Concrete precast roof panel manufacturing apparatus and manufacturing process

Abstract

The present application relates to the technical fields of concrete prefabricated component preparation, and particularly relates to a concrete prefabricated roof panel preparation equipment and a preparation process, which comprises a track frame, an automatic material distribution mechanism, a PLC control system and a vibrating platform, the automatic material distribution mechanism is installed on the top guide rail of the track frame, and the vibrating platform is fixedly arranged at the bottom of the track frame, so that the technical problems that the conventional concrete prefabricated roof panel preparation equipment cannot flexibly adjust the positioning groove die according to the size of the prefabricated panel, lacks effective concrete bubble monitoring means, cannot master the internal bubble content of the concrete in real time, and is prone to cause quality defects such as honeycomb and pitted surface of the prefabricated roof panel are solved, through the setting of the automatic material distribution mechanism, the PLC control system, the vibrating platform, the variable frequency vibrating mechanism, the detachable positioning groove die, the baffle mechanism and the bubble monitoring mechanism, the integrated preparation equipment is formed, the mechanisms work cooperatively, and the high-quality preparation of the concrete prefabricated roof panel is realized.

Description

Technical Field

[0001] This invention relates to the field of precast concrete component preparation technology, and more particularly to equipment and process for preparing precast concrete roof panels. Background Technology

[0002] As one of the core components of prefabricated buildings, the quality of precast concrete roof panels directly affects the load-bearing capacity, waterproofing performance, and service life of the building roof. Currently, the industry commonly uses vibration platforms as the core equipment for the preparation of precast concrete roof panels. Their core function is to compact the concrete mixture through vibration, expel internal air bubbles, and ensure the quality of the roof panels. Related equipment and processes must comply with the basic specifications of GB / T 45972-2025 "Technical Requirements for Complete Sets of Equipment for the Production of Concrete Panels for Prefabricated Buildings".

[0003] In the vibration molding process of existing precast concrete roof panels, the vibration mechanism of existing equipment is mostly a single fixed-frequency vibration motor, which cannot be dynamically adjusted according to the thickness of the precast concrete roof panel, the reinforcement density, and the fluidity of the concrete mixture. This results in inconsistent concrete density at the edges, corners, and central areas of the roof panel, which easily leads to defects such as honeycomb, pitting, and cracks.

[0004] Existing Chinese patent publication number CN121200178A discloses a vibration platform for precast component casting, including a conveyor roller, a material box, a vibration platform, and several adjusting devices. The vibration platform is connected to the frame of the conveyor roller via an air spring. A rectangular through-hole is provided at the top of the vibration platform, and the adjusting device is located within the rectangular through-hole. The adjusting device includes a hydraulic cylinder and a U-shaped adjusting plate. The hydraulic cylinder drives the U-shaped adjusting plate to adjust the height of the material box. This invention achieves automatic adjustment of the material box's levelness through the coordinated control of the hydraulic cylinder-driven adjusting device and a displacement sensor. This structure ensures that the bottom surface of the material box is completely in contact with the vibration transmission surface of the vibration platform under any working condition, achieving uniform and efficient vibration energy transfer. This invention solves the technical problems of platform tilting and uneven material box contact caused by the nonlinear characteristics of the support device in existing vibration platforms, ensuring the uniformity and density of the cast material and effectively improving the quality of the precast components.

[0005] However, while the aforementioned invention patent addresses the issues of platform tilt and uneven material box contact through adjustment devices, thus improving the density of the poured concrete, it suffers from the following shortcomings: excessive vibration leads to aggregate segregation, while insufficient vibration prevents the effective removal of internal air bubbles; simultaneously, the vibration platform has poor shock absorption, and the impact force generated during vibration is easily transmitted to the equipment frame and surrounding environment, affecting the equipment's service life and operational safety; existing equipment positioning slot molds are mostly integral structures, making flexible adjustments impossible based on actual application conditions; edge retaining mechanisms are mostly non-adjustable structures, making precise matching with the positioning slot mold difficult, and there is a lack of effective concrete air bubble monitoring methods, making it impossible to monitor the air bubble content inside the concrete in real time, which can easily lead to quality defects such as honeycomb and pitting on the surface of precast roof panels. Summary of the Invention

[0006] Therefore, in response to the above problems, this invention proposes a precast concrete roof panel preparation equipment and process, which solves the technical problems of traditional precast concrete roof panel preparation equipment being unable to flexibly adjust the positioning groove mold according to the size of the precast panel, lacking effective means of monitoring concrete air bubbles, and being unable to grasp the content of air bubbles inside the concrete in real time, which easily leads to quality defects such as honeycomb and pitting on the surface of the precast roof panel.

[0007] To achieve the above objectives, the present invention adopts the following technical solution: including a track frame, an automatic material placement mechanism, a PLC control system, and a vibration platform. The automatic material placement mechanism is installed on the top guide rail of the track frame and can reciprocate along the guide rail direction. The vibration platform is fixed to the bottom of the track frame and is synchronously linked with the automatic material placement mechanism. The PLC control system is electrically connected to the automatic material placement mechanism and the vibration platform respectively.

