Concrete preform and its mass production device and production method

Abstract

The application discloses a concrete prefabricated part and a batch production device and method thereof, which comprises the following steps: S1, arranging sliding forms at equal intervals or non-equal intervals along a bottom mold; S2, arranging stirrups and prestressed steel bars; S3, locking the prestressed steel bars after being stretched and tightened; S4, adjusting the interval of the sliding forms and the stirrups, and positioning the sliding form position; S5, arranging side molds, pouring in concrete materials, vibrating and compacting, and waiting for the concrete to solidify; S6, after the prefabricated part is formed, separating the side molds and folding the sliding forms; S7, hoisting and transferring the sliding forms and the side molds to the remaining idle bottom molds, repeating the step S1, and constructing the prefabricated part production line again. The application effectively reduces the number of investment of forming molds, reduces the use amount of steel materials, and has the advantages of high production efficiency, high scheduling efficiency and smooth scheduling.

Description

Technical Field

[0001] This invention relates to the field of precast concrete production technology, specifically to precast concrete components and their mass production equipment and methods. Background Technology

[0002] Prestressed concrete precast components are produced by tensioning high-strength steel bars before pouring concrete and temporarily anchoring them to a platform or steel mold. Concrete is then poured, and once it reaches a certain strength, the tension is released. Prestress is established through the bond between the concrete and the steel bars, ultimately forming standardized building components that can be transported and hoisted. Compared to traditional precast concrete components, prestressed concrete precast components exhibit superior structural performance, effectively overcoming the weakness of low tensile strength in traditional precast concrete components, significantly improving the load-bearing capacity and crack resistance of the components. They also offer significant economic benefits, saving steel consumption and reducing project costs; longer durability and service life, better adapting to harsh environments; and lightweight characteristics, facilitating transportation and installation. Therefore, their comprehensive performance improvements and long-term economic benefits have led to their widespread application in modern civil engineering, especially in precast structures in buildings, rail transit, and water conservancy projects, where they hold a dominant position.

[0003] However, the process of producing precast components using prestressed pretensioning technology is more complex than traditional processes, requiring more equipment and professional personnel, which increases the company's production costs and human resource investment.

[0004] In existing technologies, such as the Chinese utility model patent (publication number CN223071654U), a prestressed concrete slab beam using the prestressed concrete process is disclosed. Essentially, this involves using a prestressed concrete precast component production mold, which improves the stability of the mold during mold separation and produces high-quality concrete slab beams. However, most prestressed concrete precast components currently undergo steel reinforcement tensioning and concrete solidification in a single mold, with each mold producing only one component at a time, resulting in low production efficiency. To increase production capacity, it is necessary to increase the number of molds and supporting production equipment. This not only significantly increases the amount of steel required for mold making but also necessitates more human resources to support large-scale production. Furthermore, the workflow between production molds is prone to confusion, increasing management and coordination time costs, leading to unsatisfactory overall economic benefits.

[0005] Mass production of prestressed concrete precast components using the prestressing method is not simply a matter of connecting individual production molds in series along the direction of the tensioning steel bars. While connecting the molds in series, with the prestressing steel bars running through all precast components, allows for the simultaneous tensioning of prestressing steel bars in multiple components, and then cutting the bars after solidification to form independent components, thus improving tensioning efficiency and enabling mass production, it presents a significant challenge. Workers would have to cut the prestressing steel bars along the edges of the components, only between the end molds of adjacent components. The cut bars would remain embedded in the end molds, hindering demolding flexibility. Large machinery would be needed to remove them before the end molds could be dismantled and reused. Furthermore, the precast components would require centralized storage and curing until they meet usage standards. Therefore, a single series production line involves extensive handling, and the operating costs and energy expenses of large equipment increase the overall production cost of precast components, while also requiring substantial manpower to operate the machinery.

[0006] If multiple production lines are used in series to increase the output of prestressed precast components, the forming molds at the ends of the precast components in a single series production line cannot be demolded quickly and easily due to the obstruction of residual prestressed steel bars. This results in the forming molds after demolding not being able to be quickly dispatched among multiple production lines, leading to a problem of chaotic mold dispatching among multiple production lines. This, in turn, increases the amount of steel used to make the forming molds for precast components, as well as the mechanical and labor costs for management and dispatching.

