CN111186011A - Factory prefabricated automatic assembly line layout structure and production method of laminated slab beam - Google Patents

Abstract

The invention relates to a prefabricated automatic assembly line layout structure of a laminated slab beam factory, comprising: a standard mold table, a mixing station, a pouring and tamping area, a maintenance area, a demoulding cleaning area, a mold support area, a steel bar installation area, a roughening area, a fence, The formwork stacking area and the material stacking area; the circulation line is the pouring and tamping area, the curing area, the demoulding cleaning area, the formwork area, the steel bar installation area and the pouring and tamping area; the standard mold table is moved to each functional area through the mold table moving system, Below the standard die table is a die table drive device and a die table flow guide device. 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 laminated slab beams, realizes the construction of functional sub-assembly lines of prefabricated components, and is an efficient production organization method that makes full use of space and processes in succession. Reduced, the energy saving is obvious. At the same time, it has also promoted the continuous improvement of the quality and quality of prefabricated buildings, and the level of green environmental protection has been significantly improved.

Description

Automatic assembly line arrangement structure for factory prefabrication of laminated slab beams and production method

Technical Field

The invention relates to a factory-prefabricated automatic assembly line arrangement structure and a production method of a laminated slab beam, and belongs to the technical field of assembly type building engineering.

Background

The assembly type buildings are one of the important directions of green buildings and building industrialization, the novel building industrialization is greatly promoted all over the country, and the proportion of the assembly type buildings in the novel buildings is gradually increased through the construction of industrial bases. The factory prefabrication of the composite plate beam is the most common process in the assembly type building, but the specification and the size of the composite plate beam are more, and when a fixed pedestal is adopted for production, the investment is large, the work efficiency is low, and the space utilization rate is low.

Disclosure of Invention

The invention aims to overcome the defects in the prior art and provides an automatic assembly line arrangement structure and a production method for factory prefabrication of a laminated slab beam.

The automatic assembly line arrangement structure for factory prefabrication of the laminated slab beam comprises a standard die table, a stirring station, a pouring and tamping area, a maintenance area, a demolding and cleaning area, a formwork supporting area, a steel bar installation area, a napping area, a surrounding guardrail, a template stacking area and a material stacking area; the circulating assembly line sequentially comprises a pouring and tamping area, a maintenance area, a demolding and cleaning area, a formwork supporting area, a steel bar mounting area and a pouring and tamping area; the standard mould platform moves to each functional area through a mould platform moving system, and a mould platform driving device and a mould platform flowing water guiding device are arranged below the standard mould platform; the pouring and tamping area mainly comprises a vibration system, a feeding hopper system and an automatic distributing machine; the stirring station is positioned outside the pouring and tamping area and is connected to the hopper system through a concrete conveying belt; a vertical curing kiln, a lifter and a control console are arranged in the curing area; the template of the laminated plate beam mainly comprises an L-shaped side die and a bottom die of the laminated plate beam; surrounding guardrails are arranged around the production line.

Preferably, the method comprises the following steps: the mould platform moving system comprises a mould platform driving device, a mould platform flowing water guiding device, a roller conveyor, a guide wheel and a double-machine lifting type ferry vehicle.

Preferably, the method comprises the following steps: the L-shaped side mold of the laminated plate beam is provided with a pre-buried steel bar preformed hole, a laminated plate beam top truss pre-buried steel bar is arranged in the pre-buried steel bar preformed hole, a slurry leakage prevention device is inserted into the pre-buried steel bar preformed hole, and the L-shaped side mold of the laminated plate beam is reinforced with the bottom mold through a strong magnetic fixer.

