Concrete prefabricated part and batch production device and method thereof

Abstract

The invention discloses a concrete prefabricated part and a batch production device and method thereof. The batch production method comprises the following steps that S1, sliding formworks are arranged along a bottom formwork at equal intervals or non-equal intervals; s2, arranging stirrups and prestressed reinforcements; s3, the prestressed steel bars are locked after being stretched and tightened; s4, the distance between the slip form and the stirrup is adjusted, and the position of the slip form is positioned; s5, a side mold is arranged, concrete materials are poured in, vibrating and compacting are carried out, and concrete is waited to be solidified; s6, after the prefabricated part is formed, the side mold and the folding sliding mold are separated; and S7, the slip form and the side forms are hoisted and transferred to other idle bottom forms, the step S1 is repeated, and the prefabricated part production line is constructed again. According to the method, the input number of forming molds is effectively reduced, the use amount of steel is reduced, and the method has the advantages of high production efficiency, high scheduling efficiency, smooth scheduling and the like.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of concrete prefabricated part production, in particular to a concrete prefabricated part and a batch production device and method thereof. BACKGROUND

[0002] The pre-tensioning prestressed concrete prefabricated part is a standard building component that can be transported and hoisted, which is formed by pre-tensioning high-strength steel bars before pouring concrete, temporarily anchoring them on a pedestal or steel mold, then pouring concrete, relaxing the tension force after the concrete reaches a certain strength, and relying on the bonding force between the concrete and the steel bars to establish prestress.

[0003] However, the process of producing prefabricated parts using pre-tensioning prestressing technology is more complex than traditional processes, requiring more equipment and professionals, thereby increasing the production cost and human resource investment of enterprises.

[0004] In the prior art, such as the Chinese utility model patent with publication number CN223071654U, a pre-tensioning prestressed concrete slab beam is disclosed, which is essentially a concrete prefabricated part production mold using the pre-tensioning prestressing process, which can improve the stability of the mold during demolding and produce high-quality concrete slab beams. However, most pre-tensioning prestressed concrete prefabricated parts are completed in a single mold, with steel bar tensioning and concrete solidification molding. Each mold can only produce one component at a time, and the production efficiency is low. If production capacity is to be improved, the number of molds and production supporting equipment must be increased, which not only significantly increases the amount of steel required for making molds, but also requires more human resources to support large-scale production. Moreover, the work flow between production molds is prone to confusion, increasing the time cost of management and coordination, and the overall economic benefit is not satisfactory.

[0005] The large-scale production of precast concrete products by the pretensioning method cannot be achieved simply by connecting single production molds in the direction of the tensioning steel. If the production molds are connected, the prestressed steel penetrates all the precast products, and although the prestressed steel in multiple precast products can be tensioned at one time, the prestressed steel is cut off after the precast products are solidified to form independent precast products, which improves the efficiency of steel tensioning and realizes batch production. However, it is difficult for workers to cut off the prestressed steel along the edge of the precast product, and the prestressed steel after cutting off is still inserted in the end mold, which affects the demolding flexibility of the end mold. Workers need to use large mechanical equipment to remove the prestressed steel, and then remove the end mold for recycling. The precast product after molding needs to be stacked and cured to meet the use standard. It can be seen that the single connected production line has a lot of handling processes, and the use of large equipment increases the overall production cost of the precast product, and a large amount of human resources is needed to operate the mechanical equipment.

[0006] If multiple connected production lines are used to increase the yield of precast products by the pretensioning method, the end forming mold of the precast product in a single connected production line is hindered by the residual prestressed steel and cannot be quickly and conveniently demolded, which leads to the fact that the demolded forming mold cannot be quickly dispatched in multiple production lines, and the problem of mold dispatching confusion between multiple production lines occurs, thereby increasing the use of steel for making the precast product forming mold and the cost of mechanical use and human resources for management and dispatching.

[0007] Therefore, in order to solve the problems of low production efficiency, low yield, chaotic flow operation, and difficulty in controlling production cost in the prior art when producing precast concrete products by the pretensioning method, a precast concrete product and a production method thereof are proposed. SUMMARY

[0008] The purpose of the present application is to provide a precast concrete product and a batch production device and production method thereof to solve the problems raised in the background art.

[0009] To achieve the above purpose, the present application provides the following technical solutions:

[0010] The production method of the batch production device of the precast concrete product comprises a work site base and one or more sets of forming molds;

[0011] The work site base comprises one or more platforms, and each set of forming molds is arranged on the surface of the platform.

[0012] Each of the forming molds comprises two end plates, a bottom mold, one or more than one slide mold, and two side molds, the two end plates are respectively arranged at two ends of the platform, the bottom mold is arranged on the surface of the platform, the two side molds are respectively arranged at two sides of the platform, and one or more than one slide mold is arranged between the two side molds;

[0013] Each of the slide molds comprises two partition plates and one or more than one pin, and each of the pins is inserted into the connection between the two partition plates;

[0014] The slide mold has an unfolded state and a folded state;

[0015] The surface of each of the end plates and each of the slide molds is provided with one or more than one steel bar hole;

[0016] The end plate, the bottom mold, the slide mold, and the side mold form an independent prefabricated part mold cavity, the upper end of the prefabricated part mold cavity is open, and the edge gap of the prefabricated part mold cavity has no concrete leakage;

[0017] The slide mold is in the folded state in the demolding stage, and the slide mold is in the unfolded state in the non-demolding stage;

[0018] The forming mold further comprises one or more than one positioning component, one or more than one locking component, one or more than one vibrating component, and one or more than one demolding component, and the locking component comprises a first locking assembly and a second locking assembly;

[0019] In production, the following steps are included:

[0020] S1: The slide mold is arranged equidistantly or non-equidistantly along the bottom mold;

[0021] S2: The stirrup and the prestressed steel bar are arranged, and the prestressed steel bar respectively passes through the steel bar hole on the inside of the stirrup, the end plate, and the slide mold;

[0022] S3: After the prestressed steel bar is stretched and tightened, the two ends of the prestressed steel bar are respectively locked by the two groups of first locking assemblies;

[0023] S4: The spacing of the slide mold and the stirrup is adjusted, the position of the slide mold is positioned by the two groups of second locking assemblies, and the stirrup and the prestressed steel bar are fixed by binding;

[0024] S5: The side mold is arranged, the end plate, the bottom mold, the slide mold, and the side mold form an independent prefabricated part mold cavity, the concrete material is poured into the prefabricated part mold cavity, is vibrated and compacted, and is smoothed on the surface, and waits for the concrete material to solidify;

[0025] S6: After the prefabricated part is formed, the first locking assembly and the second locking assembly are released, the prestressed steel bars connected between the prefabricated parts are cut off, the side mold and the folded slide mold are separated, so that they are separated from the prefabricated parts, and the prefabricated parts remain on the bottom mold for subsequent maintenance;

[0026] S7: The disassembled slide formwork is reassembled and hoisted and transferred to the remaining idle bottom forms, step S1 is repeated, the prefabricated part production line is constructed again, and continuous production operation is performed.

