An automatic production line for kiln precast

Abstract

The utility model belongs to the prefabricated part production technical field of kiln, especially is involved in a kind of kiln prefabricated part automatic production line, including track, transfer trolley moving along track, first pouring unit and second pouring unit, be equipped with mould on transfer trolley, first pouring unit and second pouring unit are continuously arranged along mould transportation direction, transfer trolley is used to send mould to first pouring unit and from second pouring unit transfer mould that has completed double-layer pouring, mould is after first pouring unit completes first layer pouring, continuously into second pouring unit and carries out second layer pouring, without transfer trolley participation interlayer transfer.The utility model effectively solves the problem that the existing production line interlayer transfer time is long, and interlayer combination quality is unstable, improves production efficiency and interlayer combination strength.

Description

Technical Field

[0001] This utility model belongs to the field of kiln prefabrication technology, and in particular relates to an automated production line for kiln prefabrication. Background Technology

[0002] Vibration casting is a key process in the production of precast components for kiln centers. With the continuous improvement of product performance and structural requirements, double-layer or multi-layer casting has become a common process, which places higher demands on the quality of interlayer interface bonding, production cycle stability, and process consistency.

[0003] Currently, the production line uses a separate casting mode: after the first layer of casting is completed at the first station, the mold needs to be transported to the second station via transfer equipment (such as a transfer trolley or overhead crane) for the second layer of casting. This cross-station transfer production mode has revealed many shortcomings in practical applications: First, the transfer time has a significant impact on the quality of interlayer bonding. Between the completion of the first layer pouring and the start of the second layer pouring, there are inevitably steps such as mold transfer, waiting, and re-connection. The entire process can easily miss the optimal time window for interlayer bonding, resulting in excessively high initial setting degree of the first layer surface, reduced interfacial bonding strength between the first and second layers, and consequently, quality defects such as delamination, hollowness, or cracking.

[0004] Secondly, maintaining consistent production efficiency and cycle time is difficult. Cross-station material handling requires coordination across multiple stages: mold hoisting, trolley movement, and repositioning at the second station. Each stage relies on human-machine collaboration, making the entire process time-consuming and highly volatile. Especially during multi-batch continuous production, the uncertainty in the material handling process makes it difficult to stabilize the production cycle time, directly limiting the production line's capacity utilization and the improvement of automation levels. Utility Model Content

[0005] In view of the technical problems existing in the background art, this utility model provides an automated production line for kiln prefabrication components.

[0006] To achieve the above objectives, the technical solution provided by this utility model is as follows: A double-layer continuous casting production line for kiln precast components is characterized by comprising a track, a transfer trolley that moves along the track, a first casting unit and a second casting unit, wherein the transfer trolley is equipped with a mold. The first and second casting units are arranged continuously along the mold transport direction. The transfer trolley is used to transport the mold to the first casting unit and to transfer the mold that has completed double-layer casting from the second casting unit. After the mold completes the first layer of pouring in the first pouring unit, it continuously enters the second pouring unit to pour the second layer, without the need for a transfer trolley to participate in the inter-layer transfer.

[0007] Optionally, the first casting unit includes a first vibrating table, a first stirring device, and a first feeding device. The first vibrating table is provided with a first conveying roller group for transferring the mold that has completed the first layer of casting to the second casting unit.

[0008] Optionally, the second casting unit includes a second vibrating table, a second stirring device, and a second feeding device. The feeding end of the second vibrating table is provided with a guide roller to guide the mold from the first vibrating table into the center position of the second vibrating table. The second vibrating table is also provided with a second conveying roller group.

[0009] Optionally, the first vibration table and the second vibration table are at the same height and close to each other, and both the first vibration table and the second vibration table include a vibration motor, a positioning clamping roller and a vibration block.

[0010] Optionally, the first conveyor roller group includes a frame and multiple sets of conveyor rollers. The conveyor rollers are driven to rotate synchronously through a chain drive mechanism. The first conveyor roller group has the same structure as the second conveyor roller group.

