic diagram of the car landing to vibration state; Figure 9 It is a three-dimensional schematic diagram of the feeding and distributing equipment; Figure 10 It is a schematic diagram of a fabric spreading machine; Figure 11 This is the main view of the loading and distributing equipment; Among them, 1. Main track, 2. Material feeding and distributing equipment, 21. Material distributing rack, 22. Material distributing machine, 221. Material distributing bin, 222. Mixing blade, 23. Material feeding machine; 3. Steaming zone, 31. Steaming zone track, 32. Heating zone, 33. Constant temperature zone, 34. Cooling zone, 4. Demolding area, 41. Demolding frame, 42. Overhead crane; 5. Surface finishing area; 6. Concrete mixing station; 7. Trolley; 8. Mold, 81. Bottom mold, 82. End mold, 83. Side mold, 84. Mold base; 9. Mould cleaning and closing station; 10. Vibrating table; 11. Segmented track; 12. Lifting rod. DETAILED DESCRIPTION

[0022] In order to make the technical means, creative features, objectives and effects achieved by the present invention easier to understand, the present invention is further described below in conjunction with specific implementation methods.

[0023] In the description of the present invention, it should be noted that the terms "upper", "lower", "inside", "outside", "front end", "rear end", "two ends", "one end", "the other end", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation. Therefore, they cannot be understood as limiting the present invention.

[0024] The present invention relates to a prefabricated concrete part production line, which is used for producing prefabricated concrete parts. The overall production efficiency can be improved through production in the form of a production line.

[0025] like Figures 1-8As shown, the production line includes a main track 1, as well as a material feeding and distributing device 2, a finishing area 5, a steaming area 3, a demolding area 4, and a mold cleaning and closing station 9. Multiple trolleys 7 are positioned on the main track 1, each carrying a mold 8. The trolleys 7 carry the molds 8 as they travel along the main track 1. The material feeding and distributing device 2, the finishing area 5, the steaming area 3, the demolding area 4, and the mold cleaning and closing station 9 are all arranged sequentially along the main track 1. The trolleys 1 drive the molds 8 as they travel, allowing the preforms to pass through the various processing stations to achieve the final product shape.

[0026] The loading and distributing equipment 2 is used to inject concrete into the mold 7. Once the mold is filled, the concrete is fed to the finishing area 5. The loading and distributing equipment 2 includes a distributing frame 21 and a distributing boom 22 mounted on the frame 21. The distributing boom 22 is mounted on the frame 21, with the main track 1 passing underneath the frame 21. During distributing, the trolley 7 and mold 8 stop below the distributing boom 22, which then injects concrete into the mold 7. Furthermore, a loader 23 is provided to deliver concrete to the distributing boom 22.

[0027] like Figure 9 、 Figure 10 、 Figure 11 As shown, the concrete distribution boom 22 is used to distribute the concrete. Specifically, the concrete distribution boom 22 includes a distribution bin 221 and a rotating agitator mounted within the bin 221. The concrete is injected into the distribution bin 221 via a loader 23. The agitation of the agitator 222 prevents the concrete from solidifying and improves the uniformity of the distribution. A discharge port is located at the lower end of the distribution bin 221. A movable door is provided at the discharge port. Driven by a telescopic rod, the door moves to control the opening size, thereby controlling the distribution of the concrete. Directly below the door discharge port is the upper opening of the mold.

[0028] The stirring member provided in the material distribution bin 221 may be a spiral auger, or may be a plurality of stirring blades 222 fixedly provided on the surface of the stirring shaft. The stirring member is driven to rotate by a motor.

[0029] After the material distribution is completed, the mold is filled with concrete and needs to be vibrated. The corresponding setting is that a segmented track 11 is set below the material distribution machine 22. The segmented track 11 is docked with the main track 1. However, the segmented track 11 and the main track 1 are not an integrated structure, but a separate and segmented structure. At the same time, a vibration table 10 is correspondingly set below the segmented track 11, and a lifting rod 12 is also set on the lower end surface of the segmented track 11. When the lifting rod 12 drives the segmented track 1, the trolley 7 and the mold 8 to move downward, the mold 8 can fall onto the vibration table 10 and then be vibrated at high frequency on the vibration table 10; while the trolley 7 and the segmented track 11 move downward and separate from the mold 8. After the vibration is completed, the lifting rod 12 lifts the segmented track 1 upward, and then the trolley 7 and the mold 8 also rise. After the segmented track 11 is flush with the main track 1, the trolley 7 continues to move forward. The vibration table 10 is a high-frequency, low-amplitude vibration that does not cause the position of the mold to move, and can ensure that after the vibration is completed, the segmented track 1 and the trolley 7 hold the mold 8 there.

