Intelligent production line based on flow beam manufacturing of intelligent beam factory

Abstract

The utility model relates to an intelligent production line based on assembly line beam manufacturing of an intelligent beam factory. A control module controls a prefabrication module, a conveying module, a maintenance module and a finished product storage module to be matched to achieve assembly line type prefabricated beam production. According to the invention, the whole life cycle process monitoring of precast beam production, such as precast beam steel bar binding and mounting, concrete pouring and vibrating, template opening, closing and adjusting, maintenance, storage and the like, is realized, so that the remote management efficiency of precast beam production and the quality of precast beams are improved, the safety production is ensured, and the material cost is reduced.

Description

Technical Field

[0001] The utility model relates to an intelligent production line based on flow beam manufacturing in a smart beam factory, belonging to the technical field of prefabricated beam production. Background Art

[0002] With the rapid development of my country's infrastructure, large-scale simply supported to continuous bridges are widely built, and beams and slabs that need to be prefabricated are more common. At present, the traditional bridge manufacturing industry has become more mature, and the production of prefabricated beams has gradually developed towards industrialization, standardization, specialization, integration, and informatization. This will greatly improve the construction quality, safety, efficiency and environmental friendliness of bridges. However, the current development of industrialization, standardization, specialization, integration, and informatization of prefabricated beams is still insufficient, and the traditional production model still occupies a dominant position.

[0003] However, the traditional production model of prefabricated beam prefabrication and transfer processes has many common quality problems, low construction efficiency, high material waste, and high safety hazards due to management problems. Utility Model Content

[0004] The purpose of the utility model is to provide an intelligent production line based on assembly line beam making in a smart beam factory, which realizes assembly line production of prefabricated beams and promotes the remote management efficiency of prefabricated beam production as well as the improvement of quality, safety and cost-effectiveness.

[0005] In order to achieve the above-mentioned purpose, the utility model provides the following technical solutions: an intelligent production line for beam production based on a smart beam factory, the intelligent production line comprising:

[0006] Precast modules, including a reinforcement processing unit, a formwork unit, a casting unit and a vibrating unit for making precast beams;

[0007] A conveying module, comprising a conveying track and a movable platform arranged on the conveying track, wherein the movable platform is used to place the template unit and convey the precast beam;

[0008] A maintenance module, used for maintaining the prefabricated beams;

[0009] A finished product storage module, comprising a storage area for storing the prefabricated beams and a hoisting unit for hoisting the prefabricated beams;

[0010] The control module is signal-connected with the prefabrication module, the conveying module, the curing module and the finished product storage module.

[0011] Furthermore, the template unit includes an outer mold, a core mold arranged in the outer mold, and an adjustment mechanism connected to the core mold, and the adjustment mechanism is used to adjust the assembly accuracy of the core mold and the outer mold.

[0012] Furthermore, the adjustment mechanism includes an adjustment screw arranged at the top of the core mold in the vertical direction, a back-pressure beam arranged along the width direction of the core mold, a tensioning rope connected to both ends of the back-pressure beam, and a fixing structure fixedly connected to the tensioning rope, and the adjustment screw is threadedly connected to the core mold and the back-pressure beam respectively.

[0013] Furthermore, the tensioning rope includes a wire rope tightener and a wire rope connecting two ends of the wire rope tightener.

[0014] Furthermore, the movable platform includes a traveling mechanism matched with the track, a load-bearing mechanism arranged on the traveling mechanism, and an opening and closing mechanism arranged on the load-bearing mechanism for opening and closing the outer mold.

[0015] Furthermore, the opening and closing mechanism includes a sliding contact base, a sliding shoe arranged on the sliding contact base, and a driving member driving the sliding shoe to move on the sliding contact base.

[0016] Furthermore, the hoisting unit includes a slide rail and a gantry crane mechanism slidably arranged on the slide rail.

[0017] Furthermore, the extension direction of the slide rail is perpendicular to the extension direction of the conveying track, and a synchronous rail mechanism is arranged at the intersection of the slide rail and the conveying track. The synchronous rail mechanism includes a support seat, a power member installed under the support seat, and a synchronous rail arranged on the support seat. Under the action of the power member, the synchronous rail rotates to connect the slide rail or the conveying track.