[0011] Optionally, both the first and second mixing devices include a mixer and a hopper, with the hopper located directly above the mold and a valve plate inside the hopper.

[0012] Optionally, both the first and second feeding devices include a lifting guide rail, a hopper, and a lifting assembly; the lifting assembly is used to lift the casting material to a preset height and then supply it to the mixing device.

[0013] Optionally, a control cabinet is also included, which contains a control system that is electrically connected to the transfer trolley, the first casting unit, and the second casting unit, respectively, for coordinating and controlling the operation of the entire production line.

[0014] This utility model has the following advantages and beneficial effects: This invention, through the continuous arrangement of the first and second casting units and the installation of a first conveying roller group on the first vibrating table, allows the mold to be directly transferred to the second casting unit after the first layer of casting is completed, eliminating the need for a transfer trolley for inter-layer transfer. Utilizing the timing coordination function of the control system, the feeding and mixing actions of the second casting unit are performed in parallel with the vibration and transfer processes of the first casting unit. When the mold is transferred to the second vibrating table, the second layer of casting material has already been mixed and can be poured immediately. This effectively solves the problem of slow cycle time in existing production lines and improves production efficiency.

[0015] Furthermore, due to the shortened interlayer bonding time, the initial setting degree of the first layer surface is lower, allowing for better interfacial bonding with the second layer. This improves interfacial bonding strength and reduces quality defects such as delamination, hollow areas, and cracking, effectively solving the problem of unstable interlayer bonding quality in existing production lines. The entire production line achieves tight integration of various functional modules through optimized conveyor roller sets and a control system, improving equipment reliability and the continuity and stability of the production line. Attached Figure Description

[0016] Figure 1 This is a layout diagram of the automated production line for kiln prefabrication components of this utility model; Figure 2 This is a structural diagram of the casting unit of this utility model; Figure 3 This is a partial view of the automatic production line for kiln prefabrication components of this utility model.

[0017] Reference numerals: 1. Track; 2. Transfer trolley; 3. First casting unit; 31. First vibrating table; 311. First conveying roller group; 32. First mixing device; 33. First feeding device; 4. Second casting unit; 41. Second vibrating table; 411. Guide roller; 412. Second conveying roller group; 42. Second mixing device; 43. Second feeding device; 5. Mold; 6. Vibrating motor; 7. Positioning clamping roller; 8. Vibrating block; 9. Frame; 10. Conveying roller; 11. Mixer; 12. Discharge hopper; 13. Valve plate; 14. Lifting guide rail; 15. Hopper; 16. Lifting assembly; 17. Control cabinet. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are some embodiments of this utility model, but not all embodiments.

[0019] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0020] Example like Figures 1-3As shown, an automated production line for kiln precast components includes a track 1, a transfer trolley 2, a first casting unit 3, and a second casting unit 4. The track 1 is laid longitudinally along the production workshop, and the transfer trolley 2 runs back and forth along the track 1. The transfer trolley 2 is equipped with a mold 5 for carrying the blank of the kiln precast component. The first casting unit 3 and the second casting unit 4 are arranged continuously along the transport direction of the mold 5. The transfer trolley 2 is used to transport the empty mold 5 to the first casting unit 3 and to transfer the mold 5 that has completed double-layer casting from the second casting unit 4. After the mold 5 completes the first layer of pouring in the first pouring unit 3, it continuously enters the second pouring unit 4 to pour the second layer. The entire interlayer transfer process does not require the participation of the transfer trolley 2, thus realizing continuous and automated production of double-layer pouring.

[0021] Furthermore, the first casting unit 3 includes a first vibrating table 31, a first stirring device 32, and a first feeding device 33. The first vibrating table 31 is equipped with a first conveying roller group 311, which is used to transfer the mold 5 that has completed the first layer of casting to the second casting unit 4. The first feeding device 33 lifts the casting material and pours it into the first stirring device 32. After stirring and mixing, the casting material is injected into the mold 5. The first vibrating table 31 starts to vibrate to compact the casting material. After the vibration is completed, the first conveying roller group 311 automatically starts to smoothly transfer the mold 5 to the second casting unit 4.

