CN111186011B - Automatic assembly line arrangement structure for factory prefabrication of laminated plate beams and production method - Google Patents

Abstract

The invention relates to a laminated slab beam factory prefabrication automatic assembly line arrangement structure, which comprises the following steps: the device comprises a standard die table, a stirring station, a pouring and tamping zone, a maintenance zone, a demolding and cleaning zone, a die supporting zone, a steel bar installation zone, a napping zone, a surrounding guardrail, a template stacking zone and a material stacking zone; the circulating pipeline sequentially comprises a pouring and tamping zone, a maintenance zone, a demoulding and cleaning zone, a formwork supporting zone, a reinforcing steel bar installation zone and a pouring and tamping zone; the standard die table moves to each functional area through a die table moving system, and a die table driving device and a die table running water guiding device are arranged below the standard die table. The beneficial effects of the invention are as follows: the invention designs a set of automatic production line for the factory prefabrication of the superimposed sheet beam, realizes the functional partition production line construction of prefabricated parts, is an efficient production organization mode which fully utilizes space and sequential working procedures, reduces cost and saves energy obviously. Meanwhile, the quality and the quality of the assembled building are promoted to be continuously improved, and the environment-friendly level is obviously improved.

Description

A composite slab beam factory prefabrication automatic assembly line layout structure and production method

Technical Field

The invention relates to a layout structure and a production method of a composite plate beam factory prefabrication automatic assembly line, belonging to the technical field of assembled building engineering.

Background Art

Prefabricated buildings are one of the important directions of green buildings and building industrialization. All parts of the country are vigorously promoting the industrialization of new buildings. Through the construction of industrialization bases, the proportion of prefabricated buildings in new buildings is gradually increasing. Factory prefabrication of composite slab beams is the most common process in prefabricated buildings, but there are many specifications and sizes of composite slab beams. When using fixed pedestals for production, it often requires large investment, low efficiency, and low space utilization.

Summary of the invention

The purpose of the present invention is to overcome the deficiencies in the prior art and to provide a composite slab beam factory prefabrication automatic assembly line layout structure and production method.

The layout structure of the automatic assembly line for factory prefabrication of composite slab beams includes a standard formwork, a mixing station, a casting area, a curing area, a demoulding and cleaning area, a formwork support area, a steel bar installation area, a roughening area, a guardrail, a formwork stacking area and a material stacking area; the circulating assembly line is composed of a casting area, a curing area, a demoulding and cleaning area, a formwork support area, a steel bar installation area and a casting area in sequence; the standard formwork is moved to each functional area by a formwork moving system, and a formwork driving device and a formwork water guide device are arranged under the standard formwork; the casting area is mainly composed of a vibration system, a feeding hopper system and an automatic placing machine; the mixing station is located outside the casting area, and the mixing station is connected to the feeding hopper system through a concrete conveyor belt; a vertical curing kiln, an elevator and a control console are arranged in the curing area; the formwork of the composite slab beam is mainly composed of an L-shaped side formwork and a bottom formwork of the composite slab beam; and a guardrail is arranged around the production line.

Preferably, the mold platform moving system includes a mold platform driving device, a mold platform water flow guiding device, a roller conveyor, a guide wheel and a double-machine lifting shuttle bus.

As a preferred embodiment: the L-shaped side formwork of the composite slab beam is provided with reserved holes for embedded steel bars, the reserved holes for embedded steel bars are provided with embedded bars for the top truss of the composite slab beam, a slurry leakage prevention device is inserted on the reserved holes for embedded steel bars, and the L-shaped side formwork of the composite slab beam is reinforced with the bottom formwork by a strong magnetic fixer.

The method for producing a composite slab beam in a factory prefabricated automatic assembly line comprises the following steps:

Step 1: Design and layout of automated production lines; the circulating production line is divided into functional areas according to the pouring area, maintenance area, demoulding and cleaning area, formwork area, steel bar installation area, roughening area, template stacking area and material stacking area, and is arranged in a rectangular shape; along the long side of the production line, a mold platform driving device is set under each standard mold platform, and a mold platform water flow guide device is set under the longitudinal beams on both sides of the standard mold platform for the longitudinal movement of the standard mold platform; on the two short sides of the production line, a double-machine lifting shuttle bus is set for the transverse movement of the standard mold platform on the production line to realize the U-shaped circulating production line; the mixing station is located outside the pouring area, and the mixed concrete is transported to the feeding hopper system directly above the standard mold platform via a concrete conveyor belt; the production line is surrounded by guardrails;