[0018] Furthermore, the curing module includes a high-temperature steam curing unit and a spray water curing unit which are sequentially arranged along the extending direction of the conveying track.

[0019] Furthermore, the steel bar processing unit includes a processing platform for processing the bottom plate steel bar skeleton, the bottom web plate steel bar skeleton and the top plate steel bar skeleton.

[0020] The beneficial effect of the utility model is that the present application realizes assembly line production of precast beams by controlling the prefabrication module, the conveying module, the maintenance module and the finished product storage module through the control module, and realizes the process monitoring of the whole life cycle of precast beam production, including the binding and installation of precast beam reinforcement, the pouring and vibration of concrete, the opening and closing and adjustment of the formwork, the maintenance and storage, thereby improving the remote management efficiency of precast beam production and the quality of precast beams, ensuring safe production and reducing material costs.

[0021] The above description is only an overview of the technical solution of the utility model. In order to more clearly understand the technical means of the utility model and implement it according to the contents of the specification, the following is a detailed description of the preferred embodiments of the utility model in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] Figure 1 This is a schematic diagram of the structure of an intelligent production line based on assembly line beam manufacturing in a smart beam factory as shown in one embodiment of the present application.

[0023] Figure 2 for Figure 1 Schematic diagram of the structure of the template unit.

[0024] Figure 3 for Figure 1 Schematic diagram of the structure of the synchronous orbit mechanism. DETAILED DESCRIPTION

[0025] The following is a further detailed description of the specific implementation of the present invention in conjunction with the accompanying drawings and examples. The following examples are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0026] In the description of the present invention, it is necessary to understand that the terms "center", "longitudinal", "lateral", "axial", "radial", "circumferential", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention.

[0027] In addition, the terms "first" and "second" are used for descriptive purposes only and should not be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present utility model, the meaning of "plurality" is two or more, unless otherwise clearly and specifically defined.

[0028] In the present utility model, unless otherwise clearly specified and limited, the terms "installed", "connected", "connected", "fixed" and the like should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral one; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium, it can be the internal connection of two elements or the interaction relationship between two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present utility model can be understood according to the specific circumstances. In addition, in the present utility model, unless otherwise clearly specified and limited, the first feature "on" or "under" the second feature can be that the first and second features are in direct contact, or the first and second features are in indirect contact through an intermediate medium.

[0029] In the description of this specification, the description with reference to the terms "one embodiment", "some embodiments", "example", "specific example", or "some examples" means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the utility model. In this specification, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described can be combined in any one or more embodiments or examples in a suitable manner.

[0030] Please refer to Figures 1 to 3 ,An intelligent production line based on the assembly line beam production of a smart beam factory (hereinafter referred to as "intelligent production line") shown in an embodiment of the present application includes a control module, a prefabrication module 1, a conveying module, a maintenance module and a finished product storage module 8. The intelligent production line can be set up in parallel, and a return track 3 is set between two adjacent production lines, so that the mobile platform 11 can turn around and return in the storage area, avoiding the mobile platform 11 from returning from the conveying track 2, so as to improve work efficiency.

[0031] The prefabricated module 1 includes a steel bar processing unit, a template unit, a casting unit and a vibrating unit for making prefabricated beams. The steel bar processing unit includes a processing platform for processing the bottom plate steel bar skeleton, the bottom web steel bar skeleton and the top plate steel bar skeleton. A corrugated pipe is arranged in the bottom web steel bar skeleton to install a prestressing device for reducing the tensile stress of concrete under load. The prestressing device is a conventional technology and will not be described in detail here.

[0032] The template unit includes an outer mold 12, a core mold 14 arranged in the outer mold 12, and an adjustment mechanism 13 connected to the core mold 14, and the adjustment mechanism 13 is used to adjust the assembly accuracy of the core mold 14 and the outer mold 12. The outer mold 12 includes a bottom mold 121 and side molds 122 installed on both sides of the bottom mold 121. The side molds 122 and the bottom mold 121 are surrounded to form a trapezoidal cavity. The core mold 14 is placed in the trapezoidal cavity. Before placing the core mold 14, the bottom plate steel bar skeleton is placed first, and then the bottom web steel bar skeleton is placed. The bottom web steel bar skeleton is placed obliquely on the side mold 122. Finally, the core mold 14 is placed between the two bottom web steel bar skeletons, and the assembly accuracy of the core mold 14 and the outer mold 12 is adjusted by the adjustment mechanism 13.