[0008] The vibration platform includes a base, with shock-absorbing brackets at the corners of the base. A vibration table is installed on top of the base and is fixed to the base via the shock-absorbing brackets. A variable frequency vibration mechanism, which is a variable frequency vibration motor, is provided at the bottom of the vibration table and is installed on the four sides and the center area of ​​the bottom of the vibration table. A detachable positioning groove is provided on the surface of the vibration table, and a detachable edge-blocking mechanism is provided at the edge of the vibration table, located outside the positioning groove.

[0009] The positioning groove mold includes modular groove unit one and modular groove unit two. The two are quickly positioned and locked through dovetail groove and tenon structure. The modular groove unit one and modular groove unit two are provided in two sets and are installed end to end to form a rectangular frame structure.

[0010] The edge-blocking mechanism includes four edge-blocking plates arranged in a surrounding manner, which are respectively located on the four sides of the positioning groove mold. The edge-blocking plates are fixedly connected to the vibration table surface through reinforcing ribs. An air bubble monitoring mechanism for detecting air bubbles in concrete is also installed on the upper surface of the edge-blocking plates.

[0011] A space for accommodating concrete overflow is reserved between the positioning groove mold and the edge retaining mechanism.

[0012] Furthermore, the surface of the vibration table is provided with uniformly distributed ventilation holes, which are arranged in a quincunx pattern and adjacent rows of ventilation holes are staggered.

[0013] Furthermore, the frequency conversion vibration mechanism is also equipped with a vibration sensor.

[0014] Furthermore, both sides of the modular trough unit one are provided with groove frames for installing the modular trough unit two. The groove frames are provided with blind holes. The two ends of the modular trough unit two are provided with tenon plates that cooperate with the groove frames. The surface of the tenon plates is provided with threaded holes that cooperate with the blind holes. The tenon plates are connected to the groove frames by bolts. The outer surface of both the modular trough unit one and the modular trough unit two is provided with positioning blocks. The surface of the positioning blocks is provided with positioning screw holes that are arranged in a through manner.

[0015] The positioning slot mold also includes a positioning seat located on the outside of the side plate. The surface of the positioning seat is provided with a positioning screw that mates with the positioning screw hole and is locked and fixed by a nut. The positioning seat is fixedly installed to the vibration table surface with bolts.

[0016] Furthermore, the height of the modular trough unit one and the modular trough unit two is consistent with the thickness of the precast roof panel, and the inner side of the modular trough unit one and the modular trough unit two are both covered with an anti-adhesive layer.

[0017] Furthermore, the upper surface of the baffle plate is provided with an inwardly recessed groove, the surface of the groove is provided with a slidingly fitted adjusting support, the top of the adjusting support is equipped with a rotating seat, and the rotating seat is provided with an adjusting rod connected to the bubble monitoring mechanism.

[0018] Furthermore, the adjusting support is a telescopic adjusting rod, the rotating seat has a rotation angle of 360°, and is equipped with a rotation damping component;

[0019] The adjusting rod and the adjusting support are arranged perpendicularly to each other, and are used to realize the axial and radial adjustment of the bubble monitoring mechanism.

[0020] Furthermore, the bubble monitoring mechanism includes an ultrasonic bubble sensor and a display terminal.

[0021] Furthermore, the PLC control system is electrically connected to the frequency conversion vibration mechanism, the bubble monitoring mechanism, and the automatic fabric feeding mechanism, respectively.

[0022] Furthermore, the manufacturing process of the precast concrete roof panel manufacturing equipment includes the following steps:

[0023] S1: Check the secure connection of each component of the track frame, automatic material feeding mechanism, PLC control system and vibration platform. Start the self-test through the PLC control system, and adjust the linkage and coordination of each component to ensure that the automatic material feeding mechanism can move smoothly along the guide rail and move synchronously with the vibration platform. Check the reliability of the shock absorption bracket, adjust the frequency conversion vibration mechanism and vibration sensor, and clean the surface of the vibration table.

[0024] S2: Connect the two sets of modular trough unit one and modular trough unit two with the dovetail joint and the tenon structure, and tighten them with bolts to form a rectangular positioning trough mold, which can be detachably installed on the vibration table; install four side plates on its outside and fix them with reinforcing ribs, leaving space for concrete overflow; fix the positioning seat on the vibration table, and tighten the positioning trough mold again with positioning screws and nuts, and check the integrity of the inner anti-stick layer;

[0025] S3: Move the adjusting support along the slide groove on the side plate, and adjust its height, rotating seat, and adjusting rod to make the bubble monitoring mechanism accurately aligned with the positioning groove mold. Start the equipment debugging display terminal to ensure real-time bubble monitoring.

