Concrete preform production mould and method of production thereof

Abstract

The present application relates to the technical field of concrete prefabricated parts, and discloses a concrete prefabricated part production mold and a production method thereof, which comprises a bottom mold, an end mold, a side mold and a spacer mold. The spacer mold comprises two parallel spacer plates, and a group of through holes one and a group of through holes two with adjustable offset are arranged on the two spacer plates. The two spacer plates can produce transverse opening and closing movement and staggered offset movement in directions perpendicular to each other. The transverse opening and closing movement enables the spacer mold to switch between an expanded state and a contracted state. The staggered offset movement drives the group of through holes one and the group of through holes two to produce radial misalignment to clamp the steel bars, and enables the steel bar section between the two spacer plates to produce additional axial tension. The present application integrates the functions of separation, steel bar locking, prestress compensation and hoisting and transferring in the spacer mold component, realizes linkage of opening and closing demolding and hoisting and transferring, eliminates external tooling for steel bar locking, dynamically compensates for prestress loss, effectively improves mold turnover efficiency and prestress control accuracy, and reduces production process complexity and tooling cost.

Description

Technical Field

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

[0002] The long-line platform method is the mainstream process for the industrial production of prestressed concrete precast components. It enables the large-scale production of multiple components in the same batch by setting up molds, tensioning steel bars, and pouring and curing on a long strip platform.

[0003] The partition mold (also known as the separating mold or slip mold) is the core component for realizing the production of multiple components in the same batch and flexibly adjusting the length of the components. Its structure itself undertakes three interrelated and mutually restrictive functions: first, as a rigid partition to separate the casting cavities of adjacent components; second, as a positioning component to constrain the prestressed steel bars inserted in it and prevent the steel bars from shifting during the casting and vibration process; and third, as a detachable component that can be removed from the gaps of the formed components after demolding for reuse in subsequent work stations.

[0004] These three types of functions impose conflicting structural requirements on the partition mold in the three different process stages of casting, curing, and demolding: the casting stage requires the partition spacing to be locked and the edges to fit the side mold to ensure the cavity is sealed; the demolding stage requires the partition spacing to shrink and the plate surface to separate from the side wall of the component to reduce demolding resistance.

[0005] The core challenge in designing precast concrete structures lies in using the same component to meet opposing structural requirements at different technological stages, while simultaneously considering reinforcement positioning and prestress control. As the precast component industry moves towards multi-specification customization and high-turnover assembly lines, higher demands are being placed on the integration level of precast concrete, demolding and transfer efficiency, and prestress control accuracy.

[0006] In the prior art, Chinese invention patent CN120962848A discloses precast concrete components and their mass production apparatus and method. The separating component of this scheme is an openable slipform. Several pin holes are vertically arranged on both sides of the slipform. Before pouring, pins are manually inserted one by one into the corresponding pin holes of adjacent slipforms. The radial contact between the pin shaft and the hole wall limits the slipform to an open state, thus forming the pouring cavity. During demolding, the pins are manually pulled out one by one to release the limitation, and then the slipform is manually pushed to close. The positioning and fixing of the reinforcing bars and the slipform is not accomplished by the slipform's own structure, but by a second locking component independently set on the outside of the slipform. This component uses bolts or clamps to hold each reinforcing bar tightly before fixing it to the slipform, with the number of locking components corresponding one-to-one with the number of reinforcing bars. The establishment of prestress in the component relies entirely on the overall tensioning process at the front-end rebar insertion station, and the slipform and its locking component do not have the ability to actively adjust the tension of the reinforcing bars during pouring and curing.

[0007] The aforementioned existing technology has the following three prominent defects in actual production, and the cause of all three can be traced back to the structural defect that the three functions of separation, locking, and compensation are performed by three independent structures without any motion coupling relationship between them: First, the opening and closing state of the slipform relies entirely on the radial contact of the pins. The pins and pin holes have a clearance fit, which only provides a horizontal limiting force and lacks a vertical mechanical self-locking surface. During vibration, the vibration load transmitted along the height of the mold can easily cause the pins to move slightly or even come out along the hole axis, leading to instability of the slipform spacing, template displacement, and consequently, deviations in the end face dimensions of the component. Furthermore, the insertion and removal of the pins are both point-by-point manual operations, and the pin locking action has no structural connection with the subsequent lifting and transport actions. After the pins are removed, the mold still needs to be manually retracted to detach from the component sidewall. Demolding and transport are two completely separate, sequential independent processes that cannot be completed in one go through a single lifting action. The preparation time for demolding a single slipform is long and difficult to adapt to the rhythm requirements of multi-station assembly line production.

[0008] Secondly, the rebar locking function is handled by a separate second locking component. This component does not share a transmission path with the sliding formwork's opening and closing mechanism. Its installation and disassembly must be performed separately as an additional process independent of the sliding formwork setup and demolding procedures: locking components must be installed one by one before threading the rebar, tightened one by one after threading, and removed one by one before demolding. The number of locking components must match the number of rebars. The more rebars there are, the larger the number of locking components required, significantly increasing the cost of tooling procurement and on-site management. Furthermore, manual tightening of each rebar makes it difficult to ensure consistent locking torque at each locking point, easily leading to uneven locking force and rebar misalignment.

[0009] Finally, neither the slipform nor its locking components possess the structural capability to actively apply force to the reinforcing bars; they can only achieve passive restraint rather than active tensioning. After prestressed reinforcing bars are tensioned and anchored, prestress loss will occur due to various factors such as steel stress relaxation, concrete pouring disturbance, mold deformation, and temperature changes. The existing solution lacks a structural element that can continuously and actively apply additional tension to the reinforcing bars during the pouring and curing process, relying solely on secondary tensioning equipment for manual supplementary tensioning. Secondary tensioning requires additional specialized tensioning equipment and certified operators, resulting in high equipment and labor costs. Furthermore, supplementary tensioning is an intermittent operation, unable to continuously and dynamically compensate for prestress loss throughout the curing process, making it difficult to guarantee the uniformity of prestress among components in the same batch.

