A method for confirming parameters of a production line for producing an in-embed dam face permanent insulation template
By constructing a quantitative design system, the problem of mismatch between capacity and demand in production line design was solved, enabling precise capacity planning and system-level collaborative optimization, improving the foresight and robustness of the production line, and optimizing investment efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- 新疆水发建设集团有限公司
- Filing Date
- 2026-04-10
- Publication Date
- 2026-07-31
AI Technical Summary
Existing production line design methods lack systematic quantitative models, resulting in a mismatch between capacity and demand. This makes it impossible to ensure that the production line output matches the project requirements accurately, reliably, and economically in complex and dynamic engineering environments.
A quantitative design system centered on 'peak demand - effective capacity - process cycle time - production line layout - equipment collaboration' is constructed. By calculating the maximum permanent insulation area, the minimum guaranteed capacity of the production line per hour, the maximum allowable time for a single production process, and the length of the production line, the structure and program of the robot workstation are optimized to achieve system-level collaborative optimization.
It has achieved refined demand-side analysis, precise capacity planning, and system-level collaborative optimization, which has improved the foresight and robustness of production line planning, avoided capacity planning errors caused by misjudgment of demand, and optimized the overall investment efficiency.
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Abstract
Description
Technical Field
[0001] This invention relates to the field of permanent insulation board production technology for concrete surfaces, and in particular to a method for confirming the parameters of a production line for the production of embedded permanent insulation templates for dam surfaces. Background Technology
[0002] With increasingly stringent temperature control requirements for dams, and to prevent cracking caused by excessive temperature stress, as well as to extend the concrete pouring time during cold seasons, embedded permanent thermal insulation formwork for dam surfaces is a key functional component in modern high dam engineering construction in frigid regions. Embedded permanent thermal insulation formwork for dam surfaces has a complex structure, high assembly precision, and requires highly refined production process parameters. To ensure the safety, quality, and progress of the dam, the production capacity and quality of this structure must be reliable and stable. Therefore, automated production lines are often used to manufacture this formwork structure.
[0003] Therefore, the production line's capacity and reliability directly affect the progress of dam concrete pouring and the overall project quality. Dam construction has a long cycle, and the volume of concrete poured during peak and other periods differs significantly, resulting in noticeably different demands for insulation formwork. Considering factors such as production line construction costs and site occupancy, its capacity cannot be unlimitedly increased during the design phase. After long-term engineering practice and in-depth research, the inventors of this application have discovered that current methods for the preliminary planning and verification of production lines in this field have structural defects. The core problem lies in the lack of a consistent, unified quantitative logical chain, specifically manifested in several aspects: (1) The demand-side analysis is crude and lacks risk resistance: When determining production demand, existing methods usually only calculate based on the theoretical and static dam surface area, which seriously ignores the dynamic interference factors that inevitably exist in large-scale engineering projects. For example, design changes due to changes in geological conditions or structural optimization will significantly increase the actual insulation area; the concrete pouring strength is increased beyond expectations in order to catch up with the construction period; the effective construction window is shortened due to extreme weather events (such as unexpected flood season or severe cold), which requires the concentrated supply of insulation templates in a shorter period of time. These factors together cause the demand calculated based on static models to deviate significantly from reality, which creates the hidden danger of insufficient production capacity at the beginning of the construction of the production line.
[0004] (2) The capacity calculation model is seriously out of touch with engineering reality: Traditional capacity estimation simply divides the annual area by the annual theoretical working time, and the model is too idealistic. It fails to decouple and quantify the multiple independent factors affecting effective production time, such as seasonal shutdowns caused by climate, mandatory production restrictions caused by environmental protection policies, unplanned downtime caused by equipment failures, and the inherent loss of personnel efficiency in multi-shift rotation. This "one-size-fits-all" calculation method makes the calculated theoretical capacity unreliable as a basis for the hardware configuration of the production line.
