Device and method for constructing masonry walls from bricks

Abstract

A device (1) for constructing masonry walls (2) from masonry blocks (3) has the following features: - a masonry wall erecting device (4) for constructing the masonry walls (2) from the masonry blocks (3), which has a handling device (5) for handling the masonry blocks (3), - a feed conveyor (6) for feeding the masonry blocks (3) to the handling device (5) of the masonry wall erecting device (4), - a processing device (8) for processing at least a part of the masonry blocks (3), wherein the processed masonry blocks (3) intended for constructing the masonry walls (2) are transferred to the feed conveyor (6), - a receiving area (7) for receiving masonry blocks (3), wherein a part of the masonry blocks (3) received in the receiving area (7) are transferred to the processing device (8) and a part of the masonry blocks (3) received in the receiving area (7) are transferred to the feed conveyor (6).The wall-setting device (4) is movable in a production direction (x) that is essentially perpendicular to the constructed wall (2) in order to create several wall walls (2) parallel to each other.

Description

[0001] The invention relates to a device and a method for constructing masonry walls from bricks. Furthermore, the invention relates to a device for processing bricks.

[0002] Such devices and methods are known from the general state of the art. They can be used, for example, to produce masonry walls in a manufacturing hall, which are then transported to a construction site and assembled into a building. However, the known methods and devices are still relatively inefficient and have only partially established themselves on the market.

[0003] It is therefore an object of the present invention to provide a device and a method for creating masonry walls from bricks, with which greater efficiency and a higher quality of the masonry walls produced can be achieved.

[0004] According to the invention, this problem is solved by the features mentioned in claim 1.

[0005] The device according to the invention for constructing masonry walls from bricks comprises a wall-setting device, which in turn includes a handling device for handling the bricks, with which the masonry walls can be constructed fully automatically and, in particular, without any human intervention. The term "bricks" as used herein also includes products such as wooden bricks, clay blocks, or similar materials that can be used for constructing walls.

[0006] The feed belt used to supply the bricks to the handling device of the bricklaying system ensures that the handling device is always supplied with the precisely fitting bricks required to construct the respective brick wall, so that the brick walls can be constructed without interruption.

[0007] Since bricks are usually delivered in a uniform shape and size, they can be processed in a machining unit before being fed to the handling device via the conveyor belt. This ensures that only bricks actually used for constructing the wall are present on the conveyor belt. In the machining unit, the bricks are primarily separated to produce smaller bricks; however, it is also possible to drill, mill, or otherwise process the bricks.

[0008] The delivery of the masonry units to the area of ​​the device according to the invention takes place via the receiving area, where the masonry units are received and then partly transferred to the processing unit and partly to the feed conveyor. This allows masonry units that can be used without processing to go directly to the handling unit of the wall-building device, whereas masonry units requiring processing are ultimately transferred to the wall-building device via the processing unit. This adapted feeding of the feed conveyor with masonry units from the processing unit or directly from the receiving area enables the desired wall to be easily constructed using the wall-building device.

[0009] The wall-setting device is movable in a production direction that is essentially perpendicular to the wall being constructed, so that several walls can be built parallel to each other. This significantly increases the efficiency of the device according to the invention, since the wall-setting device can be used independently of the already constructed walls, as it can be moved over them. In contrast to moving the completed walls, the effort required to move the wall-setting device is considerably less.

[0010] Furthermore, vibration-free hardening of the binder, such as mortar, thin-bed mortar, or adhesive, is possible. This makes it possible to use mortars developed for conventional on-site production. In addition, the quality of the masonry is improved by avoiding early transport during the initial hardening phase.

[0011] The device according to the invention is modularly scalable, enabling the automated prefabrication of masonry walls with multiple layers of bricks of various types arranged one above the other by modifying the device, in particular by adding further components. An existing device of an older generation can be easily replaced or simply installed with components equipped for semi-automated production, which can be flexibly and individually scaled up and thus highly automated at a later date. For potential users, this means a simple, cost-effective entry into the field of automated, especially robot-assisted, manufacturing with maximum expansion flexibility up to complete automation.