[0026] S4: Concrete Mixture Preparation PLC-linked automatic material spreading mechanism prepares concrete mixture with a water-cement ratio of 0.4-0.5 and a slump of 120-150mm, and adds waterproofing agent and air-entraining agent; the PLC control system is started to realize the synchronous linkage between the automatic material spreading mechanism and the vibration platform, and the material is evenly spread into the positioning groove mold. The material spreading height is 5-10mm higher than the design thickness of the roof panel, and the overflow material is temporarily stored in the overflow material receiving space.

[0027] S5: After the fabric is finished, the variable frequency vibration mechanism is started through the PLC control system, and the vibration parameters are dynamically adjusted according to the feedback of the vibration sensor; the air is discharged through the ventilation holes of the vibration table, and the vibration stops when the bubble content drops to the preset threshold, in conjunction with the bubble monitoring mechanism.

[0028] S6: Cure the concrete along with the positioning groove mold to the preset strength, turn off all equipment, remove the bubble monitoring related components, positioning seat, and side plate in sequence, loosen the bolts to separate the groove unit, and take out the precast roof panel.

[0029] S7: Clean up any residual concrete on each component, lubricate the connection points of the modular tank, reset and store the detachable components, turn off the main power supply to the equipment, and complete the single preparation.

[0030] By adopting the aforementioned technical solution, the beneficial effects of the present invention are:

[0031] This invention integrates an automatic material feeding mechanism, a PLC control system, a vibration platform, a variable frequency vibration mechanism, a detachable positioning groove mold, a side-blocking mechanism, and a bubble monitoring mechanism to form an integrated preparation equipment. The various mechanisms work together to achieve high-quality preparation of precast concrete roof panels.

[0032] Specifically, by utilizing the coordinated setup of various structures on the vibration platform, the vibration molding effect is optimized, reducing quality defects. The variable frequency vibration mechanism uses variable frequency vibration motors, which are reasonably distributed on the four sides and the bottom center area of ​​the vibration table. Combined with vibration sensors, the vibration parameters can be dynamically adjusted according to the characteristics of the concrete mixture, avoiding aggregate segregation caused by excessive vibration and air bubble residue caused by insufficient vibration. At the same time, the surface of the vibration table is provided with quincunx-shaped ventilation holes, which can help to expel air from inside the concrete. Combined with the air bubble monitoring mechanism, air bubble residue is further reduced, avoiding quality defects such as honeycomb and pitting on the surface of the precast roof panel.

[0033] Specifically, the positioning slot mold adopts a combination structure of modular slot unit one and modular slot unit two. It achieves rapid assembly and disassembly through dovetail grooves, tenon structures and bolt connections. The combination method can be flexibly adjusted according to different specifications and sizes of prefabricated roof panels, replacing the traditional integral slot mold and greatly improving the equipment's versatility. At the same time, the positioning slot mold is locked to the vibration table surface twice through positioning seats, positioning screws and positioning screws.

[0034] The edge-blocking mechanism and the positioning groove mold also have reserved space for accommodating overflow of concrete materials, which facilitates the subsequent recycling of the overflow. At the same time, the edge-blocking mechanism is set as a detachable structure, and the bubble monitoring mechanism set on the upper part is adjustable in both the axial and radial directions, which facilitates the monitoring of bubbles in the precast concrete roof panels, thereby improving the quality of the precast concrete roof panels, reducing molding deviations, and making disassembly and replacement convenient, shortening process time and improving production efficiency. Attached Figure Description

[0035] Figure 1 This is a schematic diagram of the structure of the precast concrete roof panel preparation equipment of the present invention;

[0036] Figure 2 This is a schematic diagram of the structure of the vibration platform of the present invention;

[0037] Figure 3 This is a schematic diagram of the positioning groove mold of the present invention. Figure 1 ;

[0038] Figure 4 This is a schematic diagram of the positioning groove mold of the present invention. Figure 2 ;

[0039] Figure 5This is a schematic diagram of the disassembled structure of the vibration platform of the present invention;

[0040] Figure 6 This is the present invention. Figure 5 A schematic diagram of the structure of A in the middle;

[0041] Figure 7 This is a schematic diagram of the edge-blocking mechanism of the present invention;

[0042] In the diagram: Track frame-1, Automatic material feeding mechanism-2, PLC control system-3, Vibration platform-4, Base-401, Shock absorber bracket-402, Vibration table-403, Variable frequency vibration mechanism-404, Positioning groove mold-405, Edge guard mechanism-406, Vent hole-4031, Modular groove unit one-4051, Modular groove unit two-4052, Tenon plate-4053, Groove frame-4054, Bolt-4055, Positioning block-4056, Positioning screw-4057, Nut-4058, Positioning seat-4059, Edge guard plate-4061, Slide groove-4062, Adjusting support column-4063, Rotating seat-4064, Adjusting rod-4065, Bubble monitoring mechanism-4066. Detailed Implementation

[0043] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments. Example

[0044] refer to Figure 1 - Figure 7 This embodiment provides a precast concrete roof panel preparation equipment, the structure of which includes a track frame 1, an automatic material placement mechanism 2, a PLC control system 3, and a vibration platform 4. The automatic material placement mechanism 2 is installed on the top guide rail of the track frame 1 and can reciprocate along the guide rail direction. The vibration platform 4 is fixed at the bottom of the track frame 1 and is synchronously linked with the automatic material placement mechanism 2. The PLC control system 3 is electrically connected to the automatic material placement mechanism 2 and the vibration platform 4 respectively.