The automatic flow line production method for factory prefabrication of the laminated slab beam comprises the following steps of:

designing and arranging an automatic production line; the circulating assembly line is functionally partitioned according to a pouring area, a maintenance area, a demolding cleaning area, a formwork supporting area, a steel bar installation area, a napping area, a template stacking area and a material stacking area and is arranged in a rectangular shape; along the long side direction of a flow line, a mould platform driving device is arranged below each standard mould platform, and mould platform flow guiding devices are arranged below longitudinal beams on two sides of the standard mould platform and used for longitudinal movement of the standard mould platform; two lifting type ferry vehicles are arranged in the direction of two short edges of the production line and are used for transversely moving a standard die table on the production line to realize a square circulation production line; wherein the stirring station is positioned outside the pouring and tamping area, and the mixed concrete is conveyed to a hopper system right above the standard mould platform through a concrete conveying belt; enclosing the guardrail around the production line;

step two, mounting a side die; the method comprises the following steps that a bottom die is manufactured on a laminated slab beam by using a standard die table, a side die is customized according to the structural size of the laminated slab beam, an L-shaped steel plate structure is adopted, and pre-buried steel bar preformed holes are formed in the L-shaped side die of the laminated slab beam according to the distance between pre-buried steel bars; the side die is fixedly formed with the bottom die through a strong magnetic fixer;

step three, installing a steel bar framework; uniformly processing the semi-finished products of the reinforcement cage of the laminated slab beam in a reinforcement processing factory, and transporting the semi-finished products to a site at the inner side of a production line of a reinforcement installation area for use; the steel bars, the steel bar framework and the steel bar mesh which are put into the die are checked and accepted; after the reinforcing steel bars enter the die, arranging a protective layer cushion block according to a quincunx shape; before pouring, inserting slurry leakage prevention devices one by one on the preformed holes of the embedded steel bars;

step four, pouring concrete; concrete is intensively mixed by a mixing station, is conveyed to a feeding hopper system right above a to-be-delivered mould table through a concrete conveying belt, is fed by an automatic material distributor and is compactly vibrated by a vibration system below the mould table, and the top surface is leveled by manual assistance;

fifthly, maintaining the component in a vertical curing kiln; after the concrete pouring molding and the surface layer treatment of the laminated slab beam, the standard die platform travels to the vertical curing kiln, and the laminated slab beam and the standard die platform are conveyed to the curing kiln for high-temperature curing through a lifter; the vertical curing kiln is maintained by automatically controlling the temperature through an instrument, and the maintenance is carried out in four stages of standing, heating, constant temperature and cooling; standing at normal temperature for 2-4 hours before steaming; the temperature rising speed is not more than 20 ℃/h; the temperature in the constant temperature heating stage is not more than 60 ℃; the cooling speed is not more than 20 ℃/h; demolding when the temperature difference between the surface of the component and the external environment is not more than 20 ℃;

step six, demoulding; the member is taken out of the kiln when being cured in the curing kiln until reaching the specified hoisting and demolding strength; before the member is demoulded and lifted, a group of test blocks maintained under the same condition are pressed; when the strength of the test block group reaches over 75 percent of the design strength or meets the design requirement, demoulding and hoisting; when the mold is removed, the strong magnetic fixer is removed, and then the L-shaped side mold of the laminated plate beam is removed; after the component is demoulded, checking and accepting, spraying the engineering part, the component model and the production date according to the specification, and stacking and maintaining;

seventhly, cleaning the template; and cleaning the grout skin on the mould by using a putty shovel, then cleaning the bottom mould, and performing the flow construction of the next circulation superposed plate beam prefabrication.

The invention has the beneficial effects that: the invention designs a set of automatic production line for the factory prefabrication of the laminated plate girder, realizes the function partition assembly line construction of the prefabricated part, is an efficient production organization mode which fully utilizes space and has sequential working procedures, reduces the cost and obviously saves energy. Meanwhile, the quality and quality of the fabricated building are promoted to be improved continuously, and the level of environmental protection is obviously improved.