[0012] As a starting point for the constructed masonry walls, a modular building model or floor plan, in particular an IFC (Industry Foundation Classes) building model or IFC floor plan, can serve. This can be supplemented with information on required materials, components, and a calculated brick layout for each wall element to create a precast file, especially an IFC4 precast file. Subsequently, the sequence of all masonry walls to be produced can be visually scheduled on the production area in a planning program, and the constructed masonry walls can be stacked in suitable transport containers. The generated data set and necessary planning documents can be transferred to the handling equipment used in the system or printed out and included with a shipment.

[0013] In a highly advantageous embodiment of the invention, at least one further handling device for the automated transfer of the bricks to the processing unit or onto the conveyor belt can be assigned to the receiving area. This enables the automated distribution of the bricks received in or delivered to the receiving area either to the processing unit or onto the conveyor belt.

[0014] In order to easily transport or distribute the bricks delivered to the receiving area, it may also be provided that a conveying device for conveying grouped bricks is arranged in the receiving area.

[0015] A further advantageous embodiment of the invention can consist in the processing device having at least one further handling device for handling the bricks in the area of ​​the processing device. This enables the bricks delivered from the receiving area to the processing device to be picked up and loaded into the processing device with them.

[0016] To enable fully automated processing of the masonry units, the handling device of the processing unit can be designed to arrange the masonry units within the unit in such a way that processing can take place without further repositioning. This allows the use of a standard and relatively simple processing unit, such as a stone saw, which can optionally be supplemented with drilling and / or milling tools or other suitable tools, thus reducing overall system costs.

[0017] In a further advantageous embodiment of the invention, the wall-setting device may include a brick-setting device, a mortar application device, and a positioning belt, all of which are height-adjustable so that they can be moved over already constructed walls. This allows for easy movement of the wall-setting device and its associated components over already constructed walls, thus increasing the flexibility of the device according to the invention.

[0018] The device according to the invention can be supplemented by a control device for inspecting the bricks on the feed conveyor. Such inspection of the bricks on the feed conveyor, delivered to the handling device of the bricklaying machine, by means of the control device, ensures that the bricks on the feed conveyor are delivered to the bricklaying machine in the correct sequence, so that the machine only needs to remove the delivered bricks from the feed conveyor and process them. Any defective or damaged bricks, i.e., bricks with manufacturing defects or damaged in any other way and therefore unsuitable for use in constructing the brick wall, can be removed and replaced with the correct bricks.The inspection can generally be carried out by a person, but it is also possible to use a scanning device, such as a camera, a LIDAR scanner or similar, and an associated handling device.

[0019] In a further highly advantageous embodiment of the invention, a second wall-setting device and a second feed conveyor, to which the wall blocks are fed from the receiving area or from the processing unit, can be provided. Such a combination of two wall-setting devices and two feed conveyors in a production hall allows the entire apparatus to be expanded, enabling the production of a significantly larger number of walls. The processing unit and the receiving area can, in principle, be used for both wall-setting devices, so that despite the doubled capacity of the apparatus, the costs are by no means doubled. This is possible because both machine types have the same dimensions and can therefore, if necessary, be installed on the same floor-guided guide rails.The second wall-mounting device and the second feed conveyor thus represent a second expansion stage of the modularly expandable device according to the invention. A further advantage is that this expansion is possible at any time without major modifications to the production hall.

[0020] A third development stage of the device according to the invention can be achieved if the wall-building device includes at least one displacement device for moving the constructed wall panels transversely to the production direction and in the production direction. This allows the wall panels produced by the wall-building device to be moved to any desired position inside and, if necessary, also outside the production hall, for example, to carry out rework on them. Preferably, the displacement device is movable both in the production direction of the wall-building device and perpendicular to it, which ensures that individual wall panels can be removed from the series of constructed wall panels and subsequently moved to a desired point.

[0021] Claim 10 describes a method for constructing masonry walls from bricks.

[0022] The method according to the invention preferably utilizes the device according to the invention and provides for the receiving of masonry units in a receiving area, the transfer of a portion of the masonry units received in the receiving area to a processing device and a portion of the masonry units received in the receiving area to a feed belt, the processing of at least a portion of the masonry units in the processing device and the transfer of the processed masonry units intended for the construction of the masonry walls to the feed belt, the feeding of the masonry units to a handling device of a masonry wall erection device by means of a feed belt and the construction of the masonry walls from the masonry units by means of a masonry wall erection device having a handling device.The wall-setting device can be moved in a production direction that is essentially perpendicular to the wall being constructed, so that several walls can be built parallel to each other.

