Fabricated panel-free arc-shaped plate machining method

Abstract

The invention discloses an assembly type panel-free arc-shaped plate processing method which comprises the following steps: constructing a pouring area, fixedly building a plurality of transverse reinforcing steel bars and longitudinal arc-shaped reinforcing steel bars in the building area, pouring a pouring longitudinal rib at the bottommost layer by adopting a corresponding pouring material, and after the pouring longitudinal rib is solidified, pouring the arc-shaped plate at the bottommost layer into the pouring area. The arc-shaped building blocks are placed on the pouring longitudinal ribs at equal intervals, pouring is conducted again between the adjacent arc-shaped building blocks, pouring transverse ribs are formed, longitudinal arc-shaped steel bars are inserted into the corresponding positions of the fixed side molds on the two sides above the arc-shaped building blocks, after the pouring transverse ribs are solidified, the pouring longitudinal ribs are poured on the arc-shaped building blocks, and the steps are repeated; according to the invention, the arc-shaped plate constructed by plane piling in the conventional technology is changed into the arc-shaped plate constructed vertically, the arc-shaped plate is manufactured by a layered pouring method, the flatness of the arc-shaped plate is determined by the fixed arc-shaped inner mold and the movable arc-shaped outer mold, and the arc-shaped plate can be manufactured only by slight polishing after being manufactured; and the production efficiency and the geometric accuracy of the arc-shaped surface of the arc-shaped plate are improved.

Description

Technical Field

[0001] This invention relates to the field of prefabricated building technology, and in particular to a method for processing prefabricated panelless curved panels. Background Technology

[0002] With the development of modern industrial technology, prefabricated buildings have gradually replaced ordinary building systems in the existing technology due to their advantages such as fast construction speed, less susceptibility to weather conditions, and labor saving.

[0003] The use of curved prefabricated panels addresses a challenge in prefabricated construction. Conventional methods involve processing or manufacturing entirely with concrete in factories, which contradicts the energy-saving, environmentally friendly, and lightweight principles of prefabricated buildings. While our company offers corresponding ribbed sandwich curved panels, the curved shape of the upper surface often prevents it from maintaining its full curvature during manufacturing, requiring subsequent grinding. Furthermore, the need for a corresponding curved panel on top during casting makes it difficult to use a vibrator for timely vibration, resulting in inconsistent quality, some with numerous air pockets and shorter lifespans. Therefore, it can be concluded that... For panelless curved prefabricated panels, conventional manufacturing methods are not feasible because panelless curved prefabricated panels require stronger bonding strength. Due to the high quality requirements, existing manufacturing processes result in excessive pores, leading to poor bonding strength and making it easy for filler blocks to fall off. Panelless curved prefabricated panels are mainly used in vegetable greenhouses where both ends need to be open, as well as for single-sided open curved roof planting panels. Therefore, in order to meet the requirements of existing prefabricated buildings for curved panels, there is an urgent need for a manufacturing process that can produce panelless prefabricated curved panels. Summary of the Invention

[0004] In view of this, in order to solve the problem of producing densely ribbed sandwich panels using the current processing technology of curved assembly panels, this invention proposes a method for processing assembled panelless curved panels.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: A method for processing prefabricated, panel-less curved panels includes the following steps: Step 1: Construct a fixed arc-shaped inner mold, a movable arc-shaped outer mold, a fixed arc-shaped bottom mold, and fixed side molds on both sides to create the pouring area; Step 2: Fix and erect several horizontally spaced steel bars in the vertical direction within the building area; Step 3: Insert longitudinal arc-shaped steel bars into the fixed side formwork on both sides of the bottom layer, and then use the corresponding casting material to cast the bottom layer of longitudinal ribs. Step 4: After the cast longitudinal ribs have solidified, place arc-shaped blocks at equal intervals on the cast longitudinal ribs, with the transverse reinforcing bars located on the left and right sides of the arc-shaped blocks. Step 5: Cast the concrete again between the adjacent curved blocks to form the cast transverse ribs; Step 6: Insert longitudinal arc-shaped steel bars at the corresponding positions on the fixed side molds on both sides above the arc-shaped block; Step 7: After the horizontal ribs have solidified, cast the longitudinal ribs on the curved blocks. Step 8: Repeat steps 4 to 7 until the entire curved slab is poured. In the above steps, if the cast longitudinal rib is higher than the movable arc-shaped outer mold, the movable arc-shaped outer mold is moved upward before casting. In the above steps, after each pour, an immersion vibrator is used to vibrate the pouring material and control the flatness of the upper end.