[0007] Therefore, in order to solve the problems of low production efficiency, low output, chaotic assembly line operation and difficulty in controlling production costs when using the prestressed concrete process in the above-mentioned existing technologies, concrete precast components and their production methods are proposed. Summary of the Invention

[0008] The purpose of this invention is to provide precast concrete components and their mass production apparatus and method to solve the problems mentioned in the background art.

[0009] To achieve the above objectives, the present invention provides the following technical solution:

[0010] A production method for a precast concrete mass production device, wherein the precast concrete mass production device includes a work site foundation and one or more molding dies.

[0011] The foundation of the work site includes one or more platforms, and each set of the molding molds is set on the surface of the platform.

[0012] Each set of molding dies includes two end plates, a bottom mold, one or more sliding molds, and two side molds. The two end plates are respectively disposed at both ends of the platform, the bottom mold is disposed on the surface of the platform, the two side molds are respectively disposed on both sides of the platform, and one or more sliding molds are disposed between the two side molds.

[0013] Each of the sliding molds includes two partitions and one or more pins, each of the pins being inserted into the connection between the two partitions;

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

[0015] Each end plate and each sliding mold has one or more reinforcing bar holes on its surface;

[0016] The end plate, bottom mold, sliding mold and side mold form an independent precast component mold cavity. The upper end of the precast component mold cavity is open, and there is no concrete leakage from the edge gaps of the precast component mold cavity.

[0017] The sliding mold is in a folded state during the demolding stage and in an unfolded state during the non-demolding stage;

[0018] The molding die further 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 and a second locking assembly;

[0019] The production process includes the following steps:

[0020] S1: Sliding molds are arranged at equal or non-equal intervals along the bottom mold;

[0021] S2: Install stirrups and prestressed steel bars, with the prestressed steel bars passing through the inside of the stirrups, the end plate, and the steel bar holes on the slipform, respectively;

[0022] S3: After the prestressed steel bars are stretched and tightened, both ends are locked by two sets of first locking components;

[0023] S4: Adjust the spacing of the slip form and stirrups, position the slip form using two sets of second locking components, and tie and fix the stirrups to the prestressed steel bars;

[0024] S5: Set up the side molds, end plates, bottom molds, sliding molds and side molds 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.

[0025] S6: After the precast component is formed, release the first locking component and the second locking component, cut off the prestressed steel bars connecting the precast components, separate the side mold and the folding slip mold so that they are separated from the precast components respectively, and leave the precast components on the bottom mold for subsequent curing;

[0026] S7: After the dismantled slipform is reassembled, it is hoisted and transferred to the remaining empty bottom mold along with the side mold. Step S1 is repeated to rebuild the precast component production line and carry out continuous production operations.

[0027] Preferably, the sliding mold is composed of two partitions, the connection between the two partitions is staggered, and the connection is movably connected with a pin;

[0028] After the pin disengages from the partition joint, the two partitions move closer to each other, reducing the overall thickness of the sliding mold, which is the folded state of the sliding mold.

[0029] The pin is inserted into the partition joint, and the distance between the two partitions is fixed, which is the unfolded state of the sliding mold.

[0030] Preferably, each side mold is composed of one or more sub-molds, and the connection of each sub-mold is made by bolts;

[0031] The two side molds are connected to the end plates by bolts.

[0032] Preferably, the work site foundation also includes multiple piers, each pier being disposed between the platforms, and each end plate being fixedly connected to the surface of the pier.

[0033] Preferably, the foundation of the work site further includes multiple retaining blocks, which are linearly distributed on both sides of the platform;

[0034] The positioning component includes one or more wedge blocks, each of which is inserted between the stop block and the side mold;

[0035] The stop block pushes the edge of the side mold and the bottom mold to fit tightly together, forming the bottom edge of the precast component mold cavity, and there is no concrete leakage at the bottom edge.

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

[0037] Each of the support rods is disposed between the side mold and the platform. Each support rod consists 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 screws and the side mold. The bottom end of the support rod is fixedly connected to the surface of the platform.

[0038] The support rod pushes the edge of the side mold and the sliding mold to fit tightly together, forming the side edge of the precast component mold cavity, and there is no concrete leakage at the side edge.