[0023] The method according to the invention ensures highly efficient and precise construction of masonry walls. All process steps can be fully automated and, if necessary, monitored.

[0024] Claim 11 specifies a device for processing masonry units comprising a processing unit and a handling unit for handling the masonry units in the area of ​​the processing unit.

[0025] This device allows masonry units delivered to the handling unit to be transferred to the processing unit and processed by it. This enables the processing unit to be used independently of a masonry wall erecting unit, allowing masonry units to be processed very easily and used, if necessary at a different location, to construct a wall.

[0026] In a highly advantageous further development of this device, the handling unit of the processing unit can be designed to arrange the masonry units in such a way that the processing of the masonry units can take place without any further positioning of the processing unit itself. This allows the use of relatively simple processing units, since these are only required to carry out the processing operations intended for them and not for handling the masonry units.

[0027] The handling devices used in the device according to the invention, which can also be referred to as robots, are understood to be generally applicable units that interact with the physical world based on sensors, actuators, and information processing in various axes of movement, without specifying or referring to any particular type of handling device or robot. The handling devices can include grippers, which are automated units whose movements are not further defined when gripping stones or other components. They can be linearly guided or movable in all axes.

[0028] The following are exemplary embodiments of the invention illustrated in principle with reference to the drawing.

[0029] It shows: Fig. 1 a first embodiment of a device according to the invention; Fig. 2 a second embodiment of the device according to the invention; Fig. 3 a third embodiment of the device according to the invention; and Fig. 4 a device according to the invention for processing masonry blocks.

[0030] Fig. 1 Figure 1 shows a first embodiment of a device 1 according to the invention for constructing masonry walls 2 from masonry units 3 in a highly schematic representation. The device 1, which is preferably located in a production hall (not shown in its entirety), comprises a masonry wall erecting device 4 for constructing the masonry walls 2 from the masonry units 3, which in turn has a handling device 5 for handling the masonry units 3. The masonry units 3 are fed to the handling device 5 of the masonry wall erecting device 4 by means of a feed conveyor 6.

[0031] The bricks 3 enter the area of ​​the device 1 via a receiving area 7 which serves to receive the bricks 3. From the receiving area 7, some of the bricks 3 are transferred to the feed belt 6 and another part to a processing device 8, from where, as described in more detail below, they return to the feed belt 6 and thus ultimately to the brick moving device 4.

[0032] In receiving area 7, a conveyor 10 is provided for conveying grouped masonry units 3 within the receiving area 7. This can be, for example, a pallet or package feeder, such as a belt or similar device, if the masonry units 3 arrive in receiving area 7 on pallets or in packages. Such a pallet or package feeder can be provided for each type of unit used and adapted to the respective unit type. Furthermore, a return conveyor for unstacked pallets or packages of masonry units can be provided. The conveyor 10 also serves as a storage area for full pallets or packages and thus as a storage area for masonry units. Lintels, blind boxes, roller shutter boxes, or other installation components are also received in receiving area 7; for the sake of simplicity, these are referred to here as masonry units 3.It is also possible to bring the bricks 3 into the receiving area 7 on a conveyor belt.

[0033] Therefore, a complete wall 2 of almost any shape and size can be constructed from the wall blocks 3 using the wall assembly device 4. In this context, it should be noted that the wall blocks 3, and thus also the lintels, blind boxes, roller shutter boxes, and other components, can have not only different lengths and widths, but also different heights.

[0034] The receiving area 7 has a further handling device 11, which is capable of automatically transferring the bricks 3 either to the processing device 8 or to the feed conveyor 6. In this case, the receiving area 7 has two handling devices 11 and 12, the function of which is explained in more detail below.

[0035] The handling device 11, which is directly associated with the feed conveyor 6, destacks the pallets or packages of the bricks 3 piece by piece, layer by layer or row by row and, depending on the type of destacking, either directly to the brick stacking device 4 if no processing is required, or to the processing device 8 if processing is required.

[0036] The lintels, blind boxes and / or roller shutter boxes or other installation components are temporarily stored on a buffer belt or buffer table 13 and preferably placed on the feed belt 6 at the required position of the wall section to be prepared by means of the handling device 11 and transported to the wall mounting device 4. If processing of the lintels, blind boxes and / or roller shutter boxes or other installation components is required, these are also fed to the processing device 8.

