EP2681371B1 - Method for the continuous production of composite formwork panel elements - Google Patents

Description

Technical area

The invention relates to a method for the continuous production of plate elements for the production of composite formwork elements in the form of ceiling elements or wall elements, which are used in the field of structural engineering for the construction of buildings. Each plate element has a shuttering plate, which is equipped with fastening devices and reinforcing elements. Each formwork panel has a predetermined length for them and a predetermined geometry for them.

The composite shuttering element may be a ceiling element or a wall element. The ceiling element may, as for example EP 811 731 A1 or EP 1 907 642 B1 known and out Fig. 2 it can be seen, a plate element with a formwork plate 2, which is preferably equipped with screwed fastening devices 6, for example in the form of brackets for fixing reinforcing elements 5 and equipped with the reinforcing elements. The wall element may, as for example EP 611 852 A1 or EP 1 907 642 B1 known or off Fig. 1 or Fig. 2 it can be seen, be constructed of two plate elements each with a formwork panel 1, 2, which are each equipped with a plurality of preferably bolted fastening devices 3, 4 in the form of wall connecting elements and with reinforcing elements 5. The two plate elements 1, 2 are facing each other with their fastening devices 3, 4 and reinforcing elements 5 and are kept at their formwork panels 1, 2 of the fastening devices 3, 4 at a distance from each other, DE 19 718 111 A1 discloses a method according to the preamble of claim 1.

Technical background and conventional technique

With the help of such composite formwork elements wall and ceiling structures can be constructed in a solid-concrete shell construction, in which the formwork panels remain in prefabricated design, preferably cement-bonded flat-pressed plates, as so-called permanent formwork in the building. Such a construction method in composite formwork technology not only meets every design and technical requirement with high flexibility, but also fulfills high ecological and economic demands.

The composite formwork wall element consists of two plate elements with, for example, 24 mm thick shuttering panels in the form of cement-bonded flat-pressed plates, which are assembled industrially in the production plant to hollow, bivalve wall elements. For stabilizing the form and taking up the formwork pressure, fastening devices screwed from the inside are preferably used in the form of steel profiles as so-called "wall connectors". The wall elements are accurately mounted on the construction site and filled with fluid concrete or self-compacting concrete (SCC). The surface-forming cement-bonded flat-pressed plates should in turn be equipped with a perfect surface. As fasteners steel spacers are preferably used, which are bolted by means of galvanized countersunk screws with the shuttering panels. They connect the plate elements without penetrating the outer surface of the shuttering panels from the inside. All wall elements are manufactured ready-made and prefabricated in the factory and their formwork panels are provided with all necessary recesses and with the necessary transport anchors and with the necessary according to the static calculations reinforcement (mats, baskets, etc.).

• Zuschnitt der zementgebundenen Flachpressplatten auf die vorbestimmte Größe von Teil-Schalungsplatten auf einer Plattensäge, soweit die vorbestimmte Größe der zu produzierenden Teil-Schalungsplatte von den Abmessungen des Ausgangsmaterials abweicht. Manuelles Anschrauben von Verbindungsleisten, welche zur Befestigung der Wandverbindungselemente dienen, auf die Teil-Schalungsplatten der ersten Schalungsplatte an vordefinierten Positionen.
• Manuelles Anschrauben von Wandverbindungselementen auf die Teil-Schalungsplatten der zweiten Schalungsplatte an vordefinierten Positionen. Die Wandverbindungselemente dienen zur gegenseitigen Verbindung der beiden Schalungsplatten der Teilelemente in einem späteren Bearbeitungsschritt.
• Manueller Anbau von Verbindungsleisten zur Verbindung von mehreren Teil-Plattenelementen zu einem Gesamt-Plattenelement.
• Manuelles Bohren von Öffnungen für Elektroinstallationsarbeiten.
• Manueller Einbau der erforderlichen Mattenbewehrung für das Gesamt-Plattenelement inklusive der für die statisch wirksame Verbindung der Bewehrung der Teil-Plattenelemente erforderlichen Überlappungsbewehrung.
• Manueller Einbau der Elektroinstallation wie Elektrodosen und Leerverrohrung.
• Manueller Einbau von Abhebeankern für das Heben der zusammengefügten Gesamt-Plattenelemente mittels Kran für die weiteren Bearbeitungsschritte im Werk und auf der Baustelle.
• Zusammenfügen der ersten und der zweiten Teil-Schalungsplatte der Teil-Plattenelemente auf einer manuell bedienten Fügestation (Verpressen).
• Manueller Zusammenbau der Teil-Plattenelemente zum fertigen Verbundschalungs-Wandelement.
• Manuelle Komplettierung des Wandelementes durch Einbauen von Laibungsbrettern bei Fenster- und Türaussparungen