[0045] The automated preparation of precast concrete roof panels is achieved through the coordinated work of the above components. Among them, the top guide rail of the track rack 1 is selected as a heavy-duty linear guide rail to ensure the stable movement of the automatic batching mechanism 2; the automatic batching mechanism 2 is installed on the top guide rail of the track rack 1 through a slider and can reciprocate along the guide rail direction. The moving speed can be adjusted within the range of 0.5 - 2 m / min. Its batching hopper has a volume of 2 m³ and is equipped with a spiral batching device to achieve uniform batching of concrete; the PLC control system 3 uses a Siemens S7-1200 series PLC controller and integrates a touch screen operation panel, which is electrically connected to the automatic batching mechanism 2 and the vibration platform 4 respectively, and can achieve the linkage control, parameter setting and fault alarm of each component; the vibration platform 4 is fixed at the bottom of the track rack 1 through expansion bolts and is synchronously linked with the automatic batching mechanism 2. That is, when the automatic batching mechanism 2 moves to the designated position, the vibration platform 4 starts synchronously and stops synchronously after batching is completed, ensuring the coordination of batching and vibration. The above PLC control system 3 can be specifically selected and used according to the actual application situation.

[0046] Furthermore, in order to improve the quality of the precast roof panel prepared by the vibration platform. In this application, the vibration platform 4 is provided, which includes a base 401. Shock-absorbing brackets 402 are provided at the corners of the base 401. A vibration tabletop 403 is installed above the base 401. The vibration tabletop 403 is fixedly connected to the base 401 through the shock-absorbing brackets 402. It should be noted that the shock-absorbing brackets 402 are spring shock absorbers; a variable-frequency vibration mechanism 404 is provided at the bottom of the vibration tabletop 403. The variable-frequency vibration mechanism 404 is a variable-frequency vibration motor and is respectively installed on the four sides and the bottom center area of the corresponding vibration tabletop 403. A detachable positioning groove mold 405 is provided on the surface of the vibration tabletop 403. A detachable edge blocking mechanism 406 is provided at the edge of the vibration tabletop 403 and is located outside the positioning groove mold 405;

[0047] The positioning groove mold 405 includes a modular groove body unit one 4051 and a modular groove body unit two 4052. The two are quickly positioned and locked through a dovetail groove and a tenon structure. There are two sets of the modular groove body unit one 4051 and the modular groove body unit two 4052, and they are installed end to end to form a rectangular frame structure, which is convenient for disassembly and replacement and adapts to the preparation requirements of precast roof panels of different sizes. Among them, the above modular groove body unit two 4052 is short strip-shaped, and the above modular groove body unit one 4051 is long strip-shaped.

[0048] Specifically, in the above structure, the modular groove body unit one 4051 and the modular groove body unit two 4052 can also be quickly positioned and locked through a buckle and a card slot structure. Specifically in use, the connection method between the two can be determined according to the actual application situation. The above modular groove body unit one 4051 and the modular groove body unit two 4052 can enclose to form a square or special-shaped frame structure to adapt to the preparation of special-shaped precast roof panels.

[0049] The edge-blocking mechanism 406 includes four edge-blocking plates 4061 arranged in a surrounding manner, which are respectively located on the four sides of the positioning groove mold 405. The edge-blocking plates 4061 are fixedly connected to the vibration table surface 403 through reinforcing ribs to ensure the stability of the edge-blocking plates 4061. The upper surface of the edge-blocking plates 4061 is also equipped with a bubble monitoring mechanism 4066 for detecting air bubbles in concrete.

[0050] A space for accommodating overflowing concrete is reserved between the positioning groove mold 405 and the edge retaining mechanism 406, which facilitates the centralized treatment of concrete materials overflowing after concrete pouring.

[0051] The vibrating table surface 403 has evenly distributed ventilation holes 4031. The ventilation holes 4031 are arranged in a quincunx pattern, and adjacent rows of ventilation holes are staggered. It should be noted that the diameter of the ventilation holes 4031 is 2-3 mm (preferably 2.5 mm in this embodiment), the hole spacing is 50-80 mm (preferably 60 mm in this embodiment), and the staggered arrangement of adjacent rows of ventilation holes is 30 mm. This is used to efficiently discharge air bubbles generated in the concrete mixture during vibration, and solve the problem of component defects caused by residual air bubbles in the prior art.