[0037] If the masonry units 3 or the lintels, blind boxes, roller shutter boxes or the other installation parts are not to be fed from the handling device 11 to the feed conveyor 6, but are to be transported first to the processing device 8, the handling device 11 places them on a conveyor belt 14. From the conveyor belt 14, which can also be designed as a storage table, the masonry units 3 or the lintels, blind boxes, roller shutter boxes or the other installation parts can be taken by the further handling device 12, which is also located in the receiving area 7, and brought via another conveyor belt 15 into the area of ​​the processing device 8.

[0038] The masonry units 3 to be processed can be taken from the conveyor belt 15 by a further handling device 16, which is associated with the processing device 8, and fed to the processing device 8. In the area of ​​the handling device 16 there is a storage table 17 on which the masonry units 3 are placed before they are fed to the processing device 8 or after they have been removed from it.

[0039] The handling device 16 of the processing device 8 is capable of arranging the masonry units 3 within the processing device 8 in such a way that the processing of the masonry units 3 can take place within the processing device 8 without any further positioning. During processing, the masonry units 3 to be processed are inspected or measured for their geometry in all planes in a device (not shown) associated with either the handling device 16 or the processing device 8, and then positioned precisely within the processing device 8 according to the necessary processing operations, thus reliably guaranteeing processing in all directions and shapes. In addition to sawing, extraction, drilling, milling, and similar operations on the masonry units 3 are also possible. If necessary, the handling device 16 can be omitted, and the processing device 8 can be loaded manually.

[0040] After processing in the processing unit 8, the processed masonry units 3 are placed by the handling unit 16 onto a further conveyor belt 18, which can also be designed as a table and of which several may be provided, and returned to the handling unit 12 by means of this belt. The handling unit 12 picks up the processed masonry units 3 from the conveyor belt 18 and places them on the feed belt 6 leading to the masonry positioning unit 4. If a table is used, it is short enough for the handling unit 12 to remove the masonry units 3 from it. The excess parts of the processed masonry units 3 are also stored after processing in order to use them later if necessary, so that optimized material usage and requirements are taken into account within the framework of the device 1 and the process carried out with it.If necessary, one of the two handling devices 11 or 12 can be dispensed with if the other handling device 11 or 12 can perform all of the tasks described for both handling devices 11 or 12.

[0041] On the feed conveyor 6, all masonry units 3, i.e., both the processed and the unprocessed units, including the other components of the wall 2 to be constructed, are prepared according to the intended unit layout from a data set transmitted from the design to a control unit (not shown) and conveyed in the correct sequence for the construction of the respective wall 2 to the handling device 5 of the wall assembly device 4. The control unit of the device 1 can, in principle, be connected to all its components, so that the control unit can control and monitor all processes during the production and, if necessary, post-processing of the wall 2.

[0042] In the area of ​​the feed conveyor 6, an upstream inspection device 19 is provided for inspecting the masonry units 3 located on the feed conveyor 6. The inspection device 19 allows intervention and removal or replacement of damaged masonry units 3 and / or other components at any time before they are moved as described below.

[0043] The handling device 5 of the wall-setting device 4 individually picks up all the masonry units 3, including the other components of the wall 2 to be constructed, from the feed conveyor 6 and places them precisely according to their positioning, i.e., according to the data set generated from the planning, onto a positioning conveyor 20 of the wall-setting device 4, so that a gripper 21 of a masonry unit 22 can pick up the entire wall layer and place it in fresh mortar. In addition to the positioning conveyor 20, the gripper 21, and the masonry unit 22, the wall-setting device 4 also has a mortar application device 23. The mortar is applied fully automatically by the mortar application device 23 in a manner known per se. When placing the masonry units 3 or the other components, wall openings, gaps between multiple walls, or similar features are taken into account.

[0044] As mentioned above, the gripper 21 of the wall-positioning device 4 picks up the respective wall section from the positioning belt 20. The individual wall section 2 is constructed by the wall-positioning device 4 in a direction designated "y" perpendicular to the feed belt 6. Preferably, several wall sections 2 are constructed side by side or parallel to each other in a production lane and, if necessary, at different heights. If, as is preferred, several wall sections 2 are constructed immediately one after the other, they are arranged parallel to each other in a production direction x that is essentially perpendicular to the wall section 2 being constructed.

