L-shaped wall component lightweight production tool and component production method

Abstract

The present application relates to a kind of L-shaped wall component lightweight production tool and component production method, belong to component construction technical field.Mainly include base, vertical pole, horizontal beam, L-shaped support.Production method, including preparation lightweight tool, prefabricated concrete form, grouting material, pull connector, steel reinforcement cage, correction fixture, the concrete form and steel reinforcement cage are independently prefabricated respectively, by lightweight tool the male corner formwork in concrete form, female corner formwork, pull connector, steel reinforcement cage etc. are sequentially assembled again together, form a whole, and are poured into shape.The present application is by "lightweight tool+ split prefabrication+ sequential assembly" technical route, realizes "low cost, high efficiency, high quality, high flexibility" production goal, effectively solves the key technical problems existing in the current large-scale turnover mould platform process, such as equipment investment, complex process, many times of turnover, high material cost, inconvenient inner surface treatment etc.

Description

Technical Field

[0001] This invention relates to a lightweight production tooling and method for L-shaped wall components, belonging to the field of component construction technology. Background Technology

[0002] In recent years, guided and strongly supported by a series of national policies, my country's prefabricated building industry has developed rapidly, and the application scale of prefabricated buildings has continued to expand. Statistics show that prefabricated concrete buildings account for about two-thirds of all prefabricated buildings in my country. Currently, the most widely used prefabricated concrete technology in China is the prefabricated monolithic shear wall technology based on sleeve grouting. Its vertical components are PC components with grouting sleeves, and the vertical reinforcing bars between upper and lower layers are connected through the grouting sleeves; between components on the same floor, the horizontal reinforcing bars extending outwards on both sides of the PC wall panel are connected by setting post-pouring strips. However, this technology currently only applies to straight wall components, with post-pouring strips between components and T / L-shaped walls cast in place. This results in a still large workload for reinforcing bar binding and formwork installation and removal, which is not conducive to further improving the level of industrialization in my country's construction industry.

[0003] The reasons why T-shaped and L-shaped PC wall components have not been widely used include: (1) The corner areas of T / L-shaped shear walls are generally edge component areas that play a key role in seismic performance, but the reliability of sleeve grouting technology is insufficient. "Whether it can be fitted, whether it can be filled, and how to test it afterward" have become key issues to ensure the construction quality and safety of this technology, and there are constant doubts in engineering practice. (2) T / L-shaped wall components have various sizes, and traditional PC component molds are heavy and have high production costs. (3) T / L-shaped wall components have irregular sizes and high transportation costs.

[0004] Prefabricated modular formwork systems are a new type of prefabricated construction technology. Its basic components—the modular formwork components—are integrated cavity-type components composed of precast formwork made of high-performance cement-based materials, a steel reinforcement skeleton located within the cavities between the formwork shells, and tie rod connectors. The precast formwork serves both as templates for the concrete pouring stage within the cavity and as part of the structure, participating in structural stress as a whole with the concrete. Component types include straight, T-shaped, and L-shaped wall components, column components, and beam components. The modular formwork components are connected using a close-fitting method, with the joint reinforcement connection structure completely consistent with cast-in-place structures. Through the application of T / L-shaped components, full assembly of vertical components can be achieved, eliminating the need for on-site rebar tying and formwork installation / removal. After all components are installed in place, concrete is poured within the cavities to form the main structure, combining the advantages of prefabricated construction technology and cast-in-place concrete structures.

[0005] T / L-shaped mold wall components are generally produced using large flipping mold tables, but they also have problems such as large initial fixed investment and long production processes.

[0006] Existing L-shaped modular wall components are generally produced using large rotating mold tables. These large rotating mold tables consist of a support frame, a horizontal rotating turntable, an L-shaped bottom template, four sets of evenly arranged L-shaped side templates, and detachable support templates. When producing L-shaped modular wall components using a large rotating mold table, the first two sets of side templates are opened, the template sidewalls are cleaned, and support templates are installed according to the component dimensions. A release agent is applied to the mold table area, and a reinforcing steel frame is erected. The mold table is then closed. The turntable is then rotated 180° clockwise to repeat the pre-treatment operation. The mixture is prepared according to the setting time and proportions, and four directional, zoned material distributions are completed sequentially. After each initial setting, pressure plates are placed to compact the semi-finished product. During this process, the turntable is rotated 180° clockwise, 90°, and 180° counterclockwise to adjust its position. As needed, designated side templates are opened, corresponding support templates are removed, and the templates are repositioned and closed before continuing the process. After all the material has solidified, the side templates are opened in stages, and the formed components are lifted out.

