Building assembly type hollow wallboard forming machine and process thereof

Abstract

The building assembly type hollow wallboard forming machine comprises a forming machine rack and a forming template, a longitudinal walking driving device and walking wheels are designed at the bottom of the forming machine rack, and the longitudinal walking driving device drives the walking wheels to longitudinally walk back and forth on parallel transverse sliding rails; therefore, the forming machine rack moves back and forth in the longitudinal direction, and the template fixed on the forming machine rack is moved to the position of a set pouring wallboard; the forming template is a vertical and upright forming template; comprising a vertical upright large-surface template which is permanently fixed at the position of a forming area of a forming machine frame, side vertical upright side templates which are fixed on two sides of the forming machine frame, and a large-surface template which is used for paving an isolating membrane on a large board surface on one side of a wallboard produced in the previous batch or is fixed as required for producing a first wallboard, wherein the two vertical side molds are assembled and disassembled by the lateral side mold automatic assembling and disassembling device when the forming machine rack longitudinally moves to the position of a pouring wallboard. The fabricated wallboard is produced through vertical upright forming, the transfer workload of concrete wallboards in a field can be reduced, the occupied area of a workshop is greatly reduced, and the field production efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of hollow wall panel production technology, and in particular to a prefabricated hollow wall panel forming machine for buildings. Background Technology

[0002] Currently, the factory production of prefabricated wall panels generally adopts a moving flat mold production method. First, concrete is poured into a moving flat mold in the molding workshop, then transported to an initial curing area for about 24 hours, and then transferred to a curing workshop for at least 15 days before being shipped. If the wall panels cannot be shipped immediately, they also need to be transported to a storage workshop. While this wall panel production method has largely achieved industrialized production, it has the following shortcomings: First, the workshop area is particularly large, resulting in low site production efficiency, generally making it difficult to meet the large-scale, mass-production needs of construction projects. Second, the large-scale transportation of concrete components within the production site involves a significant workload and high energy consumption. Third, the labor intensity and labor costs remain high, naturally leading to relatively high production costs. Coupled with the inconvenience of in-site transportation and necessary off-site transport of large concrete components, this results in the current high price of prefabricated wall panels, which is the key reason why the cost of prefabricated buildings is higher than that of traditional buildings, making them difficult for the market to accept.

[0003] Another prefabricated wall panel production method is the multi-layer stacking method from the plane upwards. This method uses steel lifting formwork machinery. First, a ground formwork is used as the base formwork for the first wall panel, with movable, fixed templates as side formwork around it. After the reinforcing steel frame is placed, concrete is poured. After 24 hours, once the concrete reaches the strength for demolding, the four side templates are loosened, and the lifting formwork machine lifts the four side templates to the top of the first wall panel. The upper surface of the first wall panel serves as the base formwork for the second wall panel. The four side templates are then adjusted upwards to the height position for the second wall panel and fixed. The reinforcing steel frame is then placed, and concrete is poured again. This process is repeated, stacking the panels upwards, typically producing more than 15 wall panels. This method largely solves the problem of the large production area required by the current common method of using movable flat formwork for wall panel production. It saves space, reduces the workload of transporting concrete wall panels within the site, effectively improves the production efficiency of the production site, and to a certain extent enhances the ability to meet the large-scale production requirements of building construction projects. However, the following shortcomings exist: First, due to the large area of ​​each prefabricated wall panel, once the upper wall panels are cast, it is impossible to water and cure the previously produced bottom wall panels. This easily leads to the cast concrete burning due to insufficient water penetration, severely affecting the quality of the wall panels. Second, wall panels are generally produced one at a time, stacked every 24 hours. If 15 wall panels are stacked, it would take more than 15 days to produce. Furthermore, the last wall panel produced at the top requires at least 15 days of curing. Therefore, even if the bottom wall panel reaches its factory strength first, it will still be the last to be shipped. This prevents the "first to reach age, first to ship" principle; instead, it results in the "later to age, first to ship" and vice versa. Third, labor costs remain high, and the workers' workload is still significant. In summary, this not only fails to fully utilize the production efficiency of the production site and effectively reduce the labor intensity and labor costs, but also seriously affects the product quality of the wall panels due to the reversed product age. Summary of the Invention

[0004] This invention addresses the problems existing in the above two prefabricated wall panel production processes by proposing a prefabricated hollow wall panel forming machine. By producing prefabricated wall panels through vertical forming, the workload of transporting concrete wall panels on site can be reduced, the workshop area occupied can be greatly reduced, and the site production efficiency can be improved.