[0045] The brick-setting device 22, the mortar application device 23, and the positioning belt 20 are height-adjustable so that they can be moved over already constructed brick walls 2. This allows each constructed brick wall 2 to remain in place until it has sufficiently hardened, while the brick-setting device 4 can be moved forward in the production direction x to construct the next brick wall 2. In this case, the handling device 5 and the feed belt 6 are also height-adjustable, enabling the repositioning of brick courses at greater wall heights with efficient swivel radii.

[0046] Once the uppermost layer of wall 2 to be laid is reached, the wall positioning device 4 moves one production row in production direction x and begins producing a new wall 2. When the wall positioning device 4 reaches the last production row along production direction x, all machine components move to their uppermost position, entering the so-called overrun position. In this process, the wall positioning device 4 passes over all production rows, or rather, all produced wall 2s, up to the beginning of the floor-guided rails 24 located within the production hall.

[0047] A grid-based method enables the fixed screwing of base plates, such as those described in DE 20 2022 103 127 U1, to the floor of the production hall, so that no manual or automatic work is necessary to prepare the upcoming wall 2.

[0048] The handling devices 5, 11, 12 and 16 integrated into the device 1 replace human labor, thus enabling fully automated production of the masonry walls 2. In the area of ​​the masonry wall positioning device 4, or in a downstream area thereof, finishing work, such as the integration of electrical wiring, switches and the like, windows and plastering, can be carried out directly in the production lines, either manually or automatically.

[0049] After the required curing time, the masonry walls 2 are packaged with crossbeams and lifting straps, such as those described in EP 2 808 287 A1, made of steel or plastic, and loaded using, for example, grippers or a floor-guided loading trolley. This has the advantage that the masonry walls 2 are moved for the first time after curing.

[0050] Fig. 2 Figure 1 shows a second embodiment of the device 1 according to the invention. In this embodiment, all of the features and components of the first embodiment of the device 1 mentioned above are present. Additionally, the device has a second wall-positioning device 25 and a second feed conveyor 26, to which the wall blocks 3 are fed from the receiving area 7 or from the processing device 8. The method of feeding the wall blocks 3 from the receiving area 7 or the processing device 8 can be described as shown in Figure 1. Fig. 1 as described, however, is in Fig. 2 Not shown. The second wall-positioning device 25 and the second feed conveyor 26 are arranged as mirror images of the wall-positioning device 4 and the feed conveyor 6. The function, however, is exactly the same as described above, with the difference that, if necessary, twice the number of wall sections 2 can be produced. This can be achieved provided that the existing performance of the processing device 8 and its components, as well as the performance of the components assigned to the receiving area 7, is sufficient. Otherwise, additional components can be added for individual areas of the device 1, if necessary.

[0051] In principle, it is possible to first construct a device 1 according to Fig. 1 to assemble in a production hall and at a later date to retrofit the second wall-mounting device 25 and the second feed belt 26 in order to thus assemble the device 1 according to Fig. 2 to obtain. This may require enlarging the production hall. For this purpose, it can be designed modularly.

[0052] In Fig. 3 A third embodiment of the device 1 according to the invention is shown. In this embodiment, all of the features and components of the second embodiment of the device 1 mentioned above are present. Additionally, in this embodiment of the device 1, the wall-positioning device 4 or the wall-positioning device 25 has at least one shifting device 27 for shifting the constructed wall panels 2 in the transverse direction y to the production direction x and in the production direction x. The shifting device 27 can have, in all production series, respective transverse pallets (not shown) and sliding platforms (also not shown) between the two wall-positioning devices 4 and 25 for removing and moving the produced wall panels 2. These integrated transverse pallets and sliding platforms enable the construction of the wall panels 2 in a movable, locked, or stationary manner.Depending on whether the wall sections 2 are stationary or movable, they can be moved as needed and individually to an intermediate buffer or directly to the rework station for curing.

[0053] In principle, it is possible to first construct a device 1 according to Fig. 2 to assemble in a production hall and to retrofit the shifting device 27 at a later date in order to thus assemble the device 1 according to Fig. 3 to obtain.

