Intelligent Hoisting Robot for Prefabricated Concrete Plant
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Solution Overview
Problem
The traditional prefabricated construction method for multi-story concrete plants in the Industry's Going Upstairs (IGU) project is costly and inefficient due to high transportation and hoisting requirements, making it difficult to achieve the desired prefabrication rate and leading to the adoption of labor-intensive cast-in-place construction methods.
Innovation Solution
A construction method for a fully prefabricated multi-story concrete plant that involves prefabricating column and beam components, composite floors, and wall panels in a factory or on-site using intelligent and mechanized assembly molds. The method utilizes tower cranes, automobile cranes, or crawler cranes for vertical transportation, automatic guided vehicles for horizontal transportation, and intelligent hoisting robots capable of self-lifting and horizontal moving to install components efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional prefabricated construction method is used for multi-story concrete plant with large span and high storey height, then prefabrication rate requirement is met, but transportation and on-site hoisting costs substantially increase
Solution Approach 1:
The construction method divides the multi-story concrete plant into standardized modular units (bays) with regular plane layouts. Each module can be independently prefabricated with standardized column, beam, and floor assemblies, enabling segmented construction that reduces transportation complexity and hoisting requirements while maintaining high prefabrication rates.
Solution Approach 2:
The patent changes the dimensional parameters of structural components to be within conventional transportation and hoisting capabilities. By optimizing the span lengths, storey heights, and component weights to fall within standard ranges, the project achieves prefabrication without incurring substantial additional costs for specialized equipment and operations.
2Strength
If traditional prefabricated construction method is used with large size and heavy weight components, then structural requirements are met, but hoisting machinery configuration requirements substantially increase
Solution Approach 1:
Large structural elements are divided into smaller, manageable components that can be handled by conventional hoisting machinery. The segmentation of beams, columns, and floors into standardized modules reduces the weight and size of individual components while maintaining overall structural capacity through proper connection design and assembly configuration.
Solution Approach 2:
Components are pre-assembled into modular units at the factory before transportation to the construction site. This preliminary assembly of standardized modules with predetermined connections allows for simpler on-site hoisting operations using conventional machinery, as the complex assembly work is completed in advance under controlled factory conditions.
3Loss of energy
If labor-intensive cast-in-place construction mode is used, then construction costs are reduced, but prefabrication rate requirement is not met
Solution Approach 1:
The patent develops a universal construction system with standardized modules that can be repeatedly assembled throughout the project. This multi-functional modular approach allows the same standardized components and connection methods to be used across all bays and storeys, achieving high prefabrication rates while maintaining cost efficiency through repetition and standardization rather than labor-intensive custom construction.
Data Source
AI summary
Provided is a construction method for a fully prefabricated multi-story concrete plant, the construction method may achieve full coverage of a hoisting operation of the large beam and column prefabricated components of a floor by employing a single intelligent hoisting robot, an angle change of the track devices, an angle change of a moving device, and a self-lifting device. It is not necessary to arrange a transition track at the turn of the installation route, which saves space and installation cost, and overcomes the disadvantage of high cost caused by the traditional prefabricated construction mode of multi-story concrete plant, which needs to arrange a plurality of large hoisting equipment. It may achieve the mechanization and intelligence of the whole construction process of the fully prefabricated multi-story concrete plant.