[0027] Preferably, the slide formwork is composed of two partition plates, the connection parts of the two partition plates are staggered, and the connection parts are movably inserted with a bolt;

[0028] When the bolt is separated from the connection part of the partition plate, the two partition plates move close to each other to reduce the overall thickness of the slide formwork, which is the folded state of the slide formwork;

[0029] The bolt is inserted into the connection part of the partition plate, and the distance between the two partition plates is fixed, which is the unfolded state of the slide formwork.

[0030] Preferably, each side formwork is composed of one or more sub-molds, and the connection parts of each sub-mold are bolted;

[0031] The connection parts of the two side formworks and the end plate are bolted.

[0032] Preferably, the work site foundation further comprises a plurality of piers, each pier is arranged between the platforms, and each end plate is fixedly connected with the surface of the pier.

[0033] Preferably, the work site foundation further comprises a plurality of stop blocks, and the plurality of stop blocks are linearly distributed on both sides of the platform;

[0034] The positioning component comprises one or more wedge-shaped blocks, and each wedge-shaped block is inserted between the stop block and the side formwork;

[0035] The stop block pushes the edge of the side formwork and the bottom formwork to abut, forms the bottom edge of the prefabricated part mold cavity, and the bottom edge has no concrete leakage.

[0036] Preferably, the positioning component further comprises one or more support rods;

[0037] Each support rod is arranged between the side formwork and the platform, each support rod is composed of a positioning pin, a rod body and two screw rods, the two screw rods are rotatably inserted in the rod body, the positioning pin is inserted in the connection part of the screw rod and the side formwork, and the bottom end of the support rod is fixedly connected with the surface of the platform;

[0038] The support rod pushes the edge of the side formwork and the slide formwork to abut, forms the side edge of the prefabricated part mold cavity, and the side edge has no concrete leakage.

[0039] Preferably, the positioning component further comprises one or more positioning bolts;

[0040] Each positioning bolt is installed at the opening of the two side formworks;

[0041] The positioning bolts limit the opening of the prefabricated part mold cavity and keep the size of the opening consistent.

[0042] Preferably, the vibrating component comprises one or more vibrating motors, one or more mounting plates, one or more diffusion plates, one or more fastening bolts, one or more conducting rods, and one or more positioning rods.

[0043] Each vibrating motor is mounted on the surface of a mounting plate, and each mounting plate surface is provided with a plurality of clamping grooves.

[0044] Each diffusion plate is welded to the surface of the side mold, each conducting rod is welded to the surface of the diffusion plate, and one end of the conducting rod is in contact with the surface of the mounting plate.

[0045] Each fastening bolt is mounted on the surface of the side mold, and the fastening bolt is connected to the U-shaped port of the mounting plate surface.

[0046] Preferably, the demolding component comprises one or more material returning holes and one or more ejection bolts.

[0047] Each material returning hole is provided on the surface of the side mold, and the material returning hole penetrates the inner wall of the side mold, each ejection bolt is rotatably inserted into the material returning hole, and the inner wall of each material returning hole is provided with threads engaged with the outer wall of the ejection bolt.

[0048] Preferably, the forming mold further comprises one or more steel bar feeding mechanisms and steel bar stretching components.

[0049] The steel bar feeding mechanism feeds the steel bar, and the steel bar stretching component stretches the steel bar to apply prestress.

[0050] Preferably, in step S4:

[0051] The second locking assemblies located in the slip form are two groups, and after the two groups of second locking assemblies are locked on the surface of the prestressed steel bar, the end faces of the second locking assemblies abut against the inner walls of the two sides of the slip form.

[0052] Preferably, in step S5:

[0053] The side molds are respectively arranged on both sides of the bottom mold, the side molds are provided with positioning components outside, the positioning components abut against the bottom ends outside and the openings outside of the side molds respectively, the positioning components push the side molds to abut against the bottom mold and the edges of the slip form, thereby forming the prefabricated part mold cavity edges without concrete leakage.

[0054] Preferably, in step S5:

[0055] The concrete material is vibrated and compacted by external conduction.

[0056] The side mold outside the both sides of the preform mold cavity is provided with a vibrating component, the vibrating component generates vibration transmitted to the side mold, and the concrete material in the preform mold cavity is vibrated and compacted through the vibration of the side mold.

[0057] Preferably, in step S6,

[0058] The part where the first locking assembly and the second locking assembly end of the prestressed steel bar are exposed is cut off, the locking state of the first locking assembly and the second locking assembly is released, and the first locking assembly and the second locking assembly are separated from the prestressed steel bar;

[0059] The external force of the positioning component on the side mold is released, the side mold is separated from the preform, and the side mold is hoisted and transferred;

[0060] The locking state of the bolt between the two partition plates is released, the distance between the two partition plates is reduced, the sliding mold is in a folded state, until the prestressed steel bar is separated from the steel bar hole, the two partition plates are transferred, and the two partition plates are combined again through the bolt, and the whole is hoisted and transferred.

[0061] Preferably, in step S7,

[0062] The bottom mold has a plurality of, after the hoisting and transferring of the sliding mold and the side mold, the sliding mold and the side mold are repeated step S1, and a production line for producing preforms with a plurality of bottom molds sharing one or more sets of sliding molds and side molds is formed.

[0063] The concrete preform produced by the production method of the concrete preform batch production device has a concrete base body with the same shape as the preform mold cavity, a prestressed steel bar penetrating the whole preform, and a stirrup distributed in the preform and fixedly bundled with the prestressed steel bar.