[0054] Fig. 4 Figure 1 shows a further embodiment of the device 1. This embodiment is designed solely for processing the masonry units 3 and comprises only the processing unit 8 described above and the handling unit 16 for handling the masonry units 3 in the area of ​​the processing unit 8. In the present case, the storage table 17 is also part of this embodiment of the device 1. Furthermore, it is possible to add further elements of the device 1 described in Figure 1. Fig. 1to provide the described device 1, such as the conveyor belts 15 and / or 18.

Claims

1. Device (1) for constructing masonry walls (2) from masonry blocks (3) comprising the following features: - a masonry wall erecting device (4) for constructing the masonry walls (2) from the masonry blocks (3), which includes a handling device (5) for handling the masonry blocks (3), - a feed conveyor (6) for feeding the masonry blocks (3) to the handling device (5) of the masonry wall erecting device (4), - a processing device (8) for processing at least a portion of the masonry blocks (3), wherein the processed masonry blocks (3) intended for constructing the masonry walls (2) are transferred to the feed conveyor (6), - a receiving area (7) for receiving masonry blocks (3), wherein a portion of the masonry blocks (3) received in the receiving area (7) are transferred to the processing device (8) and a portion of the masonry blocks (3) received in the receiving area (7) are transferred to the feed conveyor (6),wherein the wall-setting device (4) is movable in a production direction (x) running substantially perpendicular to the constructed wall (2) in order to produce several wall walls (2) parallel to each other.

2. Device according to claim 1, characterized by the fact that The receiving area (7) is assigned at least one further handling device (11,12) for the automated transfer of the bricks (3) into the area of ​​the processing device (8) or onto the feed belt (6).

3. Device according to claim 1 or 2, characterized by the fact that in the receiving area (7) a conveying device (10) for conveying grouped bricks (3) is arranged.

4. Device according to claim 1, 2 or 3, characterized by the fact that the processing device (8) has at least one further handling device (16) for handling the masonry units (3) in the area of ​​the processing device (8).

5. Device according to claim 4, characterized by the fact thatthe handling device (16) of the processing device (8) is designed to arrange the masonry units (3) in the processing device (8) in such a way that the processing of the masonry units (3) in the processing device (8) can take place without further positioning of the same.

6. Device according to any one of claims 1 to 5, characterized by the fact that the wall-setting device (4) comprises a brick-setting device (22), a mortar application device (23) and a positioning belt (20) which are height-adjustable so that they can be moved over already constructed wall walls (3).

7. Device according to any one of claims 1 to 6, characterized by a control device (19) for checking the bricks (3) located on the feed conveyor (6).

8. Device according to any one of claims 1 to 7, characterized bya second wall-moving device (25) and a second feed belt (26), to which the wall stones (3) are fed from the receiving area (7) or from the processing device (8).

9. Device according to any one of claims 1 to 8, characterized by the fact that the wall-setting device (4) has at least one shifting device (27) for shifting the constructed wall walls (2) in the transverse direction (y) to the production direction (x) and in the production direction (x).

10. Method for constructing masonry walls (2) from masonry units (3) comprising the following process steps: - Picking up masonry units (3) in a picking area (7), - Transferring some of the masonry units (3) picked up in the picking area (7) to a processing unit (8) and some of the masonry units (3) picked up in the picking area (7) to a feed conveyor (6), - Processing at least some of the masonry units (3) in the processing unit (8) and transferring the processed masonry units (3) intended for constructing the masonry walls (2) to the feed conveyor (6), - Feeding the masonry units (3) to a handling unit (5) of a masonry wall erection device (4) by means of a feed conveyor (6), - Erecting the masonry walls (2) from the masonry units (3) by means of a masonry wall erection device (4) comprising a handling unit (5) and a mortar application unit (23),wherein the handling device (5) of the wall-setting device (4) is moved in a production direction (x) running substantially perpendicular to the constructed wall (2) in order to produce several wall walls (2) parallel to each other.

11. Device (1) for processing masonry units (3) comprising a processing unit (8) and a handling unit (16) for handling the masonry units (3) in the area of ​​the processing unit (8).

12. Device according to claim 11, characterized by the fact that the handling device (16) of the processing device (8) is designed to arrange the masonry units (3) in the processing device (8) in such a way that the processing of the masonry units (3) in the processing device (8) can take place without further positioning of the same.

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