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

[0040] Each of the positioning bolts is installed at the opening of the two side molds;

[0041] The positioning bolts limit the opening of the precast mold cavity, ensuring that the dimensions of the opening of the precast mold cavity are consistent.

[0042] Preferably, the vibrating component includes one or more vibrating motors, one or more mounting plates, one or more diffuser plates, one or more fastening bolts, one or more transmission rods, and one or more positioning rods;

[0043] Each vibration motor is mounted on the surface of a mounting plate, and each mounting plate surface is provided with multiple slots;

[0044] Each of the diffuser plates is welded to the surface of the side mold, and each of the conductive rods is welded to the surface of the diffuser plate, with one end of the conductive rod in contact with the surface of the mounting plate;

[0045] Each of the fastening bolts is installed on the surface of the side mold, and the fastening bolts are connected to the U-shaped opening on the surface of the mounting plate.

[0046] Preferably, the demolding component includes one or more ejection holes and one or more ejector bolts;

[0047] Each ejection hole is provided on the surface of the side mold and penetrates the inner wall of the side mold. Each ejection bolt is rotatably inserted into the ejection hole. The inner wall of each ejection hole is provided with a thread that meshes with the outer wall of the ejection bolt.

[0048] Preferably, the forming mold further includes one or more rebar placement mechanisms and rebar stretching components;

[0049] The rebar placement mechanism places the rebar, and the rebar tensioning component applies prestress to the rebar by tensioning it.

[0050] Preferably, in step S4:

[0051] The second locking components located inside the slip mold are in two sets. After the two sets of second locking components are locked onto the surface of the prestressed steel bars, the end faces of the second locking components abut against the inner walls on both sides of the slip mold.

[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 on the outside. The positioning components abut against the outside of the bottom end and the outside of the opening of the side mold. The positioning components push the side molds to abut against the edges of the bottom mold and the sliding mold, forming the edge of the precast mold cavity without concrete leakage.

[0054] Preferably, in step S5:

[0055] The concrete material is compacted using externally transmitted vibration.

[0056] Vibration components are installed on the outside of the side molds on both sides of the precast component mold cavity. The vibration generated by the vibration components is transmitted to the side molds, and the concrete material in the precast component mold cavity is compacted by the vibration of the side molds.

[0057] Preferably, in step S6:

[0058] The prestressed steel bar is cut off at the exposed ends of the first and second locking components to release the locking state of the first and second locking components and separate them from the prestressed steel bar.

[0059] Release the external force of the positioning component against the side mold, causing it to detach from the precast component, and then hoist and transfer the side mold;

[0060] Release the locking state of the two partitions by the pin, reduce the distance between the two partitions to form a sliding folding state until the prestressed steel bars are separated from the steel bar holes, transfer the two partitions, and then combine the two partitions again by the pins and hoist them as a whole for transfer.

[0061] Preferably, in step S7:

[0062] There are multiple bottom molds. After the sliding mold and side mold are hoisted and transferred, step S1 is repeated to form a production line in which multiple bottom molds share one or more sets of sliding molds and side molds to produce precast parts.

[0063] The precast concrete components produced by the production method of the precast concrete component mass production device have a concrete matrix with the same shape as the precast component mold cavity, prestressed steel bars running through the entire precast component, and stirrups distributed inside the precast component and fixedly tied to the prestressed steel bars.

[0064] Preferably, the partition plate is provided with conduit holes for placing conduits.

[0065] Preferably, the partition plate is provided with pre-embedded bolt holes for placing connecting bolts, and a pre-embedded bolt positioning sleeve for fixing connecting bolts is installed in the pre-embedded bolt holes through thread engagement.

[0066] The precast concrete components produced by the production method of the precast concrete component mass production device have a concrete matrix with the same shape as the precast component mold cavity, prestressed steel bars and wiring pipes running through the whole precast component, stirrups distributed inside the precast component and fixedly tied to the prestressed steel bars, and connecting bolts embedded at both ends of the precast component.

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

[0068] 1. By setting up a retractable slipform, this invention enables rapid separation between the slipform and the precast concrete without moving the precast concrete component, eliminates the influence of prestressed steel bars on slipform demolding, facilitates flexible scheduling of the slipform, saves labor and machinery operating costs, and also helps to improve production efficiency.