[0064] Preferably, the partition plate is provided with a wire pipe hole for placing a wire pipe.

[0065] Preferably, the partition plate is provided with a pre-buried bolt hole for placing a connecting bolt, and a pre-buried bolt positioning sleeve for fixedly connecting the bolt is installed in the pre-buried bolt hole through thread engagement.

[0066] The concrete preform produced by the production method of the concrete preform batch production device has a concrete base body with the same shape as the preform mold cavity, a prestressed steel bar penetrating the whole preform, a wire pipe, a stirrup distributed in the preform and fixedly bundled with the prestressed steel bar, and a connecting bolt embedded in both ends of the preform.

[0067] Compared with the prior art, the beneficial effects of the present application are:

[0068] 1. The present application sets up the telescopic sliding form, achieves the quick separation between the sliding form and the prefabricated part under the premise of not moving the prefabricated part, eliminates the influence of the prestressed steel on the sliding form demolding, is beneficial to the flexible scheduling of the sliding form, saves the labor cost and the mechanical operation cost, and helps to improve the production efficiency.

[0069] 2. The present application sets up the flexible scheduling sliding form and side mold, realizes that multiple production lines share one or more forming molds, improves the mold scheduling flexibility and reduces the steel material required for mold manufacturing, and the flexible scheduling of the sliding form and the side mold can effectively improve the output and production efficiency of the prefabricated part, and the crane can be used for scheduling, which is beneficial to the efficient and smooth operation between production lines. BRIEF DESCRIPTION OF DRAWINGS

[0070] Figure 1 The production method flow chart of the present application;

[0071] Figure 2 The overall structure schematic diagram of the batch production device of the present application;

[0072] Figure 3 The appearance structure schematic diagram of the forming mold of the present application;

[0073] Figure 4 The explosion structure schematic diagram of the forming mold parts of the present application;

[0074] Figure 5 The main cross-sectional structure schematic diagram of the forming mold of the present application;

[0075] Figure 6 The appearance structure schematic diagram of the end plate of the present application;

[0076] Figure 7 The structure schematic diagram of the first locking assembly locking prestressed steel of the present application;

[0077] Figure 8 The structure schematic diagram of the prestressed steel arranged on the inner side of the end plate of the present application;

[0078] Figure 9 The structure schematic diagram of the prestressed steel arranged on the sliding form of the present application;

[0079] Figure 10 The structure schematic diagram of the second locking assembly locking prestressed steel of the present application;

[0080] Figure 11 The explosion structure schematic diagram of the sliding form parts of the present application;

[0081] Figure 12 The appearance structure schematic diagram of the concrete prefabricated part in embodiment one of the present application;

[0082] Figure 13 This is a schematic diagram of the external structure of the side mold of the present invention;

[0083] Figure 14 This is a schematic diagram of the side mold cloth positioning mechanism of the present invention;

[0084] Figure 15 This is a schematic diagram of the side mold arrangement and vibration mechanism of the present invention.

[0085] Figure 16 This is a partially enlarged schematic diagram of the side mold cloth positioning mechanism of the present invention;

[0086] Figure 17 For the present invention Figure 14 Enlarged structural diagram at point A in the middle;

[0087] Figure 18 For the present invention Figure 14 Enlarged structural diagram at point B;

[0088] Figure 19 This is a schematic diagram of the external structure of the first locking component of the present invention;

[0089] Figure 20 This is a schematic diagram of the external structure of the second locking component of the present invention;

[0090] Figure 21 This is a schematic diagram of the sliding mold structure in Embodiment 4 of the present invention;

[0091] Figure 22 This is an exploded view of the sliding mold component in Embodiment 4 of the present invention;

[0092] Figure 23 This is a schematic diagram of the appearance structure of the prefabricated component in Embodiment 4 of the present invention;

[0093] Figure 24 This is a schematic diagram of the external structure of the first locking component in Embodiment Six of the present invention;

[0094] Figure 25 This is a schematic diagram of the external structure of the second locking component in Embodiment Six of the present invention.

[0095] In the picture:

[0096] 110. Platform; 120. Stand; 130. Stop; 140. Power supply box; 150. Crane track;

[0097] 210. End plate; 220. Bottom mold; 230. Sliding mold; 231. Pin; 232. Partition plate; 240. Side mold; 241. Sub-mold; 250. Rebar hole; 260. Conduit hole; 270. Embedded bolt hole; 271. Embedded bolt positioning sleeve; 280. Relief block;

[0098] 310, wedge-shaped block; 320, support rod; 330, positioning bolt;

[0099] 410, first locking assembly; 420, second locking assembly;

[0100] 510, vibration motor; 520, mounting plate; 521, clamping groove; 530, diffusion plate; 540, fastening bolt; 550, conducting rod; 560, positioning rod;

[0101] 610, material returning hole; 620, ejection bolt;

[0102] 700, prestressed steel bar; 800, stirrup; 900, wire arranging pipe; 1000, connecting bolt; 1100, concrete base body. DETAILED DESCRIPTION

[0103] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the scope of protection of the present application.

[0104] Please refer to Figures 1 to 25 The present application provides the following six embodiments:

[0105] The concrete prefabricated part batch production device, please refer to Figures 2 to 19 , including a work site foundation and one or more sets of forming molds.

[0106] The work site foundation includes one or more platforms 110, and each set of forming molds is arranged on the surface of the platform 110. The platform 110 is used to build the foundation of multiple prefabricated part production lines.

[0107] Specifically, when the number of platforms 110 is one, the number of required forming molds is one set; and when the number of platforms 110 is multiple, the number of required forming molds is two or more sets.

[0108] The arrangement of one or more platforms 110 and one or more sets of forming molds achieves the effects of improving the scheduling flexibility between production lines and reducing the amount of steel used. As the foundation of the production line, the platform 110 can be flexibly scheduled between the platforms 110, and the effect of sharing one set of molds by multiple production lines can be achieved, which effectively reduces the number of input forming molds and the amount of steel used. Not only does it ensure production efficiency, but it also makes the scheduling flexibility between production lines higher and reduces the enterprise investment cost.

[0109] In addition, the plurality of platforms 110 are arranged in parallel, and the forming molds can be uniformly dispatched by a trolley, so that the scheduling confusion between production lines can be effectively reduced, and efficient and smooth production operation is facilitated.