[0033] A safety passage and an operating platform are provided in the longitudinal direction of the outer mold 12 so that the staff can work on the operating platform provided on the top of the outer mold 12.

[0034] The adjusting mechanism 13 includes an adjusting screw 132 arranged at the top of the core mold 14 along the vertical direction, a back pressure beam 131 arranged along the width direction of the core mold 14, a tensioning rope connected to both ends of the back pressure beam 131, and a fixing structure 135 for fixing the tensioning rope. The adjusting screw 132 is threadedly connected to the core mold 14 and the back pressure beam 131 respectively. The tensioning rope includes a wire rope tightener 133 and a wire rope 134 connecting both ends of the wire rope tightener 133. Among them, two adjusting screws 132 are provided, and the two adjusting screws 132 are arranged at intervals at the top of the core mold 14 along the width direction of the core mold 14. By adjusting the wire rope tighteners 133 on both sides to make the wire rope 134 tension the back pressure beam 131, the installation angle of the core mold 14 is adjusted to meet the assembly accuracy requirements of the core mold 14 and the outer mold 12. At the same time, it is used to apply a back pressure anti-floating force to the core mold 14 to ensure the structural size of the prefabricated beam. Of course, when the assembly accuracy requirement is not met by adjusting the tension and expansion, the screw 132 can be adjusted to assist in the adjustment.

[0035] In addition, the entire adjusting structure continues to maintain the tensioned state of the core mold 14 after the assembly accuracy is adjusted, and it is removed after the bottom plate and bottom web of the precast beam are cast. This is to avoid the movement of the core mold 14 during the casting process, which affects the quality of the precast beam. After the adjusting mechanism 13 is removed, the top plate steel bar skeleton is placed on the core mold 14 and concrete is cast, thereby completing the entire precast beam manufacturing process. After the concrete solidifies, the core mold 14 is pulled out and moved to the maintenance module under the action of the conveying module for maintenance.

[0036] It should be noted that the tensioning rope is arranged in the vertical direction. In this embodiment, the fixed structure 135 is a support beam of the same length as the counter-pressure beam 131, and the support beam is fixedly arranged at the bottom of the bottom mold 121, so that when the tensioning rope is tensioned, the counter-pressure beam 131, the support beam and the tensioning rope are in a rectangular structure. In other embodiments, the fixed structure 135 can also be a fixed part, a pull ring or other structure pre-buried in the ground, as long as the above-mentioned effect can be achieved, and it is not limited here.

[0037] The conveying module comprises a conveying track 2 and a moving platform 11 arranged on the conveying track 2. The moving platform 11 is used for placing the template unit and conveying the precast beam.

[0038] The movable platform 11 includes a traveling mechanism coordinated with the track, a load-bearing mechanism arranged on the traveling mechanism, and an opening and closing mechanism (not shown) arranged on the load-bearing mechanism for opening and closing the outer mold 12. The opening and closing mechanism includes a sliding base, a sliding shoe arranged on the sliding base, and a driving member driving the sliding shoe to move on the sliding base, wherein the driving member is a hydraulic jack, and the sliding base is provided with a slope so that the sliding shoe moves on the sliding base under the action of the hydraulic jack, thereby driving the side mold 122 to move, thereby realizing the position adjustment of the side mold 122 in the horizontal and vertical directions. The opening and closing mechanism also includes a displacement sensor, which realizes real-time monitoring of the jack stroke and the template position through the displacement sensor, so as to accurately control the opening and closing of the template.

[0039] The load-bearing mechanism also includes a shock-absorbing structure (not shown), which is used for absorbing energy and reducing shock during concrete vibration and mold opening and closing.