[0069] 2. By setting up flexibly adjustable sliding molds and side molds, this invention enables multiple production lines to share one or more sets of forming molds, which improves the flexibility of mold scheduling and reduces the steel materials required for mold manufacturing. Furthermore, the flexible scheduling of sliding molds and side molds can effectively increase the output and production efficiency of preforms. The scheduling can be uniformly carried out using overhead cranes, which is conducive to efficient and smooth operation between production lines. Attached Figure Description

[0070] Figure 1 This is a flowchart of the production method of the present invention;

[0071] Figure 2 This is a schematic diagram of the overall structure of the mass production device of the present invention;

[0072] Figure 3 This is a schematic diagram of the external structure of the molding die of the present invention;

[0073] Figure 4 This is an exploded structural diagram of the molding die components of the present invention;

[0074] Figure 5 This is a schematic diagram of the main cross-sectional structure of the molding die of the present invention;

[0075] Figure 6 This is a schematic diagram of the external structure of the end plate of the present invention;

[0076] Figure 7 This is a schematic diagram of the locking prestressed steel bar structure of the first locking component of the present invention;

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

[0078] Figure 9 This is a schematic diagram of the prestressed steel reinforcement structure for slipform installation according to the present invention;

[0079] Figure 10 This is a schematic diagram of the second locking assembly locking the prestressed steel reinforcement structure of the present invention;

[0080] Figure 11 This is an exploded view of the sliding mold component of the present invention;

[0081] Figure 12 This is a schematic diagram of the appearance and structure of the precast concrete component in Embodiment 1 of the present invention;

[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 block; 320. Support rod; 330. Positioning bolt;

[0099] 410. First locking assembly; 420. Second locking assembly;

[0100] 510. Vibration motor; 520. Mounting plate; 521. Slot; 530. Diffuser plate; 540. Fastening bolt; 550. Conducting rod; 560. Positioning rod;

[0101] 610. Unloading hole; 620. Ejector bolt;

[0102] 700, prestressed steel bars; 800, stirrups; 900, conduit; 1000, connecting bolts; 1100, concrete substrate. Detailed Implementation

[0103] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

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

[0105] For information on precast concrete mass production equipment, please refer to [link / reference]. Figures 2 to 19 This includes the foundation of the work site and one or more molding dies.

[0106] The work site foundation includes one or more platforms 110, with each set of molding molds set on the surface of the platform 110. The platform 110 is used to construct the foundation for multiple prefabricated component production lines.

[0107] Specifically, when there is one base platform 110, one set of molding molds is required; when there are multiple base platforms 110, two or more sets of molding molds are required.

[0108] By setting up one or more platforms 110 and one or more sets of forming dies, the scheduling flexibility between production lines is improved and the amount of steel used is reduced. Platform 110 serves as the foundation of the production line, and the forming dies can be flexibly arranged between platforms 110, achieving the effect of multiple production lines sharing a single set of dies. This effectively reduces the number of forming dies required, lowers steel usage, not only ensures production efficiency but also increases the scheduling flexibility between production lines, reducing enterprise investment costs.

[0109] In addition, multiple platforms are arranged in parallel, and overhead cranes can be used to schedule the molding dies in a unified manner, which can effectively reduce the scheduling chaos between production lines and facilitate efficient and smooth production operations.

[0110] Each molding die 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 base 110, the bottom mold 220 is disposed on the surface of the base 110, the two side molds 240 are respectively disposed on both sides of the base 110, and one or more sliding molds 230 are disposed between the two side molds 240. The two side molds 240 are connected to the end plates 210 by bolts.

[0111] Each end plate 210 and each slipform 230 has one or more rebar holes 250 on its surface.

[0112] Each sliding mold 230 includes two partitions 232 and one or more pins 231, each pin 231 being inserted into the connection between the two partitions 232. The sliding mold 230 has an unfolded state and a folded state.

[0113] Specifically, after the pin 231 disengages 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.

[0114] 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.

[0115] It is worth noting that when there is only one slip mold 230, the slip mold 230 divides the molding die into two molding chambers, which form two concrete bases 1100 after concrete pouring.