[0007] The main problems with the existing manufacturing process for L-shaped modular wall components are:

[0008] (1) The production mold equipment is large and requires the production line to be set up in the factory. The initial investment is large and it is difficult to meet the needs of flexible production. (2) After the L-shaped steel cage is placed into the flipping formwork and fixed, it needs to be flipped and poured four times during its production process. In order to avoid occupying the formwork for a long time and to flip it as soon as possible, higher requirements are put forward for the early strength of the formwork material, which increases the material cost. (3) As part of the structure, the bonding performance between the mold shell and the cast-in-place concrete in the cavity is crucial to the integrity of the structure. However, the space in the flipping mold is limited, making it inconvenient to roughen the inner surface of the mold shell. Summary of the Invention

[0009] To address the aforementioned deficiencies in the existing technology, this invention proposes a lightweight production tooling and method for L-shaped wall components, which solves the problems encountered in the production of L-shaped combined molded wall components, such as numerous mold table flipping times, bulky mold tables, complex mold table production processes, and inconvenience in roughening the inner surface of the mold shell.

[0010] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A lightweight chemical equipment for producing L-shaped wall components is used to provide a support structure for the production of L-shaped wall components, mainly including a base, uprights, horizontal beams, and L-shaped brackets; The two sets of L-shaped supports (14) are arranged in parallel and symmetrical along the length of the tooling. Each set of L-shaped supports (14) is formed by connecting two standard rods arranged at a 90° angle. The L-shaped supports (14) are connected and fixed to the upper nodes of the two uprights (12) on the corresponding side. The corner of the L-shaped supports (14) is connected to the middle of the base (11) on the corresponding side. The L-shaped supports (14) are connected to the uprights (12) and the base (11) to form a stable triangular force unit. The two sets of triangular force units are connected as a whole by two layers of horizontal beams (13) arranged in parallel. The upper horizontal beam (13) is connected to the upper node of the uprights (12) of the two sets of triangular force units, and the lower horizontal beam (13) is connected to the lower node of the uprights (12) of the two sets of triangular force units.

[0011] Furthermore, the two sets of bases (11) are arranged parallel to each other along the length of the tooling; the base (11), upright (12), horizontal beam (13), and L-shaped bracket (14) can be made of standard profiles such as rectangular, H-shaped, angular, and grooved, and the connection at each node is achieved by welding, bolting, etc., to finally form an integrated spatial frame structure.

[0012] Furthermore, to ensure that the angle does not deviate during assembly, an angle steel (15) is placed at the inner corner of the lightweight chemical equipment (1). The angle steel (15) spans the inner side of the corner point of the two sets of L-shaped brackets (14), and a miniature tilt sensor (7) is provided on the inner side of the outer end of the two rods of the L-shaped bracket (14) to monitor the angle accuracy of the L-shaped wall components on the lightweight chemical equipment (1) in real time, so as to ensure that the forming angle of the L-shaped mold wall components is accurate.

