A smart low-carbon cement component casting and molding system

Abstract

This invention discloses an intelligent low-carbon cement component casting and molding system, including a mold opening and closing mechanism, a mold, a casting mechanism, and a control unit. The mold consists of two half-molds, each half-mold including a mold base and a module assembled from multiple replaceable modules. Each module integrates an independently controlled vibrator. The system can quickly reconstruct molding cavities of different shapes by replacing or reassembling modules, achieving mold flexibility and low-cost reuse. The control unit can independently and differentiate the vibration control of the vibrators of each module according to the three-dimensional model of the component, significantly improving the density and uniformity of the concrete. The mold base integrates a heating channel, which can utilize waste heat and other low-carbon heat sources for efficient curing, and is equipped with an exhaust channel to balance internal pressure. This invention features high production flexibility, excellent component quality, energy saving, and environmental protection, and is suitable for the intelligent production of various types of precast components.

Description

Technical Field

[0001] This invention belongs to the technical field of cement component casting equipment, specifically relating to an intelligent low-carbon cement component casting and molding system. Background Technology

[0002] Traditional precast component production typically employs integral steel molds designed for specific component shapes. While these molds offer good rigidity and high precision, they also have significant limitations: Firstly, their specialized nature means that once the product model changes, the original mold becomes obsolete or idle, resulting in high mold costs and significant warehousing pressure, making it difficult to adapt to the flexible production needs of multiple varieties and small batches. Secondly, in the vibration stage after casting, traditional molds often rely on a single vibrator attached to the outside of the mold for overall excitation, resulting in significant energy transfer losses. Furthermore, they cannot provide differentiated vibration for areas with varying thicknesses and reinforcement densities within the component, easily leading to uneven vibration, defects such as air bubbles and voids, and affecting the final mechanical properties and durability of the component.

[0003] Furthermore, existing curing processes often employ integrated steam curing kilns, which are energy-intensive, have low thermal efficiency, and are difficult to integrate efficiently with low-carbon energy sources such as waste heat from factories, thus failing to align with the development concept of green manufacturing. Although some modular or adjustable molds have been attempted in the industry, systematic solutions are still lacking in terms of achieving high-precision, high-reliability splicing and sealing, and in terms of deep integration with intelligent vibration and efficient, low-carbon curing processes.

[0004] Therefore, there is an urgent need to develop a precast component forming system that can simultaneously achieve rapid mold reconstruction and low-cost reuse, precise intelligent control of concrete vibration, and energy saving and consumption reduction in the curing process, thereby comprehensively improving the level of intelligence, economic benefits, and environmental benefits of precast component production. Summary of the Invention

[0005] To solve the above-mentioned technical problems, the present invention provides the following technical solution.

[0006] A smart low-carbon cement component casting and molding system includes a mold, a mold opening and closing mechanism, a casting mechanism, and a control unit.

[0007] The mold includes a pair of opposing half-molds. Each half-mold includes a mold base and a module assembly. The module assembly is composed of multiple independent modules. The mold base has a mounting cavity for accommodating the module assembly. One side of each module has a molding surface. The molding surfaces of all modules together form the molding cavity of the half-mold. Each module integrates a vibrator inside.

[0008] The mold opening and closing mechanism is used to drive the opening and closing of the two mold halves. The pouring mechanism is used to pour cement-based material into the complete molding cavity formed after the mold is closed. The control unit is communicatively connected to the vibrator of each module and is used to independently start and stop each vibrator and control the vibration parameters according to the pouring process.

[0009] Furthermore, the module is equipped with a sealing ring, and the sealing rings of adjacent modules are staggered along the thickness direction of the module to form at least two continuous sealing lines.

[0010] Furthermore, a heating flow channel is provided around the mounting cavity inside the mold base, and the mold base is provided with an inflow interface and an outflow interface communicating with the heating flow channel.

[0011] Furthermore, the module is a polygonal plate structure, which can form different shaped semi-cavity contours within the mounting cavity through different arrangements and combinations.