[0005] (3) Disconnected design process and lack of system-level collaboration: In the current design process, production line layout, process time setting, robot selection and programming are often isolated steps that are sequential or parallel. For example, the design of robot workstations is usually based on the general performance parameters of equipment suppliers, without being strongly correlated with the target output takt time of the entire production line. This can easily lead to performance mismatch between various process units, forming a "barrel effect," where individual processes become bottlenecks, restricting the overall production capacity, while other processes have excess equipment capacity, resulting in wasted investment.
[0006] In summary, the fundamental problem with existing technologies lies in their fragmented and experience-based design paradigms, which cannot guarantee a precise, reliable, and economical match between production line output and project requirements in complex and dynamic engineering environments. This is precisely the core technical problem that this invention aims to solve. Summary of the Invention
[0007] This invention provides a method for confirming parameters of a production line for the production of embedded dam surface permanent thermal insulation templates, aiming to solve the problems mentioned in the background art, such as the existing production line design methods relying on isolated experience and lacking a systematic quantitative model, resulting in a mismatch between capacity and demand. The invention constructs a quantitative design system with "demand peak - effective capacity - process cycle time - production line layout - equipment coordination" as the core closed loop.
[0008] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: A method for confirming parameters of a production line for producing embedded dam surface permanent insulation templates, the parameters including the maximum permanent insulation area S. max Minimum hourly production capacity S of the production line min The maximum allowable time T0 for a single production process and the length L of the production line. 总 This includes the following steps: Step 1: Based on the dam shape drawing, design requirements, and concrete pouring plan, calculate the permanent insulation area of the dam surface for each year, S1, S2...S. i Further comparison yielded the maximum annual permanent insulation area S of this dam. max ; Step 2: Calculate the minimum per-hour production capacity S of the embedded insulation template production line based on the dam's maximum annual insulation area. min ; Step 3: Based on the minimum hourly production capacity S of the embedded thermal insulation template production line min Calculate the maximum allowable time T0 for a single production process; Step 4: Based on the minimum hourly production capacity S of the embedded thermal insulation template production line min The length L of the production line is calculated. 总 ; Step 5: Based on the above calculation results and on-site inspection, complete the production line design drawings according to the site shape and available effective area; Step 6: Based on the maximum allowable time T0 for a single production process, optimize the structure, program, and number of robots so that the time required for each robot in the multi-robot collaborative workstation to complete the task is ≤T0.
[0009] Preferably, in step 1, S max The calculations take into account design changes, increased concrete pouring volume, and the impact of extreme weather.
[0010] Preferably, in step 1, S max The specific calculation formula is as follows: S max =max ( ; In the formula: S max : This represents the maximum annual permanent insulation area of the dam, in square meters; : This is the dynamic construction interference coefficient, which is adjusted according to the design documents and is taken as 1.05~1.2; Risk reserve area, calculated as a percentage of the total annual area, ranging from 5% to 20%.
[0011] Preferably, the minimum hourly production capacity S of the production line in step 2 is... min The calculation formula is: ; In the formula: S max : This represents the maximum annual permanent insulation area of the dam, in square meters; S min To meet the dam's insulation and protection requirements, this production line must produce a minimum area of embedded permanent insulation templates for the dam surface per hour, measured in square meters.
[0012] K1: The annual effective working time coefficient of the project location, which is coupled with climate and policy. K2: The monthly effective working time coefficient of the production line, which is related to equipment reliability; K3: This is the efficiency coefficient for production line personnel, which is related to personnel configuration and the number of shifts.
[0013] Preferably, step 2 further includes the following steps: using Monte Carlo simulation to verify capacity and further quantify the impact of parameter uncertainty on capacity. First, K1, K2, and K3 are set as normal distributions, and their mean and standard deviation are determined. Then, 10,000 sets of random parameter combinations are generated to calculate the minimum capacity S that must be achieved per hour. min Finally, a 95% confidence interval is output to ensure the reliability of the production capacity and obtain the minimum configuration required when designing the production line.
[0014] Preferably, the formula for calculating the annual effective working time coefficient K1 of the project location in step 2 is as follows: ; In the formula: Calculated based on historical meteorological data, with values ranging from 0.6 to 1; Related to environmental protection and production restrictions, the value is taken as 0.9~1.0.