Conventionally, the usual product dimensions for most wall elements to be manufactured require that they be assembled lengthwise from sub-elements. The maximum length of the sub-elements depends on the maximum length of the starting material - the cement-bonded Flachpressplatten.Der production flow for such composite formwork wall elements according to the prior art, for example, as described below:

• Cutting the cement-bonded flat press plates to the predetermined size of partial formwork panels on a panel saw, as far as the predetermined size of the partial formwork panel to be produced deviates from the dimensions of the starting material. Manual screwing of connecting strips, which serve for fastening the wall connecting elements, on the sub-shuttering panels of the first shuttering panel at predefined positions.
• Manual screwing of wall connection elements on the sub-formwork panels of the second formwork panel at predefined positions. The wall connecting elements serve for the mutual connection of the two formwork panels of the sub-elements in a later processing step.
• Manually attaching connection bars to connect multiple part plate elements to one overall plate element.
• Manual drilling of openings for electrical installation work.
• Manual installation of the required mesh reinforcement for the entire panel element including the overlap reinforcement required for the statically effective connection of the reinforcement of the partial panel elements.
• Manual installation of the electrical installation such as electrical boxes and empty piping.
• Manual installation of lift-off anchors for lifting the assembled total slab elements by crane for further processing steps in the factory and on the construction site.
• Assembling the first and second sub-formwork panels of the sub-panel elements on a manually operated joining station (crimping).
• Manual assembly of the part plate elements to the finished composite formwork wall element.
• Manual completion of the wall element by installing soffit boards for window and door recesses

Summary description of the invention

In order to rationalize production capacities due to increasing demand, there is therefore a need to create a largely automated production line for the production of composite formwork elements. In such a production plant is a concatenation of several machines / equipment for the production of individual parts (composite formwork panel elements in particular in the form of pairwise related plate elements for the production of wall elements, but also in the form of plate elements as composite formwork ceiling elements, each in a predetermined size and Geometry). A central control system is to be used for the coordination and logistic control of the plant. The advantages of modern, industrial production in a hall are higher efficiency of the working hour due to optimized work processes and the possibility of high utilization of the plant facilities.

The invention provides a method by which a continuous, at least largely automatable production of plate elements of the type mentioned in predetermined sizes and in predetermined geometries can be achieved, the sizes and also the geometries of the plate elements provided for formwork panels individually to the for each plate element individually predetermined dimension and geometry can be adjusted.

According to the invention, a plurality of standard plates, preferably cement-bonded flat-pressed plates, longitudinal edge are lined up along the longitudinal edge and successively joined together successively using pressure and glued together. The series is conveyed away in its longitudinal direction and thus in the transverse direction of the standard plates. By joining and gluing creates a continuously contiguous plate belt, which advances in the conveying direction, preferably is advanced stepwise. From the advancing plate belt successively individual longitudinal sections are separated in the respective predetermined length of the currently produced formwork panel.

The separation of the longitudinal sections takes place along a dividing line, which runs transversely, preferably perpendicular, to the direction of movement of the plate strip and therefore transversely to the two side edges of the plate strip. As a result of this separation successive individual plates, of which each individual plate has two mutually corresponding transversely to the direction of movement opposite side edges, which are thus formed from longitudinal sections of the two side edges of the plate band. Each of the individual plates has a length which is adapted to the respective predetermined length of the formwork panel to be produced and preferably coincides with this predetermined length.