[0052] It should be noted that the variable frequency vibration mechanism 404 is a variable frequency vibration motor, which is installed on the four sides and the bottom center area of ​​the corresponding vibration table 403. The variable frequency vibration mechanism 404 is also equipped with vibration sensors. In this embodiment, each group of variable frequency vibration motors can also be connected to the vibration eccentric block via a flexible coupling. The flexible coupling is a plum blossom-shaped flexible coupling, and both ends of the coupling are connected to the motor output shaft and the eccentric block shaft respectively using a key (Type A flat key) to ensure smooth power transmission and buffer vibration impact. The vibration eccentric block adopts a fan-shaped structure, is made of 45# steel, and has undergone heat treatment. The eccentric block thickness is 20mm, and the eccentricity is adjustable (adjustment range 5—). The vibration amplitude is adjusted by changing the relative angle of the eccentric blocks (15mm) in conjunction with the frequency converter. The variable frequency vibration motor is electrically connected to the frequency converter, which is a Siemens MM440 series with a rated power matched to the motor and a frequency adjustment range of 0-60Hz. It allows for independent adjustment of vibration frequency (10-50Hz) and amplitude (0.5-3mm). The frequency converter is connected to the PLC control system via RS485 communication with a data transmission rate of 9600bps. It can dynamically adjust the vibration parameters of each area based on the thickness, reinforcement density, and flowability of the precast concrete roof panel, ensuring uniform concrete density across the roof panel. The vibration sensors are piezoelectric accelerometers, installed at the four corners of the bottom of the vibration platform. Insulating pads are placed between the sensors and the platform to prevent electromagnetic interference. It should be noted that the selection of these components can be made according to the actual application requirements.

[0053] Modular tank unit 1 4051 has groove frames 4054 on both sides for mounting modular tank unit 2 4052. The groove frames 4054 have blind holes. Modular tank unit 2 4052 has tenon plates 4053 that mate with the groove frames 4054 at both ends. The surface of the tenon plates 4053 has threaded holes that mate with the blind holes. The tenon plates 4053 and the groove frames 4054 are connected by bolts 4055. The outer surface of both modular tank unit 1 4051 and modular tank unit 2 4052 has positioning blocks 4056. The surface of the positioning blocks 4056 has positioning screw holes that are through-hole.

[0054] The positioning slot mold 405 also includes a positioning seat 4059 located outside the side plate 4061. The surface of the positioning seat 4059 is provided with a positioning screw 4057 that mates with the positioning screw hole and is locked and fixed by a nut 4058. The positioning seat 4059 is fixedly installed with the vibration table surface 403 by bolts to achieve secondary locking of the positioning slot mold 405 and prevent the positioning slot mold 405 from shifting during vibration.

[0055] In this embodiment, the positioning screw 4057 has an L-shaped structure with threaded patterns on the vertical end surface. The horizontal part is perpendicularly connected to the positioning seat 4059. The connection between the positioning screw 4057 and the positioning block 4056 can also be set as a quick-plug connection method, depending on the actual application.

[0056] The height of modular trough unit 1 (4051) and modular trough unit 2 (4052) is the same as the thickness of the precast roof panel. The inner side of both modular trough unit 1 (4051) and modular trough unit 2 (4052) is covered with an anti-adhesion layer, which can effectively prevent concrete from sticking to the trough unit and facilitate the demolding of the precast roof panel.

[0057] The upper surface of the baffle plate 4061 is provided with an inwardly recessed groove 4062. The surface of the groove 4062 is provided with a slidingly fitted adjusting support 4063. The lower surface of the adjusting support 4063 and the groove 4062 are detachably fitted and slidably fitted. The top of the adjusting support 4063 is equipped with a rotating seat 4064. The rotating seat 4064 is provided with an adjusting rod 4065 connected to the bubble monitoring mechanism 4066.

[0058] The adjusting support 4063 is a telescopic adjusting rod, the rotating seat 4064 has a rotation angle of 360° and is equipped with a rotation damping component; the adjusting rod 4065 is set perpendicular to the adjusting support 4063 and is used to realize the axial and radial adjustment of the bubble monitoring mechanism 4066 to ensure that the monitoring range covers the entire positioning groove mold 405.

[0059] The bubble monitoring mechanism 4066 includes an ultrasonic bubble sensor and a display terminal. By adjusting the various components of the edge-blocking mechanism 406, the bubble monitoring mechanism 4066 can move above the concrete and extend into its interior, thereby enabling real-time detection of the size and content of bubbles within the concrete. Specifically, the display terminal is integrated into the touchscreen of the PLC control system 3, displaying bubble monitoring data in real time and presetting a bubble content threshold (3% in this embodiment). In practical applications, the threshold can be set according to actual conditions. When the bubble content exceeds the threshold, the PLC control system 3 issues an alarm signal and automatically adjusts the vibration parameters of the frequency conversion vibration mechanism 404. The bubble monitoring mechanism 4066 described above can also include an ultrasonic bubble sensor and an audible and visual alarm, using the audible and visual alarm to issue an alarm signal, reminding operators to handle the situation promptly and avoid producing substandard products.