[0116] It is worth noting that when the sliding mold 230 is located in the middle of the forming mold, two concrete substrates 1100 of the same length are obtained. When the sliding mold 230 is located in the non-middle area of ​​the forming mold, two concrete substrates 1100 of different lengths are obtained.

[0117] Each side mold 240 consists of one or more sub-molds 241. The connection between each sub-mold 241 is made by bolts, and the connection between the two side molds 240 and the end plate 210 is made by bolts.

[0118] 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.

[0119] 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. The piers 120 are used to provide support for the end plates 210, ensuring that the end plates 210 will not tilt during the tensioning process of the prestressed steel bars 700, and ensuring that the edges of the concrete substrate 1100 are flat.

[0120] The work site foundation also includes multiple stops 130, which are linearly distributed on both sides of the platform 110. The positioning components include one or more wedge blocks 310, each wedge block 310 being inserted between the stop block 130 and the side mold 240.

[0121] The wedge block 310 can widen the gap between the side mold 240 and the stop block 130 by external force, which on the one hand ensures the stability of the side mold 240, and on the other hand ensures 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 precast component caused by concrete leakage.

[0122] The positioning component also includes one or more support rods 320. Each support rod 320 is disposed between the side mold 240 and the base 110. Each support rod 320 consists 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. The bottom end of the support rod 320 is fixedly connected to the surface of the base 110.

[0123] The support rod 320 is used to support the opening of the side mold 240, maintaining the stability of the side mold 240 and preventing it from tipping over. Furthermore, by adjusting the screws at both ends of the support rod 320, the overall length of the support rod 320 can be adjusted, facilitating the calibration of the flatness of the opening of the side mold 240 by the operators.

[0124] The positioning component also includes one or more positioning bolts 330, each positioning bolt 330 being installed at the opening of the two side molds 240.

[0125] The positioning bolts 330 are used to limit the distance between the openings of the two opposing side molds 240, preventing deformation of the side molds 240 during the pouring and solidification of concrete, and ensuring the forming effect of the concrete components.

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

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

[0128] Specifically, the prestressed steel bar 700 is divided into a fixed end and a tensioning end. When the first locking component 410 is set at the fixed end and the tensioning end, the locking plates face opposite directions.

[0129] Specifically, when the locking plate is located at the tensioning end, the ratchet in the locking plate rotates counterclockwise to release the tensioning motion of the prestressed steel bar 700. Conversely, the locking plate at the fixed end locks the prestressed steel bar 700 in the tensioning direction, thus fixing one end of the prestressed steel bar 700.

[0130] The locking component also includes one or more second locking components 420, each of which consists of one or more positioning elements. Each positioning element consists of a U-bolt, a locking plate, and two nuts. The two nuts are rotatably mounted on both ends of the U-bolt, and the locking plate is inserted inside the U-bolt.

[0131] Specifically, the second locking component 420 is used to position the sliding form 230. After the prestressed steel bar 700 is tensioned, the staff determines the position of the sliding form 230 and fixes it to the prestressed steel bar 700 through the second locking component 420, thereby limiting the movement of the sliding form 230 and achieving the effect of fixing the position of the sliding form 230. This prevents the sliding form 230 from shifting during the concrete pouring process and ensures that the dimensions of the concrete matrix 1100 meet the expected standards.

[0132] The vibrating components include 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.

[0133] Each vibration motor 510 is mounted on the surface of the mounting plate 520, and each mounting plate 520 has multiple slots 521 on its surface.

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

[0135] Each fastening bolt 540 is installed on the surface of the side mold 240, and the fastening bolt 540 is connected to the U-shaped opening on the surface of the mounting plate 520.

[0136] After the vibrating components are installed, the vibrating motor 510 operates and generates vibration. The vibration is transmitted to the transmission rod 550 through the mounting plate 520. The diffuser plate 530 can evenly diffuse the vibration transmitted by the transmission rod 550 to the side mold 240, thereby achieving the effect of vibrating and compacting the concrete in the forming mold and ensuring the quality of the precast concrete components.

[0137] The work site foundation also includes one or more power supply boxes 140, each power supply box 140 is located on one side of the platform 110, and the power supply box 140 is used to provide power to the vibrating components.