[0015] Preferably, the formula for calculating the monthly effective working time coefficient K2 of the production line in step 2 is as follows: ; In the formula: MTBF is the time between failures of the equipment included in the production line; MTTR is the mean time to repair faulty equipment, with a value ranging from 0.9 to 1.0.
[0016] Preferably, the formula for calculating the production line personnel efficiency coefficient K3 in step 2 is: ; In the formula: The personnel operation efficiency coefficient is 0.8 to 0.95.
[0017] Preferably, the formula for calculating the maximum allowable time T0 for a single production step in step 3 is: ; and ; In the formula: S min To meet the thermal insulation and protection requirements of the dam, this production line must produce a minimum area of embedded permanent thermal insulation templates for the dam surface per hour, in square meters. L: The length of a single embedded permanent thermal insulation template for the dam surface, in meters; W: Width of a single embedded permanent thermal insulation template for the dam surface, in meters; T0: The maximum allowable time for a single production process, in minutes; T1, T2...T n: The time required for each production process, in minutes.
[0018] Preferably, the formula for calculating the total length L of the production line in step 4 is:
[0019] In the formula: L: is the length of a single embedded permanent thermal insulation template for the dam surface, in meters; The safety distance factor for facilitating robot operation when the mold is arranged on the production line is 1.2 to 1.8, depending on the size of the robot. : This represents the layout type and efficiency coefficient. It is 1.0 when the site is spacious, 0.9 when it is a U-shaped design, and 0.8 when the site is narrow and designed as a runway or a ring. This refers to the turnover frequency of the template. This value is related to the curing time of the embedded thermal insulation template in the mold. When the ambient temperature is around 15℃, the curing time should not be less than 120 minutes; when the temperature is above 30℃, the curing time should not be less than 70 minutes.
[0020] In the formula: T 熟 The setting represents the ripening time, in minutes. T0: The maximum allowable time for a single production process, in minutes.
[0021] The beneficial effects of this invention are: This invention brings about significant technological advancements in the following aspects by constructing a novel and systematic quantitative verification method: (1) A demand peak calculation model based on "risk superposition" was proposed, which improved the precision of demand-side analysis. This was achieved by introducing the "dynamic construction interference coefficient θ" and the "risk reserve area S". reserve The dual correction mechanism dynamically amplifies the theoretical dam surface area and buffers risks. This model is the first to incorporate uncertainties in engineering design into production line demand analysis in a quantifiable way, fundamentally avoiding capacity planning errors caused by misjudgment of demand and improving the foresight and robustness of production line planning.
[0022] (2) An effective capacity calculation model based on "factor decoupling" was established, achieving precise capacity planning. This invention abandons the general efficiency coefficient and innovatively decouples the factors affecting production time into three independent dimensions: climate policy (K1), equipment reliability (K2), and human factors engineering (K3). For each dimension, a sub-model conforming to its physical or managerial laws was established (e.g., K2 adopts the "availability" model from reliability engineering). Finally, through S... min =S max This method integrates the clear logic of / (number of effective months per year × number of effective days per month × number of effective hours per day). This makes the capacity calculation process transparent, traceable, and adjustable, and the calculation results are closer to the actual output capacity under complex operating conditions.
[0023] (3) A reverse design logic of "production rate determines cycle time, and cycle time determines equipment" was established, achieving system-level collaborative optimization. The essence of this method lies in using the calculated minimum production capacity S min Using a single, common source, two key design boundaries were derived in parallel: a) the process limit cycle time T0; b) the theoretical production line length L. 总 Furthermore, by setting T0 as an inviolable "red line," a "goal-oriented" optimization design is forcibly driven for the structure, programs, and quantity of robot workstations. This "demand-driven" design logic ensures that the performance of all subsystems uniformly serves the final production capacity target, breaks down information silos in traditional design, achieves high-level synergy from the overall system to the parts, avoids performance redundancy or bottlenecks, and optimizes the overall investment efficiency.