[0005] The technical solution adopted in this invention is: a prefabricated hollow wall panel forming machine, including a forming machine frame and a forming template. The bottom of the forming machine frame is designed with a longitudinal walking drive device and walking wheels. The longitudinal walking drive device drives the walking wheels to move longitudinally back and forth on a parallel transverse slide rail, thereby causing the forming machine frame to move longitudinally back and forth, moving the template fixed on the forming machine frame to the position for casting the wall panel. The forming template is a vertical forming template, including a large vertical template permanently fixed in the forming area of ​​the forming machine frame, side vertical templates fixed on both sides of the forming machine frame, and a large template with a release film laid on one side of a previously produced wall panel or fixed as required for the production of the first wall panel. When the forming machine frame moves longitudinally to the position for casting the wall panel, the two vertical templates are assembled and disassembled by an automatic side template assembly and disassembly device.

[0006] Multiple wall panel forming machines are arranged into a production line. Each production line is a single-row production line formed by multiple wall panel forming machines arranged in parallel, or a double-row or multi-row production line formed by multiple wall panel forming machines arranged in parallel.

[0007] The bottom of the molding machine frame is designed with a locking and fixing device that is opposite to the longitudinal direction of travel. After the molding template is in place at the production station, the locking and fixing device fixes and locks the three vertical templates to prevent the vertical templates from shifting and going out of shape when pouring concrete.

[0008] The production process of this invention is as follows: A permanently fixed, movable vertical large-face template and two vertical side templates are fixed on the frame of the molding machine. When producing the first wall panel, the wall panel molding machine is automatically moved to the position where the first wall panel is produced. A vertical large-face template on the other side of the first wall panel is cast is fixed on the opposite side of the permanently fixed vertical large-face template on the wall panel molding machine. Then, the reinforcing cage, along with the pre-inserted and fixed circular steel pipes and the bottom mold, is hoisted into the large-face template fixed on the other side. The large-face template and the two side templates permanently fixed on the molding machine frame are then adjusted to align with the first vertically erected template. The large formwork on the other side, which is fixed in place, is tightly assembled. After the four formworks are joined together, a cavity for pouring concrete is formed. Mechanical fixation is used, and at the same time, the steel cage, which has been placed inside the formwork, is vertically fixed in the cavity formed by the four formworks. The concrete pump is started to deliver concrete into the formwork cavity and vibrates it to make it compact. After the concrete reaches the demolding strength in 24 hours, several perforated circular steel pipes are pulled vertically upward from the top and sent to the steel cage, which has been placed in the pipe loading position of the wall panel forming machine, and arranged and fixed as required. Then, the wall panel forming machine automatically moves longitudinally to demold the wall panel. The solidified wall panel is then left to stand still at the forming station and is watered and covered for curing as usual until it reaches the required age before being loaded onto trucks and shipped out. Once the wall panel forming machine moves longitudinally away from the wall panel and reaches the working space, the production of the next wall panel in the next batch begins: First, a release film is applied to the surface of the solidified and demolded wall panel. Then, the reinforcing cage, which has been filled with perforated circular steel pipes, is hoisted into the working space of the wall panel forming area of ​​the wall panel forming machine, close to the large wall panel surface with the release film already applied. The wall panel forming machine is then started to return to its original position, allowing one large panel surface of the previous wall panel to close with the large template and side templates fixed on the wall panel forming machine, thus fixing the reinforcing cage within the cavity formed around one large wall panel surface and the three template surfaces. The concrete pump is then started to pour concrete and vibrate it to compact it. This process is repeated in a cycle, vertically stacking the already formed wall panels longitudinally in batches and according to the process on the wall panel production line.

