FI80846B - ANNLAEGGNING FOER TILLVERKNING AV BETONGELEMENT. - Google Patents

Description

1 80846

Concrete element manufacturing plant

The invention relates to a plant for the manufacture of concrete elements, comprising 5 - molds for shaping the products to be manufactured; - means for installing reinforcements in the molds and / or cavity forming devices for the molds; - pouring the fresh concrete mix of the concrete container into the mold; - means for compacting the concrete in the mold; - means for moving the mold and / or the finished product; - means for curing the concrete in the mold; 15 - means for removing the finished product from the mold; - a carriage movable along a straight track, the concrete container, the means for moving the mold and the means for removing the finished product from the mold being arranged on said carriage.

20 The industrial prefabrication of precast concrete elements was previously carried out using two different basic methods. One of them is the manufacture of so-called. in a "long line" or "fixed substrate" system, in which the molds acting as the space (cavity) forming the element are fixed, while the various devices performing technical operations run along the molds and fulfill their specific function. The second method consists of the so-called "mobile mold conveyor" or "casting line". In this method, the technical equipment is fixed, while the molds pass as if on a conveyor 30 along work points where predetermined operating steps take place (see, e.g., NLSCOTT: "The long line pre-tensioning method" [Proceedings of the 9th International Congress of the FIP, Stockholm, June 6-10, 1982; Volume 3, pp. 262-27]).

35 During the so-called "long line" method.

2 80846 using fixed molds, the reinforcements are installed in the molds, possibly prestressed, the fresh concrete is poured, compacted and hardened on a production line, usually 80 to 400 m long. One of the special features of this system is that in the case of prestressed structures, the molds must be connected for the most part non-removably to the structures which receive the load forces, or they must themselves be made suitable for receiving the load forces. As a result, oversized and expensive molds are needed. In addition, the "long line" method is considered disadvantageous because the investment costs are too high, the space requirement is too large, hardening requires a lot of local work and a lot of energy. An additional disadvantage is that it can be used for a single product, as a product change would require the entire mold to be removed and replacement is laborious and time consuming. Investing requires a lot of work, moreover, it cannot be organized cheaply. This apparently comes from the fact that workers are forced to constantly 20 along the production line, so only relatively simple products can be produced economically.

Production based on a "mobile mold conveyor" takes place in covered workshops with a high internal height and equipped with cranes, whereby 25 molds are recycled by roller or chain conveyors between the work points. Workers remain at their own workstations and perform pre-determined tasks such as opening molds, cleaning them, installing reinforcements, prestressing, cavity formation, concreting, sealing, finishing, etc.

It should be noted that the method based on the "mobile mold conveyor" system is preferred over the former "long line" or "fixed platform" system because switching to another product 35 is easier and the work done can be better organized; li 3 80846 Despite these, there are also some unfavorable additional features. First of all * although compared to the "long line" method, the investment costs are much higher due to the need for a workshop with cranes and complex 5 mechanical equipment. Maintenance is also complicated due to the number of moving parts that are subject to wear. The only advantage, namely that employees only need to do one well-trained work step, does not at all compensate for the difficulties that arise if it is necessary to regroup 10 employees. According to economic calculations, grouped operations - due to high investment costs - only become profitable after a very long period of operation.

It is an object of the invention to provide a plant for the manufacture of concrete elements 15 comprising both systems, i. all the advantageous features of the "long line" method and the "mobile mold conveyor" method while allowing all their disadvantageous features to be eliminated. A further goal is that the manufacturing plant could be assembled from small units and easily located and moved, and the exchange for another product could be carried out economically and quickly.

SE Patent Publication No. 162,807 discloses the manufacture of thin-walled elements by compression. The plant is equipped with a trolley comprising a concrete container and a mold reversibly arranged (90 °) around an axis fixed to the frame. The frame can be raised or lowered using the drive on the trolley. The product can be removed from the mold on top of the casting mattress (sand support) by turning the mold. The mold is arranged for the moving unit. This known solution does not allow the application and compaction of concrete or the finishing and dismantling of the surface of the product.

U.S. Patent No. 4,171,194 relates to a fixed mat-35 system with a fixed track and ten manufacturing wagons for performing various work steps. Each carriage is able to »perform a single step; for example, removing or tilting the mold walls, or cleaning or treating the reinforcement, or placing the inserts in the mold, or draining or finishing the concrete. The mold can be moved using a bridge crane. The mattress system involves long fixed molds that take up a lot of plant space.

SU patent 1,181,871 discloses a device 10 comprising a carriage with gripping means for moving molds, a product as well as a vibrator plate. The vibratory plate can only compact the concrete downwards, so that the product has a horizontal top surface. The trolley does not perform concrete drainage because it is set to 15 sides during drainage.

