Foldable Formwork Device for Precast Concrete Production
Solution Overview
Problem
Conventional concrete manufacturing processes using shot walls are laborious and inflexible, particularly due to the difficulty in handling large and heavy shot walls, and the cumbersome equipping of switching elements, which hinders efficient production and flexibility.
Innovation Solution
A formwork device with two articulated formwork plates that can be folded and positioned between shot walls, allowing for simultaneous production of different concrete components, equipped with magnetic holders and rollers for easier handling, and optionally featuring a heating device and vibrator for enhanced efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional shot walls are used as formwork devices, then simultaneous production of multiple concrete components is achieved, but handling difficulty and labor requirements increase due to the large size and weight of the shot walls
Solution Approach 1:
The formwork device is divided into two separate formwork plates that can be articulated together. Each plate can be handled and positioned independently, reducing the handling difficulty compared to a single large shot wall structure, while still enabling simultaneous production when positioned between two shot walls
Solution Approach 2:
The formwork plates are designed to be positioned in a folded state between shot walls, utilizing the spatial dimension efficiently. This allows the formwork device to access confined spaces and be maneuvered more easily than traditional rigid formwork systems
2Adaptability or versatility
If switching elements are manually attached to shot walls, then customization for different concrete components is achieved, but the equipping process becomes laborious and time-consuming
Solution Approach 1:
Switching elements are pre-attached to the formwork plates before they are positioned between the shot walls. This preliminary preparation allows for customization of different concrete components without the need for manual attachment during the production process, significantly reducing equipping time
Solution Approach 2:
The formwork plates serve as reusable templates that can be equipped with different switching elements for different concrete component designs. Once a plate is equipped, it can be used repeatedly for producing identical components, reducing the time required for equipping
3Productivity
If formwork plates are positioned between shot walls in conventional battery readings, then simultaneous filling of multiple cavities is achieved, but the compaction and handling process becomes complex
Solution Approach 1:
The formwork device separates the compaction function into individual formwork plates, each with its own rollers. This segmentation allows for independent compaction of each cavity between shot walls, simplifying the overall compaction process compared to coordinating a single complex system
Solution Approach 2:
The formwork plates are equipped with rollers that enable self-propelled movement and automatic positioning between shot walls. This self-service capability reduces the complexity of external compaction equipment and simplifies the handling process
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Simplifies the assembly and compaction process, reduces labor requirements, and allows for more flexible and efficient production of concrete components, including the ability to automate the handling of switching elements and adapt to various geometries.
Implementation Method 1
a worker brings the switching elements z. B. with magnetic holders on the steel-existing shot walls
Implementation Method 2
optionally featuring a heating device and vibrator for enhanced efficiency
Implementation Method 3
optionally featuring a heating device and vibrator for enhanced efficiency
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present invention relates to a formwork device (5) for a battery mold (1) for producing structural elements, in particular precast concrete elements (27, 28), the battery mold comprising at least two bulkheads (5') and the formwork device (5) comprising two facing panels (11) that are preferably hingedly connected to one another such that they can be transferred from an unfolded state to a folded state. Each facing panel (11) has a front face (12) for the mounting of formwork elements (18) and a rear face (13), the rear faces (13) of the two facing panels (11) facing each other in the folded state. The formwork device (5) is designed to be located between the bulkheads (5') in the folded state. The present invention further relates to a system that consists of a battery mold (1) and at least one formwork device (5) according to the invention, said formwork device (5) being suspended in the battery mold (1).