The individual plates are conveyed further in their longitudinal direction. The lengths of the successively separated individual plates may coincide with each other. Alternatively, the lengths of the successively separated individual plates may be different if the predetermined lengths of the formwork plates to be subsequently produced are different. For the production of panel elements, which are to be installed as composite formwork wall elements and therefore have two spaced formwork panels, For example, the two formwork panels are preferably made from a pair of sequentially separated individual panels. These therefore have the same or different lengths, which are measured in the direction of movement of the plate belt.

According to the invention, the respective length of each individual plate can be chosen freely, because this length is independent of the respective length of the standard plates by separating the single plate from a plate band, which is made by preceding juxtaposing and gluing the standard plates running and "endless" , From the respective lengths of the standard plates rather the respective width of the plate belt is determined. By means of the invention, it is therefore also possible, in particular, to produce long composite formwork elements without these having to be subsequently assembled from subelements.

After separation of the individual plates they are processed to form the predetermined geometry of the respective formwork panel, in particular for the formation of the predetermined width, which corresponds to the production of a composite formwork wall element of the respective height of the formwork panels of the wall element, and to form all cutouts to be provided. The respective predetermined widths of the two formwork panels of a wall element may be the same or different. For example, the formwork panel that is to come to rest on the building site on a building inside of the wall element, be provided with a smaller width and therefore height on the upright wall element for the connection of a ceiling element.

The shuttering panel processed in this way is then provided individually with fastening devices which are preferred for fastening wall connection elements or spacers and / or serve of reinforcing elements, and then also equipped individually with the respective required reinforcing elements.

The standard plates can be removed individually from a supply in a removal station and conveyed in their longitudinal direction successively through an edge processing station and through a glue application station. Subsequently, the standard plates are transferred to a main conveyor line whose conveying direction is transverse, preferably perpendicular, to the longitudinal direction of the standard plates and on which the standard plates are successively strung together. The further processing is carried out in individual workstations following each other along the main conveyor line. Thus, in a pressing station, the joining and gluing of the standard plates is preferably carried out in predetermined pressing steps. For this purpose, the plate belt is preferably advanced discontinuously or intermittently, so that the pressing steps in each case at a standstill, i. be performed in a movement break between two movement steps.

The pressing station is followed by a separation station, in which the individual separation of the respective leading longitudinal section of the plate strip to form the respective single plate is carried out, which is adapted individually in length to the shuttering plate to be produced in each case from the single plate. The separation is preferably also at standstill of the plate belt, for which purpose preferably a break in movement of the plate belt is used during one of the pressing steps.

On the separation station is followed by a processing station, in which the processing of the individual plates is carried out by the individual cutting of the same and on their part a fastening station follows, in which the fastening devices are fastened at predetermined points of the formwork panel, preferably screwed on. One or more reinforcement stations then connect to the fastening station, in which reinforcement elements individually adapted to the respective requirements, such as reinforcing mats and reinforcing baskets, can be attached. Other workstations that may be provided as manual workstations may join. At the end of the Hauptför-derstrecke a tilting station is provided, in which the finished plate elements are erected for removal in an intermediate storage, when these plate elements are provided for building a wall element. On the other hand, such plate elements, which are provided as ceiling elements and have been processed, can be transported horizontally - without being tilted.

The conveyance of the plates through the individual work stations takes place at least as far as the attachment station, preferably in the longitudinal direction of the individual plates, and preferably discontinuously, so that the individual work steps are carried out at standstill of the respective plate. The cycle times in individual successive workstations corresponding to the respective processing time can be adapted to each other, so that the respective processing can be carried out there at the same time as the joining and gluing the juxtaposed standard plates in the pressing station and the respective separation of the single plate in the separation station. However, the respective cycle times in workstations following the separation station can be decoupled from one another in order to optimize the overall cycle time.

In particular, according to the invention, the respective cycle time in the processing station can be decoupled from the cycle times in the separation station and the pressing station in that the separated individual plates between the separation station and the processing station in a buffer stack successively stacked from top to bottom and taken from the buffer stack from below successively and transferred to the processing station. In this case, the processing station can be at a lower level than the separation station. The individual plates are conveyed discontinuously downwards in the buffer stack, in accordance with the respective processing time in the processing station. The processing times of the individual plates in the processing station are in turn dependent on the scope of the respective cutting work, which may be different depending on the projected end geometry of the shuttering panels, for example, for their arrangement on a wall outside or inside wall. Due to the intermediate stacking of the individual plates in front of the processing station, however, a longer processing time in the processing station on the one single plate can be largely compensated by a shorter processing time of a subsequent single plate.