[0006] As a further improvement to the above technical solution: An optimized version of the above technical solution is that the height of the movable arc-shaped outer mold is greater than the sum of the height of the arc-shaped block and the height of the two cast longitudinal ribs.

[0007] An optimized version of the above technical solution is that the fixed side mold is provided with a plurality of equally spaced mounting studs, and the movable arc-shaped outer mold is provided with a connecting hole. The movable arc-shaped outer mold is detachably connected to the fixed side mold through the connecting hole, the mounting studs, and the connecting nut.

[0008] An optimized version of the above technical solution is that the distance between the fixed arc-shaped inner mold and the movable arc-shaped outer mold is equal to the thickness of the arc-shaped block.

[0009] An optimized version of the above technical solution is that the arc-shaped blocks include solid arc-shaped blocks, single-sided perforated arc-shaped blocks, and hollow arc-shaped blocks.

[0010] An optimized solution to the above technical solution is to modify steps 5 to 7 as follows: Step 11: Insert longitudinal arc-shaped steel bars into the fixed side molds on both sides above the arc-shaped block; Step 12: Cast in one go to form the horizontal ribs and the vertical ribs.

[0011] An optimized solution to the above technical solution is to place bolt connection boxes at the corresponding positions in Step 3 and Step 8 before pouring.

[0012] Compared with existing technologies, the beneficial effects of this invention are: This invention transforms the conventional method of building curved plates by stacking planar materials into a method of building curved plates vertically. Furthermore, it uses a layered casting method to manufacture the plates, thus avoiding the problem of not being able to guarantee the flatness of the upper and lower arcs in traditional manufacturing schemes. The flatness is determined by the fixed inner arc mold and the movable outer arc mold. Since only slight grinding is required after manufacturing, this improves production efficiency and the geometric accuracy of the curved surface.

[0013] The layered casting method used in this invention is different from existing construction methods, which can easily cause the casting material to flow to both ends during the vibration process, resulting in poor structural integrity and arc shape. This application can be vibrated after each layer is cast, eliminating high and low points and preventing the casting material from flowing. At the same time, the cast material after vibration is directly bonded to the blocks without air bubbles, resulting in better bonding.

[0014] The manufacturing process of this invention employs a movable arc-shaped outer mold instead of a fixed mold like the fixed arc-shaped inner mold. This is because the application involves vertical casting, which results in a considerable height. Using a fixed mold during block placement and vibration would significantly increase the construction difficulty. The movable arc-shaped outer mold allows for layered upward movement, making block placement and vibration much simpler. Furthermore, it avoids obstruction by reinforcing bars during block placement and vibration, thus greatly reducing the construction difficulty.

[0015] The prefabricated, panelless, curved panels constructed using this method have a strong bond between the casting material and the blocks. Furthermore, due to their arched shape, the blocks are supported upwards by the longitudinal and transverse ribs during use. The combined use of these two factors ensures that the panelless curved panels are safer to use, preventing the blocks from falling off. Compared to flat, panelless sandwich block prefabricated panels, they offer higher safety performance. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the three-dimensional structure of the mold used in this invention; Figure 2 for Figure 1 Enlarged structural diagram of area A in the middle; Figure 3 This is a schematic diagram of the three-dimensional structure of the finished plate of the present invention.