[0110] Each set of forming molds comprises two end plates 210, a bottom mold 220, one or more than one sliding mold 230, and two side molds 240. The two end plates 210 are respectively arranged at both ends of the platform 110, the bottom mold 220 is arranged on the surface of the platform 110, the two side molds 240 are respectively arranged at both sides of the platform 110, and the one or more than one sliding mold 230 is arranged between the two side molds 240. The connection between the two side molds 240 and the end plate 210 is bolted.

[0111] The surface of each end plate 210 and each sliding mold 230 is provided with one or more than one steel bar hole 250.

[0112] Each sliding mold 230 comprises two partition plates 232 and one or more than one latch 231, and each latch 231 is inserted into the connection between the two partition plates 232. The sliding mold 230 has an unfolded state and a folded state.

[0113] Specifically, after the latch 231 is separated from the connection between the partition plates 232, the two partition plates 232 move close to each other, reducing the overall thickness of the sliding mold 230, which is the folded state of the sliding mold 230.

[0114] The latch 231 is inserted into the connection between the partition plates 232, and the distance between the two partition plates 232 is fixed, which is the unfolded state of the sliding mold 230.

[0115] It is worth noting that when the number of sliding molds 230 is one, the sliding mold 230 divides the forming mold into two forming chambers, and after the concrete pouring, two concrete base bodies 1100 are formed.

[0116] It is worth noting that when the sliding mold 230 is located at the middle position of the forming mold, two concrete base bodies 1100 with the same length are obtained, and if the sliding mold 230 is located at a non-middle region of the forming mold, two concrete base bodies 1100 with different lengths are obtained.

[0117] Each side mold 240 is composed of one or more than one sub-mold 241, the connection between each sub-mold 241 is bolted, and the connection between the two side molds 240 and the end plate 210 is bolted.

[0118] The forming mold further comprises one or more than one positioning component, one or more than one locking component, one or more than one vibrating component, and one or more than one demolding component.

[0119] The work site foundation further comprises a plurality of piers 120, each pier 120 is arranged between the platforms 110, each end plate 210 is fixedly connected with the surface of the pier 120, the pier 120 is used to provide support for the end plate 210, to prevent the end plate 210 from tilting during the stretching of the prestressed steel bar 700, and to ensure the flatness of the edge of the concrete base body 1100.

[0120] The work site foundation further comprises a plurality of stop blocks 130, which are linearly distributed on both sides of the platform 110, and the positioning component comprises one or more wedge blocks 310, each wedge block 310 is inserted between the stop block 130 and the side mold 240.

[0121] The wedge block 310 can expand the gap between the side mold 240 and the stop block 130 by external force, which ensures the stability of the side mold 240 and the contact effect between the side mold 240 and the bottom mold 220, reduces the gap between the side mold 240 and the bottom mold 220, and prevents the problem of poor edge of the prefabricated part caused by concrete leakage.

[0122] The positioning component further comprises one or more support rods 320, each support rod 320 is arranged between the side mold 240 and the platform 110, each support rod 320 is composed of a positioning pin, a rod body and two screws, the two screws are rotatably inserted into the rod body, and the positioning pin is inserted into the connection between the screw and the side mold 240, and the bottom end of the support rod 320 is fixedly connected with the surface of the platform 110.

[0123] The support rod 320 is used to support the opening of the side mold 240, maintain the stability of the placement of the side mold 240, and prevent the side mold 240 from overturning. Secondly, by adjusting the screws at both ends of the support rod 320, the length of the support rod 320 can be adjusted, which is convenient for workers to calibrate the flatness of the opening of the side mold 240.

[0124] The positioning component further comprises one or more positioning screws 330, each positioning screw 330 is installed at the opening of the two side molds 240.

[0125] The positioning screw 330 is used to limit the distance between the openings of the two opposite side molds 240, to prevent the deformation of the side mold 240 caused by the pouring and solidification of the concrete, and to ensure the forming effect of the concrete member.

[0126] The locking component comprises one or more first locking assemblies 410, each first locking assembly 410 is composed of one or more locking pieces, each locking piece is composed of a U-shaped piece and a ratchet, and the surface of the ratchet is a involute.

[0127] The first locking assembly 410 is used to fix the two ends of the prestressed steel bar 700.

[0128] Specifically, the prestressed steel 700 is divided into a fixed end and a tension end, and the first locking assembly 410 is arranged at the fixed end and the tension end, and the locking pieces are opposite in direction.

[0129] Specifically, when the locking piece is located at the tension end, the ratchet in the locking piece rotates counterclockwise, and the tension movement of the prestressed steel 700 can be released. Conversely, the locking piece of the fixed end is locked in the tension direction of the prestressed steel 700, and one end of the prestressed steel 700 is fixed.

[0130] The locking component further comprises one or more second locking assemblies 420, each second locking assembly 420 is composed of one or more positioning members, each positioning member is composed of a U-shaped bolt, a locking piece and two nuts, the two nuts are rotatably installed at both ends of the U-shaped bolt, and the locking piece is inserted into the U-shaped bolt.

[0131] Specifically, the second locking assembly 420 is used for positioning the sliding formwork 230. After the tensioning of the prestressed steel 700 is completed, the position of the sliding formwork 230 is determined by the staff, and the sliding formwork 230 is fixed on the prestressed steel 700 by the second locking assembly 420, so as to limit the movable position of the sliding formwork 230, thereby achieving the effect of fixing the position of the sliding formwork 230, preventing the sliding formwork 230 from deviating during the concrete pouring process, and ensuring that the size of the concrete base body 1100 meets the expected standard.

[0132] The vibrating component comprises one or more vibration motors 510, one or more mounting plates 520, one or more diffusion plates 530, one or more fastening bolts 540, one or more conducting rods 550 and one or more positioning rods 560.

[0133] Each vibration motor 510 is mounted on the surface of the mounting plate 520, and each mounting plate 520 is provided with a plurality of clamping grooves 521.

[0134] Each diffusion plate 530 is welded to the surface of the side formwork 240, each conducting rod 550 is welded to the surface of the diffusion plate 530, and one end of the conducting rod 550 is in contact with the surface of the mounting plate 520.

[0135] Each fastening bolt 540 is mounted on the surface of the side formwork 240, and the fastening bolt 540 is connected with the U-shaped mouth on the surface of the mounting plate 520.