[0022] Furthermore, the second casting unit 4 includes a second vibrating table 41, a second stirring device 42, and a second feeding device 43. The feeding end of the second vibrating table 41 is equipped with guide rollers 411 to guide the mold 5 from the first vibrating table 31 into the center position of the second vibrating table 41. The second vibrating table 41 is also equipped with a second conveying roller group 412. The guide rollers 411 are positioned on both sides of the feeding end of the second vibrating table 41 to ensure precise alignment of the mold 5 and prevent misalignment. The working principle of the second feeding device 43 and the second stirring device 42 is similar to that of the first casting unit 3, completing the preparation and casting of the second layer of casting material.

[0023] Furthermore, the first vibration table 31 and the second vibration table 41 are at the same height and close to each other. Both the first vibration table 31 and the second vibration table 41 include a vibration motor 6, a positioning clamping roller 7, and a vibration block 8. The consistent height of the two vibration tables allows for a smooth transition of the mold 5 without the need for hoisting or lifting. The close proximity design controls the distance between the two tables to 50-300mm, preferably 100-200mm, ensuring rapid transfer while providing necessary space for equipment maintenance. The vibration generated by the vibration motor 6 is transmitted to the bottom of the mold 5 through the vibration block 8, and the positioning clamping roller 7 positions and clamps the mold 5 to prevent displacement during vibration.

[0024] Furthermore, the first conveyor roller group 311 includes a frame 9 and multiple sets of conveyor rollers 10, which are driven to rotate synchronously via a chain drive mechanism. The first conveyor roller group 311 has the same structure as the second conveyor roller group 412. The chain drive mechanism includes a drive chain and transmission gears. The drive chain connects to the drive shafts of the multiple sets of conveyor rollers 10, and the transmission gears are driven by a drive motor. The synchronous rotation of the multiple sets of conveyor rollers 10 ensures that the mold 5 is smoothly and uniformly transmitted to the second vibration table 41, and the transmission speed can be adjusted by a frequency converter.

[0025] Furthermore, both the first stirring device 32 and the second stirring device 42 include a mixer 11 and a hopper 12; the hopper 12 is located directly above the mold 5, and a valve plate 13 is provided inside the hopper 12. The discharge port of the hopper 12 is precisely aligned with the opening position of the mold 5. The valve plate 13 is an arc-shaped valve plate or gate plate, which is driven to open and close by a pneumatic actuator or an electric actuator to control the discharge flow rate and timing of the casting material, ensuring that the casting material is injected into the mold 5 evenly and stably.

[0026] Furthermore, both the first feeding device 33 and the second feeding device 43 include a lifting guide rail 14, a hopper 15, and a lifting assembly 16. The lifting assembly 16 is used to lift the casting material to a preset height and then supply it to the mixing device. The lifting assembly 16 includes a lifting motor, a lifting frame, and lifting pulleys. The hopper 15 is fixed on the lifting frame and moves up and down along the lifting guide rail 14 via the lifting pulleys. The lifting motor drives the hopper 15 to rise to the feed inlet position of the mixer 11, unloading the casting material into the mixer 11. After feeding is completed, the hopper 15 automatically descends to the ground to wait for the next feeding.

[0027] Furthermore, it also includes a control cabinet 17, which houses a control system. The control system is electrically connected to the transfer trolley 2, the first casting unit 3, and the second casting unit 4, respectively, and is used to coordinate and control the operation of the entire production line. The control system includes a PLC controller, a touchscreen human-machine interface, relays, contactors, and other electrical components. The PLC controller is electrically connected via cables to the traveling motor and lifting mechanism of the transfer trolley 2, the feeding device 33, stirring device 32, vibrating table 31, and conveyor roller group 311 of the first casting unit 3, and the feeding device 43, stirring device 42, and vibrating table 41 of the second casting unit 4, respectively, to achieve centralized control and coordinated management of the entire production line.