[0138] The work site foundation also includes a crane track 150, on which a hoisting crane travels, and the crane is used to meet the hoisting needs during the operation.

[0139] The demolding component includes one or more ejector holes 610 and one or more ejector bolts 620. Each ejector hole 610 is provided on the surface of the side mold 240 and the ejector hole 610 penetrates the inner wall of the side mold 240. Each ejector bolt 620 is rotatably inserted into the ejector hole 610. The inner wall of each ejector hole 610 is provided with threads that mesh with the outer wall of the ejector bolt 620.

[0140] After the concrete substrate 1100 is formed, the workers can release the positioning components, rotate the ejector bolts 620, and push out a gap between the side mold 240 and the concrete substrate 1100 to achieve the effect of rapid demolding.

[0141] 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 stretching components stretch the rebar to apply prestress.

[0142] Based on the above-mentioned precast concrete component mass production equipment, the following embodiments are proposed:

[0143] Example 1:

[0144] Please see Figure 1 The production method of precast concrete components includes the following steps:

[0145] S1: Sliding molds 230 are arranged at equal or non-equal intervals along the bottom mold 220.

[0146] S2: Arrange stirrups 800 and prestressed steel bars 700. The prestressed steel bars 700 pass through the inside of the stirrups 800, the end plate 210 and the steel bar holes 250 on the slipform 230 respectively.

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

[0148] The first locking component 410 locks one end of the prestressed steel bar 700, and the other set of first locking components 410 locks and fixes the stretched end of the prestressed steel bar 700 after the prestressed steel bar 700 is stretched.

[0149] After the first locking component 410 locks both ends of the prestressed steel bar 700, the end face of the first locking component 410 abuts against the surface of the end plate 210.

[0150] Specifically, the first locking assembly 410 consists of multiple locking parts. When the locking plate is located at the tensioning end, the ratchet in the locking plate rotates counterclockwise to release the tensioning motion of the prestressed steel bar 700. Conversely, the locking plate at the fixed end locks 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 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 together.

[0152] There are two sets of second locking components 420 located inside the slip 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 slip mold 230.

[0153] Specifically, the locking component also includes one or more second locking components 420. Each second locking component 420 consists of multiple positioning elements. Each positioning element consists of a U-bolt, a locking plate, and two nuts. The two nuts are rotatably installed at both ends of the U-bolt. The locking plate is inserted inside the U-bolt. By rotating the nuts along the U-bolt, the locking plate clamps the prestressed steel bar 700.

[0154] S5: Set up side molds 240, end plates 210, bottom molds 220, and sliding molds 230 to form independent precast component cavities with the side molds 240. Pour concrete into the precast component cavities, vibrate and compact it, and smooth the surface, waiting for the concrete to solidify.

[0155] Side molds 240 are respectively arranged on both sides of bottom mold 220. Positioning components are provided on the outside of side molds 240. The positioning components abut against the outside of the bottom end and the outside of the opening of side molds 240 respectively. The positioning components push the side molds 240 to abut against the edges of bottom mold 220 and sliding mold 230 to form a leak-free precast part cavity edge.

[0156] Specifically, by hammering a wedge-shaped block 310 between the side formwork 240 and the stop block 130, the gap between the side formwork 240 and the stop block 130 can be widened, and the inner wall of the side formwork 240 can be kept in contact with the bottom formwork 220 to prevent concrete leakage.

[0157] The stop block 130 pushes the edges 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.

[0158] The support rod 320 is used to support the opening of the side mold 240, maintaining the stability of the side mold 240 and preventing it from tipping over. Secondly, by adjusting the screws at both ends of the support rod 320, the overall length of the support rod 320 can be adjusted, facilitating the calibration of the flatness of the opening of the side mold 240 by workers. Furthermore, the support rod 320 pushes the edge of the side mold 240 to fit tightly against the edge of the sliding mold 230, forming the side edge of the precast component cavity, and preventing concrete leakage at the side edge.

[0159] The openings of the side molds 240 located on both sides of the bottom mold 220 are limited by the positioning bolts 330, forming a precast component cavity with no concrete leakage at the edges, preventing the side molds 240 from deforming during the pouring and solidification of concrete, and ensuring the molding effect of the concrete component.