[0136] When the vibrating component is installed, the vibration motor 510 operates to generate vibration, which is conducted to the conducting rod 550 through the mounting plate 520. The diffusion plate 530 can uniformly diffuse the vibration conducted by the conducting rod 550 to the side formwork 240, so as to realize the effect of vibrating and compacting the concrete in the forming mold, and ensure the quality of the concrete prefabricated part.

[0137] The work site base further comprises one or more power supply boxes 140, each of which is arranged on one side of the platform 110, and the power supply box 140 is used to provide power for the vibrating component.

[0138] The work site base further comprises a traveling track 150 on which a hoisting trolley travels, and the trolley is used to meet the hoisting needs in the work process.

[0139] The demolding component comprises one or more material return holes 610 and one or more ejection bolts 620, each of the material return holes 610 is arranged on the surface of the side mold 240 and penetrates the inner wall of the side mold 240, and each of the ejection bolts 620 is rotatably inserted into the material return hole 610, and the inner wall of each of the material return holes 610 is provided with a thread that is engaged with the outer wall of the ejection bolt 620.

[0140] After the concrete base 1100 is formed, the positioning component can be removed, the ejection bolt 620 is rotated to separate the side mold 240 from the concrete base 1100, and the effect of rapid demolding is achieved.

[0141] The forming mold further comprises one or more steel bar feeding mechanisms and steel bar stretching components, the steel bar feeding mechanism feeds the steel bars, and the steel bar stretching component stretches the steel bars to apply prestress.

[0142] Based on the above-mentioned concrete prefabricated part batch production device, the following embodiments are proposed:

[0143] Embodiment one:

[0144] Please refer to Figure 1 , a method for producing a concrete prefabricated part, comprising the following steps:

[0145] S1: The slide mold 230 is arranged equidistantly or non-equidistantly along the bottom mold 220.

[0146] S2: The stirrup 800 and the prestressed steel bar 700 are arranged, and the prestressed steel bar 700 respectively passes through the steel bar hole 250 on the slide mold 230, the end plate 210 and the inside of the stirrup 800.

[0147] S3: After the prestressed steel bar 700 is stretched and tightened, the two ends thereof are respectively locked by the two groups of first locking assemblies 410.

[0148] One end of the prestressed steel bar 700 is locked by the first locking assembly 410, and the other group of first locking assemblies 410 locks and fixes the stretched end of the prestressed steel bar 700 after the stretching of the prestressed steel bar 700 is completed.

[0149] After the two ends of the prestressed steel bar 700 are locked by the first locking assembly 410, the end surface of the first locking assembly 410 abuts against the surface of the end plate 210.

[0150] Specifically, the first locking assembly 410 is composed of a plurality of locking pieces. When the locking pieces are located at the tensioning end, the ratchet in the locking pieces rotates counterclockwise to release the tensioning movement of the prestressed steel bar 700. Conversely, the locking pieces at the fixed end are locked in the tensioning direction of the prestressed steel bar 700 to fix one end of the prestressed steel bar 700.

[0151] S4: Adjust the spacing of the slip form 230 and the stirrup 800, and position the slip form 230 by the two groups of second locking assemblies 420. The stirrup 800 is fixed between the prestressed steel bar 700.

[0152] The second locking assembly 420 located in the slip form 230 is composed of two groups. After the two groups of second locking assemblies 420 are locked on the surface of the prestressed steel bar 700, the end face of the second locking assembly 420 abuts against the inner wall of the slip form 230 on both sides.

[0153] Specifically, the locking component further includes one or more second locking assemblies 420. Each second locking assembly 420 is composed of a plurality of positioning pieces. Each positioning piece is composed of a U-shaped bolt, a locking piece, and two nuts. The two nuts are rotatably installed at both ends of the U-shaped bolt, and the locking piece is inserted into the U-shaped bolt. By rotating the nut along the U-shaped bolt, the locking piece is clamped to the prestressed steel bar 700.

[0154] S5: Lay the side mold 240. The end plate 210, the bottom mold 220, the slip form 230, and the side mold 240 form an independent prefabricated part mold cavity. The prefabricated part mold cavity is poured into concrete, vibrated and compacted, and the surface is smoothed. Wait for the concrete to solidify.

[0155] The side mold 240 is arranged on both sides of the bottom mold 220. The side mold 240 is provided with a positioning component. The positioning component abuts against the outside of the bottom end of the side mold 240 and the outside of the opening. The positioning component pushes the side mold 240 to abut against the edges of the bottom mold 220 and the slip form 230 to form a leak-proof prefabricated part mold cavity edge.

[0156] Specifically, the wedge 310 is knocked between the side mold 240 and the stop block 130 to expand the gap between the side mold 240 and the stop block 130, and the inner wall of the side mold 240 abuts against the bottom mold 220 to prevent concrete leakage.

[0157] The stop block 130 pushes the side mold 240 to abut against the edge of the bottom mold 220 to form a prefabricated part mold cavity bottom edge, and the bottom edge is leak-proof.

[0158] The support rod 320 is used to support the opening of the side mold 240, maintain the stability of the placement of the side mold 240, and prevent the side mold 240 from overturning. Secondly, by adjusting the screw rods at both ends of the support rod 320, the length of the support rod 320 as a whole can be adjusted, which is convenient for workers to calibrate the flatness of the opening of the side mold 240. Moreover, the support rod 320 pushes the side mold 240 to tightly adhere to the edge of the sliding mold 230, forming the side edge of the prefabricated part mold cavity, and the side edge has no concrete leakage.

[0159] The positioning bolt 330 is used to limit the opening of the side mold 240 on both sides of the bottom mold 220, form the prefabricated part mold cavity with no concrete leakage at the edge, prevent the deformation of the side mold 240 during the pouring and solidification of the concrete, and ensure the forming effect of the concrete member.

[0160] It is worth noting that the edge gap of the prefabricated part mold cavity can be penetrated by water, but not by concrete slurry, that is, the edge gap of the prefabricated part mold cavity is between 0.1-0.2mm, and the size of the gap cannot allow the solid components in the concrete material to pass through, thereby ensuring the flatness of the edge of the concrete prefabricated part.

[0161] The concrete material is vibrated and compacted by an external conduction vibration.