Step 2: side formwork installation; the composite slab beam uses a standard formwork platform to make a bottom formwork, the side formwork is customized according to the structural dimensions of the composite slab beam, and an L-shaped steel plate structure is adopted. Pre-embedded steel bar reserved holes are opened on the L-shaped side formwork of the composite slab beam according to the pre-embedded steel bar spacing; the side formwork is fixed to the bottom formwork by a strong magnetic fixture;

Step 3: Installation of steel bar skeleton; the semi-finished steel bar skeleton of composite slab beam is uniformly processed in the steel bar processing plant and transported to the inner site of the steel bar installation area assembly line for use; the steel bars, steel bar skeleton and steel bar mesh put into the mold are inspected and accepted; after the steel bars are put into the mold, the protective layer pads are arranged in a plum blossom shape; before pouring, the anti-leakage slurry device is inserted one by one on the reserved holes of the embedded steel bars;

Step 4: Concrete pouring: Concrete is centrally mixed by a mixing station, transported to the hopper system directly above the mold platform to be delivered via a concrete conveyor belt, discharged by an automatic placing machine and vibrated and compacted by a vibration system under the mold platform, and manually assisted top surface leveling is used;

Step 5: Components are cured in vertical curing kilns; after the composite slab beam concrete is cast and the surface is treated, the standard mold platform moves to the vertical curing kiln, and is sent into the curing kiln for high-temperature curing through a hoist together with the standard mold platform; the vertical curing kiln is automatically temperature-controlled by an instrument for curing, and the curing is divided into four stages: static stop, heating, constant temperature and cooling; before steam curing, it is statically stopped at room temperature for 2-4 hours; the heating rate does not exceed 20℃/h; the temperature in the constant temperature heating stage is not more than 60℃; the cooling rate does not exceed 20℃/h; the component surface is demoulded when the temperature difference between it and the external environment is not more than 20℃;

Step 6: demoulding; the components are cured in the curing kiln until they reach the specified lifting and demoulding strength, and then they are taken out of the kiln; before the components are demoulded and lifted, a group of test blocks cured under the same conditions are pressed first; when the strength of this group of test blocks reaches more than 75% of the design strength or the design requirements, they are demoulded and lifted; when removing the mold, first remove the strong magnetic fixer, and then remove the L-shaped side mold of the composite slab beam; after the components are demoulded, they are inspected and accepted, and the project parts, component models and production dates are sprayed according to regulations, and then they are stacked for maintenance;

Step 7: Cleaning the formwork; use a putty spatula to clean the slurry on the mold, then clean the bottom mold and enter the next cycle of prefabrication of composite slab beams.

The beneficial effects of the present invention are as follows: the present invention designs a set of automatic production lines for the factory prefabrication of composite slab beams, realizes the functional zoning assembly line construction of prefabricated components, is an efficient production organization mode that fully utilizes space and smoothly connects processes, reduces costs, and significantly saves energy. At the same time, it also promotes the continuous improvement of the quality of prefabricated buildings, and significantly improves the level of green environmental protection.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a plan view of the automatic production line for prefabrication of composite slab beams in a factory;

Figure 2 is a three-dimensional diagram of the automatic production line for prefabrication of composite slab beams in a factory;

FIG3 is a detailed schematic diagram of a prefabricated formwork system;

Figure 4 is a layout diagram of a standard die table drive device;

FIG. 5 is a flow chart of the construction process of the present invention.

Explanation of the accompanying drawings: standard formwork 1, mixing station 2, pouring area 3, concrete conveyor belt 3-1, vibration system 3-2, curing area 4, vertical curing kiln 4-1, elevator 4-2, control console 4-3, demoulding and cleaning area 5, composite slab beam 5-1, formwork 5-2, strong magnetic fixer 5-3, supporting formwork area 6, composite slab beam L-shaped side formwork 6-1, pre-embedded steel bar reserved holes 6-2, steel bar installation area 7, composite slab beam top truss pre-embedded steel bar 7-1, anti-leakage slurry device 7-2, formwork moving system 8, formwork drive device 8-1, formwork water guide device 8-2, roughening area 9, guardrail 10, formwork stacking area 11, material stacking area 12.

DETAILED DESCRIPTION

The present invention is further described below in conjunction with embodiments. The description of the following embodiments is only used to help understand the present invention. It should be noted that for those of ordinary skill in the art, without departing from the principles of the present invention, several improvements and modifications may be made to the present invention, and these improvements and modifications also fall within the scope of protection of the claims of the present invention.

The automatic assembly line layout structure for factory prefabrication of composite slab beams, by setting up a movable standard table formwork system, realizes a circulating assembly line with functional areas such as pouring area, curing area, demoulding and cleaning area, formwork area, and steel bar installation area, thereby achieving an efficient production organization mode that fully utilizes space and smoothly connects processes, reduces costs, and significantly saves energy.