Similarly, a buffer stack can be provided between the processing station and the attachment station, in which the cut formwork panels are stacked from bottom to top and also conveyed again discontinuously upwards again to a higher working level of the attachment station. As a result, different processing times in the processing station can be additionally compensated.

A further decoupling of working hours can be achieved in particular for the reinforcement stations by branching the main conveyor line, so that simultaneous processing of several plates can be carried out on the conveyor branches and also manual workstations along the conveyor line can be included in the production.

In order to produce a wall element, two individual plates successively transferred into the processing station are preferably cut to fit alternately as an inner formwork plate or an outer formwork plate. These two formwork panels should face each other in the finished composite formwork wall element with their upper sides during processing. Their trimming is preferably carried out depending on the fact that the one side edge of a single plate is defined as the foot portion of the formwork panel resulting from this single plate and the other side edge of the other single plate averted from this side edge is defined as the foot portion of the other formwork panel resulting from this other single panel.

Thereby, these two formwork panels in the tilting station, which is provided at the end of the conveyor line, can be erected about their respective foot sections in opposite tilting directions such that the upper side of the one shuttering panel faces in a direction opposite to the direction in which the upper side of the shuttering platform other formwork panel points. In addition, when the one formwork panel is displaced laterally in a direction before or in the tilting station, which is averted its foot portion, and the other formwork panel is arranged next to the first formwork panel so that the foot portions of the two formwork panels facing each other, the two formwork panels for their erection is folded like a book into the arrangement that they occupy in the finished wall element.

The individual plates are clamped on the transport pallets following the separation and conveyed to the same up to the tilting station. For the transport pallets, a return-conveying branch can be provided, on which the Pallets are conveyed back to a position behind the separation station and then fed back to the main conveyor line.

The invention will be explained below with reference to the description of a preferred embodiment and with reference to the drawings.

Brief description of the drawings:

• Fig. 1 eine schematische Perspektivansicht eines Verbundschalungs-Wandelements,
• Fig. 2 eine schematische Perspektivansicht eines Verbundschalungs-Deckenelements im T-Stoß mit einem Verbundschalungs-Wandelement,
• Fig. 3 ein schematisches Layout eine Anlage zur Durchführung eines Verfahrens gemäß der Erfindung, und
• Fig. 4 eine schematische Teil-Seitenansicht der Anlage aus Fig. 3 im Bereich der Bearbeitungsstation.

In the drawings shows:

• Fig. 1 a schematic perspective view of a composite formwork wall element,
• Fig. 2 a schematic perspective view of a composite formwork ceiling element in the T-joint with a composite formwork wall element,
• Fig. 3 a schematic layout of an installation for carrying out a method according to the invention, and
• Fig. 4 a schematic partial side view of the plant Fig. 3 in the area of the processing station.

Description of a largely automated process according to the invention for the production of plate elements for the production of composite formwork elements Item numbers of the components

1

outer wall shuttering panel

2

inner wall formwork panel

3

Wall connecting element

4

Wall connecting element

5

Mesh reinforcement

6

Matt hook

7

Core concrete filled on site after installation of the wall elements

11

standard plate

12

apron

13

Single plate

13A

Foot section of the formwork panel

13B

Foot section of the formwork panel

20

automatic removal station for standard plates

21

Destacking places for standard plates

22

Feeder conveyor system for standard plates

23

measuring device

24

edge processing

25

cleaning device

26

glue application

27

Main conveyor belt

28

pressing station

29

processing station

30

Separation station with mobile saw

31

pallet circulation

32

pallet

33

Buffer stacking means

34

Buffer stacking means

35

fixing station

36

Feeder transport units

37

Circulation and reinforcement stations

38

Work and reinforcement stations

39

Mesh welding machine

40

Work and tilt stations

41

Return conveyor branch for transport pallets

42

vertical workstations

43

joining station

In contrast to the conventional production process, the starting material, the cement-bonded flat-pressed plates (hereinafter referred to as standard plates 11), processed to a vorbewegten plate belt 12, from which successively the individual plates 13 are separated. The individual plates 13 have a sufficient size to produce therefrom the composite formwork ceiling elements consisting of a plate element, or the composite formwork wall elements consisting of their two plate elements with their wall shells 1 and 2 in one piece. The production of sub-elements and the subsequent assembly of the wall elements of individual sub-elements thus eliminated.