[0160] It is worth noting that water can pass through the edge gaps of the precast component mold cavity, but concrete slurry cannot. That is, the edge gaps of the precast component mold cavity are between 0.1-0.2mm. This size of gap prevents the solid components in the concrete from passing through, thus ensuring the smoothness of the edges of the precast concrete component.

[0161] The concrete material is compacted using externally transmitted vibration.

[0162] Vibration components are installed 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.

[0163] Specifically, the mounting plate 520 is installed on the positioning rod 560 through the slot 521. After the vibrating component is installed, the vibrating motor 510 runs and generates vibration. The vibration is transmitted through the mounting plate 520 to the transmission rod 550. The diffuser plate 530 can evenly diffuse the vibration transmitted by the transmission rod 550 to the side mold 240. The side mold 240 transmits the vibration to the concrete, making the concrete compacted from the outside to the inside, and finally forming a dense concrete material.

[0164] S6: After the precast component is formed, the first locking component 410 and the second locking component 420 are released, the prestressed steel bars 700 connecting the precast components are cut off, the side mold 240 and the folding sliding mold 230 are separated, so that they are separated from the precast components respectively, and the precast components are left on the bottom mold 220 for subsequent curing.

[0165] The sliding mold 230 consists of two partition plates 232, which are staggered at the connection point and are movably connected with pins 231.

[0166] The portion of the prestressed steel bar 700 that exposes the ends of the first locking component 410 and the second locking component 420 is cut off, releasing the locking state of the first locking component 410 and the second locking component 420 and separating them from the prestressed steel bar 700.

[0167] Release the external force of the positioning component against the side mold 240, so that it is separated from the precast component, and then lift and move the side mold 240.

[0168] Specifically, the demolding process of the side mold 240 is as follows: rotate the ejector bolt 620 to create a gap between the side mold 240 and the concrete substrate 1100, thereby separating the side mold 240 from the surface of the concrete substrate 1100.

[0169] Release the locking state of the pin 231 between the two partitions 232, reduce the distance between the two partitions 232, form the sliding form 230 in a folded state until the prestressed steel bar 700 is separated from the steel bar hole 250, transfer the two partitions 232, and then combine the two partitions 232 again through the pin 231, and hoist and transfer the whole assembly.

[0170] S7: After the dismantled slip mold 230 is reassembled, it and the side mold 240 are respectively hoisted and transferred to the remaining idle bottom mold 220. Step S1 is repeated to rebuild the precast component production line and carry out continuous production operations.

[0171] It is worth noting that there are multiple bottom molds 220. After the sliding molds 230 and side molds 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 components. During mass production, multiple sets of sliding molds 230 and side molds 240 are uniformly scheduled through overhead cranes, which can ensure the flexibility and smoothness of scheduling between production lines, avoid production chaos, and reduce the input of human resources. Secondly, it saves steel consumption, that is, it is not necessary to equip each production line with complete molds, and it is not necessary to make a large number of duplicate molds. Only molds of different shapes need to be made for producing precast components of different shapes.

[0172] Please see Figure 11 and Figure 12 The precast concrete component produced by the above production method has a concrete matrix 1100 with the same shape as the precast component mold cavity, a prestressed steel bar 700 that runs through the entire precast component, and stirrups 800 that are distributed inside the precast component and fixedly tied to the prestressed steel bar 700.

[0173] Specifically, the length of the precast concrete components is 1-12 meters, the height is 2-3 meters, and the diameter of the prestressed steel bars is 4-8 mm.

[0174] Example 2:

[0175] Based on the content of Embodiment 1 above, another embodiment is proposed:

[0176] Please see Figures 21 to 23 Each end plate 210 and each sliding mold 230 has one or more conduit holes 260 on its surface.

[0177] The precast concrete component produced by the production method proposed in Example 1 has a concrete matrix 1100 with the same shape as the precast component mold cavity, a prestressed steel bar 700 that runs through the entire precast component, stirrups 800 that are distributed inside the precast component and fixedly tied to the prestressed steel bar 700, and a wiring conduit 900 for laying the line.

[0178] Example 3:

[0179] Based on the content of Embodiment 2 above, another embodiment is proposed:

[0180] Please see Figures 21 to 23 The partition plate 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 through thread engagement.

