Prefabricated laminated wallboard forming method

Abstract

The invention relates to the technical field of buildings, provides a prefabricated laminated wallboard forming method, and solves the problem that filling is not solid due to design defects of an existing prefabricated slab conveying line. The device comprises a conveying rail, a forming mold is arranged on the conveying rail, and a reinforcement cage is arranged in the forming mold; the discharging assembly is arranged above the conveying rail and comprises a plurality of discharging ports arranged in the conveying direction of the conveying rail, and each discharging port is provided with an opening and closing component; the controller is in communication connection with the conveying rail and the opening and closing parts, and CAD contour data of multiple sets of forming molds and reinforcement cages are pre-stored in the controller; an opening and closing instruction of the discharging opening is generated through pre-stored CAD contour data, and the problems that aggregate is separated and filling is not solid due to direct pouring in a steel bar dense area are solved.

Description

Technical Field

[0001] The invention relates to the technical field of construction, and in particular to a method for forming a prefabricated composite wall panel. Background Art

[0002] Precast panels are modules or panels used in construction projects. These concrete precast units are manufactured and processed at a precast yard and then transported directly to the construction site for installation. They have numerous uses in construction, such as the cement slabs covering ditches along highways and the cement slabs used as insulation on roofs. Precast panels come in both solid and hollow cores. The purpose of hollow core precast panels is simply to avoid stress in the hollow core, making it useless to pour concrete into it. This allows the unloaded areas to be left hollow, reducing weight and costs. For example, they can be used as non-load-bearing walls.

[0003] Chinese Patent Publication No. CN111456318A discloses a precast panel, a method for manufacturing a precast panel, a method for stacking a precast panel, and a construction method. The precast panel comprises: a precast panel body; a plurality of concrete components, each of which is a long strip structure, and the plurality of concrete components are arranged in parallel and spaced apart on the precast panel body, the length direction of each concrete component being perpendicular to or parallel to the length direction of the precast panel body, a portion of the concrete component being fixed in the precast panel body, and another portion of the concrete component protruding from the upper surface of the precast panel body; and since precast panels for different purposes have steel cages of different densities built in, direct casting in areas with dense steel bars will cause the slurry to hit the surface of the steel cage due to insufficient fluidity of the concrete, resulting in aggregate separation and incomplete filling. Summary of the Invention

[0004] Therefore, in order to solve the above problems, the present invention provides a method for forming prefabricated composite wall panels to solve the problem of inaccurate filling caused by design defects in existing prefabricated panel conveying lines.

[0005] To achieve the above object, the present invention is achieved through the following technical solutions:

[0006] A method for forming a prefabricated composite wall panel, characterized by comprising the following steps:

[0007] S1. A forming mold is transported via a conveyor rail, wherein a steel cage is pre-installed in the forming mold;

[0008] S2. A material discharge assembly is arranged above the conveying rail, including a square material discharge port and a circular material discharge port arranged along the conveying direction, and each material discharge port is provided with an opening and closing component;

[0009] S3. Execute the following control steps through the controller:

[0010] Manually select or manually add CAD contour data of the forming mold on the current conveyor rail;

[0011] According to the selected forming die CAD contour data, the forming die is classified into plate type or column type according to the width threshold;

[0012] Selecting a corresponding blanking port according to the contour type of the forming die;

[0013] The CAD vector data of the steel cage bound to the selected forming mold is called to obtain the adjacent transverse steel bar spacing D, and each steel bar spacing D is compared with the critical spacing parameter C one by one. When the D≤C area moves below the discharge port, the discharge port is closed, and when the D>C area moves below the discharge port, the discharge port is opened. The controller is communicated with the conveying rail and each of the opening and closing components, and the controller pre-stores the CAD contour data of multiple sets of forming molds and steel cages.

[0014] Furthermore, the opening strategy of the feeding port is:

[0015] When the forming mold is a plate type, activating the square blanking port;

[0016] When the forming mold is cylindrical, the circular blanking port is activated.

[0017] Furthermore, the width threshold is 800 mm.

[0018] Furthermore, the calculation formula of the critical spacing parameter C is: C=α·S+β, wherein α is the fluidity attenuation coefficient, with a value range of -0.7≤α≤-0.3, S is the measured value of the concrete slump, and β is the basic spacing compensation, with a value range of 100mm≤β≤150mm.