Production of a plate band from the standard plates

The standard plates 11 are delivered on pallets. The standard plates are introduced by means of a hall crane from their deposit in an automatic removal station 20. This removal station consists in the example of 2 x 2 Entstapelplätzen 21, which are secured to each other with fences or photocells so that a safe loading and unloading on the one Entstapelplatz in undisturbed removal from the second Entstapelplatz is possible.

From the Entstapelplätzen 21 is a standard plate 11 is removed from the stack and placed on a feeder conveyor system 22. Each destacking space is provided for the same or a different length type of the standard plates 11. The height of each stack of plates is automatically reported to the control system, ie the storageists receive a visual and audible signal in good time when a new pallet with standard plates has to be fed. Placed on the conveyor system, the standard plates 11 are guided in their longitudinal direction by a measuring device 23, which checks the plate with respect to a constant thickness. Should a standard plate 11 this value, for example by bowls on the ends, Production error and the like exceed, it is deported without further processing by means of a discharge device from the conveyor system in a container. At the same time, the measuring device 23 notifies the control system of rejects.

Profiling of standard plates

• Nut bzw. Feder ohne Fase an der Außenseite der Standardplatte 11
• Nut bzw. Feder mit Fase an der Außenseite der Standardplatte 11 ("Schwedennut") - Standardfase: 3 mm
• Nut bzw. Feder mit Fase an der Außenseite der Standardplatte 11 ("Schwedennut") - Fase: 6 mm (V-Nut sichtbar)

After the measuring device 23, the standard plates 11 are automatically guided in their longitudinal direction by an edge processing station 24, in which during the passage at the two longitudinal edges of the standard plate 11 then groove or spring are milled. For this purpose, the machine is equipped with a feeder, from which the standard plates are automatically centered and aligned with their longitudinal direction to the conveying direction. In principle, three types of edges can be provided:

• Tongue or tongue without chamfer on the outside of the standard plate 11th
• Tongue or groove with bevel on the outside of the standard plate 11 ("Swedish groove") - standard bevel: 3 mm
• Tongue or groove with chamfer on the outside of the standard plate 11 ("Swedish groove") - Chamfer: 6 mm (V-groove visible)

After the edge processing station for profiling the edge, a cleaning device 25 is arranged, which cleans the machined surfaces for the glue application.

Alternatively, a compound of the standard plates 11 to a plate belt 12 without elaboration of a tongue or spring is possible.

glue

The glue application station 26 is attached on one side to the feeder conveyor system 22. Here, the grooves are automatically charged with glue during their passage. The order quantity is matched with the conveying speed.

The milled and glue-provided for standard plates 11 reach immediately after the glue application station 26, the wider main conveyor belt 27, to which the standard plates are fed with their longitudinal direction perpendicular to the conveying direction of the main conveyor belt and which leads in the production direction perpendicular to the longitudinal direction of the standard plate 11 to the pressing station 28 , Here, the deduction of the plates in the main direction of conveyance is accelerated so as not to interrupt the continuous conveyance at the feeder conveyor system 22.

Press

The standard plates 11 are successively drawn into the pressing system of the pressing station 28 and aligned to a "continuous" plate, a plate belt 12, piece by piece and longitudinal edge along the longitudinal edge, aligned and pressed and thereby glued. This operation takes place in cyclic operation (discontinuous). The accuracy of the plate alignment of the standard plates 11 to each other during alignment and pressing is controlled and possibly there is an error message (optical and acoustic signal, as well as a message to the control system).

The plate belt 12, which is thus always newly produced, in which the glue joints are oriented perpendicular to the longitudinal direction of the plate strip, already has sufficient stability immediately after the pressing of the standard plates, so that it can be further processed and advanced.