GB Patent 1,305,110 discloses a production line for prestressed concrete products. The production line comprises a structure in which all manufacturing operations are centralized on a frame structure. The structure 20 is based on a mold rotation system comprising stations for performing various manufacturing operations. The molds are mounted on the inner perimeter of the "support hall".

The object of the invention is to provide a solution by means of which the device could be put into operation with a cheap and mini-25 mi workload on site, it could be moved even long distances, the use of special parts could be avoided, additional requirements are easy maintenance and production capacity variability. An additional task was set that not only multi-purpose products could be produced, but also the simultaneous manufacture of different products.

The invention is based on a combination of several partial observations, namely that heavy molds and load-bearing structures - used in "long line" technology - as well as cranes and expensive and complex conveyors used in group technology

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5 80846 must be deleted. An additional finding is that, with the exception of curing, all technical steps can be performed in a single location if a combined manufacturing unit is used which, with all the necessary special equipment, is capable of performing all essential manufacturing tasks such as lifting (moving), turning, cutting and unloading. Accordingly, the present invention provides a plant for the manufacture of concrete elements in which the element manufacturing space is formed by reusable molds. The manufacturing plant according to the invention is characterized in that the trolley is formed as a combined manufacturing unit comprising surface finishing devices mainly comprising a roll for spreading, shaping or patterning the upper surface of the product and moving the multi-purpose beam unit, the lifting unit wherein the concrete container, the at least one additional vibrator, the cavity forming devices, the hanging elements and the turning members 20 for disassembling the products are interchangeably arranged on said beam unit of the combined manufacturing unit, said molds being portable and rotatable located within the area of operation of the combined manufacturing unit. Preferably, the manufacturing plant is provided with a turntable to facilitate the handling of the products, which turntable is in cooperation with the combined manufacturing unit. In the apparatus of the invention, the beam unit is preferably arranged in such a way that it can be moved transversely on the frame beam of the combined production unit by means of a drive device. The bar unit has one or more additional vibrators. For moving the self-moving concreting unit along the track, a drive device is provided for moving the concreting unit in the longitudinal direction.

With the manufacturing plant according to the invention, all tasks are performed in one single place, except for curing.

Compared to known manufacturing devices and manufacturing methods, the invention has several advantageous features. The most important of the technical advantages is that it is a 'multi-purpose' combined manufacturing unit, not only in chronological order, but because different products can be selected at the same time. The most important advantage is considered to be that the production capacity can be varied within wide limits.

Further, after unloading, the various units and equipment can be easily transported in containers to any desired location.

One technical advantage should be mentioned - as its economic impact is also considerable - that many structures (which make previous manufacturing methods as complex as possible) can be omitted. Thus, for example, a work-20 workshop with cranes or separate crane tracks, multi-complex machine platforms, special equipment for receiving load forces, or heavy and long molds are no longer needed; conveyors, rollers, chains and cranes with worker maintenance become unnecessary. In addition, 25 much smaller manufacturing sites, less and better organized workforce are needed. Because most transfer tasks can be waived, significant energy savings can be made.

From the above, it is clear that the invention 30 offers economic advantages in that the so-called special equipment requirements related to the production volume are lower than in either the "long line" or "mobile mold conveyor" or "casting line" method. As the means of production are insignificant in weight and a significant part of the additional investment 35 becomes unnecessary, considerable progress can be made.

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7 80846 possible savings. Furthermore, transport and assembly costs are lower compared to traditional methods. The same savings can be demonstrated in terms of production and maintenance costs. The cost of transporting the device even to long mats is reasonable.

- The invention will be described on the basis of the drawings in detail by means of the preferred embodiment, which serves as an example. In the drawings: Fig. 1 is a side view of a device according to the invention, showing three different manufacturing steps (a, b, c), Fig. 2 is a plan view of the same device, Fig. 3 is a section taken along line III-III of Fig. 2; 2 is a section taken along line IV-IV, Fig. 5 is a section taken along line V-V of Fig. 2, Fig. 6 is a cross-section of another embodiment.

Fig. 1 shows a side view of a combined manufacturing unit 2, which forms an integral part of the apparatus according to the invention, in various manufacturing steps, producing by way of example - railway concrete sleepers described in product 9. The sleepers are made in molds 1, each of which can be made simultaneously. 2 x 5 pieces of product 9 (Figure 2).

In Fig. 1a, above the product 9, the multi-purpose beam unit 2a - which represents the most important part of the combined manufacturing unit 2 - can be seen in the raised position 30. The beam unit 2a performs, among other things, all the necessary transfer operations of the molds 1, e.g. gripping, raising and lowering.

Figures 1a, 2a and 3 illustrate a stack of sleepers arranged in a curing chamber 6, which can be conveniently assembled and disassembled, respectively. The known steam generating unit 10 supplies thermal energy to the curing chamber 6. The beam unit 2a stacks the sleepers (stacking), also suitable for assembling the curing chamber 6, by placing the chamber cover 6a in place.