In view of the characteristics of the planar components of the composite slab beam, according to the process flow of prefabricated slab beam formwork, steel bar installation, concrete pouring, maintenance, and demoulding, a standard formwork platform 1 (9.0m long and 3.5m wide, used as the prefabricated bottom formwork of the composite slab beam) is set as a functional partition (operating platform), and multiple standard formwork platforms 1 form a circulating production line. The standard formwork platform 1 is moved to each functional area by a formwork platform moving system 8 composed of a roller conveyor, guide wheels, and a double-machine lifting shuttle installed under the formwork platform. Among them, the pouring area 3 is mainly composed of a vibration system 3-2, a feeding hopper system, and an automatic distributor. The concrete mixed by the mixing station 2 is transported to the feeding hopper system via a concrete conveyor belt 3-1, and the concrete pouring is completed by an automatic distributor. Considering that the top surface of the composite beam often has embedded reinforcement 7-1 of the top truss of the composite slab beam, the leveling of the concrete surface on the top of the slab is completed with manual assistance. After the composite slab beam 5-1 is cast, it moves from the standard formwork platform 1 into the vertical curing kiln 4-1 for high-temperature curing, and then enters the demoulding and cleaning area 5, the supporting formwork area 6, the steel bar installation area 7 and the pouring area 3 in sequence to form a circulating production line.

As shown in Figures 1-4, the layout structure of the automatic assembly line for prefabrication of composite slab beams in the factory includes a standard formwork 1, a mixing station 2, a pouring area 3, a curing area 4, a demoulding and cleaning area 5, a formwork support area 6, a steel bar installation area 7, a roughening area 9, a guardrail 10, a template stacking area 11, and a material stacking area 12. The circulating assembly line is the pouring area 3, the curing area 4, the demoulding and cleaning area 5, the formwork support area 6, the steel bar installation area 7, and the pouring area 3 in sequence. The standard formwork 1 is moved to each functional area by a formwork moving system 8. The formwork moving system 8 includes a formwork driving device 8-1, a formwork water guide device 8-2, a roller conveyor, a guide wheel, and a double-machine lifting shuttle. A formwork driving device 8-1 and a formwork water guide device 8-2 are provided below the standard formwork 1. The mixing station 2 is located outside the pouring area 3, and the mixing station 2 is connected to the pouring area 3 through a concrete conveyor belt 3-1. The curing area 4 includes a vertical curing kiln 4-1, a hoist 4-2 and a control console 4-3. The template 5-2 is mainly composed of an L-shaped side form 6-1 and a bottom form of a composite slab beam. The L-shaped side form 6-1 of the composite slab beam is provided with a pre-embedded steel bar reserved hole 6-2, and the pre-embedded steel bar reserved hole 6-2 is provided with a composite slab beam top truss pre-embedded steel bar 7-1, and a slurry leakage prevention device 7-2 is inserted on the pre-embedded steel bar reserved hole 6-2. The L-shaped side form 6-1 of the composite slab beam is reinforced with the bottom form by a strong magnetic fixer 5-3. A guardrail 10 is provided around the production line.

As shown in FIG5 , the automatic assembly line production method for prefabrication of composite slab beams in a factory includes the following steps:

Step 1: Design and layout of automated production lines. The area occupied by the automated production line of a single composite slab beam is 105m×28m in length×width, and the length×width of the standard formwork platform 1 is 9.0m×3.5m. The circulating line is divided into functional areas according to the pouring area 3, the curing area 4, the demoulding and cleaning area 5, the formwork area 6, the steel bar installation area 7, the roughening area 9, the formwork stacking area 11, and the material stacking area 12, and is arranged in a rectangular shape. Along the long side of the line, a formwork platform driving device 8-1 is set under each standard formwork platform 1 (4 are set per formwork platform, about 1m away from the end), and a formwork platform water flow guide device 8-2 (spacing 2m) is usually set under the longitudinal beams on both sides of the formwork platform to ensure the longitudinal movement of the standard formwork platform 1; on the two short sides of the line, a double-machine lifting shuttle is set for the lateral movement of the standard formwork platform 1 on the line to realize the U-shaped circulating line. The mixing station 2 is located outside the pouring area 3, and the mixed concrete is transported to the hopper system directly above the mold platform through the concrete conveyor belt 3-1. The entire production line (except the delivery area of the demoulding area components) is surrounded by yellow steel mesh fences (pedestrian access channels are opened as needed).