From this plate slab 12 thus obtained, the element geometries of the shuttering panels 1, 2 can be worked out in the processing station 29 final.

Separating single plates from the plate band

The plate strip 12 is shortened immediately after the pressing of the standard plates 11 in the production order for each formwork panel 1, 2 individually predetermined length, so that from the separated longitudinal sections of the plate strip 12, the individual plates 13 in the respective predetermined length of the formwork panels 1, 2 arise , For this purpose, a separation station 30 is provided with a movable in the conveying direction of the plate belt 12 saw or other mobile separation device following the pressing station 28. The cut occurs when the plate band 12 is stationary, i. during the pressing time when joining standard plates 11 in the pressing station 28. The individual specification of the cutting position is controlled by the control system. At the same time, this separating device 30 is provided with a plotter which also labels the individual plates 13 produced with the cut during the pressing operations.

• Bezeichnung der in der Bearbeitungsstation 29 zu erzeugenden Elemente, d.h. Schalungsplatte für Deckenelement oder Wandelement, Laibungsbrett-Typ, etc.
• Klassifizierung von eventuellen Einbauteilen, z.B. Elektrodosen
• Markierung an dem jeweils vorgesehenen Fußabschnitt der Schalungsplatte für ein Wandelement.

The following markings are provided:

• Designation of the elements to be produced in the processing station 29, ie shuttering panel for ceiling element or wall element, reveal board type, etc.
• Classification of possible built-in components, eg electrical boxes
• Marking on the respectively provided foot portion of the formwork panel for a wall element.

Pallet circulation 31 and processing of Single plates for the production of shuttering panels for ceiling elements or wall elements:

The pallet circulation 31 consists of workpiece carriers 32, so-called transport pallets 32, which contain simple centering devices and as a workpiece support an easily replaceable wear grating or wear mandrels for processing the processing station 29 (eg water jet plant or similar Zuschneideanlage) included.

Transport pallet 32 (workpiece carrier):

After cutting the plate strip 12 into individual elements, the individual plates 13, all further process steps now take place on the transport pallets 32. These consist of rolled profiles as edge supports and are equipped with an easily replaceable grid as support surface. On the edge profiles centering devices are provided at the corners, which allow easy alignment and fixing of the transport pallets 32 in the individual workstations. The transport of the transport pallets 32 takes place e.g. via roller blocks and friction wheels, the position detection via limit switches.

Loading the transport pallets with single plates:

After cutting to length from the plate belt 12 in the corresponding individual plates 13 for the production of shuttering panels 1, 2 for ceiling elements or wall elements, according to specification from the control system, the individual plates 13 are then raised and lowered rollers, which between the grids of the transport pallets 32 after can be moved up, moved over the transport pallet 32 and positioned by lowering the rollers under the grate on the transport pallet 32. The individual plates 13 are aligned on the grid by simple alignment units on stops on the transport pallet 32. As soon as the release from the controller, namely the control system comes, the transport pallets 32 are then moved, preferably in the longitudinal direction of the single plate, in a first stacking position. Here, the transport pallets 32 are lifted by means of a special buffer stacking device 33 and stacked one above the other from top to bottom and discontinuously conveyed down to a lower processing level (see. Fig. 4 ). The centering devices serve this purpose the transport pallets 32 of the exact positioning or as protection against falling over. This stacker 33 serves as a time buffer.

The following describes the further processing of the single plates mainly for the production of panel elements for wall elements. The further processing of the individual plates for the production of ceiling elements is done accordingly in adaptation to this purpose.

Processing station 29 (water jet cutting):

The next transport pallet 32 from the stacking device 33 with the individual plate 13 lying thereon is removed from the stacking device 33 below and retracted after ready message of the processing station 29 in this processing station in the longitudinal direction of the single plate, and aligned to the existing there on the table top centering cones. In the processing station 29, the position of the single plate 11 and its respective foot section 13A or 13B of the formwork panel 1, 2 to be produced in the erected wall element longitudinal side edge on the transport pallets 32 is checked, and the processing by cutting can finally be adapted to the situation.