[0017] In the diagram: 1. Fixed arc-shaped inner mold; 2. Movable arc-shaped outer mold; 3. Fixed arc-shaped bottom mold; 4. Fixed side mold; 5. Horizontal reinforcing bars; 6. Longitudinal arc-shaped reinforcing bars; 7. Install stud assembly; 8. Connecting hole; 9. Connecting nut. Detailed Implementation

[0018] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0019] In the description of this invention, unless otherwise stated, "a plurality of" means two or more; the terms "upper," "lower," "left," "right," "inner," "outer," "front end," "rear end," "head," "tail," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. Furthermore, the terms "first," "second," "third," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0020] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0021] Example 1 This technical solution is mainly for the purpose of producing the attached document. Figure 3 The specific steps for producing the panelless curved plate shown are as follows: Step 1: Construct a fixed arc-shaped inner mold 1, a movable arc-shaped outer mold 2, a fixed arc-shaped bottom mold 3, and two fixed side molds 4 to create the pouring area, as shown in the attached diagram. Figure 1 With appendix Figure 2 As shown, the distance between the fixed arc-shaped inner mold 1 and the movable arc-shaped outer mold 2 is equal to the thickness of the arc-shaped block. This ensures that the pouring material will not enter the groove of the arc-shaped block during the subsequent pouring process, thus avoiding any impact on its use. At the same time, it can also limit the front and rear surfaces of the arc-shaped block, preventing it from moving easily during the pouring process, ensuring the quality and aesthetics of the plate. When it does not move, the spacing between the arc-shaped blocks on the finished assembled plate is almost equal, making it more aesthetically pleasing. To facilitate movement, a number of equally spaced mounting studs 7 are provided on the fixed side mold 4, and a connecting hole 8 is provided on the movable arc-shaped outer mold 2. The movable arc-shaped outer mold 2 is detachably connected to the fixed side mold 4 through the connecting hole 8, the mounting studs 7, and the connecting nut 9. At the same time, the nut can be loosened to increase the gap when placing the arc-shaped block, and the nut can be tightened after placement to make the two arc surfaces of the arc-shaped block fit closely with the fixed arc-shaped inner mold 1 and the movable arc-shaped outer mold 2.

[0022] Step 2: In the vertical direction within the building area, fix and erect several equidistant horizontal steel bars 5, as shown in the attached diagram. Figure 1 As shown; Step 3: Insert longitudinal arc-shaped steel bars 6 into the two fixed side molds 4 at the bottom layer, place bolt connection boxes at the corresponding positions on the fixed arc-shaped bottom mold 3, and fix them with counterweights. Then, pour the bottom layer of cast longitudinal ribs with the corresponding casting material. Step 4: After the cast longitudinal ribs have solidified, place arc-shaped blocks at equal intervals on the cast longitudinal ribs, with the transverse reinforcing bars 5 located on the left and right sides of the arc-shaped blocks. Step 5: On the outer side, pour concrete again between adjacent arc-shaped blocks to form cast transverse ribs; Step 6: Insert longitudinal arc-shaped steel bars 6 at corresponding positions on the two fixed side molds 4 above the arc-shaped block; Step 7: After the horizontal ribs have solidified, cast the longitudinal ribs onto the curved blocks. Step 8: Repeat steps 4 to 7 until the entire curved plate is poured. During the pouring process, selectively place bolt connection boxes at the left and right ends and fix them with counterweights. At the same time, when pouring the last layer of longitudinal ribs, place bolt connection boxes on the upper surface. This way, after the pouring is completed, the bolt connection boxes are tightly bonded to the pouring material, which facilitates subsequent connections. With better bonding force, the subsequent connections are more secure. During the repeated pouring process in step 8, if the pouring longitudinal rib is higher than the movable arc-shaped outer mold 2, the movable arc-shaped outer mold 2 is moved upwards before pouring is carried out again. The height of the movable arc-shaped outer mold 2 is greater than the sum of the height of the arc-shaped block and the height of the two casting longitudinal ribs. Before the movable arc-shaped outer mold 2 is moved, the casting longitudinal ribs at the upper and lower ends of the arc-shaped block can be processed. After the block is moved, there is enough space to overlap with the lower casting longitudinal rib, thus preventing the loss of casting material.

[0023] Meanwhile, in the above steps, after each pour, an immersion vibrator is used to vibrate the pouring material and control the flatness of the upper end. Since the original flat surface processing has high and low points, the vibration process will cause the pouring material to flow, making it difficult to build the upper arc surface. However, by using the manufacturing method in this technical solution, the arc surface is turned into a vertical surface, so there are no high and low points. Therefore, sufficient vibration can be carried out, reducing the porosity in the pouring material and improving the bonding force with the blocks.