[0024] (4) A probabilistic capacity verification method was introduced, providing confidence interval support for decision-making. As the preferred solution, Monte Carlo simulation was adopted, treating the key efficiency coefficients (K1, K2, K3) as random variables. Through tens of thousands of random sampling calculations, the final output S was obtained. min The 95% confidence interval. This elevates the "deterministic" design of production line capacity to a higher level of "probabilistic" risk assessment, providing decision-makers with more scientific and comprehensive data support when facing uncertainty. Detailed Implementation
[0025] As a preferred embodiment 1, a method for confirming the parameters of a production line for producing embedded dam surface permanent insulation templates includes the following parameters: maximum permanent insulation area Smax, minimum hourly production capacity Smin of the production line, maximum allowable time T0 for a single production process, and total length L of the production line. The method comprises the following steps: Step 1: Based on the dam shape drawing, design requirements, and concrete pouring plan, calculate the permanent insulation area of the dam surface for each year, S1, S2...S. iFurther comparison yielded the maximum annual permanent insulation area S of this dam. max ; Step 2: Calculate the minimum per-hour production capacity S of the embedded insulation template production line based on the dam's maximum annual insulation area. min ; Step 3: Based on the minimum hourly production capacity S of the embedded thermal insulation template production line min Calculate the maximum allowable time T0 for a single production process; Step 4: Based on the minimum hourly production capacity S of the embedded thermal insulation template production line min The length L of the production line is calculated. 总 ; Step 5: Based on the above calculation results and on-site inspection, complete the production line design drawings according to the site shape and available effective area; Step 6: Based on the maximum allowable time T0 for a single production process, optimize the structure, program, and number of robots so that the time required for each robot in the multi-robot collaborative workstation to complete the task is ≤T0.
[0026] Preferably, in step 1, S max The calculations take into account design changes, increased concrete pouring volume, and the impact of extreme weather.
[0027] Preferably, the specific formula for calculating Smax in step 1 is as follows: S max =max ( ; This formula means: First, for each year's planned insulation area... Multiply by a dynamic construction interference coefficient corresponding to that year. This is to amplify the potential risk of increased area in that year. Then, the area of all amplified years is calculated. Take the maximum value from the middle. Finally, add a risk reserve area on top of this. This yields a maximum annual area prediction that fully considers various risks throughout the entire construction period. and The relationship is a simple multiplication relationship, that is... .
[0028] For example, a high arch dam project in a high mountain canyon area has harsh climatic conditions and a short construction window.
[0029] Step 1: Determine the maximum annual permanent insulation area Smax Formula: S max =max
[0030] Step 1.1: Find the theoretical peak year According to the construction plan, the theoretical insulation area is largest in the third year: S3 = 38500m² 2 Step 1.2: Apply dynamic construction interference coefficient
[0031] The third year is crucial for the arch dam's sealing, as the concrete pouring intensity is at its highest. Design changes and adjustments to the construction plan are highly likely, leading to an increase in the actual area. Therefore, we have chosen a year with a higher risk factor. =1.18.
[0032] Calculate the enlarged area: S3× =38500m 2 ×1.18=45430m 2 Assuming S is calculated in other years i × All less than 45430m 2 Therefore: max(S) i × )=45430m 2 Step 1.3: Increase the area of risk reserve ( ) Technical rationale: Considering unknown risks such as extreme weather (e.g., exceptionally long rainy seasons), an additional buffer is needed. For such high-risk projects, 15% of the annual theoretical area S3 is allocated as a reserve.
[0033] Calculate the reserve area: =38500m 2 ×15%=38500×0.15=5775m 2 Step 1.4: Calculate S max S max =max(S i × )+ =45430m 2 +5775m 2 =51205m 2 After risk correction, the production line must be able to handle a maximum annual insulation area of 51,205 square meters.
[0034] In the formula: S max : This represents the maximum annual permanent insulation area of the dam, in m². 2 ; : This is the dynamic construction interference coefficient, which is adjusted according to the design documents and is taken as 1.05~1.2; Risk reserve area, calculated as a percentage of the total annual area, ranging from 5% to 20%.