Here, the wall geometries, incl. All cutouts are generated from the glued single plate 13, which are optimized with respect to the crop. It can be combined on a transport pallet 32 several small wall panels. Both formwork panels 1 and 2 of a wall element are always produced in direct succession. In addition to shuttering panels, soffit boards or other special geometries such as stair stringers, etc., are produced from the excess lengths of the clamping, as specified in the control system.

The cutting of the individual plates takes place, inter alia, depending on which of the two side edges of the single plate 13 is provided as a respective foot portion of the finished outer formwork panel 1 or inner formwork panel 2 in the finished wall element. The finished assembled formwork panels in the form of plate elements are tilted at the end of production in a tilting station 40 about their respective foot section and thereby erected. In addition, the tops of the cut individual plates should be facing each other after their assembly in the finished wall element. Therefore, it is preferable to cut the successive two single plates 13 provided for one and the same wall member already in the work station 29 such that the one side edge of the one single plate 13 is provided as the foot portion 13A of one shuttering plate and the other Side edge of the other single plate 13 is provided as a foot portion 13 B of the other formwork panel. This can be achieved that the tops of the two plates are facing each other by merely tilting in reverse tilting directions as in the finished wall element. This will be explained further below in the description of the tilting stations 40.

If the processing is completed by cutting the single plate 13 into the respective geometry of the respective formwork panel 1, 2, the control receives a signal and at the same time the transport pallet 32 are extended with the already processed single plate in a further buffer stacking device 34 and a transport pallet 32nd with the next single plate from the stacking device 33 retracted into the processing station.

Behind the processing station 29, therefore, a further buffer-stacking device 34 is provided, with the difference that here is stacked from bottom to top (see. Fig. 4 ).

Attachment station 35 (in the example: screwing station), application of the wall connection elements 3, 4):

From the stacking device 34, the transport pallets 32 are now automatically retracted after ready notification of the screwing 35 in the longitudinal direction of the individual plates in the screwing, again centered and the processing can be done there.

The wall connecting elements 3, 4 are manufactured separately and placed on feeder transport units 36, of which the wall connecting elements 3, 4 then, sorted by type and type, are supplied to the screwing station 35. Thus, always at least one or more wall connecting elements 3, 4 are always available per type in engagement with the screwing 35 available.

The robot in the screwing station 35 is provided both with special, suitable for the wall connecting elements 3, 4 gripping and setting device (s), as well as with a multi-screw device for fixing the wall connecting elements 3, 4 on the cut individual plates 13. The screws are fed automatically.

For the production of plate elements, which are provided as ceiling elements, the assembly is carried out with fasteners, for example - like Fig. 2 visible - as a mounting bracket 6 ( Fig. 2 ) are formed for the reinforcing elements 5, and the screwing the same accordingly.

After all the wall connecting elements 3, 4 are screwed, the controller receives a signal and now at the same time the transport pallet 32 with the processed plate from the mounting station 35 extended and a transport pallet 32 retracted from the second stacking device 34.

Manual stations:

Subsequent to the attachment station 35, the transport pallets 32 are separated into one or more delivery branches (two delivery branches in the example), for example, by displacing each second transport pallet laterally into the second delivery branch. On the circulation workstations 37, the reinforcing mats 5 are then loaded manually by means of a handling crane and then the loaded plates on the transport pallets 32 are conveyed further in parallel into the next workstations 38. Subsequently, the installation of reinforcing baskets, so far statically required.

The insertion of the mesh reinforcement 5 can also be done automatically. The mat reinforcement 5 can be manufactured by a fully automatic mat welding system 39 individually for each individual wall element to be produced.

In the next two workstations 38, the cutouts produced in the processing station 29 are removed with a light crane with suction crosspieces and stored in containers or boxes. Also here the mesh reinforcement 5 is added according to the specifications and installed the transport anchor.

Activities to be performed at workstations 38:

• Screw on the matte hook 6 (where required)
• Attach additional reinforcement
• Attach mesh reinforcement 5
• Spacer for mesh reinforcement 5 (4 pcs./wall) - otherwise the wall connecting elements 3 act as a support
• Secure transport anchor

Work and tilt stations 40 and return track 41 for empty transport pallets 32:

After manual processing, the transport pallets 32 are further conveyed in the longitudinal direction of the plates to the area above the tilting stations 40. For this purpose, the transport pallets 32 are lowered. On the tilting stations 40, the transport pallets 32 are erected by about 80 ° and the plate elements attached to the crane cross members for further transport in the vertical work stations 42 and removed in the vertical position of the transport pallet 32.