[0181] The precast concrete component produced by the production method proposed in Example 1 has a concrete matrix 1100 with the same shape as the precast component mold cavity, prestressed steel bars 700 and wiring pipes 900 penetrating 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.

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

[0183] Example 4:

[0184] Based on the content of Embodiment 3 above, another embodiment is proposed:

[0185] Please see Figures 21 to 23 Each end plate 210 has a clearance block 280 on one side surface and each sliding mold 230 has a clearance block 280 on both sides surface.

[0186] The precast concrete component produced by the production method proposed in Example 1 has a concrete matrix 1100 with the same shape as the precast component mold cavity, prestressed steel bars 700 and wiring pipes 900 penetrating 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.

[0187] Specifically, the precast concrete components are 1-12 meters long, 2-3 meters high, and have 700mm prestressed steel bars with a diameter of 4-8mm. The bottom ends of both sides of the precast components have notches for overlapping with other precast concrete components.

[0188] Example 5:

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

[0190] The compaction method involves using a concrete vibrator to compact the concrete.

[0191] Specifically, the concrete vibrator is inserted into the precast component cavity along the 240 opening of the side mold to vibrate evenly and continuously.

[0192] It is worth noting that during this process, the vibrating component of the vibrator can slide continuously along the opening of the side mold 240 to perform continuous vibration operation.

[0193] Example 6:

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

[0195] Please see Figure 24 The locking element in the first locking assembly 410 is replaced by a one-way locking mechanism consisting of a sleeve with a tapered port and two plugs.

[0196] Specifically, the prestressed steel bar 700 is inserted into a sleeve with a tapered end, and a plug is placed between the tapered end 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 tension end of the prestressed steel bar 700 is opposite to the direction of the fixed end. That is, after the tensioning of the prestressed steel bar 700 stops, the plug is inserted into the tapered port and hammered to fix the tensioning end of the prestressed steel bar 700 and prevent it from shrinking back.

[0198] Please see Figure 25 The positioning element in the second locking assembly 420 is replaced by a sleeve with a notch and a bolt that is rotatably inserted into the sleeve.

[0199] Specifically, the notch is used for the sleeve two to be flexibly engaged with the outside of the prestressed steel bar 700, and tightening the bolts will bring the prestressed steel bar 700 into contact with the inner wall of the sleeve two, thereby fixing the sleeve two to the surface of the prestressed steel bar 700.

[0200] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

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; The sliding mold (230) is composed of two partitions (232), and the connection between the two partitions (232) is staggered, and a pin (231) is movably inserted at the connection. 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); Each of the end plates (210) and each sliding mold (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 cavity. Pour concrete into the precast cavity, vibrate and compact it and smooth the surface, and wait for the concrete to solidify. S6: After the precast component is formed, it is cut off at the part of the prestressed steel bar (700) where the first locking component (410) and the second locking component (420) are exposed, thereby releasing the locking state of the first locking component (410) and the second locking component (420) and separating them from the prestressed steel bar (700); 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, release the external force resistance of the positioning component on the side mold (240) so that it is separated from the precast components, and hoist 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 the sliding form (230) in a folded state 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), hoist and transfer the whole, and leave the precast part on the bottom form (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: 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.

3. 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).

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 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 part mold cavity, and there is no concrete leakage at the bottom edge.

5. 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.

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 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.

7. The production method of the precast concrete component mass production device according to claim 1, characterized in that: The vibrating components include 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).

8. 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 ejection hole (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 ejection bolt (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).

9. 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.

10. 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 on 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).

11. The production method of the precast concrete component mass production device according to claim 10, 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 outside of the bottom end and the outside of the opening of the side molds (240). The positioning components push the side molds (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.

12. The production method of the precast concrete component mass production device according to claim 10, 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).

13. The production method of the precast concrete component mass production device according to claim 12, 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.

14. The precast concrete components produced by the production method of the precast concrete component mass production apparatus according to claim 13 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).

15. The production method of the precast concrete component mass production device according to claim 13, characterized in that: The partition (232) is provided with a conduit hole (260) for placing conduits.

16. 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 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.

17. The precast concrete components produced by the production method of the precast concrete component mass production apparatus according to claim 16 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) 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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