[0013] The method for producing L-shaped thin-shell wall components based on the above-mentioned L-shaped wall components using lightweight chemical equipment includes lightweight chemical equipment (1), precast concrete mold shell (2), hole plugging material (3), tie rod connector (4), steel reinforcement cage (5), and alignment clamp (6). The concrete mold shell (2) and the steel reinforcement cage (5) are precast independently. With the help of lightweight chemical equipment (1), the external corner mold shell (21), internal corner mold shell (22), tie rod connector (4), and steel reinforcement cage (5) inside the concrete mold shell (2) are assembled together in sequence to form a whole, which is then cast. The specific steps include: S1: Precast concrete formwork (2) and steel reinforcement cage (5): According to the detailed design drawings of the project, a certain number of concrete formwork (2) and steel reinforcement cage (5) are precast. The concrete formwork (2) includes external corner formwork (21), internal corner formwork (22), connecting corner bracket (23), toothed groove (24), and bolt holes (25). The connecting corner bracket (23) is embedded in the external corner formwork (21), and the bolt holes (25) are evenly reserved on the internal corner formwork (22). S2: Place two corner mold shells (22) on the lightweight chemical equipment (1). The two corner mold shells (22) are located on the upper surfaces of the inner corners of the L-shaped bracket (14). During this process, it is important to ensure that the corner mold shells (22) are in close contact with the upper surface of the L-shaped bracket (14). S3: Cast the joint of the external corner mold shell (21), and use the plugging material (3) to seal the gaps of the joint of the two external corner mold shells (21) and the connecting corner bracket (23) and the tooth groove (24) tightly, so that the two external corner mold shells (21) can be tightly joined. S4: Arrange tie rods (4) and steel reinforcement cage (5): Install tie rods (4) on the corner formwork (21), and place steel reinforcement cage (5) in the inner corner of the corner formwork (21) according to the construction drawings. The spacing of tie rods (4) is consistent with the spacing of stirrups in steel reinforcement cage (5). S5: Install the internal corner formwork (22). Place the two internal corner formworks (22) on the upper surfaces of the two sides of the steel reinforcement frame (5) in an L-shape, so that the installed tie rod connectors (4) correspond one-to-one with the bolt holes (25) reserved on the internal corner formwork (22). S6: Install clamps and correct deflection: Make correction clamps (6) to clamp the corresponding external corner molds (21) and internal corner molds (22) on both sides of the L-shaped wall component to ensure that the wall thickness meets the design requirements of the drawings; at the same time, screw some discs into the bolt holes (25) in advance to ensure that the wall thickness meets the requirements; S7: Tighten the disc bolts (42) corresponding to the inner disc in the bolt hole (25), and use the plugging material (3) to seal the inner corner seam in the middle of the inner corner mold shell (22) and the bolt holes (25) on the inner corner mold shell (22). Furthermore, the pull-up connector (4) includes a pull rod (41) in the middle and nuts (42) at both ends.

[0014] Furthermore, the tie rod (41) in the tie connector (4) is a slender rod-shaped structure made of metal or basalt fiber material.

[0015] Furthermore, the external corner mold shell (21) may or may not have holes. The external corner mold shell (21) without holes has a nut (42) pre-embedded in which the tie rod (41) of the tie rod can be screwed in. The internal corner mold shell (22) has bolt holes (25) and a certain production tolerance. The tie rods of the external corner mold shell (21) and internal corner mold shell (22) on both sides are achieved by plugging the bolt holes (25) and screwing in the nuts (42).

[0016] Furthermore, the external corner mold shell (21), the steel reinforcement skeleton (5), and the internal corner mold shell (22) are stacked sequentially, and do not need to be flipped during the production process.

[0017] Furthermore, in S1, a miniature tilt sensor is set at the inner corner of the lightweight chemical equipment (1) to monitor the included angle accuracy of the L-shaped wall component on the lightweight chemical equipment (1) in real time, so as to ensure that the forming angle of the L-shaped mold wall component is accurate.

[0018] Furthermore, the external corner mold shell (21) and the internal corner mold shell (22) are prefabricated from high-strength concrete; the plugging material (3) is also made of high-strength concrete.

[0019] Furthermore, during the production of L-shaped formwork wall components, visual feedback control devices for component quality are arranged on both sides of the lightweight chemical installation (1) to monitor the component assembly process in real time. The AI ​​algorithm automatically identifies the quality conditions such as the appearance of the formwork concrete, the alignment of the reinforcing bars, the position of the embedded parts, and the joint gaps, and marks and generates inspection reports in real time, replacing manual quality inspection and improving inspection efficiency and consistency. After the L-shaped formwork wall components are assembled, the overall point cloud data of the components, obtained by the component quality visual feedback control device, is automatically compared with the BIM design model to analyze the component assembly error, generate an error report with millimeter-level accuracy, and the data is synchronously uploaded to the production management system to form a quality traceability chain.