[0035] Preferably, the minimum hourly production capacity S of the production line in step 2 is... min The calculation formula is: ; This formula is a model that converts "total annual demand area" into "minimum hourly capacity". The logic is: Annual demand area (S max ) ÷ Annual effective production hours = Hourly production capacity.
[0036] : Indicates "number of effective months per year". 12 months × annual effective working time coefficient (Taking into account both work stoppages caused by climate and policy), this gives the number of months that can actually be worked in a year.
[0037] : Indicates "monthly effective days". 30 days × monthly effective working time coefficient (This includes downtime caused by equipment failure), which gives the actual number of working days in a month.
[0038] : Indicates "effective hours per day". 24 hours × personnel efficiency coefficient (Taking into account shift work and staff rest), the actual effective production hours in a day are obtained.
[0039] Therefore, the denominator The result is the "annual effective production hours".
[0040] In the formula: S max : This represents the maximum annual permanent insulation area of the dam, in m². 2 ; S min To meet the dam's thermal insulation and protection requirements, this production line must produce a minimum area (in m²) of embedded permanent thermal insulation templates for the dam surface per hour. 2 .
[0041] K1: The annual effective working time coefficient of the project location, which is coupled with climate and policy. K2: The monthly effective working time coefficient of the production line, which is related to equipment reliability; K3: This is the efficiency coefficient for production line personnel, which is related to personnel configuration and the number of shifts.
[0042] Preferably, the formula for calculating the annual effective working time coefficient K1 of the project location in step 2 is as follows: ; Taking a region in northwestern Xinjiang, my country as an example, we calculate the annual effective work coefficient, monthly effective work coefficient, and personnel efficiency coefficient.
[0043] Step 2.1: Calculate the annual effective working coefficient
[0044] formula:
[0045] calculate (Climate Impact Coefficient): Historical data shows that the lowest winter temperature in this region can reach -45℃, with a long period of low temperatures, and an average of 78 days a year when operations are impossible due to the weather.
[0046] =(365 days - 78 days) / 365 days = 287 / 365 ≈ 0.786 calculate (Policy Impact Coefficient): Environmental protection-related production restrictions are expected to result in 30 days of work stoppage.
[0047] =(365 days - 3 days) / 365 days = 335 / 365 ≈ 0.918 calculate : =0.786 × 0.918 ≈ 0.721 Calculations show that production can only be carried out legally and appropriately for about 72.1% of the time each year in this region.
[0048] In the formula: Calculated based on historical meteorological data, with values ranging from 0.6 to 1; Related to environmental protection and production restrictions, the value is taken as 0.9~1.0.
[0049] Preferably, the formula for calculating the monthly effective working time coefficient K2 of the production line in step 2 is as follows: ; Step 2.2: Calculate the monthly effective working factor
[0050] Formula (Equipment Availability):
[0051] Substituting the equipment reliability data: Mean Time Between Failures (MTBF) = 420 hours, Mean Time To Repair (MTTR) = 6 hours. The above equipment mainly refers to the polyurethane high-pressure equipment, air compressor, industrial robot, automated mold and trolley used in the production of embedded dam surface permanent insulation template. These data were selected based on the data summarized during the actual trial production and debugging process.
[0052] calculate : =1-[6 / (420+6)]=1-(6 / 426)≈1-0.01408≈0.986, which shows that the equipment is available 98.6% of the time on workable days.
[0053] In the formula: MTBF is the time between failures of the equipment included in the production line; MTTR is the mean time to repair faulty equipment, with a value ranging from 0.9 to 1.0.
[0054] Preferably, the formula for calculating the production line personnel efficiency coefficient K3 in step 2 is: ; Step 2.3: Calculate the personnel efficiency coefficient
[0055] formula: =
[0056] Determined time data: Theoretical shift time (three shifts): 24 hours / day; Actual shift time (excluding shift handover and meal breaks): 22.5 hours / day Determine the personnel efficiency coefficient: =0.88 (This is an empirical value based on industrial engineering assessment, taking into account factors such as fatigue and short rest periods, as well as the skill level of workers in northern Xinjiang.) calculate : =(22.5 / 24)×0.88=0.9375×0.88=0.825. The calculation shows that, within the available equipment time, personnel effectively utilize only 82.5% of the time.