[0012] Furthermore, the module is square when viewed from above.

[0013] Furthermore, it also includes a spraying mechanism for spraying a release agent onto the molding surface of the module.

[0014] Furthermore, adjacent modules are positioned and connected by positioning pins, and the modules are fixed to the mounting cavity of the mold base by fasteners.

[0015] Furthermore, it also includes a truss and a ground rail, with the casting mechanism and spraying mechanism slidably mounted on the truss, and the mold opening and closing mechanism slidably mounted on the ground rail.

[0016] The intelligent low-carbon cement component casting and molding system provided in this application brings significant technical benefits through modular, intelligent, and integrated design, specifically in the following aspects:

[0017] 1. High mold versatility, significantly reducing mold costs: By decomposing the traditional integral mold into standardized mold bases and freely assembleable modular modules, the system can quickly reconstruct molding cavities of different shapes by simply replacing or rearranging some modules. This solves the pain points of large mold investment and large storage space when producing multiple varieties and small batches of precast components, realizing "one mold for multiple uses" and significantly reducing the total cost of ownership of molds.

[0018] 2. Differentiated vibration improves the density and uniformity of components: Each module integrates an independently controllable vibrator, which, combined with a control unit, allows for precise programmed control of the vibration area, timing, and intensity (frequency and amplitude). This system can implement differentiated and optimized vibration strategies for key areas such as thick cross-sections and densely reinforced areas of components, effectively eliminating air bubbles and voids, ensuring uniform concrete density, and thus improving the mechanical properties and durability of the components.

[0019] 3. Energy Saving and Environmental Protection: Compared to traditional methods of high-power, full-area vibration compaction of the entire mold, this system's distributed, independent vibration can precisely apply energy to areas requiring compaction, avoiding energy waste and achieving better compaction results while reducing power consumption. The heating channels integrated into the mold base can be connected to factory waste heat systems or low-carbon heat sources such as solar energy, enabling energy recycling. The channel heating method boasts high thermal efficiency and uniform, controllable temperature, significantly shortening the curing cycle and accelerating mold turnover. Attached Figure Description

[0020] Figure 1 This is a plan view of the casting and molding system.

[0021] Figure 2 This is a three-dimensional view of the casting and molding system.

[0022] Figure 3 This is a structural diagram of the casting mechanism.

[0023] Figure 4 This is a structural diagram of the spraying mechanism.

[0024] Figure 5 This is a 3D model of a half-model.

[0025] Figure 6 This is a structural diagram of the module.

[0026] Component name and part number:

[0027] 100. Mold opening and closing mechanism; 110. Sliding platform; 120. Drive module; 121. Fixing frame; 122. Mold frame; 123. Screw; 124. Screw sleeve; 125. Mold opening and closing motor;

[0028] 200. Mold; 210. Half mold; 211. Mold base; 212. Module; 213. Inlet port; 214. Outlet port; 220. Module; 221. Molding surface; 222. Vibrator; 223. Locating pin; 224. Fastener; 225. Sealing ring; 230. Sprue;

[0029] 300. Pouring mechanism; 310. Pouring moving module; 320. Pouring head;

[0030] 400. Spraying mechanism; 410. Spraying moving module; 420. Rotary cylinder; 430. Spraying head;

[0031] 500, ground rail; 600, truss. Detailed Implementation

[0032] The present invention will now be described in further detail with reference to the accompanying drawings and specific embodiments.

[0033] In the following embodiments, the same or similar reference numerals denote the same or similar components or components having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0034] In the description of this invention, it should be understood that terms such as center, longitudinal, transverse, length, width, thickness, upper, lower, front, rear, left, right, vertical, horizontal, top, bottom, inner, outer, clockwise, counterclockwise, etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing and simplifying the description of this invention; therefore, they should not be construed as limiting this invention. Furthermore, terms such as first, second, etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features shown. In the description of this invention, unless otherwise expressly specified and limited, terms such as installation, connection, linking, etc., should be interpreted broadly, and those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0035] refer to Figures 1 to 6 The intelligent low-carbon cement component casting and molding system provided in this application mainly includes a mold 200, a mold opening and closing mechanism 100, a casting mechanism 300, a spraying mechanism 400, and a control unit.