[0024] Meanwhile, the curved blocks in the technical solution have the following three situations, which affect the final application scenarios of the prefabricated panels, specifically including: ① Solid curved blocks are mainly used for locations where curved surfaces are required in prefabricated buildings.

[0025] ② Single-sided perforated arc-shaped blocks, with the perforation facing upwards, are used for planting greenery, such as in green roof panels and park construction. ③ Hollow arc-shaped blocks are used in locations that require natural light, such as greenhouses and artistic buildings.

[0026] Example 2 Example 2 optimizes certain steps in Example 1. For applications where strength requirements are not high, such as planting curved slabs in parks, steps 5 to 7 in Example 1 can be modified as follows: Step 11: Insert longitudinal arc-shaped steel bars 6 into the two fixed side molds 4 on both sides above the arc-shaped block; Step 12: Cast in one go to form the horizontal ribs and the vertical ribs.

[0027] Therefore, more material is vibrated during the subsequent vibration process, and the vibration effect is slightly worse than that in Example 1. However, the structural performance of the prefabricated panel is still within the standard range. However, by adopting the modified scheme of Example 2, one pouring step is reduced, which results in higher construction efficiency.

[0028] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A method for processing prefabricated, panel-less curved panels, characterized in that, Includes the following steps: Step 1: Construct a fixed arc-shaped inner mold (1), a movable arc-shaped outer mold (2), a fixed arc-shaped bottom mold (3), and fixed side molds on both sides (4) to build the pouring area; Step 2: Fix and erect several horizontal steel bars that are evenly distributed in the vertical direction within the building area (5). Step 3: Insert longitudinal arc-shaped steel bars (6) into the fixed side molds (4) on both sides of the bottom layer, and then use the corresponding casting material to cast the bottom layer of longitudinal ribs. Step 4: After the cast longitudinal ribs have solidified, place arc-shaped blocks at equal intervals on the cast longitudinal ribs, with the transverse steel bars (5) located on the left and right sides of the arc-shaped blocks. Step 5: Cast the concrete again between the adjacent curved blocks to form the cast transverse ribs; Step 6: Insert longitudinal arc-shaped steel bars (6) at the corresponding positions on the two fixed side molds (4) above the arc-shaped block. Step 7: After the horizontal ribs have solidified, cast the longitudinal ribs on the curved blocks. Step 8: Repeat steps 4 to 7 until the entire curved slab is poured. In the above steps, when the cast longitudinal rib is higher than the movable arc-shaped outer mold (2), the movable arc-shaped outer mold (2) is moved up before casting. In the above steps, after each pour, an immersion vibrator is used to vibrate the pouring material and control the flatness of the upper end.

2. The method for processing prefabricated panelless curved panels according to claim 1, characterized in that, The height of the movable arc-shaped outer mold (2) is greater than the height of the arc-shaped block plus the sum of the heights of the two cast longitudinal ribs.

3. The method for processing prefabricated panelless curved sheet metal according to claim 1, characterized in that, The fixed side mold (4) is provided with a plurality of equally spaced mounting stud groups (7), and the movable arc-shaped outer mold (2) is provided with a connecting hole (8). The movable arc-shaped outer mold (2) is detachably connected to the fixed side mold (4) through the connecting hole (8), the mounting stud groups (7) and the connecting nut (9).

4. The method for processing prefabricated panelless curved panels according to claim 1, characterized in that, The distance between the fixed arc-shaped inner mold (1) and the movable arc-shaped outer mold (2) is equal to the thickness of the arc-shaped block.

5. The method for processing prefabricated panelless curved sheet metal according to claim 1, characterized in that, The arc-shaped blocks include solid arc-shaped blocks, single-sided perforated arc-shaped blocks, and hollow arc-shaped blocks.

6. The method for processing prefabricated panelless curved sheet metal according to claim 1, characterized in that, Modify steps 5 through 7 as follows: Step 11: Insert longitudinal arc-shaped steel bars (6) into the fixed side molds (4) on both sides above the arc-shaped block. Step 12: Cast in one go to form the horizontal ribs and the vertical ribs.

7. The method for processing prefabricated panelless curved panels according to claim 1, characterized in that, In Step 3 and Step 8, bolt connection boxes are placed at the corresponding positions before pouring.

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