[0020] By adopting the above technical solution, the present invention has at least one of the following beneficial effects compared with the prior art: 1. Reduce equipment investment and production costs Lightweight chemical equipment occupies a small area and is easy to process, requiring no large-scale production line, thus significantly reducing initial fixed investment; the mold shell and steel reinforcement frame are prefabricated separately, facilitating mass production and improving production efficiency; the absence of a mold turning table reduces the requirements for early strength of the mold shell material, thereby reducing material costs.

[0021] 2. Simplify production processes and improve production efficiency. The method of "processing the mold shell and the steel reinforcement skeleton separately and then assembling them together" is adopted to form a simplified L-shaped component production process; the external corner mold shell → steel reinforcement skeleton → internal corner mold shell are stacked and assembled in sequence without flipping during the production process; this avoids the complicated process of "four-time directional zoning material placement + multiple rotation and adjustment" in the existing technology.

[0022] 3. Ensure production quality Angle steel and miniature tilt sensors are installed at the inner corners of the lightweight chemical fittings to monitor the accuracy of the mold angle in real time, ensuring the accurate forming angle of the component (90°) and avoiding the deviation of the L-shaped wall assembly angle; the mold shell and steel reinforcement skeleton are produced separately, which facilitates the roughing treatment of the inner surface of the mold shell, improves the bonding performance between the mold shell and the cast-in-place concrete in the cavity, and ensures the integrity of the structure.

[0023] 4. Enhance production flexibility and adaptability This tooling allows for the flexible and on-demand processing and production of L-shaped wall components on or near the construction site; it meets the needs of flexible production and is adaptable to the production of L-shaped formwork wall components of different sizes and for different projects.

[0024] 5. Optimize the reliability of component connections The external corner mold shell has a pre-embedded nut, and the internal corner mold shell has a hole (with a certain production tolerance). The two mold shells are pulled apart by plugging the hole and screwing in the nut, which ensures the reliability of the connection and takes into account the production tolerance. High-strength plugging material is used to seal the connection seam, internal corner seam and bolt hole to ensure the sealing and integrity of the component.

[0025] 6. Facilitates quality control and calibration A special calibration clamp is set up to hold the external and internal corner molds of the L-shaped wall components to ensure that the wall thickness meets the design requirements of the drawings; some discs can be pre-screwed into the bolt holes to further ensure the accuracy of the wall thickness. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall production process of the L-shaped wall component of the present invention, which is a lightweight chemical equipment. Figure 2 This is a schematic diagram of the external corner mold shell of the present invention; Figure 3 This is a schematic diagram of the internal corner mold shell of the present invention; Figure 4 This is a schematic diagram of the pull-up connector of the present invention; Figure 5 This is a schematic diagram of the assembly of the two external corner mold shells of the present invention; Figure 6 This is a schematic diagram of the casting process for the connecting seam of the external corner mold shell of the present invention; Figure 7 This is a schematic diagram of the tie rod connector and the steel reinforcement cage of the present invention; Figure 8 This is a schematic diagram of the installation of the internal corner mold shell of the present invention; Figure 9 This is a schematic diagram of the connection of the calibration clamp and the sealing of the internal corner seams and bolt holes of the present invention. Detailed Implementation

[0027] The following is in conjunction with the appendix Figure 1-9 The present invention will be further described in detail below to facilitate a clear understanding of the invention, but these descriptions do not constitute a limitation thereof.

[0028] In the description of this invention, it should be noted that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limiting this invention.

[0029] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0030] like Figure 2-9 As shown, the lightweight production tooling and method for the L-shaped wall component in Embodiment 1 above includes lightweight tooling 1, precast concrete mold shell 2, hole plugging material 3, tie rod connector 4, steel reinforcement cage 5, and alignment clamp 6. The concrete mold shell 2 and the steel reinforcement cage 5 are precast independently. With the help of lightweight tooling 1, the external corner mold shell 21, internal corner mold shell 22, tie rod connector 4, steel reinforcement cage 5, etc. in the concrete mold shell 2 are assembled together in sequence to form a whole, and then cast into shape.