Drawings

FIG. 1 is a plan view of an automatic production line for factory prefabrication of composite slabs;

FIG. 2 is a perspective view of an automatic production line for factory prefabrication of composite slabs;

FIG. 3 is a detailed view of a prefabricated formwork system;

FIG. 4 is a layout view of a standard die table drive;

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

Description of reference numerals: the system comprises a standard mould platform 1, a stirring station 2, a pouring and tamping area 3, a concrete conveying belt 3-1, a vibration system 3-2, a maintenance area 4, a vertical maintenance kiln 4-1, a lifter 4-2, a control console 4-3, a demoulding and cleaning area 5, a laminated plate beam 5-1, a template 5-2, a strong magnetic fixer 5-3, a mould supporting area 6, a laminated plate beam L-shaped side mould 6-1, a pre-embedded steel bar preformed hole 6-2, a steel bar mounting area 7, a laminated plate beam top truss pre-embedded steel bar 7-1, a slurry leakage prevention device 7-2, a mould platform moving system 8, a mould platform driving device 8-1, a mould platform water guiding device 8-2, a napping area 9, a surrounding guardrail 10, a mould plate stacking area 11 and a material stacking area 12.

Detailed Description

The present invention will be further described with reference to the following examples. The following examples are set forth merely to aid in the understanding of the invention. It should be noted that, for those skilled in the art, it is possible to make various improvements and modifications to the present invention without departing from the principle of the present invention, and those improvements and modifications also fall within the scope of the claims of the present invention.

The automatic assembly line arrangement structure for the prefabricated superimposed sheet beam factory realizes the circulation assembly line of the functional partitions such as the pouring area, the maintenance area, the demolding cleaning area, the formwork supporting area and the steel bar installation area by setting the movable standard platform formwork system, achieves the efficient production organization mode of fully utilizing the space and the procedure in order, reduces the cost and obviously saves energy.

Aiming at the characteristics of the plane component of the laminated slab beam, according to the technological processes of prefabricated slab beam formwork erection, steel bar installation, concrete pouring, maintenance and demolding, a standard formwork table 1 (with the length of 9.0m and the width of 3.5m, serving as a prefabricated bottom formwork of the laminated slab beam) is arranged as a functional partition (an operation platform), and a plurality of standard formwork tables 1 form a circulating assembly line. The standard die table 1 moves to each functional area through a die table moving system 8 which is composed of a roller conveyer, a guide wheel, a double-machine lifting ferry vehicle and the like and is arranged below the die table. Wherein, the pouring and pounding area 3 mainly comprises a vibration system 3-2, a feeding hopper system and an automatic distributing machine. The mixed concrete in the mixing station 2 is transported to a hopper system through a concrete conveying belt 3-1, and the concrete is poured by an automatic distributing machine. Considering that the top surface of the composite beam is often provided with the embedded ribs 7-1 of the truss on the top of the composite beam, the leveling of the concrete surface on the top of the plate is completed by manual assistance. After the laminated plate beam 5-1 is poured, the laminated plate beam travels from the standard die table 1 to enter a vertical curing kiln 4-1 for high-temperature curing, and then sequentially enters a demolding cleaning area 5, a formwork supporting area 6, a steel bar mounting area 7 and a pouring and tamping area 3 to form a circulating production line.