[0028] During operation, the transfer trolley 2 transports the empty mold 5 from the mold preparation area to the first vibration table 31 of the first casting unit 3. The first feeding device 33 is activated, lifting the casting material to the first mixing device 32. After mixing, the first layer of casting material is injected into the mold 5 through the discharge hopper 12. The first vibration table 31 is activated to vibrate, making the first layer of casting material compact and form.

[0029] When the first vibration table 31 starts to vibrate (or after the vibration has continued for a preset time), the control system synchronously triggers the feeding and stirring actions of the second casting unit 4, and the second feeding device 43 and the second stirring device 42 begin to prepare the second layer of casting material.

[0030] After the first layer of vibration is completed, the first conveyor roller group 311 automatically starts, smoothly transferring the mold 5 to the second vibration table 41. At this time, the second layer of casting material has been mixed.

[0031] After the mold 5 is positioned in the second vibration table 41, it is precisely guided to the center position by the guide roller 411. The valve plate 13 of the second stirring device 42 immediately opens, and the second layer of casting material is poured into the mold 5. The second vibration table 41 starts vibrating, making the second layer of casting material compact and formed.

[0032] After the second layer of vibration is completed, the second conveyor roller group 412 sends the mold 5 to the unloading position. The transfer trolley 2 takes out the mold 5 that has completed double-layer casting and transports it to the unloading area for subsequent curing, demolding and other processes.

[0033] The above are merely preferred embodiments of this utility model and are not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. An automated production line for kiln prefabrication components, characterized in that, It includes a track (1), a transfer trolley (2) that moves along the track (1), a first casting unit (3) and a second casting unit (4), and the transfer trolley (2) is equipped with a mold (5); The first casting unit (3) and the second casting unit (4) are arranged continuously along the transport direction of the mold (5). The transfer trolley (2) is used to transport the mold (5) to the first casting unit (3) and to transfer the mold (5) that has completed double-layer casting from the second casting unit (4). After the first layer of pouring is completed in the first pouring unit (3), the mold (5) continuously enters the second pouring unit (4) to pour the second layer.

2. The automated production line for kiln prefabricated components according to claim 1, characterized in that, The first casting unit (3) includes a first vibration table (31), a first stirring device (32) and a first feeding device (33). The first vibration table (31) is provided with a first conveying roller group (311) for transferring the mold (5) that has completed the first layer of casting to the second casting unit (4).

3. The automated production line for kiln prefabricated components according to claim 2, characterized in that, The second casting unit (4) includes a second vibration table (41), a second stirring device (42), and a second feeding device (43). The feeding end of the second vibration table (41) is provided with a guide roller (411) to guide the mold (5) from the first vibration table (31) into the center position of the second vibration table (41). The second vibration table (41) is also provided with a second conveying roller group (412).

4. The automated production line for kiln precast components according to claim 3, characterized in that, The first vibration table (31) and the second vibration table (41) are at the same height and close to each other. Both the first vibration table (31) and the second vibration table (41) include a vibration motor (6), a positioning clamping roller (7) and a vibration block (8).

5. The automated production line for kiln precast components according to claim 3, characterized in that, The first conveyor roller group (311) includes a frame (9) and multiple conveyor rollers (10), which are driven to rotate synchronously by a chain drive mechanism; the first conveyor roller group (311) has the same structure as the second conveyor roller group (412).

6. The automated production line for kiln precast components according to claim 3, characterized in that, The first stirring device (32) and the second stirring device (42) both include a mixer (11) and a hopper (12); the hopper (12) is located directly above the mold (5), and a valve plate (13) is provided inside the hopper (12).

7. The automated production line for kiln precast components according to claim 3, characterized in that, The first feeding device (33) and the second feeding device (43) both include a lifting guide rail (14), a hopper (15) and a lifting component (16); the lifting component (16) is used to lift the casting material to a preset height and then supply it to the mixing device.

8. The automated production line for kiln prefabricated components according to claim 1, characterized in that, It also includes a control cabinet (17), which is equipped with a control system; the control system is electrically connected to the transfer trolley (2), the first casting unit (3), and the second casting unit (4) respectively, and is used to coordinate and control the operation of the entire production line.

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