[0031] As attached Figure 1 As shown in the figure, a lightweight tooling 1 for producing L-shaped wall components in this embodiment provides a support structure for the production of L-shaped wall components. It mainly includes a base 11, uprights 12, horizontal beams 13, and L-shaped supports 14. Two sets of L-shaped supports 14 are arranged parallel and symmetrically along the length of the tooling. Each set of L-shaped supports 14 is formed by connecting two standard rods arranged at a 90° angle. The two rods are welded and fixed to the upper nodes of the two uprights 12 on the corresponding side. The corners of the L-shaped supports 14 are welded to the middle of the corresponding base 11. The L-shaped supports 14, together with the vertical connection between the uprights 12 and the base 11, form a stable triangular force-bearing unit. The two sets of triangular force-bearing units are connected as a whole by two layers of horizontal beams 13 arranged parallel to each other. The upper horizontal beam 13 is connected to the upper nodes of the uprights 12 of the two sets of triangular force-bearing units, and the lower horizontal beam 13 is connected to the lower nodes of the uprights 12 of the two sets of triangular force-bearing units.

[0032] In this embodiment, the two sets of bases 11 are arranged parallel to each other along the length of the tooling. The bases 11, uprights 12, horizontal beams 13, and L-shaped supports 14 are all made of galvanized square steel pipe profiles, and each node is rigidly connected by full welding to ultimately form an integrated spatial frame structure.

[0033] To ensure that the angle does not deviate during assembly, an angle steel 15 is placed at the inner corner of the lightweight chemical assembly 1. The angle steel 15 spans the inner side of the corner points of the two sets of L-shaped brackets 14, and miniature tilt sensors 7 are installed on the inner side of the outer ends of the two rods of the L-shaped brackets 14 to monitor the included angle accuracy of the L-shaped wall components on the lightweight chemical assembly 1 in real time, so as to ensure the accurate forming angle of the L-shaped mold wall components.

[0034] The production method specifically includes the following steps: S1: Precast concrete formwork 2 and reinforcing steel frame 5: According to the detailed design drawings of the project, a certain number of precast concrete formwork 2 and reinforcing steel frame 5 are constructed, wherein the concrete formwork 2 includes the external corner formwork 21 (e.g., Figure 2 As shown), the inner corner mold shell 22 (as shown) Figure 3 As shown), connecting angle brackets 23, toothed grooves 24, and bolt holes 25 are provided. The connecting angle brackets 23 are pre-embedded in the external corner mold 21, and the bolt holes 25 are evenly pre-drilled on the internal corner mold 22. Miniature tilt sensors are installed on the angle steel 100 at the inner corner of the L-shaped support 14 of the lightweight chemical installation 1 to monitor the included angle accuracy of the L-shaped wall components on the lightweight chemical installation 1 in real time, ensuring the accurate forming angle of the L-shaped mold wall components. The external corner mold 21 and internal corner mold 22 are prefabricated from high-strength concrete.

[0035] S2: As Figure 5 As shown, two external corner mold shells 22 are placed on the lightweight chemical equipment 1. The two external corner mold shells 22 are located on the upper surfaces of the inner corners of the L-shaped bracket 14, respectively. During this process, it is necessary to ensure that the external corner mold shells 22 are tightly fitted to the upper surface of the L-shaped bracket 14. In this embodiment, the upper surfaces of the two rods of the L-shaped bracket 14 are provided with continuous positioning ribs. The positioning ribs extend along the length of the square steel tube, and the height of the ribs is 2mm~5mm. The cross-section of the ribs is semi-circular or trapezoidal. The bottom surface of the external corner mold shell 21 is provided with a positioning groove that cooperates with the positioning ribs. The depth of the positioning groove is 0.5mm~1mm greater than the height of the positioning ribs. When the external corner mold shell 21 is placed on the L-shaped bracket 14, it achieves horizontal limitation through the rib-groove interlocking, while retaining the vertical demolding gap.

[0036] S3: As Figure 6 As shown, when casting the joint of the external corner mold shell 21, the gaps of the connecting corner bracket 23 and tooth groove 24 at the splicing point of the two external corner mold shells 21 are sealed tightly with the hole-sealing material 3, so that the two external corner mold shells 21 can be tightly joined together.