[0162] The side mold 240 on both sides of the prefabricated part mold cavity is externally provided with a vibrating component, the vibrating component generates vibration and conducts the vibration to the side mold 240, and the side mold 240 vibrates to compact the concrete material in the prefabricated part mold cavity.

[0163] Specifically, the mounting plate 520 is installed on the positioning rod 560 through the clamping groove 521, after the vibrating component is installed, the vibration motor 510 operates to generate vibration, the vibration is conducted to the conduction rod 550 through the mounting plate 520, the diffusion plate 530 can uniformly diffuse the vibration conducted by the conduction rod 550 to the side mold 240, the side mold 240 conducts the vibration to the concrete, the concrete is vibrated and compacted from the outside to the inside, and finally the compacted concrete material is formed.

[0164] S6: After the prefabricated part is formed, the first locking assembly 410 and the second locking assembly 420 are released, the prestressed steel bars 700 connected between the prefabricated parts are cut off, the side mold 240 and the folding sliding mold 230 are separated, and the prefabricated parts are separated from the side mold 240 and the folding sliding mold 230, respectively, and the prefabricated parts remain on the bottom mold 220 for subsequent maintenance.

[0165] The sliding mold 230 is composed of two partition plates 232, the connection between the two partition plates 232 is distributed in a staggered manner, and the connection is movably inserted with a bolt 231.

[0166] The first locking assembly 410 and the second locking assembly 420 are cut off at the positions where the ends of the first locking assembly 410 and the second locking assembly 420 are exposed from the prestressed steel bar 700, the locking state of the first locking assembly 410 and the second locking assembly 420 is released, and the first locking assembly 410 and the second locking assembly 420 are separated from the prestressed steel bar 700.

[0167] The external force of the positioning component against the side mold 240 is released, the side mold 240 is separated from the prefabricated part, and the side mold 240 is hoisted and transferred.

[0168] Specifically, the side mold 240 is demolded as follows: the ejection bolt 620 is rotated to eject the gap between the side mold 240 and the concrete base 1100, so that the side mold 240 is separated from the surface of the concrete base 1100.

[0169] The locking state of the bolt 231 between the two partitions 232 is released, the distance between the two partitions 232 is reduced, the folding state of the slip form 230 is formed, the prestressed steel bar 700 is separated from the steel bar hole 250, the two partitions 232 are transferred, and the two partitions 232 are combined again through the bolt 231. The whole is hoisted and transferred.

[0170] S7: The slip form 230 after disassembly is assembled again and hoisted and transferred to the remaining idle bottom mold 220 together with the side mold 240, the step S1 is repeated, the prefabricated part production line is constructed again, and continuous production operation is performed.

[0171] It is worth noting that the bottom mold 220 has multiple, the slip form 230 and the side mold 240 after hoisting and transferring repeat the step S1, and form multiple production lines for producing prefabricated parts with one or more sets of slip forms 230 and side molds 240 shared by multiple bottom molds 220. In the batch production process, multiple sets of slip forms 230 and side molds 240 are uniformly scheduled by the travelling crane, which can ensure the scheduling flexibility and smoothness of the production line, avoid confusion in production operation, and reduce the amount of human resources investment. Secondly, the amount of steel used is saved, that is, it is not necessary to equip each production line with a complete mold, and a large number of duplicate molds do not need to be made, but only molds of different types need to be made for making prefabricated parts of different shapes.

[0172] Please refer to Figure 11 and Figure 12 The concrete prefabricated part produced by the above production method has a concrete base 1100 with the same shape as the mold cavity of the prefabricated part, a prestressed steel bar 700 penetrating the whole prefabricated part, and a stirrup 800 distributed in the prefabricated part and fixedly bundled with the prestressed steel bar 700.

[0173] Specifically, the length of the concrete prefabricated part is 1-12 meters, the height is 2-3 meters, and the diameter of the prestressed steel bar 700 is 4-8 mm.

[0174] Example two:

[0175] Based on the content in the above embodiment one, another embodiment is proposed:

[0176] Please refer to Figures 21 to 23 The surface of each end plate 210 and each sliding form 230 is provided with one or more pipe holes 260.

[0177] The concrete precast part produced by the production method proposed in embodiment one has a concrete base body 1100 with the same shape as the precast part mold cavity, prestressed steel bars 700 penetrating the whole precast part, stirrups 800 distributed in the interior of the precast part and fixedly bundled with the prestressed steel bars 700, and wire routing pipes 900 for laying wires.

[0178] Embodiment three:

[0179] Based on the content in the above embodiment two, another embodiment is proposed:

[0180] Please refer to Figures 21 to 23 The partition plate 232 is provided with a pre-bolt hole 270 for placing a connecting bolt 1000, and a pre-bolt positioning sleeve 271 for fixedly connecting the bolt 1000 is installed in the pre-bolt hole 270 through thread engagement.

[0181] The concrete precast part produced by the production method proposed in embodiment one has a concrete base body 1100 with the same shape as the precast part mold cavity, prestressed steel bars 700 and wire routing pipes 900 penetrating the whole precast part, stirrups 800 distributed in the interior of the precast part and fixedly bundled with the prestressed steel bars 700, and connecting bolts 1000 embedded in both ends of the precast part.

[0182] Specifically, the length of the concrete precast part is 1-12 meters, the height is 2-3 meters, and the diameter of the prestressed steel bars 700 is 4-8 mm.

[0183] Embodiment four:

[0184] Based on the content in the above embodiment three, another embodiment is proposed:

[0185] Please refer to Figures 21 to 23 One side surface of each end plate 210 and both side surfaces of each sliding form 230 are provided with a clearance block 280.

[0186] The concrete precast part produced by the production method proposed in embodiment one has a concrete base body 1100 with the same shape as the precast part mold cavity, prestressed steel bars 700 and wire routing pipes 900 penetrating the whole precast part, stirrups 800 distributed in the interior of the precast part and fixedly bundled with the prestressed steel bars 700, and connecting bolts 1000 embedded in both ends of the precast part.

[0187] Specifically, the length of the concrete prefabricated part is 1-12 meters, the height is 2-3 meters, the diameter of the prestressed steel bar 700 is 4-8 mm, and the bottom end of the prefabricated part on both sides has a notch for lapping the rest of the concrete prefabricated part.