[0010] In summary, in the existing long-line production system, the three core functions of slipform opening and closing demolding, steel bar locking and positioning, and prestress loss compensation are realized by three sets of structurally independent devices with unrelated motion relationships. The functions cannot share drive paths or be completed collaboratively in the same action sequence. This results in a large number of tooling, lengthy production processes, low mold turnover efficiency, and insufficient prestress control accuracy, making it difficult to meet the needs of efficient, flexible, and low-cost industrial production of precast components. Summary of the Invention

[0011] The purpose of this invention is to provide a mold for producing precast concrete components and a method for producing the same, in order to solve the problems mentioned in the background section.

[0012] To achieve the above objectives, the present invention provides the following technical solution: A precast concrete component production mold includes a bottom mold, an end mold, a side mold, and a spacer mold. The spacer mold includes two parallel partitions. The two partitions are respectively provided with a first group of through holes and a second group of through holes. The first group of through holes and the second group of through holes have an adjustable offset along the horizontal radial direction of the reinforcing bars. The two partitions can generate lateral opening and closing motion and staggered offset motion, wherein the direction of the lateral opening and closing motion and the direction of the staggered offset motion are perpendicular to each other and do not interfere with each other; The partition also includes a transfer locking assembly, which includes a boom and a synchronization assembly. When the boom moves vertically up and down, it drives the synchronization assembly to cause the two partitions to perform the lateral opening and closing motion. The lateral opening and closing motion increases or decreases the distance between the two partitions, causing the partition mold to switch between an expanded state and a contracted state. The transfer locking assembly also includes a fastening unit that drives the two partitions to produce the interlaced offset movement; The staggered offset motion drives the change in offset, causing the steel reinforcement segment between the two partitions to tilt and deform, thereby generating additional axial tensile force.

[0013] Preferably, the number, diameter, and arrangement of the through-hole group one and the through-hole group two correspond one-to-one; When the offset is zero, the first through hole group and the second through hole group are concentric to allow the reinforcing bars to pass through; When the offset increases, the inner walls of the first through-hole group and the second through-hole group overlap horizontally to clamp the reinforcing bar.

[0014] Preferably, the top of the boom is provided with a lifting section.

[0015] Preferably, multiple sets of the synchronization components are arranged along the length of the boom; Each synchronization component includes a connecting component one and a connecting component two, which are respectively fixed to the inner sides of two partitions. The connecting component one and the connecting component two are respectively provided with guide grooves. Each synchronization assembly also includes a slide bar, which is disposed inside the boom and within the guide groove, and has limiting portions at both ends; The guide groove includes an inclined section.

[0016] Preferably, the fastening unit includes a threaded sleeve and a threaded section disposed in the middle of the slide bar; The threaded sleeve is fixed inside the rod and engages with the threaded section for transmission; the slide bar is axially limited and can only rotate around its own axis. The slide bar passes through the guide groove; When the boom is raised or lowered, it drives the slide rod to move together. The slide rod slides along the inclined section. The reaction force of the groove wall on the slide rod causes the connecting component one and the connecting component two to have a relative lateral displacement, thereby driving the two partitions to open and close. When the slide bar rotates, the threaded engagement drives the threaded sleeve and the hanging rod to move laterally along the slide bar axis, thereby causing the two partition plates to produce the aforementioned staggered offset movement.

[0017] Preferably, the guide groove further includes a locking section one and a locking section two, both of which are vertical grooves and are parallel to each other; When the slide bar is in locking section one or locking section two, the vertical groove wall forms a lateral limit on the slide bar, locking the distance between the two partitions; The first locking section corresponds to the position of the maximum distance between the two partitions, and the second locking section corresponds to the position of the minimum distance between the two partitions.

[0018] Preferably, the two partition plates are also provided with pre-embedded component positioning holes, which are pre-embedded conduit holes or pre-embedded bolt positioning holes.

[0019] The method for producing precast concrete components, using the aforementioned precast concrete component production molds, includes the following steps: S1. Place the partition mold at the set position on the bottom mold so that the two partitions are in the unfolded state and the through hole group one and through hole group two are concentric. S2. Insert the reinforcing bar into the end formwork at one end, pass it through each interval formwork in sequence, and then exit it from the end formwork at the other end. Apply a pre-stress to the reinforcing bar as a whole, and then fix both ends of the reinforcing bar to the end formwork. S3. Drive the two partitions to produce an alternating offset movement, so that the through hole group one and through hole group two produce relative displacement along the horizontal radial direction, thereby clamping the steel bar and causing the steel bar segment between the two partitions to produce tilt deformation. S4. Close the side molds to form a casting cavity, pour concrete into the cavity and vibrate it to compact it, and cure it to the demolding strength. S5. First, remove the side molds, leaving the precast parts on the bottom mold; then drive the two partitions to generate a lateral opening and closing motion and retract inward, so that the partition plate surface separates from the side walls of the precast parts on both sides, and lift the partition mold out as a whole from the gap between the precast parts.

[0020] Preferably, in step S5, after the side formwork is removed, the hoisting part at the top of the hoisting rod is lifted upward by the hoisting equipment. During the upward movement of the hoisting rod, the sliding rod of the synchronous component slides along the guide groove from locking section one through the inclined section to locking section two, and simultaneously drives the two partition plates to retract inward, so that the partition plate surface separates from the side walls of the precast parts on both sides, and the partition mold is lifted out as a whole from the gap between the precast parts, while the precast parts remain on the bottom formwork.