[0037] S4: As Figure 7 As shown, tie rod connectors 4 are arranged (e.g. Figure 4 (As shown) and the reinforcing steel skeleton 5: Tie rods 4 are installed on the external corner formwork 21, and the reinforcing steel skeleton 5 is placed at the inner corner of the external corner formwork 21 according to the construction drawings. The spacing of the tie rods 4 is consistent with the spacing of the stirrups in the reinforcing steel skeleton 5. The tie rods 4 include a tie rod 41 in the middle and nuts 42 at both ends. The tie rod 41 in the tie rods 4 is a slender rod structure supported by metal or basalt fiber material. One side of the external corner formwork 21 has a hole and the other side does not. The side without holes has a nut 42 pre-embedded to screw into the tie rod 41 of the tie rods 41 of the tie rods 4. The internal corner formwork 22 has bolt holes 25 with a certain production tolerance. The tie rods of the external corner formwork 21 and the internal corner formwork 22 are achieved by plugging the bolt holes 25 and screwing in the nuts 42. In step S4, a slow-setting pressure-sensitive adhesive layer with a thickness of 3mm to 8mm is pre-attached or sprayed onto the bottom surface of the inner corner of the corner mold 21. After the steel reinforcement skeleton 5 is placed, its bottom longitudinal reinforcement is temporarily bonded and fixed to the inner surface of the corner mold 21 through the pressure-sensitive adhesive layer. After on-site installation and concrete pouring in the cavity, the pressure-sensitive adhesive layer is wrapped by the concrete and loses its adhesiveness, forming a protective layer of the designed thickness between the steel reinforcement skeleton 5 and the inner surface of the corner mold 21. The bonding strength of the pressure-sensitive adhesive layer is 0.1MPa to 0.5MPa, and the pressure-sensitive adhesive layer is completely degraded within 72 hours in the alkaline environment of concrete.

[0038] S5: As Figure 8 As shown, install the internal corner formwork 22. Place the two internal corner formwork 22 pieces on the upper surfaces of the two sides of the steel reinforcement frame 5 in an L-shape, so that the installed tie rod connector 4 corresponds one-to-one with the bolt holes 25 reserved on the internal corner formwork 22.

[0039] S6: As Figure 9 As shown, the installation of clamps and correction of deflection are performed: Correction clamps 6 are fabricated to hold the corresponding external corner molds 21 and internal corner molds 22 on both sides of the L-shaped wall component, ensuring that the wall thickness meets the design requirements. The correction clamps 6 have slots at both ends, which respectively engage with the external corner molds 21 and internal corner molds 22. At least six sets of correction clamps 6 are arranged around the perimeter of the external corner molds 21 and internal corner molds 22.

[0040] At the same time, a portion of the disc is pre-screwed into the bolt hole 25 to ensure that the wall thickness meets the requirements.

[0041] S7: As Figure 9 As shown, tighten the disc bolts 42 corresponding to the inner disc of the bolt hole 25, and use the plugging material 3 to seal the inner corner seam of the inner corner mold shell 22 and the bolt holes 25 on the inner corner mold shell 22. The plugging material 3 is a high-strength concrete material. The outer corner mold shell 21, the steel reinforcement skeleton 5, and the inner corner mold shell 22 are stacked in sequence and do not need to be flipped during the production process.

[0042] In this embodiment, in step S1, the miniature tilt sensor 7 installed at the inner corner of the lightweight chemical equipment 1 is a dual-axis tilt sensor, which detects the tilt angles α and β of the two rods of the L-shaped bracket 14 relative to the horizontal plane, respectively; in each process of steps S2 to S8, the tilt angle data is transmitted to the controller in real time, and the controller performs closed-loop control according to the following logic: When |α-β|>1°, it is determined that the tooling is tilted as a whole, the process is suspended and an alarm is triggered, prompting the adjustment of the leveling bolts on the base 11; When |α-β|≤1° but |90°-(α+β)|>0.5°, it is determined to be an angle deviation of the L-shaped wall component. The controller outputs a signal to drive the adjusting screw of the correction clamp 6 to automatically tighten, or prompts to add or remove wedge shims between the external corner mold shell 21 and the L-shaped bracket 14 until |90°-(α+β)|≤0.3°.