[0036] refer to Figure 5 and Figure 6 The mold 200 is the core of this system, consisting of a pair of opposing half-molds 210, each with a pouring port 230 facing the pouring mechanism 300. Each half-mold 210 includes a rigid mold base 211 and a module 212 assembled from multiple replaceable independent modules 220. The mold base 211 has a mounting cavity in the middle to accommodate the module 212. Each module 220 has a precision-machined forming surface 221 on one side, and the forming surfaces 221 of all modules 220 together form the forming half-cavity of the half-mold 210. This invention allows for rapid conversion and reconstruction of the mold 200 by replacing the corresponding modules 220, making it particularly suitable for producing cement components with only local structural differences within the same series. While ensuring the versatility of the mold 200, it significantly reduces production costs and changeover time.

[0037] Furthermore, a heating flow channel is prefabricated within the cavity surrounding the mold base 211, with an inlet port 213 and an outlet port 214 on its side for connecting to an external heat circulation system. Additionally, an exhaust channel is provided inside the mold base 211. One end of this exhaust channel connects to the external environment from the side wall or top of the mold base 211, while the other end passes through the mold base 211 and extends to the mounting cavity, connecting to the air passage on the back of the module 212, ultimately leading to the highest point of the molding half-cavity or an area prone to air accumulation. During the heating and curing process of the mold 200, the exhaust channel is used to smoothly discharge the water vapor generated during cement hydration, maintain pressure balance within the cavity, and prevent the formation of pores or surface defects in the component due to steam pressure buildup.

[0038] Furthermore, each module 220 is a polygonal plate structure, preferably square in this embodiment. This square design facilitates standardized production and inventory management of the module 220, reducing manufacturing and maintenance costs. In addition, the regular shape makes the machining of the sealing groove and the arrangement of the sealing ring 225 more uniform and reliable, which helps to ensure the effectiveness of the misaligned sealing structure.

[0039] Furthermore, each module 220 integrates a vibrator 222. When the module 220 is installed in the mold base 211, it is connected to the control unit (not shown in the figure) via an electrical connection interface, allowing each vibrator 222 to be controlled independently. The connection between modules 220 is precisely positioned by positioning pins 223 and fixed to the mold base 211 by fasteners 224. In terms of sealing, each module 220 has a groove on its side with an elastic sealing ring 225 embedded therein, and the sealing rings 225 of adjacent modules 220 are staggered in the direction perpendicular to the molding surface 221, thereby forming a multi-layer labyrinth-like sealing structure at the splicing interface, effectively preventing slurry leakage.

[0040] The mold opening and closing mechanism 100 is mounted on a set of ground rails 500 and can slide along the ground rails 500 as a whole. The mechanism includes a sliding platform 110 slidably connected to the ground rails 500, on which two sets of drive modules 120 are symmetrically mounted. Each drive module 120 includes a fixed frame 121 fixedly mounted on the sliding platform 110 and a mold frame 122 slidably connected to the platform via a linear guide rail. The half mold 210 in the mold 200 is fixedly mounted on the mold frame 122. The driving action is driven by the mold opening and closing motor 125 through a belt drive structure to drive the screw sleeve 124 on the fixed frame 121 to rotate. The screw sleeve 124 meshes with the screw 123 fixed on the mold frame 122, thereby converting the rotational motion into the precise linear motion of the screw 123 and the mold frame 122, realizing the mutual closing or opposite opening of the two half molds 210.

[0041] refer to Figure 3 and Figure 4Both the casting mechanism 300 and the spraying mechanism 400 are mounted on the truss 600 spanning the production line. The casting mechanism 300 includes a casting moving module 310 and a casting head 320 connected to its end. The spraying mechanism 400 includes a spraying moving module 410, the end of which is connected to a rotating cylinder 420, on which a spraying head 430 is mounted. The rotating cylinder 420 can drive the spraying head 430 to rotate, thereby enabling spraying operations on the inner cavities of the two open half-molds 210. Both the casting moving module 310 and the spraying moving module 410 are two-axis moving modules 212 that can move laterally and rise and fall along the truss 600. This is prior art, so its structure will not be described in detail here.