[0060] The PLC control system 3 is electrically connected to the frequency conversion vibration mechanism 404, the bubble monitoring mechanism 4066, and the automatic concrete placing mechanism 2. It should be noted that the PLC control system 3 can preset the moving speed, material quantity, and material placing path of the automatic concrete placing mechanism 2, controlling it to move smoothly along the guide rail and distribute material evenly. Simultaneously, the PLC control system 3 receives vibration parameters from the vibration sensor and bubble data from the bubble monitoring mechanism 4066, dynamically adjusting the vibration frequency and amplitude of the frequency conversion vibration mechanism 404 to ensure the concrete is vibrated and compacted, and that the bubble content meets requirements. When equipment malfunctions (such as uneven material distribution, abnormal vibration, or excessive bubbles), the PLC control system 3 promptly issues an alarm signal and automatically stops the operation of the relevant components, facilitating troubleshooting by operators.

[0061] In the above structure, the automatic material distribution mechanism 2 includes a material distribution guide rail, a moving material distribution hopper, and a flow regulating valve. The bottom of the material distribution hopper is conical to facilitate the discharge of concrete mixture. The moving material distribution hopper is driven by a servo motor and a ball screw to achieve precise movement, and the movement speed is adjustable. The flow regulating valve is located at the discharge port of the moving material distribution hopper and is a pneumatic butterfly valve. The valve opening and closing is controlled by a cylinder. The automatic material distribution mechanism is connected to the PLC control system and can preset material distribution parameters (moving speed, flow rate, material distribution path) according to the size of the vibration platform and the thickness of the precast concrete roof panel to achieve uniform material distribution with a material distribution uniformity error of ≤5%, avoiding the uneven material distribution problem caused by manual material distribution. At the same time, it works in conjunction with the vibration process. After the material distribution is completed, the vibration process is automatically triggered to improve production efficiency, which is different from the existing settings where material distribution and vibration are disconnected.

[0062] In this embodiment, through the coordinated arrangement of the above-mentioned structures, when in use, the tenon plates 4053 and groove frames 4054 at both ends of the modular trough unit 1 4051 and the modular trough unit 2 4052 are interlocked and reinforced with positioning screws 4057. The perimeter plates 4061 are sequentially installed on the periphery of the modular trough unit 1 4051 and the modular trough unit 2 4052. When each perimeter plate 4061 is installed, the positioning screws 4057 are simultaneously engaged and fixed with the positioning blocks 4056, and locked with nuts 4058. Then, the positioning seat 4059 is fixedly installed with the vibration table 403. This provides a secondary reinforcement for the modular trough unit 1 4051 and the modular trough unit 2 4052, preventing the modules from shifting or cracking due to vibration after concrete pouring, which would affect the quality of the subsequent precast concrete roof panels.

[0063] It should be noted that there is a reserved space for concrete overflow between the side plate 4061 and the modular trough unit 1 4051 and the modular trough unit 2 4052, which facilitates the subsequent recycling and reuse of concrete overflow.

[0064] Then, the adjustable bubble monitoring mechanism 4066 provided on the upper surface of the edge plate 4061, together with the rotating seat 4064, adjusting support column 4063, adjusting rod 4065 and slide 4062, can adjust the moving position of the bubble monitoring mechanism 4066 and its own axial and radial positions, so as to monitor the bubble situation of the precast concrete roof panel in real time.

[0065] The automatic material placement mechanism 2, under the control of the PLC control system 3, controls the concrete material to fall into the positioning groove mold 405 to prepare the precast concrete roof panel. Example

[0066] This embodiment provides a process for preparing precast concrete roof panels, using the precast concrete roof panel preparation equipment described in Embodiment 1, and includes the following steps:

[0067] S1: Check the firmness of the connections of each component, including the track frame 1, automatic material feeding mechanism 2, PLC control system 3, and vibration platform 4. Start the self-test through PLC control system 3, and adjust the linkage and coordination of each component to ensure that the automatic material feeding mechanism 2 can move smoothly along the guide rail and move synchronously with the vibration platform 4. Check the reliability of the shock absorption bracket 402, adjust the frequency conversion vibration mechanism 404 and vibration sensor, and clean the surface of the vibration table 403.

[0068] S2: Connect the two sets of modular trough unit 1 4051 and modular trough unit 2 4052 with the dovetail groove and the tenon structure, and lock them with bolts 4055 to form a rectangular positioning trough mold 405, which can be detachably installed on the vibration table 403; install four baffle plates 4061 on its periphery and fix them with reinforcing ribs, leaving space for concrete overflow; fix the positioning seat 4059 to the vibration table 403, and lock the positioning trough mold 405 a second time with positioning screws 4057 and nuts 4058, and check the integrity of the inner anti-adhesion layer;

[0069] S3: Move the adjusting support column 4063 along the slide groove 4062 on the side plate 4061, and adjust its height, rotating seat 4064, and adjusting rod 4065 so that the bubble monitoring mechanism 4066 is accurately aligned with the positioning slot mold 405. Start the equipment debugging display terminal to ensure real-time monitoring of bubbles.