As shown in fig. 1-4, the automatic assembly line layout structure for the factory prefabrication of the composite slab beam comprises a standard die table 1, a stirring station 2, a pouring area 3, a maintenance area 4, a demolding cleaning area 5, a formwork supporting area 6, a steel bar installation area 7, a napping area 9, a guardrail 10, a template stacking area 11 and a material stacking area 12. The circulating production line sequentially comprises a pouring and tamping area 3, a maintenance area 4, a demoulding and cleaning area 5, a formwork supporting area 6, a reinforcing steel bar mounting area 7 and a pouring and tamping area 3. The standard mould platform 1 moves to each functional area through a mould platform moving system 8, the mould platform moving system 8 comprises a mould platform driving device 8-1, a mould platform flowing water guiding device 8-2, a roller conveyor, a guide wheel and a double-machine lifting type ferry vehicle, and the mould platform driving device 8-1 and the mould platform flowing water guiding device 8-2 are arranged below the standard mould platform 1. The mixing station 2 is located outside the casting and tamping zone 3, and the mixing station 2 is connected to the casting and tamping zone 3 by a concrete conveyor belt 3-1. The curing area 4 comprises a vertical curing kiln 4-1, a lifter 4-2 and a console 4-3. The template 5-2 mainly comprises an L-shaped side mold 6-1 of the laminated slab beam and a bottom mold, the L-shaped side mold 6-1 of the laminated slab beam is provided with a pre-buried steel bar preformed hole 6-2, a top truss pre-buried steel bar 7-1 of the laminated slab beam is arranged in the pre-buried steel bar preformed hole 6-2, a slurry leakage prevention device 7-2 is inserted into the pre-buried steel bar preformed hole 6-2, and the L-shaped side mold 6-1 of the laminated slab beam is reinforced with the bottom mold through a strong magnetic fixer 5-3. Surrounding guardrails 10 are arranged around the production line.

As shown in fig. 5, the automatic flow line production method for the factory prefabrication of the laminated slab beam comprises the following steps:

the method comprises the step one of automatically designing and arranging the production line. The occupied area length multiplied by the width of the single laminated plate beam automatic production line is 105m multiplied by 28m, the length multiplied by the width of a standard mould table 1 is 9.0m multiplied by 3.5m, and the circulating production line is functionally partitioned according to a pouring region 3, a maintenance region 4, a demoulding cleaning region 5, a formwork supporting region 6, a reinforcing steel bar installation region 7, a galling region 9, a template stacking region 11 and a material stacking region 12 and is arranged in a rectangular shape. Along the long side direction of a flow line, a mould platform driving device 8-1 is arranged below each standard mould platform 1 (4 mould platforms are arranged, the distance from the end is about 1m), and meanwhile, mould platform flow water guide devices 8-2 (the distance is 2m) are usually arranged below longitudinal beams on two sides of the mould platform so as to ensure that the standard mould platform 1 moves longitudinally; and two lifting type ferry vehicles are arranged in the direction of two short edges of the production line and are used for transversely moving the standard die table 1 on the production line to realize a square circulation production line. Wherein the mixing station 2 is positioned outside the pouring and pounding area 3, and the mixed concrete is conveyed to a hopper system right above the mould platform through a concrete conveying belt 3-1. The periphery of the whole production line (except the demoulding area component delivery area) is protected by yellow steel bar net enclosure guardrails (people enter and exit channels are arranged as required).

And step two, mounting the side die. The bottom die is manufactured by the aid of the standard die table 1 for the composite slab beam, the side die is customized according to the structural size of the composite slab beam, an L-shaped steel plate structure is adopted, and pre-buried steel bar preformed holes 6-2 are formed in the L-shaped side die 6-1 of the composite slab beam according to pre-buried steel bar intervals. The side die system is fixedly formed with the bottom die through a strong magnetic fixer 5-3. The quality of the formwork should be accurate in geometric dimension of each part, square in four corners, free of twisting deformation, free of slurry leakage of abutted seams and clean in the formwork. The side die used for the first time is self-checked after the first part is supported, and the side die can be used after being checked and accepted by a production supervisor, inspectors and technicians in a combined mode. The template used in the turnover must be self-checked.

And step three, installing the steel reinforcement framework. The semi-finished products (including the plate top truss type embedded ribs) of the reinforcement frameworks of the composite slabs are processed in a reinforcing steel bar processing factory in a unified mode and are transported to a site on the inner side of a 7-assembly line of a reinforcement installation area for use. The steel bars, the steel bar framework and the steel bar mesh which are put into the die must be checked and accepted; after the reinforcing steel bars enter the die, arranging a protective layer cushion block according to a quincunx shape, and strictly prohibiting walking and treading on the reinforcing steel bars; tools or other sundries for brushing the release agent cannot be put on the steel bars. Before pouring, inserting the slurry leakage prevention devices 7-2 one by one on the preformed holes 6-2 of the embedded steel bars.