[0042] The system workflow is as follows: First, based on the 3D model of the component, the corresponding modules 220 are assembled in the mounting cavity of the mold base 211 to form the module 212 with the required contour and fixed. Next, the mold opening and closing mechanism 100 drives a pair of half-molds 210 to approach each other but not close. The spraying moving module 410 drives the spraying head 430 to enter between the half-molds 210, and the rotating cylinder 420 drives the spraying head 430 to rotate, spraying the mold release agent onto the forming cavity surface of the two half-molds 210 respectively. Subsequently, the mold opening and closing motor 125 drives the two half-molds 210 to close precisely. Then, the moving module 212 of the pouring mechanism 300 drives the pouring head 320 to move to the pouring port 230 and begin pouring concrete into the sealed cavity. At the same time, the central control system starts the intelligent vibration program based on the 3D model information of the component, independently controlling the vibrators 222 in different area modules 220 to vibrate according to the preset intensity, frequency and timing, realizing intelligent coordination between pouring and vibration. After pouring, a circulating heat medium is introduced through the heating channel in the mold base 211 to perform programmed heating and curing of the mold 200, accelerating cement solidification. After curing, the mold opening and closing mechanism 100 moves along the ground rail 500 to the demolding station, drives the half mold 210 to open, and the forming component is removed by the lifting device, completing the production cycle.

[0043] The scope of protection of this invention includes, but is not limited to, the above embodiments. The scope of protection of this invention is defined by the claims. Any substitutions, modifications, or improvements to this technology that are easily conceived by those skilled in the art fall within the scope of protection of this invention.

Claims

1. A system for casting and forming a smart low-carbon cement component, characterized in that, include: The mold (200) includes a pair of opposing half molds (210), each half mold (210) including a mold base (211) and a module (212), the module (212) being assembled from multiple independent modules (220), the mold base (211) having a mounting cavity for accommodating the module (212), one side of each module (220) having a molding surface (221), the molding surfaces (221) of all modules (220) together forming the molding half cavity of the half mold (210); each module (220) has a vibrator (222) integrated inside. A mold opening and closing mechanism (100) is used to drive the opening and closing of the two halves of the mold (210); A casting mechanism (300) is used to cast cement-based material into the complete molding cavity formed after mold closing; The control unit is communicatively connected to the vibrator (222) of each module (220) and is used to independently start and stop each vibrator (222) and control the vibration parameters according to the pouring process; The module (220) is equipped with a sealing ring (225), and the sealing rings (225) of adjacent modules (220) are staggered along the thickness direction of the module (212) to form at least two continuous sealing lines; adjacent modules (220) are positioned and connected by positioning pins (223), and the module (220) is fixed to the mounting cavity of the mold base (211) by fasteners (224).

2. The intelligent low-carbon cement component pouring forming system according to claim 1, characterized in that, A heating channel is provided around the mounting cavity inside the mold base (211), and the mold base (211) is provided with an inflow interface (213) and an outflow interface (214) that communicate with the heating channel.

3. The system as claimed in claim 1, wherein, The module (220) is a polygonal plate structure that can form different shaped semi-cavity contours in the mounting cavity through different arrangements and combinations.

4. The intelligent low-carbon cement component pouring forming system according to claim 3, characterized in that, The module (220) is square when viewed from above.

5. The system as claimed in claim 1, wherein, It also includes a spraying mechanism (400) for spraying a release agent onto the molding surface (221) of the module (212).

6. The system as claimed in claim 1, wherein, It also includes a truss (600) and a ground rail (500), the casting mechanism (300) and the spraying mechanism (400) are slidably mounted on the truss (600) respectively, and the mold opening and closing mechanism (100) is slidably mounted on the ground rail (500).

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