[0043] In this embodiment, during the production of L-shaped mold wall components, a component quality visual feedback control device is arranged on both sides of the lightweight chemical equipment (1) to monitor the component assembly process in real time. The AI ​​algorithm automatically identifies the quality conditions such as the appearance of the mold concrete, the alignment of the steel bars, the position of the embedded parts, and the joint gaps, and marks and generates a test report in real time to replace manual quality inspection and improve the efficiency and consistency of the test. After the L-shaped formwork wall components are assembled, the overall point cloud data of the components, obtained by the component quality visual feedback control device, is automatically compared with the BIM design model to analyze the component assembly error, generate an error report with millimeter-level accuracy, and the data is synchronously uploaded to the production management system to form a quality traceability chain.

[0044] This invention achieves the production goals of "low cost, high efficiency, high quality, and high flexibility" through the technical route of "lightweight chemical equipment + modular prefabrication + sequential assembly". It effectively solves the key technical problems existing in the current large-scale flipping mold table process, such as large equipment investment, complex process, many flipping times, high material cost, and inconvenient internal surface treatment.

[0045] The above are merely preferred embodiments of the present invention and do not constitute any limitation on the structure of the present invention. The arrangement and quantity of the present invention are not limited to this example and can be optimized according to actual engineering conditions. Any modifications, equivalent changes, and decorations made to the above embodiments based on the technical principles of the present invention, without departing from the scope of the present invention, are still within the scope of the present invention.

Claims

1. A lightweight chemical processing equipment (1) for producing L-shaped wall components, used to provide a supporting structure for the production of L-shaped wall components, characterized in that: It mainly includes a base (11), a vertical pole (12), a horizontal beam (13), and an L-shaped bracket (14). The two sets of L-shaped supports (14) are arranged in parallel and symmetrical along the length of the tooling. Each set of L-shaped supports (14) is formed by connecting two rods arranged at a 90° angle. The L-shaped supports (14) are connected and fixed to the upper nodes of the two uprights (12) on the corresponding side. The corner of the L-shaped supports (14) is connected to the middle of the base (11) on the corresponding side. The L-shaped supports (14) are connected to the uprights (12) and the base (11) to form a stable triangular force unit. The two sets of triangular force units are connected as a whole by two layers of horizontal beams (13) arranged in parallel. The upper horizontal beam (13) is connected to the upper node of the uprights (12) of the two sets of triangular force units, and the lower horizontal beam (13) is connected to the lower node of the uprights (12) of the two sets of triangular force units.

2. The lightweight chemical equipment for producing an L-shaped wall component according to claim 1, characterized in that: Two sets of bases (11) are arranged parallel to each other along the length of the tooling; the base (11), upright (12), horizontal beam (13), and L-shaped bracket (14) can be made of standard profiles such as rectangular, H-shaped, angular, and grooved. The connection at each node is achieved by welding, bolting, etc., and finally an integrated spatial frame structure is formed.