[0021] Preferably, in step S1, multiple spacer molds are arranged along the length of the bottom mold according to the length of the precast component. The spacer molds are arranged at equal or unequal intervals to separate precast component forming cavities with the same or different lengths.

[0022] Compared with the prior art, the beneficial effects of the present invention are: 1. In this invention, the lateral opening and closing motion and the staggered offset motion are set as two independent motion dimensions with mutually perpendicular directions. The two are not coupled or interfere with each other. Therefore, they can be completed by the same set of transfer and locking components through the same slide rod in different process stages in a time sequence. There is no need to configure independent drive structures for the four functions of separation, locking, compensation and transfer.

[0023] 2. This invention integrates the opening and closing demolding action of the partition mold with the hoisting and transportation action through a transfer locking component. The hoisting action can automatically complete the partition shrinkage demolding, eliminating the need for manual insertion and removal of pins and manual retraction of templates. This shortens the demolding preparation time for a single partition mold and improves mold turnover efficiency. The vertical locking section of the guide groove can achieve pure mechanical self-locking. In the locked state, the lateral load generated by vibration cannot drive the slide rod to move along the groove, avoiding the problem of loosening and displacement under vibration due to the lack of vertical constraint surface in the existing pin structure, thus ensuring the stability of component forming accuracy.

[0024] 3. This invention achieves the locking and positioning of reinforcing bars through the staggered offset movement of the spacer itself. The locking action is completed synchronously with the rotation of the sliding rod. There is no need to configure independent locking components that correspond one-to-one with the number of reinforcing bars, nor is it necessary to perform the installation and disassembly of the locking components as an additional process separate from the sliding formwork layout and demolding process. This reduces the number of tools and management costs, and avoids the problem of uneven locking force caused by manual tightening of each bar.

[0025] 4. This invention utilizes staggered offset to induce tilting deformation in the reinforcing bar segments, automatically generating additional axial tension. The magnitude of this additional axial tension can be continuously adjusted by rotating the sliding rod, achieving dynamic self-compensation for prestress loss. Since this compensation process can be carried out synchronously and continuously with pouring and curing, compared to the existing technology that relies on intermittent manual secondary tensioning, it can more promptly compensate for changes in prestress loss caused by factors such as steel stress relaxation and mold deformation. It eliminates the need for secondary tensioning equipment and professional operators, shortens the production cycle, and helps ensure the uniformity and stability of prestress in the same batch of components. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the unfolded side mold and steel bar arrangement structure of the production mold of the present invention; Figure 2 This is a schematic diagram of the production mold assembly structure of the present invention; Figure 3 This is a schematic diagram of the overall structure of the spacer module of the present invention; Figure 4 This is a side view of the spacer structure of the present invention; Figure 5 This is a schematic diagram of the exploded structure of the synchronization component of the present invention; Figure 6 This is a cross-sectional view of the fastening unit of the present invention; Figure 7 This is a top view of the spacer mold structure when the through hole group one and through hole group two are concentric. Figure 8 This is a schematic diagram of the main structure of the spacer mold when the through hole group one and through hole group two are concentric. Figure 9 This is a top view of the spacer mold structure when the through hole group one and through hole group two are eccentrically positioned according to the present invention. Figure 10 This is a schematic diagram of the main structure of the spacer mold in the eccentric state of the through hole group one and through hole group two of the present invention; Figure 11 This is a partial enlarged front view structural diagram of the spacer mold in the eccentric state of the through hole group one and through hole group two of the present invention.

[0027] In the picture: 100, bottom mold; 200, end mold; 300, side mold; 400. Spacing mold; 401. Through hole group one; 402. Through hole group two; 403. Embedded conduit hole; 404. Embedded bolt positioning hole; 500. Transfer locking assembly; 510. Lifting boom; 511. Lifting unit; 520. Synchronization component; 521. Connecting component one; 522. Connecting component two; 523. Guide groove; 5231. Locking section one; 5232. Inclined section; 5233. Locking section two; 524. Slide rod; 5241. Limiting part; 530. Fastening unit; 531. Screw sleeve; 532. Threaded section. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0029] Please see Figures 1 to 11 The present invention provides the following five embodiments: The concrete precast component production mold is suitable for the industrial production of prestressed concrete precast components using the long-line pedestal method. Multiple bottom molds can be arranged in parallel within the production site, and multi-station assembly line operation can be achieved with the help of transferable mold components.

[0030] Please see Figure 1 and Figure 2 The mold is composed of a bottom mold 100, an end mold 200, a side mold 300 and a spacer mold 400. The spacer mold 400 integrates multiple functions such as cavity separation, steel bar locking, prestress compensation and rapid demolding and transfer. A set of transfer locking components 500 realizes two-dimensional partition movement control.

[0031] It is worth noting that the lateral opening and closing motion and the staggered offset motion correspond to two orthogonal degrees of freedom of the diaphragm motion: the lateral opening and closing motion occurs in the direction perpendicular to the steel bar axis and perpendicular to the diaphragm plate surface, directly determining the diaphragm spacing; the staggered offset motion occurs in the direction perpendicular to the steel bar axis and parallel to the diaphragm plate surface, directly determining the radial misalignment of the two sets of through holes.