[0057] In the formula: The personnel operation efficiency coefficient is 0.8 to 0.95.
[0058] Step 2.4: Calculate the annual effective production hours Number of valid months per year = 12 months × =12 × 0.721 = 8.652 months Monthly valid days = 30 days × =30 × 0.986 = 29.58 days Daily effective hours = 24 hours × =24 × 0.825 = 19.8 hours Annual effective production hours = 8.652 months × 29.58 days / month × 19.8 hours / day ≈ 5,065 hours Calculations show that although there are 365 days in a year, after taking into account the region's climate, policies, equipment, and personnel, the actual time available for production is only equivalent to 5,065 consecutive hours.
[0059] Step 2.5: Calculation
[0060] = / Annual effective production hours = 51205㎡ / 5065h ≈ 10.11m 2 / h The production line must produce at least 10.11 square meters of qualified insulation templates per hour to meet the demanding requirements of the dam construction in the most critical years.
[0061] Preferably, the formula for calculating the maximum allowable time T0 for a single production step in step 3 is: ; and ; In the formula: S min To meet the dam's thermal insulation and protection requirements, this production line must produce a minimum area (in m²) of embedded permanent thermal insulation templates for the dam surface per hour. 2 ; L: The length of a single embedded permanent thermal insulation template for the dam surface, in meters; W: Width of a single embedded permanent thermal insulation template for the dam surface, in meters; T0: The maximum allowable time for a single production process, in minutes; T1, T2...T n : The time required for each production process, in minutes.
[0062] Step 3: Calculate the maximum allowable time for a single operation.
[0063] According to the production process of embedded dam surface permanent insulation template =Available time per hour / Template area to be produced per hour formula:
[0064] Step 3.1: Determine the area of a single template piece The actual dimensions of the embedded permanent thermal insulation formwork for the dam surface are: length L = 1.2m, width W = 1.0m. Area of a single template: L×W=1.2m×1.0m=1.2m 2 Step 3.2: Calculate the number of templates to be produced per hour. Number of templates to be produced per hour = / Area of a single template = (10.11m²) 2 / h) / (1.2m 2 / block) = 8.425 blocks / h Step 3.3: Calculate the limiting beat
[0065] =60 minutes / 8.425 pieces ≈ 7.12 minutes / piece On the entire production line, the time spent on any production process (such as cleaning, assembly, mold placement, pouring, and mold removal) must not exceed 7.12 minutes; otherwise, the entire line's capacity will not meet the minimum requirement. This value is a rigid constraint for all equipment selection and process optimization.
[0066] Preferably, the length L of the production line in step 4 总 The calculation formula is:
[0067] In the formula: L: is the length of a single embedded permanent thermal insulation template for the dam surface, in meters; The safety distance factor for facilitating robot operation when the mold is arranged on the production line is 1.2 to 1.8, depending on the size of the robot. : This represents the layout type and efficiency coefficient. It is 1.0 when the site is spacious, 0.9 when it is a U-shaped design, and 0.8 when the site is narrow and designed as a runway or a ring.
[0068] This refers to the turnover frequency of the template. This value is related to the curing time of the embedded thermal insulation template in the mold. When the ambient temperature is around 15℃, the curing time should not be less than 120 minutes; when the temperature is above 30℃, the curing time should not be less than 70 minutes.
[0069] As a preferred embodiment 2, step 2 further includes the following steps: using Monte Carlo simulation to verify production capacity and further quantify the impact of parameter uncertainty on production capacity. First, K1, K2, and K3 are set as normal distributions, and their mean and standard deviation are determined. Then, 10,000 sets of random parameter combinations are generated to calculate the minimum production capacity S that must be achieved per hour. min Finally, a 95% confidence interval is output to ensure the reliability of the production capacity and obtain the minimum configuration required when designing the production line.
[0070] As a preferred embodiment 3, step 4: calculate the theoretical length of the production line.