[0030] like Figure 8 As shown, two vibration tables 10 are provided, one on each side of the outer side of the segmented track 11. The mold 8 is longer than the segmented track 11 and the ends of the trolley 7. During the fall, both ends of the mold 8 can land on the vibration tables 10. The segmented track and trolley move downward, separating from the mold. The vibration table 10 operates at a high frequency and low amplitude, which does not cause the mold to move.

[0031] Furthermore, a concrete mixing station 6 and a concrete tanker are required. Concrete is mixed and coagulated in the concrete mixing station 6. The concrete tanker is then used to transport the concrete from the concrete mixing station 6 to the loader. After the loader transports the prepared concrete from the concrete mixing station, it travels to the loader 23, where it feeds the concrete into the concrete distributor 22.

[0032] The finishing area 5 is used to finish the upper surface of the mold 8. It requires manual labor to hold a flat tool such as a plate to finish the upper surface of the mold, so that the upper surface of the mold is flat and ensures that the finished concrete prefabricated part meets the requirements. Finishing can be done along the plane of the upper opening of the mold 8.

[0033] like Figure 7As shown, the curing zone 3 is used to steam-cure precast concrete components. This process allows the concrete components to quickly solidify and form, and after curing, they meet the designed strength requirements. The curing zone is a large enclosed space that can be considered a large production workshop. From the inlet to the outlet of the curing zone 3, there are a heating zone 32, a constant temperature zone 33, and a cooling zone 34. In the heating zone 32, the concrete temperature gradually rises. In the constant temperature zone 33, the temperature remains constant. In the cooling zone 34, the concrete temperature gradually decreases. Concrete temperature control is achieved by controlling the internal temperature of each zone within the curing zone. Curtains, etc., are installed between the zones within the curing zone 3 to achieve temperature zoning. The air temperature and humidity within the curing zone 3 are relatively high, and controlling the temperature and humidity is suitable for the curing and solidification of the concrete.

[0034] In addition, several curing area tracks 31 are provided within the curing area. The trolley 7, carrying the mold 8, travels along the curing area tracks 31 within the curing area 3. The trolley 7 and mold 8 travel intermittently within the curing area 3, advancing approximately one position every three minutes. The curing area tracks 31 extend from the entrance to the exit of the curing area 3, with both ends of the curing area tracks 31 docking with the main track 1. Multiple curing area tracks 31 are provided, and they are parallel to each other. This allows for efficient use of the space within the curing area, allowing multiple molds to be cured simultaneously. After the concrete is cured, the trolley 7 and mold 8 return to the main track 1 and travel along it to the demolding area 4.

[0035] like Figure 3 As shown, the demolding area 4 is used to remove the finished precast concrete part from the mold. In the demolding area 4, workers open the mold. A demolding frame 41 is installed in the demolding area, and an overhead crane 42 is mounted on top of the demolding frame 41. The main track 1 passes under the demolding frame 41. When the trolley 7 and mold 8 pass under the demolding frame 41, the overhead crane 42 lifts the finished precast concrete part from the mold 8. Alternatively, the part can be directly hoisted onto a transport vehicle. After the precast concrete part is demolded, the trolley and the mold continue to the mold cleaning and closing station 9.

[0036] At the mold cleaning and closing station 9, workers clean the inside of the mold with cleaning tools. After cleaning, the mold is closed to form a complete mold cavity, mainly by locking the joints between the end and side molds. After the mold cleaning and closing are completed, the trolley 7 continues to move forward with the mold 8, reaching the loading and distributing position again, and enters the next process cycle.

[0037] The present invention requires the use of a mold to form a concrete prefabricated part.