[0032] Since the directions of motion of the two are perpendicular to each other, the projection of the motion component in any dimension onto the other dimension is zero. Geometrically, they do not project onto each other or superimpose on each other. Therefore, driving the motion in one dimension will not cause unexpected displacement in the other dimension. This is the structural basis for the transfer locking component 500 to be driven by two independent motion modes, namely, lateral opening and closing through axial movement and staggered offset through rotation around the axis, without interfering with each other. It is also the fundamental reason why the four functions of cavity separation, rebar locking, prestress compensation, and hoisting and transfer can be integrated into the same component without conflicting with each other.

[0033] The following describes the specific structure and working method in detail through multiple embodiments in different application scenarios.

[0034] Example 1 Equal-spacing batch production molds for precast concrete components: This embodiment is used for the large-scale mass production of long components such as precast piles and precast beams of the same specification. Multiple standard components of the same length can be produced in a single batch.

[0035] Please see Figure 1 In this embodiment, the bottom formwork 100 is a long strip platform structure with a flat steel plate laid on the surface as a casting support base; two sets of end formwork 200 are vertically fixed at both ends of the bottom formwork 100, and the plate surface is provided with steel bar holes corresponding to the reinforcement design for the prestressed steel bars to pass through and be anchored at the ends.

[0036] During the production process, the end mold 200 remains fixed, eliminating the need for frequent disassembly and assembly. This ensures stable maintenance of the baseline accuracy for tensioning on the long line and avoids dimensional errors caused by repeated positioning.

[0037] Two sets of side molds 300 are arranged on both sides of the length of the bottom mold 100. The docking positions of the side molds 300 and the bottom mold 100, and the side molds 300 and the end molds 200 are respectively provided with reserved holes. After being locked by bolts, the three together form a concrete pouring cavity with an open top. The side molds 300 adopt a detachable form with bolt locking. After demolding, they can be quickly hoisted and transported to other work stations for reuse, effectively improving the turnover efficiency of the molds.

[0038] In this embodiment, multiple spacer molds 400 are configured and arranged at equal intervals along the length of the bottom mold 100 inside the casting cavity, dividing the overall cavity into multiple independent precast component forming cavities of the same length, and multiple components of the same specification can be produced in a single batch.

[0039] Please see Figure 3 and Figure 4 The spacer 400 is the core functional component of the entire mold set, mainly consisting of two parallel vertical partitions and a set of transfer and locking components 500.

[0040] Two vertically parallel partitions can generate relative motion in two dimensions. The first is a lateral opening and closing motion perpendicular to the steel bar axis, which is used to shrink and detach the component during demolding and to expand and form a cavity when the component is poured into place. The second is an interlacing offset motion along the axis of the slide bar 524, which is used to clamp the steel bar to achieve locking and generate additional tensile force to compensate for prestress.

[0041] Two partitions are respectively provided with through hole group 1 401 and through hole group 2 402. The number, diameter and arrangement of the two through holes correspond one-to-one with the steel bar hole group of the end mold 200. The two sets of through holes are offset along the horizontal radial direction of the reinforcing bars.d Offset d When the value is 0, through hole group 1 401 and through hole group 2 402 are completely concentric, and prestressed steel bars can be smoothly installed; offset d When the size is increased to the maximum value, the inner walls of the two sets of through holes interlock and firmly clamp the internal steel bars. At the same time, the outer edges of the two partitions are completely aligned, which can tightly fit the inner wall of the side mold 300 and ensure the sealing of the molding cavity.

[0042] This integrated design with dual-partition, dual-dimensional motion combines cavity separation and rebar locking functions into a single component, replacing the separate separation mold and rebar locking fixtures in traditional production methods. This significantly reduces the number of tooling components, simplifies production processes, and lowers the procurement and management costs of tooling.

[0043] Please see Figure 5 and Figure 6 The transfer locking assembly 500 has the functions of driving the partition to open and close, interlocking and locking, and overall hoisting and transfer. It consists of a lifting rod 510 and multiple sets of synchronous components 520. The multiple sets of synchronous components 520 are evenly arranged along the length of the lifting rod 510, which can ensure that the two partitions are subjected to uniform force and that the opening, closing and offset actions are synchronous and stable.

[0044] The top of the boom 510 is provided with a lifting part 511, which can be a lifting hole or an integrated lifting lug. In this embodiment, the lifting hole is used to connect external lifting equipment to realize the overall lifting and cross-station transfer of the partition mold 400. This integrated lifting design does not require additional lifting tools, and the lifting action can simultaneously trigger the shrinkage and demolding action of the partition, eliminating the need to adjust the demolding gap separately and effectively improving the efficiency of the transfer operation.

[0045] Please see Figure 5 Each synchronization component 520 comprises three parts: a first connecting component 521, a second connecting component 522, and a fastening unit 530. The first connecting component 521 and the second connecting component 522 are respectively fixed to the opposite side surfaces of the two partitions, and the first connecting component 521 is embedded in the internal cavity of the second connecting component 522. The width of the cavity is greater than the overall width of the first connecting component 521, allowing the first connecting component 521 to move laterally along the axis of the slide rod 524.

[0046] The maximum travel of the connecting component 521 and the maximum offset of the two sets of through holes. d When the through hole group 1 401 and the through hole group 2 402 are completely concentric, the outer wall of one side of the connecting component 1 521 is in close contact with the corresponding inner wall of the connecting component 2 522. At this time, the two sides of the partition are staggered. When offset dWhen the maximum value is reached, the outer wall of the other side of connecting component 1 521 is in close contact with the corresponding inner wall of connecting component 2 522, at which point the edges of the two partitions are completely aligned. This embedded connection structure provides stable guiding support for the staggered offset of the partitions, and precisely controls the maximum offset through stroke limit, avoiding excessive offset that could lead to deformation of the reinforcing bars or damage to the edges of the through holes. At the same time, the overall structure is compact and occupies little space inside the cavity.