[0040] An earth pressure gauge is provided below the conveying track 2 , and the earth pressure gauge is connected to the measuring instrument and the control module signal, so that the staff can monitor the position of the mobile platform 11 in real time.

[0041] The curing module is used to maintain the prefabricated beams, and the curing module includes a high-temperature steam curing unit 4 and a spray water curing unit 5 which are sequentially arranged along the extension direction of the conveying track 2. The high-temperature steam curing unit 4 includes a high-temperature steam curing shed, which is built according to the standard of a constant temperature curing room and uses biomass fuel. The fuel is placed in a biomass generator, and the combustion reaction is sufficient without waste, and no gas harmful to the atmosphere is generated. This is a prior art and will not be described in detail here.

[0042] The finished product storage module 8 includes a storage area for storing precast beams and a hoisting unit for hoisting the precast beams. The hoisting unit includes a slide rail 6 and a gantry crane mechanism 7 slidably arranged on the slide rail 6. The gantry crane mechanism 7 is a prior art and will not be described in detail here.

[0043] In this embodiment, the extension direction of the slide rail 6 is perpendicular to the extension direction of the conveying track 2. A synchronous track mechanism 9 is provided at the intersection of the slide rail 6 and the conveying track 2. The synchronous track mechanism 9 includes a support seat 91, a power member (not shown) installed below the support seat 91, and a synchronous track 92 provided on the support seat 91. Under the action of the power member, the synchronous track 92 rotates to connect the slide rail 6 or the conveying track 2. The power member is a driving motor.

[0044] The control module is connected to the prefabrication module 1, the conveying module, the curing module and the finished product storage module 8 by signals to control the cooperation of each module. The control module includes an intelligent hydraulic system, a variable frequency vibration system, a mobile pedestal control system and a steam curing control system.

[0045] The intelligent hydraulic system realizes automatic extension and retraction of the jack through the electromagnetic reversing valve, drives the sliding shoe and the side mold 122 to slide along the sliding contact base, realizes the adjustment of the side mold 122 in the horizontal and vertical directions, and realizes real-time monitoring of the jack stroke and the template position through the displacement sensor to accurately control the opening and closing of the template.

[0046] The variable frequency vibration system includes a variable frequency vibrator, a PLC control cabinet, a digital display touch tablet computer, an intelligent variable frequency vibration program, etc. The variable frequency vibrator is a touch-type vibrator, and the touch-type vibrator is attached to the outer mold 12. The variable frequency vibration system realizes human-computer interaction through devices such as a digital display touch tablet computer, thereby controlling the start and stop of the variable frequency vibrator, the adjustment of vibration intensity, the vibration sequence and the vibration time, thereby realizing intelligent, visualized and intensive vibration of concrete without physical contact.

[0047] The mobile pedestal control system includes a return control system, a walking control system, a wireless remote control, and a monitoring system. The mobile pedestal 11 is commanded by the wireless remote control, and the moving speed is adjustable in multiple gears. The walking control system and the return control system are combined to control the movement of the pedestal to perform assembly-line construction operations in the workshop. At the overlap of the working area of ​​the mobile pedestal 11 and the lifting unit, in order to ensure safety and controllability, the gantry's allowed posture is monitored in real time, and the mobile pedestal 11 is monitored by video at the same time, and long-distance inspections and shouting can be carried out to ensure the safe movement of the mobile pedestal 11.

[0048] After the precast beam is moved to the high-temperature steam curing shed on the mobile pedestal 11, the steam curing control system automatically adjusts the temperature in the shed according to the set temperature curve, and monitors in real time through the temperature sensor set in the high-temperature steam curing shed, achieving high efficiency and energy saving to improve the strength and elastic modulus of concrete, avoiding manual monitoring of temperature and manual adjustment of valves. The steam curing control system is equipped with an audible and visual warning component, which reminds the staff to move the precast beam in time at the beginning, during and after steam curing, and at the same time, ensures that there are no personnel who have not evacuated in time in the steam curing shed before the steam curing function is turned on, to avoid safe construction and ensure the personal safety of the staff.