Step 2: Side formwork installation. The base formwork of the composite slab beam is made using the standard formwork platform 1. The side formwork is customized according to the structural dimensions of the composite slab beam and adopts an L-shaped steel plate structure. Pre-embedded steel bar reserved holes 6-2 are opened on the L-shaped side formwork 6-1 of the composite slab beam according to the spacing of the pre-embedded steel bars. The side formwork system is fixed to the base formwork by a strong magnetic fixture 5-3. The quality of the formwork should ensure that the geometric dimensions of each part are accurate, the four corners are square, there is no torsion or deformation, the joints do not leak slurry, and the inside of the mold is clean. For the side formwork used for the first time, self-inspection shall be carried out after the first piece is supported, and it shall be jointly accepted by the production supervisor together with the inspection personnel and technical personnel. It can only be used after passing the acceptance. The template used for turnover must be self-inspected.

Step 3: Installation of steel bar skeleton. The semi-finished steel bar skeleton of the composite slab beam (including the embedded steel bars of the truss type at the top of the slab) is processed uniformly in the steel bar processing plant and transported to the inner site of the steel bar installation area 7 assembly line for use. The steel bars, steel bar skeleton, and steel mesh that are put into the mold must be inspected and accepted; after the steel bars are put into the mold, the protective layer pads are arranged in a plum blossom shape, and it is strictly forbidden to walk or step on the steel bars; tools for applying isolation agents or other debris shall not be placed on the steel bars. Before pouring, anti-leakage devices 7-2 are inserted one by one on the reserved holes 6-2 for the embedded steel bars.

Step 4: Concrete pouring. Concrete is centrally mixed by the mixing station 2, transported to the hopper system directly above the mold platform to be delivered via the concrete conveyor belt 3-1, unloaded by the automatic placing machine and vibrated and compacted by the vibration system 3-2 under the mold platform, and manually assisted top surface leveling is adopted.

Step 5: Curing of components in vertical curing kiln. After the composite slab beam concrete is cast and the surface layer is treated, the formwork moves to the vertical curing kiln 4-1, and is sent into the curing kiln for high-temperature curing together with the formwork through the elevator 4-2. The vertical curing kiln 4-1 is automatically temperature-controlled by the instrument for curing, and the curing is carried out in four stages: static stop, heating, constant temperature, and cooling. Before steam curing, it is statically stopped at room temperature for 2-4 hours; the heating rate should not exceed 20℃/h; the temperature in the constant temperature heating stage should not be greater than 60℃; the cooling rate should not exceed 20℃/h; the temperature difference between the surface of the component and the external environment is not greater than 20℃ before demolding.

Step 6: Demolding. The components are cured in the curing kiln until they reach the specified lifting and demoulding strength and then removed from the kiln. Before the components are demoulded and lifted, a group of test blocks cured under the same conditions must be pressed first; only when the strength of this group of test blocks reaches more than 75% of the design strength or the design requirements, can they be demoulded and lifted. When demolding, first remove the strong magnetic fixer 5-3, and then remove the L-shaped side formwork 6-1 of the composite slab beam. When demolding, it is forbidden to hit the template with a sledgehammer, and it is also forbidden to directly hit the components. After the components are demolded, they should be inspected and accepted in a timely manner, and the project parts, component models and production dates should be sprayed according to regulations, and then stacked for maintenance.

Step 7: Cleaning the formwork. Use a putty shovel to clean the slurry on the mold, then clean the bottom mold and enter the next cycle of prefabrication of composite slab beams.

Claims (2)

