A method for forming a prefabricated composite wall panel

Abstract

The present application relates to the field of building technology, provide a kind of prefabricated composite wallboard forming method, solve the problem of filling not real due to design defects caused by existing prefabricated plate conveying line.This application comprises: conveying rail, the forming mould is provided on the conveying rail, the reinforcing cage is provided in the forming mould;Blanking assembly, located above the conveying rail, including a plurality of blanking ports arranged along the conveying direction of conveying rail, each blanking port is provided with opening and closing component;Controller, in communication connection with the conveying rail and each opening and closing component, the controller has pre-stored multiple sets of CAD profile data of forming mould and reinforcing cage;The opening and closing instructions of blanking port are generated using pre-stored CAD profile data, to avoid the problem of aggregate separation and filling not real caused by directly pouring in steel dense area.

Description

Technical Field

[0001] This invention relates to the field of building technology, and specifically to a method for forming prefabricated composite wall panels. Background Technology

[0002] Precast slabs are modular components or panels used in construction projects. These are precast concrete parts manufactured and processed in a prefabrication yard, then transported directly to the construction site for installation. Precast slabs have many uses in construction, such as the cement slabs used to cover ditches along roadsides and the cement slabs used as insulation layers on roofs. Precast slabs come in two types: solid and hollow. The purpose of making hollow precast slabs is simply that the hollow areas of the slab are not subject to stress, so filling these areas with concrete is pointless. Therefore, leaving these unloaded areas empty reduces weight and saves costs, for example, when used as non-load-bearing walls.

[0003] Chinese Patent Publication No. CN111456318A discloses a precast slab, a method for manufacturing the precast slab, a method for stacking the precast slab, and a construction method. The precast slab includes: a precast slab body; and multiple concrete components, each concrete component being a long strip structure. The multiple concrete components are arranged parallel and spaced on the precast slab body, and the length direction of each concrete component is perpendicular to or parallel to the length direction of the precast slab body. A part of the concrete component is fixed in the precast slab body, and another part of the concrete component protrudes from the upper surface of the precast slab body. However, since precast slabs for different purposes contain steel cages with different densities, direct pouring in areas with dense steel reinforcement can cause insufficient concrete fluidity, resulting in the slurry hitting the surface of the steel cage and causing aggregate separation and incomplete filling. Summary of the Invention

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

[0005] To achieve the above objectives, the present invention is implemented through the following technical solution: A method for forming prefabricated composite wall panels, characterized by comprising the following steps: S1. The forming mold is conveyed via a conveyor rail, and a steel cage is pre-placed inside the forming mold; S2. A feeding assembly is provided above the conveying rail, including square feeding ports and round feeding ports arranged along the conveying direction, and each feeding port is provided with an opening and closing component; S3. Perform the following control steps via the controller: Manually select or add the CAD contour data of the forming mold on the current conveyor rail; Based on the selected CAD contour data of the molding die, the molding die is classified into plate type or column type according to the width threshold; Select the corresponding blanking port according to the contour type of the forming mold; The controller calls the CAD vector data of the reinforcing cage bound to the selected forming mold, obtains the spacing D of adjacent transverse reinforcing bars, compares each reinforcing bar spacing D with the critical spacing parameter C one by one, and closes the feeding port when the area of ​​D≤C moves below the feeding port, and opens the feeding port when the area of ​​D>C moves below the feeding port. The controller is communicatively connected to the conveying rail and each of the opening and closing components. The controller has pre-stored CAD contour data of multiple forming molds and reinforcing cages.

[0006] Furthermore, the feeding port opening strategy is as follows: When the forming mold is plate-shaped, the square discharge port is activated; When the forming mold is cylindrical, the circular discharge port is activated.

[0007] Furthermore, the width threshold is 800mm.

[0008] Furthermore, the calculation formula for the critical spacing parameter C is: C=α·S+β, where α is the fluidity attenuation coefficient, with a value range of -0.7≤α≤-0.3, S is the measured value of concrete slump, and β is the basic spacing compensation amount, with a value range of 100mm≤β≤150mm.

[0009] Furthermore, the conveying speed of the conveyor rail is automatically adjusted according to the type of molding die.

[0010] Furthermore, when the forming mold is plate-shaped, the conveying speed of the conveying rail is 6-8 m / min, and when the forming mold is column-shaped, the conveying speed of the conveying rail is 5-6 m / min.

[0011] Furthermore, when the rebar spacing D ≤ the critical spacing parameter C, the controller performs the following operations: The conveying speed of the conveyor rail is reduced to 50% of its original speed.

[0012] Furthermore, the conveyor rail initiates a manual intervention mode before the forming mold leaves below the feeding assembly: Stop delivery; If the concrete slurry level in the molding mold is insufficient, the discharge port is manually opened for compensation pouring, and the conveying is manually restarted after completion.

[0013] Furthermore, the discharge port also includes a compensation discharge port, which is opened for compensation pouring.

[0014] Furthermore, the slump of the concrete slurry provided by the compensation discharge port is 20-30mm higher than that of the square discharge port and the round discharge port.