[0071] =Layout coefficient × Safety factor × (Total template length corresponding to hourly production capacity) formula:
[0072] Step 4.1: Calculate the total template flow length required to meet production capacity. When the embedded dam surface permanent insulation formwork is produced using a circular assembly line operation, the formwork is connected end to end in order to achieve a certain production capacity per hour. The production capacity, the total length of templates that the production line needs to accommodate simultaneously.
[0073] calculate: / L=(10.11m 2 / h) / (1.2m) = 8.425m / h Step 4.2: Apply the safety distance coefficient
[0074] The production of embedded dam surface permanent insulation templates is carried out using large industrial robots. Therefore, gaps must be left between the molds to allow for the safe operation of the robot arm and for operator inspection and maintenance.
[0075] Select large robots, take =1.8. This means that the length occupied by each workstation is 1.8 times the length of the template itself.
[0076] calculate: ×( / L)=1.4×8.425≈11.795 meters Step 4.3: Apply layout type and efficiency coefficient ω This embodiment takes into account the limited space and adopts a U-shaped layout. Although the U-shaped line saves space, the material flow efficiency is lower than that of the straight line, and a longer line is required to achieve the same production capacity.
[0077] The U-shaped layout coefficient ω is set to 0.9.
[0078] Step 4.4: Mold Turnover Frequency
[0079] Because the average annual temperature in northern Xinjiang is relatively low, calculations are based on an ambient temperature of 15℃. The integer value is 17. calculate : =ω×[ ×( / L)]× =0.9×11.795 meters×17≈200.515 meters After considering the U-shaped layout and robot safety space, the requirement of 10.11m is met. 2 The theoretical minimum length of the production line required for a capacity of [number] h is approximately 200.515 meters. During detailed design, all equipment must be arranged within this length range.
Claims
1. A method for confirming parameters of a production line used in the production of embedded dam surface permanent thermal insulation templates, characterized in that, Includes the following steps: Step 1: Based on the dam shape drawing, design requirements, and concrete pouring plan, calculate the permanent insulation area of the dam surface for each year, S1, S2...S. i Further comparison yielded the maximum annual permanent insulation area S of this dam. max ; Step 2: Calculate the minimum per-hour production capacity S of the embedded insulation template production line based on the dam's maximum annual insulation area. min ; Step 3: Based on the minimum hourly production capacity S of the embedded thermal insulation template production line min Calculate the maximum allowable time T0 for a single production process; Step 4: Based on the minimum hourly production capacity S of the embedded thermal insulation template production line min The length L of the production line is calculated. 总 ; Step 5: Based on the above calculation results and on-site inspection, complete the production line design drawings according to the site shape and available effective area; Step 6: Based on the maximum allowable time T0 for a single production process, optimize the structure, program, and number of robots so that the time required for each robot in the multi-robot collaborative workstation to complete the task is ≤T0.
2. The method for confirming the parameters of a production line for producing embedded dam surface permanent insulation templates according to claim 1, characterized in that, In step 1, S max The calculations take into account design changes, increased concrete pouring volume, and the impact of extreme weather.
3. The method for confirming the parameters of a production line for producing embedded dam surface permanent insulation templates according to claim 2, characterized in that, In step 1, S max The specific confirmation method is as follows: First, determine the planned insulation area for each year. Multiply by a dynamic construction interference coefficient corresponding to that year. This is done to amplify the potential risk of increased area in that year, and then, the area of all amplified years is combined... Take the maximum value from the middle values, and finally, add a risk reserve area on top of that. This allows us to obtain a maximum annual area prediction that fully considers various risks throughout the entire construction period.
4. The method for confirming the parameters of a production line for producing embedded dam surface permanent insulation templates according to claim 1, characterized in that, The minimum hourly production capacity S of the production line in step 2 min The specific confirmation method is as follows: based on the dam's maximum annual permanent insulation area S max Divide by the annual effective production hours to obtain the minimum guaranteed production capacity S per hour of the production line. min The annual effective production hours are obtained by multiplying the annual effective months by the monthly effective days and then by the daily effective hours. The annual effective months are obtained by multiplying the number of months (12) by the annual effective working time coefficient K1 of the project location. The monthly effective days are obtained by multiplying the average number of days in a month (30) by the monthly effective working time coefficient K2 of the production line. The daily effective hours are obtained by multiplying the number of hours in a day (24) by the production line personnel efficiency coefficient K3.