[0188] Embodiment five:

[0189] Based on the above contents in embodiments one to four, another embodiment is proposed:

[0190] The vibration mode adopts a concrete vibrator to vibrate and compact.

[0191] Specifically, the concrete vibrator is inserted into the prefabricated part mold cavity along the opening of the side mold 240 for uniform and continuous vibration.

[0192] It is worth noting that during this process, the vibration part matched with the vibrator can continuously slide along the opening of the side mold 240 for continuous vibration work.

[0193] Embodiment six:

[0194] Based on the above contents in embodiments one to four, another embodiment is proposed:

[0195] Please refer to Figure 24 , the locking part in the first locking assembly 410 is replaced by a one-way locking mechanism composed of a sleeve with a tapered port and two plugs.

[0196] Specifically, the prestressed steel bar 700 is inserted into the sleeve with a tapered port, and the plug is placed between the tapered port and the prestressed steel bar 700. As the prestressed steel bar 700 is stretched, the plug moves with the prestressed steel bar 700 to clamp the fixed end of the prestressed steel bar 700.

[0197] It is worth noting that the direction of the tapered port at the stretched end of the prestressed steel bar 700 is opposite to the arrangement direction of the fixed end, that is, after the stretched end of the prestressed steel bar 700 stops stretching, the plug is inserted into the tapered port and is hammered to be fastened, so as to fix the stretched end of the prestressed steel bar 700 and prevent it from shrinking.

[0198] Please refer to Figure 25 , the positioning part in the second locking assembly 420 is replaced by a sleeve two with an opening and a bolt rotatingly inserted into the sleeve two.

[0199] Specifically, the opening is used to flexibly connect the sleeve two outside the prestressed steel bar 700, and tightening the bolt can make the prestressed steel bar 700 abut against the inner wall of the sleeve two, so as to fix the sleeve two on the surface of the prestressed steel bar 700.

[0200] It will be apparent to those skilled in the art that the application is not limited to the details of the above-exemplified embodiments and that the present application can be implemented in other particular forms without departing from the spirit or essential characteristics of the present application. The embodiments should therefore be considered in all respects as illustrative and not restrictive, the scope of the application being indicated by the appended claims rather than by the above description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. No reference signs in the claims should be considered as limiting the scope of the claims with respect to the figures of the patent document.

Claims

1. A production method for a batch production device for precast concrete components, characterized in that: The precast concrete mass production equipment includes a work site foundation and one or more molding dies. The foundation of the work site includes one or more platforms (110), and each set of the molding molds is set on the surface of the platform (110); Each set of molding dies includes two end plates (210), a bottom mold (220), one or more sliding molds (230), and two side molds (240). The two end plates (210) are respectively disposed at both ends of the platform (110), the bottom mold (220) is disposed on the surface of the platform (110), the two side molds (240) are respectively disposed on both sides of the platform (110), and one or more sliding molds (230) are disposed between the two side molds (240). Each of the sliding molds (230) includes two partitions (232) and one or more pins (231), each of the pins (231) being inserted into the connection between the two partitions (232); The sliding mold (230) has an unfolded state and a folded state; Each end plate (210) and each slipform (230) has one or more reinforcing bar holes (250) on its surface; The end plate (210), bottom mold (220), sliding mold (230) and side mold (240) form an independent precast component mold cavity. The upper end of the precast component mold cavity is open, and there is no concrete leakage at the edge gap of the precast component mold cavity. The sliding mold (230) is in a folded state during the demolding stage and in an unfolded state during the non-demolding stage; The molding die also includes one or more positioning components, one or more locking components, one or more vibrating components, and one or more demolding components, wherein the locking components include a first locking assembly (410) and a second locking assembly (420); The production process includes the following steps: S1: Sliding molds (230) are arranged at equal or non-equal intervals along the bottom mold (220); S2: Arrange stirrups (800) and prestressed steel bars (700), with the prestressed steel bars (700) passing through the inside of the stirrups (800), the end plate (210), and the steel bar holes (250) on the slipform (230), respectively; S3: After the prestressed steel bar (700) is stretched and tightened, its two ends are locked by two sets of first locking components (410); S4: Adjust the spacing between the slip form (230) and the stirrups (800), position the slip form (230) using two sets of second locking components (420), and tie and fix the stirrups (800) and the prestressed steel bars (700); S5: Set up side molds (240), end plate (210), bottom mold (220), sliding mold (230) and side molds (240) to form independent precast component cavities. Pour concrete into the precast component cavities, vibrate and compact it and smooth the surface, and wait for the concrete to solidify. S6: After the precast component is formed, release the first locking assembly (410) and the second locking assembly (420), cut off the prestressed steel bars (700) connecting the precast components, separate the side mold (240) and the folding sliding mold (230) so that they are separated from the precast components respectively, and leave the precast components on the bottom mold (220) for subsequent curing. S7: After the dismantled slip mold (230) is reassembled, it is hoisted and transferred to the remaining empty bottom mold (220) along with the side mold (240). Step S1 is repeated to rebuild the precast production line and carry out continuous production operations.

2. The production method of the precast concrete component mass production device according to claim 1, characterized in that: The sliding mold (230) is composed of two partitions (232), the two partitions (232) are staggered at the connection, and the connection is movably connected with a pin (231); After the pin (231) is disengaged from the connection of the partition (232), the two partitions (232) move closer to each other, reducing the overall thickness of the sliding mold (230), which is the folded state of the sliding mold (230); The pin (231) is inserted into the connection of the partition (232), and the distance between the two partitions (232) is fixed, which is the unfolded state of the sliding mold (230).

3. The production method of the precast concrete component mass production device according to claim 1, characterized in that: Each of the side molds (240) consists of one or more sub-molds (241), and the connection of each sub-mold (241) is made by bolts; The two side molds (240) are connected to the end plate (210) by bolts.

4. The production method of the precast concrete component mass production device according to claim 1, characterized in that: The foundation of the work site also includes multiple piers (120), each pier (120) is set between the platforms (110), and each end plate (210) is fixedly connected to the surface of the pier (120).