3. A method for producing an L-shaped thin-shell wall component based on the L-shaped wall component of any one of claims 1-2, comprising the lightweight chemical assembly (1), a precast concrete mold shell (2), grouting material (3), tie rod connectors (4), a reinforcing steel skeleton (5), and a correction clamp (6), characterized in that: The concrete formwork (2) and the reinforcing steel frame (5) are prefabricated independently. With the help of lightweight chemical equipment (1), the external corner formwork (21), internal corner formwork (22), tie rod connector (4), and reinforcing steel frame (5) inside the concrete formwork (2) are assembled together in sequence to form a whole, which is then cast. The specific steps include: S1: Precast concrete formwork (2) and steel reinforcement cage (5): According to the detailed design drawings of the project, a certain number of concrete formwork (2) and steel reinforcement cage (5) are precast. The concrete formwork (2) includes external corner formwork (21), internal corner formwork (22), connecting corner bracket (23), toothed groove (24), and bolt holes (25). The connecting corner bracket (23) is embedded in the external corner formwork (21), and the bolt holes (25) are evenly reserved on the internal corner formwork (22). S2: Place two corner mold shells (22) on the lightweight chemical equipment (1). The two corner mold shells (22) are located on the upper surfaces of the inner corners of the L-shaped bracket (14). During this process, it is important to ensure that the corner mold shells (22) are in close contact with the upper surface of the L-shaped bracket (14). S3: Cast the joint of the external corner mold shell (21), and use the plugging material (3) to seal the gaps of the joint of the two external corner mold shells (21) and the connecting corner bracket (23) and the tooth groove (24) tightly, so that the two external corner mold shells (21) can be tightly joined. S4: Arrange tie rods (4) and steel reinforcement cage (5): Install tie rods (4) on the corner formwork (21), and place steel reinforcement cage (5) in the inner corner of the corner formwork (21) according to the construction drawings. The spacing of tie rods (4) is consistent with the spacing of stirrups in steel reinforcement cage (5). S5: Install the internal corner formwork (22). Place the two internal corner formworks (22) on the upper surfaces of the two sides of the steel reinforcement frame (5) in an L-shape, so that the installed tie rod connectors (4) correspond one-to-one with the bolt holes (25) reserved on the internal corner formwork (22). S6: Install clamps and correct deflection: Make correction clamps (6) to clamp the corresponding external corner molds (21) and internal corner molds (22) on both sides of the L-shaped wall component to ensure that the wall thickness meets the design requirements of the drawings; at the same time, screw some discs into the bolt holes (25) in advance to ensure that the wall thickness meets the requirements; S7: Tighten the disc bolts (42) corresponding to the inner disc of the bolt hole (25), and use the plugging material (3) to seal the inner corner seam in the middle of the inner corner mold shell (22) and the bolt holes (25) on the inner corner mold shell (22).

4. The method for producing L-shaped thin-shell wall components according to claim 3, characterized in that: The pull-up connector (4) includes a middle pull rod (41) and nuts (42) at both ends.

5. The method for producing L-shaped thin-shell wall components according to claim 4, characterized in that: The tie rod (41) in the tie connector (4) is a slender rod-shaped structure made of metal or basalt fiber material.

6. The method for producing L-shaped thin-shell wall components according to claim 3, characterized in that: The external corner mold shell (21) may or may not have holes. The external corner mold shell (21) without holes has a nut (42) pre-embedded in which the tie rod (41) of the tie rod can be screwed in. The internal corner mold shell (22) has bolt holes (25) and a certain production tolerance. The tie rods of the external corner mold shell (21) and internal corner mold shell (22) on both sides are achieved by plugging the bolt holes (25) and screwing in the nuts (42).

7. The method for producing L-shaped thin-shell wall components according to claim 3, characterized in that: The external corner mold shell (21), the steel reinforcement skeleton (5), and the internal corner mold shell (22) are stacked in sequence and do not need to be flipped during the production process.

8. The method for producing L-shaped thin-shell wall components according to claim 3, characterized in that: In S1, a miniature tilt sensor is installed at the inner corner of the lightweight chemical equipment (1) to monitor the included angle accuracy of the L-shaped wall component on the lightweight chemical equipment (1) in real time, so as to ensure that the forming angle of the L-shaped mold wall component is accurate.

9. The method for producing L-shaped thin-shell wall components according to claim 3, characterized in that: The external corner mold shell (21) and the internal corner mold shell (22) are prefabricated from high-strength concrete; the plugging material (3) is also made of high-strength concrete.

10. The method for producing L-shaped thin-shell wall components according to claim 3, characterized in that: During the production of L-shaped formwork wall components, visual feedback control devices for component quality are arranged on both sides of the lightweight chemical equipment (1) to monitor the component assembly process in real time. The AI ​​algorithm automatically identifies the quality conditions such as the appearance of the formwork concrete, the alignment of the reinforcing bars, the position of the embedded parts, and the gap of the joints. The system marks and generates inspection reports in real time, replacing manual quality inspection and improving inspection efficiency and consistency. After the L-shaped formwork wall components are assembled, the overall point cloud data of the components, obtained by the component quality visual feedback control device, is automatically compared with the BIM design model to analyze the component assembly error, generate an error report with millimeter-level accuracy, and the data is synchronously uploaded to the production management system to form a quality traceability chain.

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