[0038] For example, the mold for a prefabricated water channel consists of a steel template and a bottom mold 71. The steel template forms a trapezoidal or trapezoidal-like cavity, and a bottom mold 81 is positioned within the cavity. The steel template and bottom mold 81 work together to form a U-shaped water channel.

[0039] like Figure 4 、 Figure 5 、 Figure 6 As shown, further, the mold is installed on the trolley 7. A mold base 84 is fixed on the trolley 7. The steel template includes two end templates 82 and two side templates 83, the two side templates 83 are opposite to each other, and the two end templates 82 are opposite to each other. The side templates 83 and the end templates 82 are connected to form a mold cavity. The bottom mold 81 is located in the mold cavity. The lower ends of the end templates 82 and the side templates 83 are hingedly connected to the mold base 84, and the end templates 82 and the side templates 83 can be rotated around the axis to open the mold. Bolts, nuts and fixing seats are used to connect the end templates 82 and the side templates 83. The bolts are opened when the mold is opened, and the slots on the bolt barrel fixing seat are matched when the mold is closed, and then fixed with nuts.

[0040] The present invention also discloses a concrete precast part production process, which mainly includes the following steps using the above-mentioned concrete precast part production line: 1) After loading concrete from the concrete mixing plant, the concrete tank truck is transported to the location of the loading and distributing equipment, and then the prepared concrete is transported to the distributing machine through the loader.

[0041] 2) The concrete placing machine injects concrete into the mold; after the concrete is poured into the mold, some concrete overflows from the upper opening of the mold. The lifting rod descends and the mold falls onto the vibration table. The segmented track and the trolley follow the lifting rod and detach from the mold. Then, the vibration table vibrates to make the concrete in the mold more dense. After the vibration is completed, the lifting rod is lifted up until the segmented track is aligned with the main track, and the trolley moves forward along the main track; after the next mold moves into place, the concrete placing machine pours concrete into the mold again, and the above process is repeated. For a specific diagram, see Figure 8 shown.

[0042] Concrete is poured into the mold using a concrete placing boom. Once the concrete is poured into the mold, the trolley moves forward along the main track. After the next mold is moved into position, the concrete placing boom pours concrete into the mold again. During the pouring process, the mold is in a vibrating state to ensure a dense pour of concrete.

[0043] 3) The trolley moves the completed mold to the finishing area, where staff use hand-held tools to finish the finishing, mainly to clean the excess concrete on the surface of the mold.

[0044] After the surface finishing is completed, the trolley continues to move forward along the main track.

[0045] 4) The cart carrying the mold moves to the steaming area, where it undergoes steaming for a period of time, typically five hours. The cart moves intermittently within the steaming area, advancing once every three minutes to the next cart position. This means that at any given position, the cart and mold remain stationary for three minutes. A group of carts also enters the steaming area every three minutes at the entrance and exit. Multiple parallel steaming tracks are installed within the steaming area. This means that every three minutes, a group of carts exits the steaming area exit, followed by a group of carts entering the steaming area entrance. The carts within the steaming area move forward one body length overall.

[0046] 5) After steam curing is complete, the trolley carrying the mold moves along the main track to the demolding area. After the staff removes the mold, the fully formed precast concrete component can be seen. The completed channel precast component is lifted out using an overhead crane, or it can be directly hoisted onto a transport vehicle. The trolley continues to move forward with the mold.

[0047] 6) The trolley carries the demoulded mold to the cleaning and closing station, where the staff cleans the inner surface of the mold and then closes the mold. The trolley carries the mold to the loading and distributing equipment to start the next cycle.

[0048] In this technical solution, the main track connects the loading and distributing equipment, finishing area, steaming area, demoulding area, and mold cleaning and closing stations. A trolley, which carries the mold along the main track, enables streamlined production of all steps in the production of precast concrete parts, thereby improving work efficiency. Furthermore, through reasonable process design, highly efficient production of precast parts is achieved through the assembly line.

[0049] The basic principles, main features, and advantages of the present invention are shown and described above. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The above embodiments and descriptions are merely illustrative of the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of protection claimed in the present invention is defined by the appended claims and their equivalents.