[0019] Furthermore, the conveying speed of the conveying rail is automatically adjusted according to the type of the forming mold.

[0020] Furthermore, when the forming mold is a plate type, the conveying speed of the conveying rail is 6-8 m / min, and when the forming mold is a column type, the conveying speed of the conveying rail is 5-6 m / min.

[0021] Furthermore, when the steel bar spacing D ≤ the critical spacing parameter C, the controller performs the following operations:

[0022] The conveying speed of the conveying rail is reduced to 50% of the original speed.

[0023] Furthermore, the conveyor rail starts a manual intervention mode before the forming die leaves below the blanking assembly:

[0024] Stop conveying;

[0025] If the height of the concrete slurry in the prefabricated template is insufficient, the discharge port is opened manually to perform compensation pouring, and the conveying is manually restarted after completion.

[0026] Furthermore, the discharge port also includes a compensation discharge port, and the compensation discharge port is opened to perform compensation pouring.

[0027] Furthermore, the slump of the concrete slurry provided by the compensation discharge port is 20-30 mm higher than that of the square discharge port and the circular discharge port.

[0028] Compared with the prior art, the present invention has the following beneficial effects:

[0029] 1. The present invention sets multiple discharge ports along the conveying direction of the conveyor rail. Through different types of discharge ports, the conveyor line can cast wide plate-type components and narrow columnar components. The opening and closing instructions of the discharge ports are generated by using pre-stored CAD contour data, avoiding the problems of aggregate separation and incomplete filling caused by direct casting in areas with dense steel bars.

[0030] 2. The present invention sets different conveying speeds for the conveyor rail according to different types of forming molds, thereby avoiding the problem of honeycomb holes caused by insufficient vibration of thick columnar components due to high-speed conveying.

[0031] 3. The present invention reduces the conveying speed after passing through the steel-dense area, so that the concrete slurry in the adjacent area of ​​the steel-dense area flows to the steel-dense area, which is used to ensure that the components are also fully filled in the steel-dense area.

[0032] 4. During the casting and forming process of precast panels, the slurry discharge speed is affected by factors such as the remaining amount in the slurry storage tank, which makes it difficult to completely match the theoretically set conveying speed of the conveyor rail and the opening and closing time of the discharge port. The manual intervention mode of the conveyor rail can make up for the missing casting volume, and the concrete slurry provided by the compensation discharge port has a higher slump, which can make the supplementary slurry combine with the cast body more quickly, quickly self-level, reduce vibration time, shorten working hours, and do not affect the forming strength of the component. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 This is a schematic structural diagram of an embodiment of the present invention;

[0034] Figure 2 This is a schematic structural diagram of the blanking component according to an embodiment of the present invention.

[0035] Description of Figure Numbers:

[0036] Conveyor rail 1; forming mold 11;

[0037] Blanking assembly 2; square blanking port 21; circular blanking port 22; compensation blanking port 23;

[0038] Opening and closing component 3; opening and closing frame 31; gear 32; driving cylinder 33;

[0039] Controller 4. DETAILED DESCRIPTION

[0040] The following will describe the implementation methods of the present invention in detail with reference to specific embodiments, so that the implementation process of how the present invention applies technical means to solve technical problems and achieve technical effects can be fully understood and implemented accordingly.

[0041] Example: Figures 1 to 2 As shown, a method for forming a prefabricated composite wall panel includes:

[0042] A conveyor rail 1 is provided with a forming die 11, and a steel cage (not shown) is provided in the forming die 11;

[0043] The material discharge assembly 2 is provided above the conveying rail 1 and includes a plurality of material discharge openings arranged along the conveying direction of the conveying rail 1. The material discharge openings include a square material discharge opening 21 and a circular material discharge opening 22. Each material discharge opening is provided with an opening and closing component 3;

[0044] The controller 4 is in communication with the conveyor rail 1 and each of the opening and closing components 3. The controller 4 pre-stores CAD outline data of multiple sets of forming molds 11 and steel cages. The controller 4 is configured to perform the following operations:

[0045] Manually select or manually add the CAD contour data of the forming mold currently on the conveyor rail 1;

[0046] According to the selected forming die CAD contour data, the forming die 11 is classified into a plate type or a column type according to a width threshold;

[0047] Select the corresponding blanking port according to the contour type of the forming die 11;

[0048] Call the CAD vector data of the steel cage bound to the selected forming mold 11, obtain the adjacent transverse steel bar spacing D, compare each steel bar spacing D with the critical spacing parameter C one by one, when the D≤C area moves below the discharge port, the discharge port is closed, and when the D>C area moves below the discharge port, the discharge port is opened; according to the real-time speed v of the conveyor rail, calculate the time point t when each steel bar spacing area moves below the discharge port, and close the corresponding opening and closing components at the corresponding time point t.