[0070] S4: PLC-linked automatic material distribution mechanism 2 prepares concrete mixture with a water-cement ratio of 0.4-0.5 and a slump of 120-150mm, and adds waterproofing agent and air-entraining agent; the PLC control system is started to realize the synchronous linkage between the automatic material distribution mechanism 2 and the vibration platform 4, and the material is evenly distributed into the positioning groove mold 405. The material distribution height is 5-10mm higher than the design thickness of the roof panel, and the overflow material is temporarily stored in the overflow material receiving space.

[0071] S5: After the fabric is finished, the variable frequency vibration mechanism 404 is started by the PLC control system 3, and the vibration parameters are dynamically adjusted according to the feedback of the vibration sensor; the air is discharged through the ventilation hole 4031 of the vibration table 403, and the bubble monitoring mechanism 4066 monitors the air. The vibration stops when the bubble content drops to the preset threshold.

[0072] S6: Cure the concrete along with the positioning groove mold 405 to the preset strength, turn off all equipment, and remove the bubble monitoring related components, positioning seat 4059, and side plate 4061 in sequence. Loosen the bolts 4055 to separate the groove unit and take out the precast roof panel.

[0073] S7: Clean up any residual concrete on each component, lubricate the connection points of the modular tank, reset and store the detachable components, turn off the main power supply to the equipment, and complete the single preparation.

[0074] It should be noted that the specific placement of the embedded components of the precast concrete roof panel can be determined according to the actual application, and the placement process can be carried out in conjunction with existing technologies. Therefore, this embodiment will not be described in detail.

[0075] In this embodiment, an operation clearance notch is provided on the bottom or side wall of the positioning seat 4059. When the positioning seat 4059 is locked to the positioning block 4056 by the positioning screw 4057, the notch precisely avoids the locking bolt 4055 at the connection between modular groove unit 1 4051 and modular groove unit 2 4052. After unscrewing the positioning screw 4057 and removing the positioning seat 4059, the bolt 4055 connecting the groove unit is not obstructed, and the operator can directly disassemble it. In practical applications, the components between the positioning groove mold 405 and the edge retaining mechanism 406 do not interfere with each other during installation, enabling disassembly in step S6.

[0076] Although the invention has been specifically shown and described in conjunction with preferred embodiments, those skilled in the art should understand that various changes in form and detail may be made to the invention without departing from the spirit and scope of the invention as defined in the appended claims, all of which shall be within the scope of protection of the invention.

Claims

1. Equipment for preparing precast concrete roof panels, characterized in that, The system includes a track frame (1), an automatic material placement mechanism (2), a PLC control system (3), and a vibration platform (4). The automatic material placement mechanism (2) is installed on the top guide rail of the track frame (1) and can reciprocate along the guide rail. The vibration platform (4) is fixed at the bottom of the track frame (1) and is synchronously linked with the automatic material placement mechanism (2). The PLC control system (3) is electrically connected to the automatic material placement mechanism (2) and the vibration platform (4). The vibration platform (4) includes a base (401), a shock-absorbing bracket (402) is provided at the corner of the base (401), a vibration table (403) is installed on the top of the base (401), the vibration table (403) is fixedly connected to the base (401) through the shock-absorbing bracket (402), a frequency conversion vibration mechanism (404) is provided at the bottom of the vibration table (403), the frequency conversion vibration mechanism (404) is a frequency conversion vibration motor, and is respectively installed on the four sides and the bottom center area of ​​the corresponding vibration table (403), a detachable positioning groove mold (405) is provided on the surface of the vibration table (403), and a detachable edge guard mechanism (406) is provided on the edge of the vibration table (403), and is located outside the positioning groove mold (405); The positioning groove mold (405) includes modular groove unit one (4051) and modular groove unit two (4052). The two are quickly positioned and locked through dovetail groove and tenon structure. The modular groove unit one (4051) and modular groove unit two (4052) are provided in two sets and are installed end to end to form a rectangular frame structure. The edge-blocking mechanism (406) includes four edge-blocking plates (4061) arranged in a surrounding manner, and located on the four sides of the positioning groove mold (405). The edge-blocking plates (4061) are fixedly connected to the vibration table (403) by reinforcing ribs. The upper surface of the edge-blocking plates (4061) is also equipped with a bubble monitoring mechanism (4066) for detecting concrete bubbles. A space for accommodating concrete overflow is also reserved between the positioning groove mold (405) and the edge retaining mechanism (406); The vibration table (403) has evenly distributed ventilation holes (4031) on its surface. The ventilation holes (4031) are arranged in a plum blossom shape, and the adjacent rows of ventilation holes are staggered. The frequency conversion vibration mechanism (404) is also equipped with a vibration sensor.