[0049] The present application realizes assembly-line production of precast beams by controlling the prefabrication module, the conveying module, the maintenance module and the finished product storage module through a control module, and realizes process monitoring of the entire life cycle of precast beam production, including binding and installation of precast beam reinforcement, pouring and vibration of concrete, opening and closing of formwork and adjustment, maintenance, storage, etc., thereby improving the remote management efficiency of precast beam production and the quality of precast beams, ensuring safe production and reducing material costs.

[0050] The technical features of the above-described embodiments may be arbitrarily combined. To make the description concise, not all possible combinations of the technical features in the above-described embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0051] The above-mentioned embodiments only express several implementation methods of the utility model, and the description is relatively specific and detailed, but it cannot be understood as limiting the scope of the utility model patent. It should be pointed out that for ordinary technicians in this field, several modifications and improvements can be made without departing from the concept of the utility model, which all belong to the protection scope of the utility model. Therefore, the protection scope of the utility model patent shall be based on the attached claims.

Claims

1. An intelligent production line based on the assembly line of smart beam factory, characterized in that: The intelligent production line comprises: Precast modules, including a reinforcement processing unit, a formwork unit, a casting unit and a vibrating unit for making precast beams; A conveying module, comprising a conveying track and a movable platform arranged on the conveying track, wherein the movable platform is used to place the template unit and convey the precast beam; A maintenance module, used for maintaining the prefabricated beams; A finished product storage module, comprising a storage area for storing the prefabricated beams and a hoisting unit for hoisting the prefabricated beams; The control module is signal-connected with the prefabrication module, the conveying module, the curing module and the finished product storage module.

2. The intelligent production line based on the smart beam factory assembly line as claimed in claim 1 is characterized in that: The template unit includes an outer mold, a core mold arranged in the outer mold, and an adjustment mechanism connected to the core mold, wherein the adjustment mechanism is used to adjust the assembly accuracy of the core mold and the outer mold.

3. The intelligent production line based on the smart beam factory assembly line as claimed in claim 2 is characterized in that: The adjustment mechanism includes an adjustment screw arranged at the top of the core mold in the vertical direction, a back-pressure beam arranged along the width direction of the core mold, a tensioning rope connected to both ends of the back-pressure beam, and a fixing structure fixedly connected to the tensioning rope. The adjustment screw is threadedly connected to the core mold and the back-pressure beam respectively.

4. The intelligent production line based on the smart beam factory assembly line as claimed in claim 3 is characterized in that: The tensioning rope comprises a wire rope tightener and a wire rope connecting two ends of the wire rope tightener.

5. The intelligent production line based on the smart beam factory assembly line as claimed in claim 2 is characterized in that: The movable platform comprises a running mechanism matched with the track, a load-bearing mechanism arranged on the running mechanism, and an opening and closing mechanism arranged on the load-bearing mechanism for opening and closing the outer mold.

6. The intelligent production line based on the smart beam factory assembly line as claimed in claim 5 is characterized in that: The opening and closing mechanism comprises a sliding contact base, a sliding shoe arranged on the sliding contact base, and a driving member for driving the sliding shoe to move on the sliding contact base.

7. The intelligent production line based on the assembly line of the smart beam factory as claimed in claim 1 is characterized in that: The hoisting unit comprises a slide rail and a gantry crane mechanism slidably arranged on the slide rail.

8. The intelligent production line based on the assembly line of the smart beam factory as claimed in claim 7 is characterized in that: The extension direction of the slide rail is perpendicular to the extension direction of the conveying track. A synchronous rail mechanism is arranged at the intersection of the slide rail and the conveying track. The synchronous rail mechanism includes a support seat, a power member installed under the support seat and a synchronous rail arranged on the support seat. Under the action of the power member, the synchronous rail rotates to connect the slide rail or the conveying track.

9. The intelligent production line based on the assembly line of the smart beam factory as claimed in claim 1 is characterized in that: The curing module comprises a high-temperature steam curing unit and a spray water curing unit which are sequentially arranged along the extending direction of the conveying track.

10. The intelligent production line based on the assembly line of the smart beam factory as claimed in claim 1 is characterized in that: The steel bar processing unit comprises a processing platform for processing a bottom plate steel bar skeleton, a bottom web plate steel bar skeleton and a top plate steel bar skeleton.

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