[0049] By setting up multiple discharge ports along the conveying direction of the conveyor rail 1, the conveyor line can cast wide plate-type components and narrow columnar components through different types of discharge ports. The opening and closing instructions of the discharge ports are generated using pre-stored CAD contour data to avoid the problems of aggregate separation and incomplete filling caused by direct casting in areas with dense steel bars.

[0050] Among them, the opening and closing component 3 provided on the circular blanking port 22 uses an electric butterfly valve. The opening and closing component 3 provided on the square blanking port 21 includes: opening and closing frames 31 symmetrically arranged on both sides of the opening of the square blanking port 21, gears 32 provided at the ends of each opening and closing frame 31, and driving cylinders 33 respectively connected to both ends of each opening and closing frame 31. Both types of opening and closing components 3 are existing technical means and will not be elaborated here.

[0051] The controller 4 uses an industrial controller. The operator selects pre-stored template CAD data (such as "PK-850×3000 plate type") through the HMI human-machine interface, or uploads a custom DXF file. The controller 4 extracts the template width W = 850 mm, determines it as the plate type (W > 800 mm), and activates the square blanking port 21. The square blanking port 21 can be set with a larger span and can fill the inside of the plate-shaped forming die 11 faster than the circular blanking port 22.

[0052] The calculation formula for the critical spacing parameter C is: C = α·S + β, where α is the fluidity attenuation coefficient, and its value range is -0.7 ≤ α ≤ -0.3; S is the measured value of the concrete slump; β is the base spacing compensation amount, and its value range is 100 mm ≤ β ≤ 150 mm.

[0053] The selection of the fluidity attenuation coefficient α is based on the fluidity level of the concrete slurry. For high-fluidity concrete slurry with a slump of 150 < S ≤ 180 mm, the fluidity attenuation coefficient α is taken between -0.4 and -0.3; for medium-fluidity concrete slurry with a slump of 80 < S ≤ 150 mm, the fluidity attenuation coefficient α is taken between -0.6 and -0.4; for low-fluidity concrete slurry with a slump of 50 < S ≤ 80 mm, the fluidity attenuation coefficient α is taken between -0.7 and -0.6.

[0054] The selection of the base spacing compensation amount β is based on the aggregate particle size of the concrete slurry. For concrete slurry with a particle size ≤ 10 mm, the base spacing compensation amount β is taken as 100 - 120 mm; for concrete slurry with a particle size of 20 - 25 mm, the base spacing compensation amount β is taken as 120 - 150 mm.

[0055] The conveying speed of the conveying rail 1 is automatically adjusted according to the type of the forming die 11; different conveying speeds of the conveying rail 1 are set for different types of the forming die 11 to avoid the problem of honeycomb holes caused by under-vibration due to high-speed conveying of column-shaped members with a larger thickness.

[0056] When the forming die 11 is of the plate type, the conveying speed of the conveying rail 1 is 6 m / min. When the forming die 11 is of the column type, the conveying speed of the conveying rail 1 is 5 m / min.

[0057] When the steel bar spacing D ≤ the critical spacing parameter C, the controller performs the following operations:

[0058] The conveying speed of the conveying rail 1 is reduced to 50% of the original speed.

[0059] By reducing the conveying speed after passing through the area with dense steel bars, the concrete slurry in the adjacent areas of the area with dense steel bars will flow to the area with dense steel bars, which is used to ensure that the components in the area with dense steel bars are also fully filled. At the same time, reducing the speed can extend the workers' vibration time and allow the bubbles to be discharged more fully.

[0060] The conveyor rail 1 starts the manual intervention mode before the forming die 11 leaves the bottom of the blanking assembly 2:

[0061] Stop conveying;

[0062] If the height of the concrete slurry in the prefabricated template 11 is insufficient, the feed opening is opened manually to perform compensation pouring, and the conveying is manually restarted after completion.