Fig. 3 shows a lifting unit 2f operating to move the beam unit 2a vertically.

Two different positions of the beam unit 2a can be seen in Figure Ib: on the left side the beam unit 2a is in the raised position with the concrete container 2b suspended 10 on it, while on the right side it rests on the mold 1 and additional vibrators 2d compact fresh concrete.

Fig. 2b illustrates a surface finishing device 2c, which is e.g. a leveling roller and which is attached to the frame beam 2i of the combined manufacturing unit 2. By means of the leveling roller 15, the fresh concrete poured into the molds 1 can be applied, shaped and patterned from the surface (pattern pattern). One or more cavity devices 2e may be arranged on the beam unit 2a.

If it is intended to manufacture prestressed products 20 9, the tension-generating devices 8 are arranged in line with the pre-stapled reinforcements, said devices 8 being started by a hydraulic drive unit 8a. The vibrators 2d (arranged above and being only in a secondary position) cooperate with the vibrator table 3 (or vibrator racks) carrying the molds 1, which is the main compactor of the concrete.

When compaction is completed, the combined manufacturing unit 2 places the molds 1 containing compacted fresh concrete in the curing chamber 6, from where - after 30 predetermined curing times - the molds 1 are transferred again to the vibrator table 3. The prestressing wedges are then cut by the cutting unit 4 bundle) are cut and removed from the molds 1 by means of a beam unit 2a. The cutting unit 4 of the cutting-35 can be, for example, a known welding converter (generator).

After the emptied molds 1 have been cleaned and oiled,

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9 The 80846 process can be restarted by installing new reinforcements.

Fig. 2b shows a top view of one mold 1, in which several pieces 5 (2x5) of product 9 can be produced simultaneously. The mold 1 rests on the vibrator table 3 and the prestressing device 8 actuated by the hydraulic drive unit 8a is connected to it.

Fresh concrete is fed into the molds 1 from a concrete tank 2b attached to the bundling element 10 2k of the beam unit 2a. As can be seen from Fig. 4, the beam unit 2a holds the concrete container 2b in the upper position by means of the lifting unit 2f, below which a mold 1 is provided - supported by a vibrator table 3. The figure also shows a shear-welding unit 4 for welding the reinforcements during installation and which can be relocated if desired. The combined manufacturing unit 2 has a drive device 2g for moving said unit along its entire path.

Figures 1e, 2c and 5 illustrate the manufacturing step during which the beam unit 20 2a of the combined manufacturing unit 2 places the product stack 9 removed from the mold on the pivot frame 5 and, gripping the pivot members 21 from below, it pivots the package. The product package 9 (bundle) is then cut to final size by means of a shear-welding unit 4 and multi-row stacks are formed. The stacks are further moved with 25 forklifts to 7 storage locations.

Figure 6 shows a second embodiment of the apparatus according to the invention, according to which the combined manufacturing unit 2 comprises one or more fixed bodies which cannot be moved longitudinally. Therefore, the concrete container 30 2b is not suspended on the beam unit, but is driven by the self-propelled unit 2h.

The equipment according to the invention can advantageously be used in factories where the degree of production is suitable or if the equipment has to be set up repeatedly. It can be advantageously used for sites where production has to take place in a certain place, according to said site.

Claims (2)

10 80846 A plant for the manufacture of concrete elements, comprising - molds (1) for shaping the products (9) to be manufactured; - means for installing reinforcements in the molds (1) and / or cavity forming devices (loose pieces 2e) for the molds (1); - a concrete container (2b) for pouring fresh concrete mix into the mold; - means for compacting the concrete in the mold; - means for moving the mold and / or the finished product (9); - means for curing the concrete in the mold (1); - means for removing the finished product (9) from the mold (1); - a trolley movable along a straight track (11), wherein the concrete container (2b), the means 20 for moving the mold and the means for removing the finished product from the mold are arranged on said trolley, characterized in that the trolley is formed as a combined manufacturing unit (2), comprises surface finishing devices (2c) mainly comprising a roll 25 for spreading, shaping or patterning the upper surface of the product (9), and a multi-purpose beam unit (2a), a lifting unit (2f) for moving said beam unit (2a) vertically, and a drive device (2j) for moving the lifting unit (2f) in the transverse direction, wherein the concrete container 30 (2b), the at least one additional vibrator (2d), the cavity forming devices (2e), the suspension elements (2k) and the turning members (21) for unloading the products (9) are interchangeably ), wherein said molds (1) are further portable 35 (movable) and reversible by means of the combined production unit II li 80846 (2), and that said means for curing concrete in the mold consist of a collapsible curing chamber (6) # located in the operating range of the combined production unit (2). Manufacturing plant according to Claim 1, characterized in that it is provided with a turntable (5) for facilitating the handling of the products (9), which turntable is in cooperation with the combined production unit (2). 10 80846