[0009] Compared with the prior art, the present invention has the following advantages: This invention employs a vertical wall panel forming machine. Based on the wall panel production time of approximately 24 hours, wall panels are repeatedly stacked on one side of the large panel surface of the vertical wall panel forming machine along the length of the ground rail that moves longitudinally. Once the wall panels produced earlier reach their designated age, they can be loaded onto trucks and shipped out at any time at the production station. The order of shipment, from first to last reaching the designated age, is unrestricted, allowing for the infinite recycling of the production site and maximizing its production efficiency.

[0010] Compared to existing mobile flat mold wall panel forming machinery, this application perfectly combines the wall panel production forming workshop, initial curing workshop, static curing workshop, and finished product storage warehouse into one, requiring only one-quarter of the workshop (site) space needed for wall panel production using the mobile flat mold production method.

[0011] The wall panel production method of this application, which uses a vertical stacking method from a plane upward, not only significantly reduces the workshop space occupied by production, but also increases the utilization rate of the production site by more than 50% in terms of time occupied, enabling the production site to be kept constantly occupied and the production line can operate in an infinite cycle.

[0012] Compared to the planar upward vertical stacking method of production machinery, this application uses a vertically upright stacking method for automatic production of wall panels. The wall panels are formed by pulling tubes vertically upward. Although there are no gaps between the wall panel surfaces, water can be poured into the interior of the wall panels for curing through the vertical holes in the wall panels. This completely solves the problem of insufficient watering and curing of the wall panels, thereby ensuring the product quality of the wall panels.

[0013] Significantly reduced factory construction investment: ① Compared to mobile flat mold machinery production sites and workshops, it reduces site investment costs by 75% under the same production capacity premise. ② Compared to planar upward vertical stacking production machinery, it increases site utilization by 50% under the same production capacity premise, further reducing site investment costs.

[0014] Significantly reduced overall production costs: Compared with moving flat mold machinery and planar stacking production machinery, this application significantly improves production efficiency, minimizes labor consumption, and greatly reduces the overall cost of the wall panel production and forming process, thereby reducing the production cost of the entire wall panel production and forming process by more than 60%. Attached Figure Description

[0015] Figure 1 This is a structural schematic diagram of a prefabricated hollow wall panel forming machine according to the present invention; Figure 2 This is a schematic diagram of the arrangement of the forming templates in the wall panel forming machine of the present invention; In the diagram: 1 is the molding machine frame, 2 is the wall panel forming area of ​​the wall panel molding machine, 3 is the locking and fixing device, 4 is the traveling wheel, 5 is the parallel transverse slide rail, 6 is the longitudinal traveling drive device, 7 is the side mold, 8 is the vertical upright large surface template, and 9 is the automatic side mold assembly and disassembly device. Detailed Implementation

[0016] 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. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention are within the scope of protection of the present invention.

[0017] from Figure 1 , Figure 2 It is understood that the wall panel forming machine of the present invention includes a forming machine frame and a forming template. The bottom of the forming machine frame is designed with a longitudinal walking drive device and walking wheels. The longitudinal walking drive device drives the walking wheels to move longitudinally back and forth on a parallel transverse slide rail, thereby causing the forming machine frame to move longitudinally back and forth, moving the template fixed on the forming machine frame to the set position for casting the wall panel. The forming template is a vertical forming template, including a large vertical template permanently fixed in the forming area of ​​the forming machine frame, side vertical templates fixed on both sides of the forming machine frame, and a large template with a release film laid on one side of the wall panel produced in the previous batch or fixed as required for producing the first wall panel. When the forming machine frame moves longitudinally to the position for casting the wall panel, the two vertical templates are assembled and disassembled by an automatic side template assembly and disassembly device.

[0018] The bottom of the molding machine frame is designed with a locking and fixing device that is opposite to the longitudinal direction of movement. When the permanently fixed template on the molding machine frame is in place at the production station, the locking and fixing device fixes and locks the three vertical templates to prevent the vertical templates from shifting and moving during concrete pouring.