[0063] The discharge port further includes a compensation discharge port 23 , which is opened for compensation pouring.

[0064] The slump of the concrete slurry provided by the compensation discharge port 23 is 20-30 mm higher than that of the square discharge port 21 and the circular discharge port 22 .

[0065] During the casting and forming process of precast panels, the discharge speed of the slurry is affected by factors such as the remaining amount in the slurry storage tank, which makes it difficult to completely match the theoretically set conveying speed of the conveyor rail and the opening and closing time of the discharge port. The manual intervention mode of the conveyor rail 1 can make up for the missing casting amount, and the concrete slurry provided by the compensation discharge port 23 has a higher slump, which can make the supplementary slurry combine with the cast body more quickly, reduce the vibration time, shorten the working hours, and do not affect the forming strength of the component.

[0066] Although the present invention has been particularly shown and described in conjunction with preferred embodiments, it will be understood by those skilled in the art that various changes in form and details may be made to the present invention without departing from the spirit and scope of the invention as defined in the appended claims, and all such changes are within the scope of protection of the present invention.

Claims

1. A method for forming a prefabricated composite wall panel, characterized in that: The following steps are involved: S1. A forming mold is transported via a conveyor rail, wherein a steel cage is pre-installed in the forming mold; S2. A material discharge assembly is arranged above the conveying rail, including a square material discharge port and a circular material discharge port arranged along the conveying direction, and each material discharge port is provided with an opening and closing component; S3. Execute the following control steps through the controller: Manually select or manually add CAD contour data of the forming mold on the current conveyor rail; According to the selected forming die CAD contour data, the forming die is classified into plate type or column type according to the width threshold; Select a corresponding blanking port according to the contour type of the forming mold; The CAD vector data of the steel cage bound to the selected forming mold is called to obtain the adjacent transverse steel bar spacing D, and each steel bar spacing D is compared with the critical spacing parameter C one by one. When the D≤C area moves below the discharge port, the discharge port is closed, and when the D>C area moves below the discharge port, the discharge port is opened. The controller is communicated with the conveying rail and each of the opening and closing components, and the controller pre-stores the CAD contour data of multiple sets of forming molds and steel cages.

2. A method for forming a prefabricated composite wall panel according to claim 1, characterized in that: The opening strategy of the feeding port is: When the forming mold is a plate type, activating the square blanking port; When the forming mold is cylindrical, the circular blanking port is activated.

3. The method for forming a prefabricated composite wall panel according to claim 1, wherein: The width threshold is 800 mm.

4. A method for forming a prefabricated composite wall panel according to claim 1, characterized in that: The calculation formula of the critical spacing parameter C is: C=α·S+β, wherein α is the fluidity attenuation coefficient, and the value range is -0.7≤α≤-0.3; S is the measured value of the concrete slump; β is the basic spacing compensation, and the value range is 100mm≤β≤150mm.

5. The method for forming a prefabricated composite wall panel according to claim 1, wherein: The conveying speed of the conveying rail is automatically adjusted according to the type of the forming mold.

6. A method for forming a prefabricated composite wall panel according to claim 5, characterized in that: When the forming mold is a plate type, the conveying speed of the conveying rail is 6-8 m / min; when the forming mold is a column type, the conveying speed of the conveying rail is 5-6 m / min.

7. The method for forming a prefabricated composite wall panel according to claim 1, wherein: When the steel bar spacing D ≤ the critical spacing parameter C, the controller performs the following operations: The conveying speed of the conveying rail is reduced to 50% of the original speed.

8. The method for forming a prefabricated composite wall panel according to claim 1, wherein: The conveyor rail starts the manual intervention mode before the forming die leaves the bottom of the blanking assembly: Stop conveying; If the height of the concrete slurry in the prefabricated template is insufficient, the discharge port is opened manually to perform compensation pouring, and the conveying is manually restarted after completion.

9. The method for forming a prefabricated composite wall panel according to claim 8, wherein: The discharge port also includes a compensation discharge port, and the compensation discharge port is opened to perform compensation pouring.

10. The method for forming a prefabricated composite wall panel according to claim 9, characterized in that: The slump of the concrete slurry provided by the compensation discharge port is 20-30 mm higher than that of the square discharge port and the circular discharge port.

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