Claims

1. A precast concrete production line comprising a main track and material loading and distributing equipment, a finishing area, a steaming and curing area, a demoulding area, and mold cleaning and closing stations arranged along the main track; the molds are mounted on a trolley and follow the trolley along the main track; The material feeding and distributing equipment includes a distributing machine frame and a distributing machine arranged on the distributing machine frame; the main track passes through the bottom of the distributing machine frame; the material feeding machine feeds the material into the distributing machine; A demoulding frame is provided in the demoulding area, and an overhead crane for hoisting is provided on the demoulding frame; the main track passes under the demoulding frame; The steam curing area is a closed space, in which a number of steam curing area tracks are arranged, and the steam curing area tracks are connected to the main track; the steam curing area is divided into a temperature rising area, a constant temperature area and a temperature falling area.

2. The precast concrete production line according to claim 1, characterized in that: It also includes a concrete mixing plant and a concrete tanker truck for transporting concrete from the concrete mixing plant to the loading and distributing equipment.

3. The precast concrete production line according to claim 2, characterized in that: The material distributing machine includes a material distributing bin and a stirring member rotatably arranged in the material distributing bin; the lower end surface of the material distributing bin is a material discharging port; the material discharging port is controlled by a bin door driven by a telescopic rod.

4. The precast concrete production line according to claim 3, characterized in that: A segmented track which is not integrated with the main track is arranged below the material placing machine; a vibration platform is arranged below the segmented track; a lifting rod is arranged on the lower end surface of the segmented track; and the lifting rod drives the segmented track to move up and down.

5. The precast concrete production line according to claim 1, characterized in that: The stirring member is a spiral auger or a stirring shaft with a plurality of stirring blades fixedly arranged on the surface.

6. A precast concrete production line according to any one of claims 1 to 5, characterized in that: The mold includes a steel template and a bottom mold; the steel template forms a trapezoidal mold cavity structure, and the bottom mold is arranged in the mold cavity.

7. The precast concrete production line according to claim 6, characterized in that: The mold base is fixed on the trolley; the steel template includes two end templates and two side templates; the end templates and the side templates are hingedly connected to the mold base; the butt joints of the end templates and the side templates are connected by bolts.

8. The precast concrete production line according to any one of claims 1 to 5, characterized in that: In the finishing area, the staff hold the finishing tools to do the finishing; in the mold cleaning and closing station, the staff hold the cleaning tools to clean and close the mold.

9. A process for producing precast concrete parts, characterized in that: Using the precast concrete production line according to claim 4, The following steps are included: 1) The prepared concrete is transported to the concrete placing boom through the loader; at this time, the trolley with the mold moves to the corresponding segmented track under the concrete placing boom; 2) The concrete placing machine injects concrete into the mold. After the concrete is poured into the mold, the lifting rod descends and the mold falls onto the vibration table. The trolley and segmented track follow the lifting cylinder to descend. The two ends of the mold are placed on the vibration table and separated from the trolley. The vibration table vibrates. After the vibration is completed, the lifting rod is lifted up until the segmented track is aligned with the main track, and the trolley moves forward along the main track. After the next mold is moved into place, the concrete placing boom pours concrete into the mold again; 3) After the concrete is poured into the mold, it moves to the finishing area, where the staff will use hand-held tools to finish the finishing. After the finishing is completed, the trolley continues to move forward along the main track; 4) The trolley moves the mold to the steaming area and steam-cures it for a period of time; The trolley moves forward intermittently in the steaming area; 5) After steaming is completed, the trolley carries the mold along the main track to the demoulding area. After the staff opens the mold, the formed channel prefabricated part is hoisted out using an overhead crane; 6) The trolley carries the demoulded mold to the cleaning and mold closing station, where the staff cleans the inner surface of the mold and closes the mold. Then, the trolley carries the mold to the position of the loading and distributing equipment to start the next work cycle.

10. The process for producing precast concrete parts according to claim 9, characterized in that: In step 4, the process from the carriage and the mold entering the steam curing area to exiting the steam curing area lasts for 5 hours; the carriage moves forward once every 3 minutes; and every 3 minutes, a group of carriages moves out of the steam curing area exit, and then a group of carriages moves into the steam curing area entrance.

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