[0019] Multiple wall panel forming machines are arranged into a production line. Each production line is a single-row production line formed by multiple wall panel forming machines arranged in parallel, or a double-row or multi-row production line formed by multiple wall panel forming machines arranged in parallel.

[0020] The production process of this invention is as follows: A permanently fixed, movable vertical large-face template and two vertical side templates are fixed on the frame of the molding machine. When producing the first wall panel, the wall panel molding machine is automatically moved to the position where the first wall panel is produced. A vertical large-face template on the other side of the first wall panel is cast is fixed on the opposite side of the permanently fixed vertical large-face template on the wall panel molding machine. Then, the reinforcing cage, along with the pre-inserted and fixed circular steel pipes and the bottom mold, is hoisted into the large-face template fixed on the other side. The large-face template and the two side templates permanently fixed on the molding machine frame are then adjusted to align with the first vertically erected template. The large formwork on the other side, which is fixed in place, is tightly assembled. After the four formworks are joined together, a cavity for pouring concrete is formed. Mechanical fixation is used, and at the same time, the steel cage, which has been placed inside the formwork, is vertically fixed in the cavity formed by the four formworks. The concrete pump is started to deliver concrete into the formwork cavity and vibrates it to make it compact. After the concrete reaches the demolding strength in 24 hours, several perforated circular steel pipes are pulled vertically upward from the top and sent to the steel cage, which has been placed in the pipe loading position of the wall panel forming machine, and arranged and fixed as required. Then, the wall panel forming machine automatically moves longitudinally to demold the wall panel. The solidified wall panel is then left to stand still at the forming station and is watered and covered for curing as usual until it reaches the required age before being loaded onto trucks and shipped out. Once the wall panel forming machine moves longitudinally away from the wall panel and reaches the working space, the production of the next wall panel in the next batch begins: First, a release film is applied to the surface of the solidified and demolded wall panel. Then, the reinforcing cage, which has been filled with perforated circular steel pipes, is hoisted into the working space of the wall panel forming area of ​​the wall panel forming machine, close to the large wall panel surface with the release film already applied. The wall panel forming machine is then started to return to its original position, allowing one large panel surface of the previous wall panel to close with the large template and side templates fixed on the wall panel forming machine, thus fixing the reinforcing cage within the cavity formed around one large wall panel surface and the three template surfaces. The concrete pump is then started to pour concrete and vibrate it to compact it. This process is repeated in a cycle, vertically stacking the already formed wall panels longitudinally in batches and according to the process on the wall panel production line.

[0021] The specific steps for producing prefabricated hollow wall panels for buildings according to this invention are as follows: 1. Place the pre-processed steel cage in the steel cage loading area of ​​the wall panel forming machine, and feed the round steel pipes with holes in the wall panel into the steel cage, arranging and fixing them as required.

[0022] 2. Move the wall panel forming machine to the designated production operation space for the wall panel.

[0023] 3. Lay a release film on one side of the large panel of the wall panel that has been produced in the previous batch on the production line, or fix the large template of the first wall panel to be produced as required.

[0024] 4. Hoist the steel cage with the fixed perforated circular steel pipe and the base template to the forming station of the wall panel forming machine.

[0025] 5. Start the wall panel forming machine and move it longitudinally back to its original position, then press the permanent template fixed on the forming machine frame against the steel reinforcement cage.

[0026] 6. Adjust the bottom fastening and locking device of the wall panel forming machine, press the large mold fixed on the wall panel forming machine against the steel cage and accurately position it in the set position, and at the same time adjust and lock the side molds on both sides according to the mold installation requirements.

[0027] 7. Start the concrete pump to pour concrete into the forming template of the wall panel forming machine and vibrate it to compact it.

[0028] 8. After the concrete reaches a certain strength, water it for initial curing as needed.

[0029] 9. Generally, after 24 hours, the wall panel forming machine will start producing the next batch of wall panels, and the production operation will be carried out in a batch cycle.