[0015] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention sets up multiple discharge ports along the conveying direction of the conveying rail. Through different types of discharge ports, the conveying line can cast wide plate-shaped components and narrow column-shaped components. The opening and closing commands of the discharge ports are generated using pre-stored CAD contour data, avoiding the problems of aggregate separation and incomplete filling caused by direct casting in areas with dense reinforcement.

[0016] 2. This invention sets different conveying speeds for different types of molding dies to avoid honeycomb holes caused by under-vibration in thick columnar components due to high-speed conveying.

[0017] 3. This invention reduces the conveying speed after passing through the densely reinforced area, causing the concrete slurry from the adjacent areas to flow towards the densely reinforced area, thereby ensuring that the component is also fully filled in the densely reinforced area.

[0018] 4. During the casting process of precast slabs, the discharge speed of the slurry is affected by factors such as the amount of slurry remaining in the slurry storage tank, making it difficult to completely match the theoretically set conveying speed of the conveying rail and the opening and closing time of the discharge port. The manual intervention mode of the conveying rail can make up for the missing amount of casting, while the concrete slump of the slurry provided by the compensation discharge port is higher, which can make the supplemented slurry combine with the cast body more quickly, achieve rapid self-leveling, reduce vibration time, shorten working hours, and without affecting the forming strength of the component. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of an embodiment of the present invention; Figure 2 This is a schematic diagram of the material feeding assembly structure in an embodiment of the present invention.

[0020] Explanation of icon numbers: Conveyor rail 1; Forming mold 11; Feeding assembly 2; Square feeding port 21; Round feeding port 22; Compensating feeding port 23; Opening and closing component 3; opening and closing frame 31; gear 32; drive cylinder 33; Controller 4. Detailed Implementation

[0021] The following will describe in detail the implementation of the present invention with reference to specific embodiments, so that the process of how the present invention uses technical means to solve technical problems and achieve technical effects can be fully understood and implemented accordingly.

[0022] Example: Figures 1 to 2 As shown, a method for forming prefabricated composite wall panels includes: Conveying rail 1, on which a forming mold 11 is provided, and a steel cage (not shown in the figure) is provided inside the forming mold 11; The feeding assembly 2 is located above the conveying rail 1 and includes a plurality of feeding ports arranged along the conveying direction of the conveying rail 1. The feeding ports include a square feeding port 21 and a round feeding port 22. Each feeding port is provided with an opening and closing component 3. Controller 4 is communicatively connected to the conveyor rail 1 and each of the opening and closing components 3. Controller 4 has pre-stored CAD outline data of multiple sets of forming molds 11 and reinforcing cages. Controller 4 is configured to perform the following operations: Manually select or add the CAD outline data of the forming mold on the current conveyor rail 1; Based on the selected molding die CAD contour data, the molding die 11 is classified into plate type or column type according to the width threshold; Select the corresponding blanking port according to the contour type of the forming mold 11; The CAD vector data of the rebar cage bound to the selected forming mold 11 is called to obtain the spacing D of adjacent transverse rebars. Each rebar spacing D is compared with the critical spacing parameter C one by one. When the area with D≤C moves to below the discharge port, the discharge port is closed. When the area with D>C moves to below the discharge port, the discharge port is opened. According to the real-time speed v of the conveyor rail, the time point t when each rebar spacing area moves to below the discharge port is calculated. At the corresponding time point t, the corresponding opening and closing component is closed.

[0023] By setting multiple discharge ports along the conveying direction of conveyor rail 1, the conveyor line can cast wide plate-shaped components and narrow column-shaped components through different types of discharge ports. The opening and closing commands 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 reinforcement.

[0024] Among them, the opening and closing component 3 on the circular discharge port 22 is an electric butterfly valve, and the opening and closing component 3 on the square discharge port 21 includes: opening and closing frames 31 symmetrically arranged on both sides of the opening of the square discharge port 21, gears 32 arranged at the ends of each opening and closing frame 31, and drive cylinders 33 connected to each opening and closing frame 31 at both ends. Both types of opening and closing components 3 are existing technologies and will not be described in detail here.

[0025] The controller 4 is 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 = 850mm, determines it as a plate type (W>800mm), and activates the square discharge port 21. The square discharge port 21 can be set with a larger span, and can fill the plate forming mold 11 faster than the round discharge port 22.

[0026] The calculation formula for the critical distance parameter C is: C=α·S+β, where α is the fluidity attenuation coefficient, with a value range of -0.7≤α≤-0.3, S is the measured value of concrete slump, and β is the basic distance compensation amount, with a value range of 100mm≤β≤150mm.

[0027] The fluidity attenuation coefficient α is selected according to the fluidity level of the concrete slurry: for high-fluidity concrete slurry with a slump of 150<S≤180mm, the fluidity attenuation coefficient α is taken between -0.4 and -0.3; for medium-fluidity concrete slurry with a slump of 80<S≤150mm, the fluidity attenuation coefficient α is taken between -0.6 and -0.4; for low-fluidity concrete slurry with a slump of 50<S≤80mm, the fluidity attenuation coefficient α is taken between -0.7 and -0.6.