1. A layout structure of an automatic assembly line for prefabrication of composite slab beams in a factory, characterized in that it comprises a standard mold platform (1), a mixing station (2), a pouring area (3), a curing area (4), a demoulding and cleaning area (5), a mold support area (6), a steel bar installation area (7), a roughening area (9), a fence (10), a template stacking area (11) and a material stacking area (12); the circulating assembly line is sequentially composed of a pouring area (3), a curing area (4), a demoulding and cleaning area (5), a mold support area (6), a steel bar installation area (7) and a pouring area (3); the standard mold platform (1) is moved to each functional area by a mold platform moving system (8), and a mold platform driving device (8-1) and a mold platform water flow guide device (8-2) are provided below the standard mold platform (1); the pouring area (3) is mainly composed of a vibration system (3-2), a feeding hopper system and an automatic material distributor; the mixing station (2) is located outside the pouring area (3), and the mixing station ( 2) is connected to the hopper system through a concrete conveyor belt (3-1); a vertical curing kiln (4-1), an elevator (4-2) and a control console (4-3) are provided in the curing area (4); the template (5-2) of the composite slab beam (5-1) is mainly composed of an L-shaped side template (6-1) and a bottom template of the composite slab beam; a guardrail (10) is provided around the production line; the mold platform moving system (8) includes a mold platform driving device (8-1), a mold platform water flow device (6-2) and a mold platform water flow device (6-3); A guide device (8-2), a roller conveyor, a guide wheel and a double-machine lifting shuttle bus; the L-shaped side formwork (6-1) of the composite slab beam is provided with a pre-embedded steel bar reserved hole (6-2), the pre-embedded steel bar reserved hole (6-2) is provided with a composite slab beam top truss pre-embedded steel bar (7-1), a slurry leakage prevention device (7-2) is inserted on the pre-embedded steel bar reserved hole (6-2), and the L-shaped side formwork (6-1) of the composite slab beam is reinforced with the bottom formwork through a strong magnetic fixer (5-3). 2. A method for producing a composite slab beam in a factory prefabricated automatic assembly line, characterized in that it comprises the following steps: Step 1: Design and layout of an automated production line; the circulating production line is functionally divided into a pouring area (3), a curing area (4), a demoulding and cleaning area (5), a mold support area (6), a steel bar installation area (7), a roughening area (9), a template stacking area (11) and a material stacking area (12), and is arranged in a rectangular shape; along the long side of the production line, a template driving device (8-1) is arranged under each standard template (1), and a template flow guide device (8-2) is arranged under the longitudinal beams on both sides of the standard template (1) for longitudinal movement of the standard template (1); in the short side directions of the production line, a double-machine lifting shuttle vehicle is arranged for the transverse movement of the standard template on the production line to realize a U-shaped circulating production line; wherein the mixing station (2) is located outside the pouring area (3), and the mixed concrete is transported to the feeding hopper system directly above the standard template (1) via a concrete conveyor belt (3-1); the production line is surrounded by a guardrail (10); Step 2: installing the side formwork; the composite slab beam uses a standard formwork platform (1) to make a bottom formwork, the side formwork is customized according to the structural dimensions of the composite slab beam, and an L-shaped steel plate structure is adopted. Pre-embedded steel bar reserved holes (6-2) are opened on the L-shaped side formwork (6-1) of the composite slab beam according to the spacing of the pre-embedded steel bars; the side formwork is fixed to the bottom formwork by a strong magnetic fixer (5-3); Step 3: Installation of steel bar skeleton; the semi-finished steel bar skeleton of the composite slab beam is uniformly processed in the steel bar processing plant and transported to the steel bar installation area (7) for use in the inner field of the assembly line; the steel bars, steel bar skeleton and steel mesh put into the mold are inspected and accepted; after the steel bars are put into the mold, the protective layer pads are arranged in a plum blossom shape; before pouring, the anti-leakage device (7-2) is inserted one by one on the reserved holes (6-2) of the embedded steel bars; Step 4: concrete pouring; the concrete is centrally mixed at the mixing station (2), transported to the hopper system directly above the mold platform to be delivered via the concrete conveyor belt (3-1), discharged by the automatic placing machine and vibrated and compacted by the vibration system (3-2) under the mold platform, and the top surface is leveled with manual assistance; Step 5: curing the component in a vertical curing kiln; after the composite slab beam concrete is cast and the surface layer is treated, the standard mold platform (1) moves to the vertical curing kiln (4-1), and is sent into the curing kiln for high-temperature curing together with the standard mold platform (1) through the elevator (4-2); the vertical curing kiln (4-1) is automatically temperature-controlled by an instrument for curing, and the curing is carried out in four stages: static stop, heating, constant temperature and cooling; before steam curing, it is statically stopped at room temperature for 2-4 hours; the heating rate does not exceed 20°C/h; the temperature in the constant temperature heating stage is not greater than 60°C; the cooling rate does not exceed 20°C/h; the component is demoulded when the temperature difference between the surface of the component and the external environment is not greater than 20°C; Step 6: demoulding; the component is cured in the curing kiln until it reaches the specified lifting and demoulding strength and then removed from the kiln; before the component is demoulded and lifted, a group of test blocks cured under the same conditions are pressed first; when the strength of this group of test blocks reaches more than 75% of the design strength or the design requirements, demoulding and lifting are carried out; when removing the mold, first remove the strong magnetic fixer (5-3), and then remove the L-shaped side mold of the composite slab beam (6-1); after the component is removed from the mold, it is inspected and accepted, and the project location, component model and production date are sprayed according to regulations, and then stacked for maintenance; Step 7: Cleaning the formwork; use a putty spatula to clean the slurry on the mold, then clean the bottom mold and enter the next cycle of prefabrication of composite slab beams.