And step four, pouring concrete. The concrete is intensively mixed by a mixing station 2, is transported to a feeding hopper system right above a die table to be delivered by a concrete conveying belt 3-1, is compacted by the blanking of an automatic distributing machine and the vibration of a vibration system 3-2 below the die table, and adopts the manual assistance for top surface leveling.

And step five, maintaining the component in a vertical curing kiln. After the concrete pouring forming and the surface layer processing of the composite slab beam, the mold platform travels to the vertical curing kiln 4-1 and is sent to the curing kiln for high-temperature curing together with the mold platform through the hoister 4-2. The vertical curing kiln 4-1 is used for automatic temperature control curing through an instrument, and curing is carried out in four stages of standing, temperature rising, constant temperature and temperature lowering. Standing at normal temperature for 2-4 hours before steaming; the temperature rising speed is not more than 20 ℃/h; the temperature in the constant temperature heating stage is not more than 60 ℃; the cooling speed is not more than 20 ℃/h; when the temperature difference between the surface of the component and the external environment is not more than 20 ℃, the component can be demoulded.

And step six, demolding. And (5) curing the member in a curing kiln until the member reaches the specified hoisting and demolding strength, and taking out the member from the kiln. Before the member is demoulded and lifted, a group of test blocks with the same condition must be maintained by pressing; only when the strength of the test block group reaches over 75 percent of the design strength or meets the design requirement, the test block group can be demolded and lifted. When the mould is disassembled, the strong magnetic fixer 5-3 is disassembled, and then the L-shaped side mould 6-1 of the laminated plate beam is disassembled. When the form is removed, the form is forbidden to be hammered by a sledge hammer, and the component can not be directly impacted. And (4) after the component is demoulded, checking and accepting in time, spraying the engineering part, the component model and the production date according to the specification, and stacking and maintaining.

And seventhly, cleaning the template. And cleaning the grout skin on the mould by using a putty shovel, then cleaning the bottom mould, and performing the flow construction of the next circulation superposed plate beam prefabrication.

Claims (4)