[0028] The basic distance compensation amount β is selected according to the aggregate particle size of the concrete slurry: for concrete slurry with a particle size ≤10mm, the basic distance compensation amount β is 100-120mm; for concrete slurry with a particle size of 20-25mm, the basic distance compensation amount β is 120-150mm.

[0029] The conveying speed of the conveying rail 1 is automatically adjusted according to the type of the forming mold 11; different conveying speeds of the conveying rail 1 are set for different types of the forming mold 11, so as to avoid the problem of honeycomb voids caused by insufficient vibration of thick columnar members due to high-speed conveying.

[0030] When the forming mold 11 is a plate type, the conveying speed of the conveying rail 1 is 6m / min, and when the forming mold 11 is a column type, the conveying speed of the conveying rail 1 is 5m / min When the rebar spacing D ≤ the critical spacing parameter C, the controller performs the following operations: Reduce the conveying speed of the conveying rail 1 to 50% of the original speed.

[0031] By reducing the conveying speed after passing through the dense rebar area, the concrete slurry in the adjacent area of the dense rebar area flows to the dense rebar area, which ensures that the member is also fully filled in the dense rebar area. Meanwhile, the speed reduction can extend the vibrating time for workers, so that air bubbles can be discharged more sufficiently.

[0032] The conveying rail 1 starts the manual intervention mode before the forming mold 11 leaves the lower part of the blanking assembly 2: Stop conveying; If the height of the concrete slurry in the forming mold 11 is insufficient, manually open the blanking port for supplementary pouring, and manually restart the conveying after completion.

[0033] The discharge port also includes a compensation discharge port 23, which is opened for compensation pouring.

[0034] The slump of the concrete slurry provided by the compensation discharge port 23 is 20-30mm higher than that of the square discharge port 21 and the round discharge port 22.

[0035] During the casting process of precast slabs, the discharge speed of the slurry is affected by factors such as the amount of slurry remaining in the slurry storage tank, making it difficult to completely match the theoretically set conveying speed of the conveying rail and the opening and closing time of the discharge port. The manual intervention mode of the conveying rail 1 can make up for the missing amount of casting, while the concrete slump of the compensation discharge port 23 is higher, which can make the supplemented slurry combine with the cast body more quickly, reduce the vibration time, shorten the working time, and not affect the forming strength of the component.

[0036] Although the invention has been specifically shown and described in conjunction with preferred embodiments, those skilled in the art should understand that various changes in form and detail may be made to the invention without departing from the spirit and scope of the invention as defined in the appended claims, all of which shall be within the scope of protection of the invention.

Claims

1. A method for forming prefabricated composite wall panels, characterized in that, Includes the following steps: S1. The forming mold is conveyed via a conveyor rail, and a steel cage is pre-placed inside the forming mold; S2. A feeding assembly is provided above the conveying rail, including square feeding ports and round feeding ports arranged along the conveying direction, and each feeding port is provided with an opening and closing component; S3. Perform the following control steps via the controller: Manually select or add the CAD contour data of the forming mold on the current conveyor rail; Based on the selected CAD contour data of the molding die, the molding die is classified into plate type or column type according to the width threshold; Select the 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 spacing D of adjacent transverse steel bars. Each steel bar spacing D is compared with the critical spacing parameter C one by one. When the area of ​​D≤C moves to the bottom of the discharge port, the discharge port is closed. When the area of ​​D>C moves to the bottom of the discharge port, the discharge port is opened. The controller is communicatively connected to the conveying rail and each of the opening and closing components. The controller has pre-stored CAD contour data of multiple sets of forming molds and steel cages. The width threshold is 800mm; The calculation formula for the critical spacing parameter C is: C=α·S+β, where α is the fluidity attenuation coefficient, with a value range of -0.7≤α≤-0.3, S is the measured value of concrete slump, and β is the basic spacing compensation amount, with a value range of 100mm≤β≤150mm; The conveying speed of the conveyor rail is automatically adjusted according to the type of molding die; When the forming mold is plate-shaped, the conveying speed of the conveying rail is 6-8 m / min; when the forming mold is column-shaped, the conveying speed of the conveying rail is 5-6 m / min. When the rebar spacing D ≤ the critical spacing parameter C, the controller performs the following operation: reduces the conveying speed of the conveyor rail to 50% of its original speed.

2. The method for forming a prefabricated composite wall panel according to claim 1, characterized in that, The feeding port opening strategy is as follows: When the forming mold is plate-shaped, the square discharge port is activated; When the forming mold is cylindrical, the circular discharge port is activated.

3. The method for forming a prefabricated composite wall panel according to claim 1, characterized in that, The conveyor rail initiates manual intervention mode before the forming mold leaves below the unloading assembly: Stop delivery; If the concrete slurry level in the molding mold is insufficient, the discharge port is manually opened for compensation pouring, and the conveying is manually restarted after completion.

4. The method for forming a prefabricated composite wall panel according to claim 3, characterized in that: The discharge port also includes a compensation discharge port, which is opened for compensation pouring.

5. The method for forming a prefabricated composite wall panel according to claim 4, characterized in that: The slump of the concrete slurry provided by the compensation discharge port is 20-30mm higher than that of the square discharge port and the round discharge port.

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