2. The precast concrete roof panel preparation equipment according to claim 1, characterized in that: The first modular trough unit (4051) has groove frames (4054) on both sides for mounting the second modular trough unit (4052). The groove frames (4054) have blind holes. The second modular trough unit (4052) has tenon plates (4053) that mate with the groove frames (4054) at both ends. The surface of the tenon plates (4053) has threaded holes that mate with the blind holes. The tenon plates (4053) are connected to the groove frames (4054) by bolts (4055). The outer surfaces of the first modular trough unit (4051) and the second modular trough unit (4052) are each equipped with positioning blocks (4056). The surface of the positioning blocks (4056) has through-hole positioning screw holes. The positioning slot mold (405) also includes a positioning seat (4059) located outside the side plate (4061). The surface of the positioning seat (4059) is provided with a positioning screw (4057) that matches the positioning screw hole, and is locked and fixed by a nut (4058). The positioning seat (4059) is fixedly installed with the vibration table surface (403) by bolts.

3. The precast concrete roof panel preparation equipment according to claim 2, characterized in that: The height of the modular trough unit one (4051) and the modular trough unit two (4052) is the same as the thickness of the precast roof panel, and the inner side of the modular trough unit one (4051) and the modular trough unit two (4052) are both covered with an anti-adhesive layer.

4. The precast concrete roof panel preparation equipment according to claim 3, characterized in that: The upper surface of the baffle plate (4061) is provided with an inwardly recessed groove (4062), and the surface of the groove (4062) is provided with a slidingly fitted adjusting support (4063). A rotating seat (4064) is installed at the top of the adjusting support (4063), and an adjusting rod (4065) connected to the bubble monitoring mechanism (4066) is provided on the rotating seat (4064).

5. The precast concrete roof panel preparation equipment according to claim 4, characterized in that: The adjusting support (4063) is a telescopic adjusting rod, and the rotating seat (4064) has a rotation angle of 360° and is equipped with a rotation damping component; The adjusting rod (4065) and the adjusting support (4063) are arranged perpendicularly to each other to realize the axial and radial adjustment of the bubble monitoring mechanism (4066).

6. The precast concrete roof panel preparation equipment according to claim 1, characterized in that: The bubble monitoring mechanism (4066) includes an ultrasonic bubble sensor and a display terminal.

7. The precast concrete roof panel preparation equipment according to claim 1, characterized in that: The PLC control system (3) is electrically connected to the frequency conversion vibration mechanism (404), the bubble monitoring mechanism (4066), and the automatic fabric feeding mechanism (2), respectively.

8. A process for preparing precast concrete roof panels, used in the equipment for preparing the precast concrete roof panels as described in claim 4, characterized in that, Includes the following steps: S1: Check the connection of each component of the track frame (1), automatic material feeding mechanism (2), PLC control system (3) and vibration platform (4). Start the self-test through PLC control system (3), and adjust the linkage and coordination of each component to ensure that the automatic material feeding mechanism (2) can move smoothly along the guide rail and be synchronously linked with the vibration platform (4). Check the reliability of the shock absorption bracket (402), adjust the frequency conversion vibration mechanism (404) and vibration sensor, and clean the surface of the vibration table (403). S2: Connect the two sets of modular trough unit one (4051) and modular trough unit two (4052) with the dovetail groove and the tenon structure, and lock them with bolts (4055) to form a rectangular positioning trough mold (405), which can be detachably installed on the vibration table (403); install four side plates (4061) on its periphery and fix them with reinforcing ribs, leaving space for concrete overflow; fix the positioning seat (4059) on the vibration table (403), and lock the positioning trough mold (405) a second time with positioning screws (4057) and nuts (4058), and check the integrity of the inner anti-adhesion layer; S3: Move the adjusting support column (4063) along the slide groove (4062) on the side plate (4061), and adjust its height, rotating seat (4064), and adjusting rod (4065) so that the bubble monitoring mechanism (4066) is accurately aligned with the positioning slot mold (405). Start the equipment debugging display terminal to ensure real-time monitoring of bubbles. S4: PLC-linked automatic material distribution mechanism (2) for preparing concrete mixture with water-cement ratio of 0.4-0.5 and slump of 120-150mm, adding waterproofing agent and air-entraining agent; starting the PLC control system to realize the synchronous linkage between the automatic material distribution mechanism (2) and the vibration platform (4), uniformly distributing the material into the positioning groove mold (405), with the material distribution height being 5-10mm higher than the design thickness of the roof panel, and the overflow material being temporarily stored in the overflow material receiving space; S5: After the fabric is finished, the frequency conversion vibration mechanism (404) is started by the PLC control system (3), and the vibration parameters are dynamically adjusted according to the feedback of the vibration sensor; the air is discharged through the ventilation hole (4031) of the vibration table (403), and the bubble monitoring mechanism (4066) monitors it. The vibration stops when the bubble content drops to the preset threshold. S6: Cure the concrete along with the positioning groove mold (405) to the preset strength, shut down all equipment, and remove the bubble monitoring related components, positioning seat (4059), and side plate (4061) in sequence. Loosen the bolts (4055) to separate the groove unit and take out the precast roof panel. S7: Clean up any residual concrete on each component, lubricate the connection points of the modular tank, reset and store the detachable components, turn off the main power supply to the equipment, and complete the single preparation.

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