[0047] Both connecting component 1 521 and connecting component 2 522 are provided with guide grooves 523, and the two sets of grooves are symmetrically arranged about the lifting rod 510. The guide groove 523 consists of three grooves connected in sequence: a vertically upward locking section 1 5231, an inclined section 5232 with a sloping transition, and a vertically upward locking section 2 5233, wherein locking section 1 5231 and locking section 2 5233 are parallel to each other.

[0048] This three-section trough path design allows for the conversion of movement direction via the inclined section 5232, transforming the vertical lifting force transmitted by the boom 510 into a lateral driving force that drives the opening and closing of the partition. Meanwhile, the upper and lower vertical locking sections can correspond to the two workstations of pouring and demolding / transfer, respectively. Pure mechanical self-locking is achieved by relying on the lateral constraints of the vertical trough wall, without the need for additional locking components.

[0049] Please see Figure 6 The synchronization component 520 also includes a slide rod 524, which is disposed inside the lifting rod 510 and passes through the guide grooves 523 on both sides; the fastening unit 530 consists of a threaded sleeve 531 and a threaded section 532 disposed in the middle of the slide rod 524. The threaded sleeve 531 is fixedly installed inside the lifting rod 510, and the threaded section 532 of the slide rod 524 engages with the threaded sleeve 531 for transmission.

[0050] The slide bar 524 is divided into three sections: the two ends are limiting parts 5241, which in this embodiment adopts a hexagonal head form to be compatible with conventional tools such as pneumatic wrenches for driving rotation; the middle section is a threaded section 532, which engages with the internal thread of the threaded sleeve 531 for transmission; and the section between the limiting part 5241 and the threaded section 532 is a smooth rod section, which is inserted into the guide groove 523.

[0051] The stepped surface formed between the limiting part 5241 and the smooth rod section abuts against the outer wall of the connecting component 522, thus axially limiting the slide rod 524, which can only rotate around its own axis and cannot move axially. This axial limiting structure allows the slide rod 524 to rotate and drive the threaded sleeve 531 and the hanging rod 510 to move laterally along the axis through threaded engagement, thereby driving the two partitions to offset. The rotational drive can precisely adjust the offset by controlling the number of rotations, adapting to different locking force requirements and prestress compensation requirements. It is also compatible with conventional pneumatic tools on site, making operation convenient and requiring no special equipment.

[0052] During pouring, the lateral load generated by vibration cannot drive the slide bar 524 to shift along the groove, keeping the diaphragm spacing stable and preventing issues such as mold bulging or displacement. The dimensional accuracy of the component end face is controllable. During demolding and transport, the diaphragm spacing remains fixed, preventing accidental opening or closing due to hoisting sway, ensuring a safe and stable transport process. The overall purely mechanical structure is suitable for the dusty and humid production environment of precast component plants, has a low failure rate, and requires only periodic lubrication maintenance, resulting in low operating costs and a long service life.

[0053] When the boom 510 is driven to rise and fall vertically by the lifting equipment, it will drive the slide bar 524 to move vertically synchronously along the guide groove 523. When the slide bar 524 slides along the inclined section 5232, the reaction force of the groove wall will push the connecting component 1 521 and the connecting component 2 522 to move laterally relative to each other, thereby driving the two partitions to complete the opening and closing action.

[0054] When the slide rod 524 is in the locking section 1 5231, the distance between the two partitions is at its maximum, corresponding to the working position of the pouring operation. At this time, the vertical groove wall forms a lateral limit on the slide rod 524, and the partition position is stable and self-locking. When the lifting rod 510 drives the slide rod 524 upward, the slide rod 524 enters the inclined section 5232 from the locking section 1 5231, and the distance between the two partitions continues to decrease until the slide rod 524 enters the locking section 2 5233, and the distance between the partitions reaches the minimum value, corresponding to the demolding and transfer state. Lateral locking is also achieved by the vertical groove wall. When the lifting rod 510 drives the slide rod 524 downward, the process is reversed, and the partitions reset from the minimum distance to the maximum distance and automatically lock.

[0055] This linkage design, which automatically shrinks and demolds upon lifting and can be manually opened and positioned upon lowering, completely eliminates the need for manual adjustment of demolding gaps and manual insertion and removal of pins. The demolding preparation time for a single spacer mold 400 is effectively shortened. Combined with the parallel production layout of multiple bottom molds 100, the spacer mold 400 can be quickly transferred and reused across workstations, further improving mold utilization and adapting well to the production rhythm of large-scale assembly line operations.

[0056] When the limiting part 5241 of the slide rod 524 is rotated, the slide rod 524 is axially limited and cannot move. The thread engagement will drive the threaded sleeve 531 and the hanger 510 to move laterally along the axis of the slide rod 524. Through the connecting assembly 521, one of the partitions will be offset relative to the other partition, so that the through hole group 401 and the through hole group 402 will be radially misaligned, clamping the through prestressed steel bar and realizing mechanical locking.

[0057] As the offset increases further, it will eventually reach the maximum offset. dThe steel bars between the two partitions will undergo slight tilting deformation due to misalignment, automatically generating additional axial tensile force. This can dynamically offset the prestress loss caused by various factors such as steel stress relaxation, concrete pouring disturbance, and mold deformation, thus maintaining the stability of the steel bar tension in each forming cavity.

[0058] Specifically, the threaded section 532 of the slide rod 524 and the threaded sleeve 531 are connected by a helical drive. Each full rotation of the slide rod 524 around its own axis causes a lateral displacement of the connecting assembly 521 along the axial direction of the slide rod 524, which is the amount of displacement equal to the offset between the first through-hole assembly 401 and the second through-hole assembly 402. d The increment, or offset d The offset is positively correlated with the number of rotations of slide bar 524; the number of rotations can be directly read or controlled by the rotation count of driving tools such as pneumatic hammers, therefore the offset... d The adjustment accuracy depends on the design value of the thread lead. The smaller the lead, the smaller the offset increment per turn, and the higher the adjustment accuracy.