5. The production method of the precast concrete component mass production device according to claim 1, characterized in that: The foundation of the work site also includes multiple blocks (130), which are linearly distributed on both sides of the platform (110); The positioning component includes one or more wedge blocks (310), each of the wedge blocks (310) being inserted between the stop block (130) and the side mold (240); The stop block (130) pushes the edge of the side mold (240) and the bottom mold (220) to fit tightly together, forming the bottom edge of the precast component mold cavity, and there is no concrete leakage at the bottom edge.

6. The production method of the precast concrete component mass production device according to claim 1, characterized in that: The positioning component also includes one or more support rods (320); Each of the support rods (320) is disposed between the side mold (240) and the platform (110). Each support rod (320) consists of a positioning pin, a rod body and two screws. The two screws are respectively rotatably inserted into the inside of the rod body, and the positioning pin is inserted into the connection between the screw and the side mold (240). The bottom end of the support rod (320) is fixedly connected to the surface of the platform (110). The support rod (320) pushes the edge of the side mold (240) and the sliding mold (230) to fit tightly together, forming the side edge of the precast part mold cavity, and there is no concrete leakage at the side edge.

7. The production method of the precast concrete component mass production device according to claim 1, characterized in that: The positioning component also includes one or more positioning bolts (330); Each of the positioning bolts (330) is installed at the opening of the two side molds (240); The positioning bolt (330) limits the opening of the preform mold cavity to maintain consistent dimensions at the opening of the preform mold cavity.

8. The production method of the precast concrete component mass production device according to claim 1, characterized in that: The vibrating component includes one or more vibrating motors (510), one or more mounting plates (520), one or more diffuser plates (530), one or more fastening bolts (540), one or more transmission rods (550), and one or more positioning rods (560); Each vibration motor (510) is mounted on the surface of a mounting plate (520), and each mounting plate (520) is provided with a plurality of slots (521); Each of the diffuser plates (530) is welded to the surface of the side mold (240), and each of the conductive rods (550) is welded to the surface of the diffuser plate (530), with one end of the conductive rod (550) in contact with the surface of the mounting plate (520); Each of the fastening bolts (540) is mounted on the surface of the side mold (240), and the fastening bolts (540) are connected to the U-shaped opening on the surface of the mounting plate (520).

9. The production method of the precast concrete component mass production device according to claim 1, characterized in that: The demolding component includes one or more ejection holes (610) and one or more ejection bolts (620); Each of the ejection holes (610) is provided on the surface of the side mold (240), and the ejection hole (610) penetrates the inner wall of the side mold (240). Each of the ejection bolts (620) is rotatably inserted into the ejection hole (610). The inner wall of each ejection hole (610) is provided with a thread that meshes with the outer wall of the ejection bolt (620).

10. The production method of the precast concrete component mass production device according to claim 1, characterized in that: The forming mold also includes one or more rebar placement mechanisms and rebar stretching components; The rebar placement mechanism places the rebar, and the rebar tensioning component applies prestress to the rebar by tensioning it.

11. The production method of the precast concrete component mass production device according to claim 1, characterized in that: in, In step S4: There are two sets of second locking components (420) located in the sliding mold (230). After the two sets of second locking components (420) are locked onto the surface of the prestressed steel bar (700), the end face of the second locking component (420) abuts against the inner walls on both sides of the sliding mold (230).

12. The production method of the precast concrete component mass production device according to claim 11, characterized in that: in, In step S5: The side molds (240) are respectively arranged on both sides of the bottom mold (220). The side molds (240) are provided with positioning components on the outside. The positioning components abut against the bottom outside of the side mold (240) and the outside of the opening. The positioning components push the side mold (240) to abut against the edges of the bottom mold (220) and the sliding mold (230) to form the edge of the precast mold cavity without concrete leakage.

13. The production method of the precast concrete component mass production device according to claim 11, characterized in that: in, In step S5: The concrete material is compacted using externally transmitted vibration. Vibration components are provided on the outside of the side molds (240) on both sides of the precast component mold cavity. The vibration generated by the vibration components is transmitted to the side molds (240), and the concrete material in the precast component mold cavity is compacted by the vibration of the side molds (240).

14. The production method of the precast concrete component mass production device according to claim 11, characterized in that: in, In step S6: Cut off the portion of the prestressed steel bar (700) that exposes the ends of the first locking assembly (410) and the second locking assembly (420), release the locking state of the first locking assembly (410) and the second locking assembly (420), and separate them from the prestressed steel bar (700); Release the external force of the positioning component against the side mold (240) so that it is separated from the precast part, and then lift and transfer the side mold (240); Release the locking state of the pin (231) between the two partitions (232), reduce the distance between the two partitions (232), form a folded state of the sliding form (230) until the prestressed steel bar (700) is removed from the steel bar hole (250), transfer the two partitions (232), and combine the two partitions (232) again through the pin (231) and transfer them as a whole by hoisting.

15. The production method of the precast concrete component mass production device according to claim 14, characterized in that: wherein, In step S7: The bottom mold (220) has multiple units. After the sliding mold (230) and side mold (240) are hoisted and transferred, step S1 is repeated to form a production line in which multiple bottom molds (220) share one or more sets of sliding molds (230) and side molds (240) to produce precast parts.

16. The precast concrete components produced by the production method of the precast concrete component mass production apparatus according to claim 15 are characterized in that: The precast concrete component has a concrete matrix (1100) with the same shape as the precast component mold cavity, prestressed steel bars (700) running through the entire precast component, and stirrups (800) distributed inside the precast component and fixedly tied to the prestressed steel bars (700).

17. The production method of the precast concrete component mass production device according to claim 15, characterized in that: The partition (232) is provided with a conduit hole (260) for placing conduits.

18. The production method of the precast concrete component mass production apparatus according to claim 17, characterized in that: The partition (232) is provided with a pre-embedded bolt hole (270) for placing the connecting bolt (1000), and a pre-embedded bolt positioning sleeve (271) for fixing the connecting bolt (1000) is installed in the pre-embedded bolt hole (270) by thread engagement.

19. The precast concrete components produced by the production method of the precast concrete component mass production apparatus according to claim 18, characterized in that: The precast concrete component has a concrete matrix (1100) with the same shape as the precast component mold cavity, prestressed steel bars (700) and wiring pipes (900) running through the entire precast component, stirrups (800) distributed inside the precast component and fixedly tied to the prestressed steel bars (700), and connecting bolts (1000) embedded at both ends of the precast component.

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