5. The method for confirming the parameters of a production line for producing embedded dam surface permanent insulation templates according to claim 4, characterized in that, Step 2 further includes the following steps: using Monte Carlo simulation to verify capacity, further quantifying the impact of parameter uncertainty on capacity. First, K1, K2, and K3 are set as normal distributions, and their mean and standard deviation are determined. Then, 10,000 sets of random parameter combinations are generated to calculate the minimum hourly capacity S that must be achieved. min Finally, a 95% confidence interval is output to ensure the reliability of the production capacity and obtain the minimum configuration required when designing the production line.
6. A method for confirming the parameters of a production line for producing embedded dam surface permanent insulation templates according to any one of claims 4 or 5, characterized in that, The specific method for confirming the annual effective working time coefficient K1 of the project location in step 2 is as follows: The annual effective working time coefficient K1 of the project location is determined by the local climate influence coefficient. Multiply by the policy impact coefficient Received, among which Calculated based on historical meteorological data, Related to environmental protection-related production restrictions, etc.
7. A method for confirming parameters of a production line for producing embedded dam surface permanent insulation templates according to any one of claims 4 or 5, characterized in that, The specific method for confirming the monthly effective working time coefficient K2 of the production line in step 2 is as follows: The monthly effective working time coefficient K2 of the production line is obtained by calculating the equipment availability rate. The equipment availability rate is the sum of the mean time between failures (MTBF) of the equipment included in the production line divided by the sum of the mean time between failures (MTBF) of the equipment included in the production line and the mean time to repair (MTTR) of the faulty equipment.
8. A method for confirming the parameters of a production line for producing embedded dam surface permanent insulation templates according to any one of claims 4 or 5, characterized in that, The specific method for confirming the production line personnel efficiency coefficient K3 in step 2 is as follows: the production line personnel efficiency coefficient K3 is calculated by dividing the actual shift time by the theoretical shift time, and then multiplying by the personnel operation efficiency coefficient. get.
9. The method for confirming the parameters of a production line for producing embedded dam surface permanent insulation templates according to claim 1, characterized in that, The specific method for determining the maximum allowable time T0 for a single production process in step 3 is as follows: The maximum allowable time T0 for a single production process is the available time per hour divided by the area of templates to be produced per hour, where the available time per hour is 60 minutes in an hour, and the area of templates to be produced per hour is the minimum guaranteed production capacity S of the embedded thermal insulation template production line per hour. min Divide by the area of a single embedded permanent insulation template for the dam surface. The area of a single embedded permanent insulation template for the dam surface is the length L of the single embedded permanent insulation template for the dam surface multiplied by the width W of the single embedded permanent insulation template for the dam surface. T0 needs to meet the requirement of not less than the time required for each production process.
10. The method for confirming the parameters of a production line for producing embedded dam surface permanent insulation templates according to claim 1, characterized in that, The length L of the production line in step 4 总 The specific confirmation method is as follows: the length L of the production line 总 By layout type and efficiency coefficient Multiply by a coefficient Multiply by the quotient of the production line's guaranteed hourly capacity Smin and the length L of a single embedded dam surface permanent insulation template, and then multiply by the template turnover frequency. ; in: The safety distance factor for facilitating robot operation when molds are arranged on the production line is determined based on the size of the robot. : This represents the layout type and efficiency coefficient. It is 1.0 when the site is spacious, 0.9 when it is a U-shaped design, and 0.8 when the site is narrow and designed as a runway or a ring. : This represents the template turnover frequency. This value is related to the curing time of the embedded thermal insulation template within the mold on the dam surface, and is the curing time T. 熟 The quotient of the maximum allowable time T0 for a single production process, when related to ambient temperature, is as follows: when the ambient temperature is around 15℃, the curing time shall not be less than 120 minutes; when the temperature is above 30℃, the curing time shall not be less than 70 minutes.