[0059] The steel reinforcement section between the two partitions is offset d After tilting deformation occurs, an angle of inclination is formed between the axis of the steel bar segment and the original straight direction. θ , θ With offset d The angle of inclination increases with the increase of the tensile force; the tilting deformation causes the tensile force originally transmitted along the axial direction of the steel bar to generate an axial component increment in the tilted part of the steel bar, that is, an additional axial tensile force, which increases with the tilt angle. θ It increases with the increase of the offset, that is, it increases with the increase of the offset. d Furthermore, it increases with the number of rotations of the slide bar 524, and the three show a monotonically increasing relationship.

[0060] Accordingly, on-site operators can adjust the offset by controlling the number of rotations of the slide bar 524 based on the prestress loss of the reinforcing bars monitored by the tensioning equipment. d With tilt angle θ This allows for continuous adjustment of the additional axial tension, enabling targeted compensation for prestress loss without relying on empirical estimation or additional tensioning equipment.

[0061] This integrated design of staggered locking and prestress compensation eliminates the need for additional secondary tensioning equipment and professional operators, saving the independent tensioning process and shortening the overall production cycle. At the same time, the amount of prestress compensation can be precisely controlled by the number of rotations of the slide bar 524, which can adapt to prestressed steel bars of different diameters and different design stress levels, ensuring the uniformity and stability of the mechanical properties of the finished components.

[0062] Example 2 Based on the content of Embodiment 1 above, another embodiment is proposed: Methods for producing precast concrete components: S1. First, clean the surface of the steel plate of the bottom mold 100 and confirm that the end molds 200 at both ends of the bottom mold 100 are in a fixed position.

[0063] S2. Based on the length design of the precast components, determine the layout positions of multiple spacer molds 400. Use a lifting device to hoist the spacer molds 400 to the corresponding positions on the surface of the bottom mold 100 in sequence. At this time, the spacer molds 400 are in the maximum spacing locked state corresponding to the locking section 5231. The through hole group 1 401 and the through hole group 2 402 are concentric, and the edges of the two partitions are staggered.

[0064] S3. Then, the prestressed steel bar is inserted into the end form 200 at one end, passes through the through holes of all the spacer forms 400 in sequence, and finally comes out from the end form 200 at the other end. After applying the preset prestress to the steel bar as a whole, the two ends of the steel bar are fixed and anchored to the end forms 200 on both sides.

[0065] S4. After tensioning and anchoring are completed, rotate the sliding rod 524 limiting part 5241 of each partition mold 400 to drive the connecting component 1 521 to move laterally relative to the connecting component 2 522, causing the two sets of through holes to produce radial offset; as the offset increases, the outer edges of the two partitions gradually become flush until the maximum offset is reached. At this time, the inner wall of the through hole firmly locks the reinforcing bar, and the reinforcing bar generates additional axial tensile force due to misalignment and tilt, thus completing the prestress compensation.

[0066] The number of rotations of the slide bar 524 can be pre-calculated based on the designed prestress loss, or the number of rotations can be adjusted in real time based on the prestress monitoring data of the tensioning equipment to achieve targeted compensation for prestress loss.

[0067] S5. Hoist the side molds 300 on both sides to align with the sides of the bottom mold 100, align the reserved holes, and then insert bolts to tighten them, so that the inner wall of the side mold 300 and the flush edge of the spacer mold 400 are tightly fitted to form a sealed precast component forming cavity; then pour concrete into each forming cavity, vibrate to compact it, and then let it stand for curing according to the curing system until the concrete strength reaches the demolding strength requirement.

[0068] S6. After curing to the demolding strength, first remove the locking bolts of the two side molds 300 and hoist the side molds 300 to the edge of the remaining bottom molds 100 for later use; then cut the steel bars inside the partition mold 400 along the opposite side surface of the two partitions so that there are no steel bars obstructing the partition mold 400.

[0069] At this time, the hoisting part 511 at the top of the hoisting rod 510 is lifted upward at a uniform speed through the hoisting equipment, which drives the slide rods 524 of all synchronous components 520 to move upward synchronously. The slide rods 524 slide along the guide groove 523 from the locking section 1 5231 through the inclined section 5232 to the locking section 2 5233, which synchronously drives the two partitions to retract inward, so that the partition plate surface is completely separated from the side walls of the precast parts on both sides, eliminating the demolding friction resistance. Continue to lift and the entire partition mold 400 can be lifted out of the gap between the precast parts.

[0070] The hoisted-out spacer mold 400 can be directly transferred to the bottom mold 100 station to be produced. The reverse slide bar 524 adjusts the two sets of through holes to a concentric state, and at the same time, it is lowered into position so that the slide bar 524 is reset to the locking section 5231. The spacer mold 400 returns to the unfolded state with the maximum spacing and can be put into the next batch of production.

[0071] The formed precast concrete components will remain on the surface of the bottom mold 100 for subsequent curing until the curing period is over and they are transferred to the stacking area. This process eliminates the need to lift and transfer components immediately after demolding, allowing for flexible production scheduling and reducing the number of times components are lifted, thus lowering the risk of component damage from impacts.

[0072] Example 3 Non-uniformly spaced custom-made precast concrete component production molds: This embodiment is used to produce customized prefabricated components of different lengths and specifications in the same batch, which is suitable for the production needs of small-batch, multi-specification orders.