[0030] 10. Finished wall panels that have been demolded and are stationary at the molding station should be cured by watering and covering them as usual. After reaching the required age for shipment, they should be loaded onto trucks and shipped out in sequence.

[0031] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of this patent should be determined by the appended claims.

Claims

1. A prefabricated hollow wall panel forming machine, comprising a forming machine frame and a forming template, characterized in that: The bottom of the molding machine frame is designed with a longitudinal walking drive device and walking wheels. The longitudinal walking drive device drives the walking wheels to move longitudinally back and forth on the parallel transverse slide rail, thereby causing the molding machine frame to move longitudinally back and forth, moving the template fixed on the molding machine frame to the position of the set casting wall panel. The molding template is a vertically upright molding template, including a large vertically upright template permanently fixed in the molding area of ​​the molding machine frame, side vertically upright side molds fixed on both sides of the molding machine frame, and a large template with a release film laid on one side of the wall panel produced in the previous batch or fixed as required for the production of the first wall panel. The two vertically upright side molds are installed and demolded by the side mold automatic installation and demolding device when the molding machine frame moves longitudinally to the position of the casting wall panel.

2. The prefabricated hollow wall panel forming machine according to claim 1, characterized in that: Multiple wall panel forming machines are arranged into a production line. Each production line is a single-row production line formed by multiple wall panel forming machines arranged in parallel, or a double-row or multi-row production line formed by multiple wall panel forming machines arranged in parallel.

3. The prefabricated hollow wall panel forming machine according to claim 1, characterized in that: The bottom of the molding machine frame is designed with a locking and fixing device that is opposite to the longitudinal direction of travel. After the molding template is in place at the production station, the locking and fixing device fixes and locks the three vertical templates to prevent the vertical templates from shifting and going out of shape when pouring concrete.

4. The process of a prefabricated hollow wall panel forming machine as described in any one of claims 13, characterized in that: A permanently fixed, movable vertical large-face template and two vertical side templates are fixed to the frame of the forming machine. When producing the first wall panel, the wall panel forming machine is automatically moved to the position for producing the first wall panel. A vertical large-face template for the other side of the first wall panel is fixed to the opposite side of the permanently fixed vertical large-face template on the forming machine. Then, the reinforcing cage, along with the pre-inserted and fixed circular steel pipes and the bottom mold, is hoisted into the large-face template fixed to the other side. The large-face template and the two side templates permanently fixed to the forming machine frame are then adjusted to align with the previously fixed vertical templates. One side of the large formwork is tightly assembled, and the four side formworks are joined together to form a cavity for pouring concrete. Mechanical fixation is used, and at the same time, the steel cage, which has been placed inside the formwork, is vertically fixed in the cavity formed by the four side formworks. The concrete pump is started to deliver concrete into the formwork cavity and vibrate it to make it compact. After the concrete reaches the demolding strength in 24 hours, several perforated circular steel pipes are pulled vertically upward from the top and sent to the steel cage, which has been placed in the pipe loading position of the wall panel forming machine, and arranged and fixed as required. Then, the wall panel forming machine automatically moves longitudinally to demold the wall panel. The solidified wall panel is then left to stand still at the forming station and is watered and covered for curing as usual until it reaches the required age before being loaded onto trucks and shipped out. Once the wall panel forming machine moves longitudinally away from the wall panel and reaches the operating space, the production of the next wall panel in the next batch begins: First, a release film is applied to the surface of the solidified and demolded wall panel. Then, the reinforcing cage, which has been filled with perforated circular steel pipes, is hoisted into the wall panel forming area of ​​the forming machine along with the bottom mold, close to the large wall panel surface with the release film applied. The forming machine is then started to return to its original position, allowing one large panel surface of the previous wall panel to close with the large template and side molds fixed on the forming machine. This fixes the reinforcing cage within the cavity formed by the large wall panel surface and the three template surfaces. The concrete pump is then started to pour concrete and vibrate it to compact it. This process is repeated in a cycle, vertically stacking the already formed wall panels longitudinally in batches according to the process flow on the wall panel production line.

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