1. A prefabricated automatic assembly line layout structure of a laminated plate beam factory is characterized in that: comprising a standard die table (1), a mixing station (2), a pouring and tamping area (3), a maintenance area (4), a demoulding cleaning area ( 5), the formwork area (6), the reinforcement installation area (7), the pulling area (9), the fence (10), the formwork stacking area (11) and the material stacking area (12); the circulation line is the pouring and tamping area in turn (3), maintenance area (4), demoulding cleaning area (5), form support area (6), reinforcement installation area (7) and pouring and tamping area (3); standard die table (1) moves through the die table moving system (8) Move to each functional area, the standard die table (1) is provided with a die table driving device (8-1) and a die table flow guide device (8-2); the pouring and tamping area (3) is mainly composed of a vibration system ( 3-2), a feeding hopper system and an automatic distributing machine; the mixing station (2) is located outside the pouring and tamping area (3), and the mixing station (2) is connected to the feeding hopper system through the concrete conveyor belt (3-1); the curing area (4) There is a vertical curing kiln (4-1), a hoist (4-2) and a console (4-3) inside; the formwork (5-2) of the laminated beam (5-1) is mainly composed of laminated The plywood beam is composed of an L-shaped side mold (6-1) and a bottom mold; a fence (10) is arranged around the production line. 2. The prefabricated automatic assembly line layout structure of the laminated slab beam factory according to claim 1, characterized in that: the mold table moving system (8) comprises a mold table driving device (8-1), a mold table flow guide device (8-2) ), roller conveyors, guide wheels and double lift shuttles. 3. The factory prefabricated automatic assembly line layout structure of the laminated plate beam according to claim 1, is characterized in that: the L-shaped side mold (6-1) of the laminated plate beam is provided with pre-embedded steel bar reserved holes (6-2), The pre-embedded reinforcement (7-1) of the top truss of the superimposed slab beam is arranged in the reserved hole (6-2) for the embedded steel bar, and the slurry leakage prevention device (7-2) is inserted into the reserved hole (6-2) of the pre-embedded steel bar. The L-shaped side mold (6-1) of the laminated plate beam is reinforced with the bottom mold by a strong magnetic fastener (5-3). 4. a factory prefabricated automatic assembly line production method of laminated plate beam, is characterized in that, comprises the following steps: Step 1: Design and layout of the automated production line; the circulation line is divided into the pouring and tamping area (3), the maintenance area (4), the demoulding cleaning area (5), the formwork support area (6), the reinforcing bar installation area (7), and the roughening area. (9) The template stacking area (11) and the material stacking area (12) are functionally partitioned and arranged in a rectangular shape; along the long side of the assembly line, a die table driving device (8-1) is provided below each standard die table (1). At the same time, mold table flow guide devices (8-2) are installed under the longitudinal beams on both sides of the standard mold table (1) for the longitudinal movement of the standard mold table (1). It is used for the lateral movement of the standard mold table on the assembly line to realize the mouth-shaped circulation assembly line; the mixing station (2) is located outside the pouring and tamping area (3), and the mixed concrete is transported to the standard by the concrete conveyor belt (3-1). The feeding hopper system directly above the die table (1); the fence (10) around the production line is enclosed; Step 2: side mold installation; the laminated plate beam uses a standard mold table (1) to make a bottom mold, and the side mold is customized according to the structure and size of the laminated plate beam, and adopts an L-shaped steel plate structure, and the laminated plate beam L-shaped side mold (6-1) is placed on the Pre-embedded steel reinforcement holes (6-2) are opened according to the spacing of the embedded steel bars; the side mold is fixed and formed with the bottom mold by a strong magnetic fixer (5-3); Step 3: Reinforcement frame installation; The semi-finished product of the superimposed slab beam reinforcement frame is uniformly processed in the reinforcement processing plant, and transported to the inner side of the assembly line in the reinforcement installation area (7) for use; After moulding, arrange the protective layer pads according to the plum-shaped pattern; before pouring, install the anti-leakage slurry devices (7-2) on the reserved holes (6-2) of the pre-embedded steel bars one by one; Step 4: concrete pouring; Concrete is concentrated and mixed by the mixing station (2), and is transported to the feeding hopper system directly above the mold table to be delivered through the concrete conveyor belt (3-1), and is discharged through the automatic placing machine and the vibration under the mold table The system (3-2) is vibrated and dense, and artificially assisted top surface leveling is adopted; Step 5: Maintenance of the component vertical curing kiln; after the composite slab beam concrete is poured and formed and the surface layer is treated, the standard mold table (1) travels to the vertical curing kiln (4-1), and the elevator (4-2) together with the standard The mold table (1) is sent to the curing kiln for high-temperature curing; the vertical curing kiln (4-1) is maintained through automatic temperature control by the instrument, and the curing is carried out in four stages: static stop, heating, constant temperature and cooling; before steam curing, stop at normal temperature 2-4 hours; the heating rate should not exceed 20℃/h; the temperature in the constant temperature heating stage should not exceed 60℃; the cooling rate should not exceed 20℃/h; Step 6: demoulding; the component is maintained in the curing kiln until reaching the specified lifting and demolding strength, and the kiln is released; before the component is demolded and lifted, a group of maintenance test blocks under the same conditions are pressed; when the strength of the group of test blocks reaches the design strength When it is more than 75% or design requirements, it shall be demoulded and lifted; when demoulding, first remove the strong magnetic fixer (5-3), and then remove the L-shaped side formwork (6-1) of the laminated beam; Check and accept, and spray the project parts, component models and production dates according to the regulations, and then store them for maintenance; Step 7: Template cleaning; use a putty shovel to clean the pulp skin on the mold, then clean the bottom mold, and enter the next cycle of prefabrication of superimposed slab beams.

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