[0073] In this embodiment, the structure and installation method of the bottom mold 100, end mold 200, and side mold 300 are consistent with those in Embodiment 1. The main structure of the spacer mold 400 and the working principle of the transfer locking assembly 500 are also exactly the same as those in Embodiment 1. The difference is that the spacer molds 400 in the casting cavity are arranged at non-equal intervals. The positioning of each spacer mold 400 is adjusted according to the component length requirements of the order, and multiple precast component forming cavities of different lengths are separated, without the need for additional customization of special spacer molds of different sizes.

[0074] This flexible and adjustable layout significantly enhances the mold's flexible production capabilities. When faced with multi-specification, small-batch orders, production line changes can be completed simply by adjusting the layout of the existing 400-part spacer mold. The changeover cycle is short and the cost is low, enabling a rapid response to the market's customized needs.

[0075] Meanwhile, the hoisting and transportation, opening and closing demolding, steel bar locking and prestress compensation functions of the 400-type interval mold remain unchanged. After the change of type, there is no need to adjust the operation process, and the operators can quickly get started without additional training, which ensures the operation efficiency and product quality stability of customized production.

[0076] The production process in this embodiment is basically the same as that in embodiment two. The only difference is that the positioning of each mold is adjusted according to the customized length requirements in the 400 interval mold layout stage. The remaining processes of threading, tensioning, locking, casting, demolding, and transfer remain unchanged.

[0077] Example 4 Precast wall panel production mold with embedded conduit: This embodiment is used to produce precast concrete wall panels with built-in pipelines, realizing the integrated molding and precise positioning of embedded parts and component body.

[0078] In this embodiment, the structure of the bottom mold 100, end mold 200, and side mold 300, as well as the structure and working principle of the transfer locking assembly 500 of the spacer mold 400, are consistent with those of Embodiment 1. The difference is that on the two partitions of the spacer mold 400, in addition to the through hole group 1 401 and through hole group 2 402 corresponding to the main reinforcement, multiple sets of pre-embedded conduit holes 403 are also provided. The diameter of the pre-embedded conduit holes 403 matches the outer diameter of commonly used conduits in engineering, and the hole arrangement is completely consistent with the pipeline routing design of the precast wall panel.

[0079] When the partition mold 400 is set up and the through holes of the two sets of main reinforcement bars are concentric, the pre-embedded conduits can be passed through the pre-embedded conduit holes 403 of each partition mold 400 in sequence, and the two ends are limited to the outside of the partition by temporary fixing parts; the subsequent reinforcement locking, side mold 300 closing, and concrete pouring and curing procedures are the same as in Example 1. After demolding, the pre-embedded conduits are integrally formed with the concrete wall, and the position of the conduits is precisely defined by the hole positions of the partition mold 400. The positioning error is much lower than that of the traditional manual laying method, and no additional special conduit positioning tooling is required, which simplifies the production process.

[0080] This integrated embedded component design incorporates pipeline positioning functionality into the 400-cell mold, further enhancing the mold's integration. The prefabricated wall panels produced have precise pipeline positioning, eliminating the need for additional slotting and wiring during on-site construction. This significantly improves the on-site installation efficiency of prefabricated buildings and reduces on-site workload.

[0081] Example 5 Precast component production mold with embedded bolts: This embodiment is used to produce precast components with pre-embedded connecting bolts, and is suitable for the production of precast beams, columns, precast wall panels and other components that require subsequent splicing and installation.

[0082] In this embodiment, the structure of the bottom mold 100, end mold 200, and side mold 300, as well as the structure and working principle of the transfer locking assembly 500 of the spacer mold 400, are consistent with those in Embodiment 1. The difference is that, in addition to the through hole group 1 401 and through hole group 2 402 corresponding to the main reinforcement, multiple sets of pre-embedded bolt positioning holes 404 are also provided on the two partition plates of the spacer mold 400. The diameter of the pre-embedded bolt positioning holes 404 matches the diameter of the pre-embedded bolt, and the hole positions correspond to the design positions of the connection nodes of the components.

[0083] After the spacer 400 is installed, the shank of the pre-embedded bolt is inserted into the pre-embedded bolt positioning hole 404 from the outside of the spacer. The bolt head remains in the precast component forming cavity, and the end of the shank is temporarily locked to the outer wall of the spacer with a nut, thus achieving precise fixing of the pre-embedded bolt. The subsequent procedures for rebar installation and tensioning, staggered locking, side formwork 300 closure, and pouring and curing are the same as in Example 1. During demolding, the temporary nut at the end of the bolt is first released, and then the spacer 400 is lifted, allowing the bolt to be precisely embedded in the end face of the precast component.

[0084] Using the rigid plate of the spacer mold 400 for bolt positioning provides a much higher positioning accuracy than traditional binding methods, ensuring alignment accuracy during subsequent component assembly. Furthermore, it eliminates the need for additional dedicated bolt positioning molds, reducing tooling types and lowering production costs. Simultaneously, the installation and removal of pre-embedded bolts can be carried out concurrently with the placement and demolding of the spacer mold 400, without disrupting production cycles and ensuring high production efficiency.

[0085] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered in all respects as exemplary and non-limiting, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

Claims

1. A precast concrete component production mold, comprising a bottom mold (100), an end mold (200), a side mold (300), and a spacer mold (400), wherein the spacer mold (400) comprises two parallel partition plates, characterized in that: The two partition plates are provided with a first group of through holes (401) and a second group of through holes (402) respectively. The first group of through holes (401) and the second group of through holes (402) have an adjustable offset along the horizontal radial direction of the reinforcing bar. The two partitions can generate lateral opening and closing motion and staggered offset motion, wherein the direction of the lateral opening and closing motion and the direction of the staggered offset motion are perpendicular to each other and do not interfere with each other; The partition module (400) also includes a transfer locking assembly (500), which includes a boom (510) and a synchronization assembly (520). When the boom (510) moves vertically up and down, the synchronization assembly (520) drives the two partitions to produce the lateral opening and closing motion. The lateral opening and closing motion increases or decreases the distance between the two partitions, causing the partition module (400) to switch between an expanded state and a contracted state. The transfer locking assembly (500) also includes a fastening unit (530) that drives the two partitions to produce the interleaved offset movement. The staggered offset motion drives the change in offset, causing the steel reinforcement segment between the two partitions to tilt and deform, thereby generating additional axial tensile force.

2. The precast concrete component production mold according to claim 1, characterized in that: The number, diameter and arrangement of the through hole group one (401) and the through hole group two (402) correspond one-to-one; When the offset is zero, the first through hole group (401) and the second through hole group (402) are concentric to allow the reinforcing bars to pass through; When the offset increases, the inner walls of the first through hole group (401) and the second through hole group (402) overlap horizontally and radially to clamp the reinforcing bar.

3. The precast concrete component production mold according to claim 1, characterized in that: The top of the boom (510) is provided with a hoisting part (511).

4. The precast concrete component production mold according to claim 1, characterized in that: The synchronization components (520) are arranged in multiple sets along the length of the boom (510); Each set of synchronization components (520) includes a first connecting component (521) and a second connecting component (522) respectively fixed to the inner sides of two partitions. The first connecting component (521) and the second connecting component (522) are respectively provided with guide grooves (523). Each synchronization component (520) also includes a slide bar (524), which is disposed inside the boom (510) and in the guide groove (523). The slide bar (524) has limiting parts (5241) at both ends. The guide groove (523) includes an inclined section (5232).

5. The precast concrete component production mold according to claim 4, characterized in that: The fastening unit (530) includes a threaded sleeve (531) and a threaded section (532) disposed in the middle of the slide bar (524). The threaded sleeve (531) is fixed inside the rod (510) and engages with the threaded section (532) for transmission. The slide rod (524) is axially limited and can only rotate around its own axis. The slide rod (524) passes through the guide groove (523); When the boom (510) is raised or lowered, it drives the slide rod (524) to move together. The slide rod (524) slides along the inclined section (5232). The reaction force of the groove wall on the slide rod (524) causes the connecting component one (521) and the connecting component two (522) to produce relative lateral displacement, thereby driving the two partitions to open and close. When the slide bar (524) rotates, the threaded engagement drives the threaded sleeve (531) and the hanging rod (510) to move laterally along the axial direction of the slide bar (524), thereby causing the two partition plates to produce the aforementioned staggered offset motion.

6. The precast concrete component production mold according to claim 5, characterized in that: The guide groove (523) further includes a locking section one (5231) and a locking section two (5233), wherein the locking section one (5231) and the locking section two (5233) are both vertical grooves and are parallel to each other; When the slide bar (524) is in locking section one (5231) or locking section two (5233), the vertical groove wall forms a lateral limit on the slide bar (524) to lock the distance between the two partitions; The first locking section (5231) corresponds to the position of the maximum distance between the two partitions, and the second locking section (5233) corresponds to the position of the minimum distance between the two partitions.

7. The precast concrete component production mold according to claim 1, characterized in that: The two partition plates are also provided with pre-embedded component positioning holes, which are pre-embedded conduit holes (403) or pre-embedded bolt positioning holes (404).

8. A method for producing precast concrete components, characterized in that: The method of using a precast concrete component production mold according to any one of claims 1 to 7 includes the following steps: S1. Place the partition mold (400) at the set position on the bottom mold (100) so that the two partitions are in the unfolded state and the through hole group one (401) and through hole group two (402) are concentric. S2. Insert the steel bar into one end formwork (200), pass it through each interval formwork (400) in sequence, and then exit it from the other end formwork (200). After applying the pre-stress to the steel bar as a whole, fix both ends of the steel bar to the end formwork (200). S3. Drive the two partitions to produce an alternating offset movement, so that the through hole group one (401) and through hole group two (402) produce relative displacement along the horizontal radial direction, thereby clamping the steel bar and causing the steel bar segment between the two partitions to produce tilt deformation. S4. Close the side mold (300) to form a casting cavity, pour concrete into the cavity and vibrate it to compact it, and cure it to the demolding strength; S5. First, remove the side mold (300) and leave the precast parts on the bottom mold (100); then drive the two partitions to generate a lateral opening and closing motion and shrink inward, so that the partition plate surface is separated from the side wall of the precast parts on both sides, and lift the partition mold (400) out as a whole from the gap between the precast parts.

9. The method for producing precast concrete components according to claim 8, characterized in that: In step S5, after removing the side formwork (300), the hoisting part (511) at the top of the hoisting rod (510) is lifted upward by the hoisting equipment. During the upward movement of the hoisting rod (510), the sliding rod (524) of the synchronous component (520) is driven to slide along the guide groove (523) from the locking section one (5231) through the inclined section (5232) to the locking section two (5233), which simultaneously drives the two partition plates to shrink inward, so that the partition plate surface is separated from the side wall of the precast parts on both sides, and the partition mold (400) is lifted out as a whole from the gap between the precast parts, while the precast parts are left on the bottom formwork (100).

10. The method for producing precast concrete components according to claim 8, characterized in that: In step S1, multiple spacer molds (400) are arranged along the length of the bottom mold (100) according to the length design of the precast component. The spacer molds (400) are arranged with equal or non-equal spacing to separate the precast component forming cavities with the same or different lengths.

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