Of the two formwork panels, which were cut in succession in the processing station 29 for one and the same wall element, at the junction of the main conveyor line or in the working and circulating stations 37, 38, a formwork panel has been laterally displaced in a direction corresponding to the foot section 13A this is a formwork panel averted. As a result, the two formwork panels are fed into the two tilting stations 40 in such a way that they are arranged side by side with mutually facing foot sections 13A, 13B. Thereby, these two formwork panels can be folded around their respective foot section 13A, 13B like a book in opposing tilting directions and then erected in that relative position which they occupy in the finished wall element in the vertical processing stations 42 and then in the joining station 43.

After erecting and transporting away the shuttering panels in the tilting stations 40, the now empty transport pallets 32 are pivoted back into the horizontal position and conveyed back in front of the stacking device 33. Arrived between the separation station 30 and the processing station 29, are the empty transport pallets 32 are fed before or into the first stacking device 33 and can be equipped with individual plates 13 again.

The plate elements removed by the tilting stations 40 by crane are completed at so-called vertical workstations 42 in manual work steps and prepared for the assembly of the first and the second formwork panel 2 having plate elements (compression).

The joining (pressing) of these two plate elements takes place on a manually operated joining station 43.

After pressing the two plate elements to a composite formwork wall element, the wall element is completed by installing soffit boards from the blanks, which were previously stored in the last two workstations 38, window and door recesses. After any necessary cosmetic post-processing steps, the finished composite formwork wall elements are stored in transport racks.

If the plate elements have been processed and equipped for the production of ceiling elements, they need not be erected in the tipping stations, but can be removed horizontally from the respective transport pallet and then stored.

Advantages of the production process:

In contrast to the conventional production process, the cement-bonded flat-pressed plates are processed into a pre-moved plate belt 12. The slat has a sufficient size to form therefrom the formwork panels 2 for composite formwork ceiling elements, each consisting of a plate member with a formwork panel 2 equipped and reinforced for this use ( Fig. 2 ), or the shuttering panels 1, 2 for composite formwork wall elements, consisting of the two plate elements with the assembled shuttering panels 1 and 2 ( Fig. 1 ) in one piece. The production of sub-elements and the subsequent assembly of the ceiling or wall elements of individual sub-elements thus eliminated.

Furthermore, the continuous processing by means of the plate belt 12, from which the individual plates 13 can each be separated individually with the required lengths, results in considerable material savings through reduced waste of the starting material, the cement-bonded flat-pressed plates. Further material savings result from the elimination of necessary overlap reinforcements and so-called connecting strips, which must be provided in the conventional assembly of the composite formwork elements from the prefabricated sub-elements. The almost seamless prefabrication of the formwork panels results in an improved surface quality of the end product.

Dimensional tolerances of the product are considerably improved, since the influences of the tolerances of the sub-elements and inaccuracies in the assembly of the composite formwork element from the sub-elements are eliminated.

The production costs for the composite formwork wall elements is significantly reduced, since many work steps can be automated and the planning and manufacturing of sub-elements is eliminated and the associated logistics costs, material and parts handling and additional work steps such as the assembly of the sub-elements are saved.

The controlled and mainframe-controlled production of the composite formwork panel elements also improves the documentation of the precursors and the end product used. The production statistics can be accessed and monitored at any time.

Claims (8)

1. Method for the continuous production of panel elements for the production of composite shuttering elements, of which each panel element comprises a shuttering panel (1, 2) of an in each case predetermined geometry with predetermined length and the shuttering panel is equipped with fastening devices (3, 4) and reinforcement elements (5, 6), in which method a plurality of standard panels (11), of which each includes two opposite longitudinal edges, are lined-up with longitudinal edge to longitudinal edge on a main conveyor line and are joined and glued to one another while applying a pressing force, so that a moved-forward panel band (12) is created from the joined and glued-together standard panels (11), from which individual longitudinal portions are separated successively, so that individual panels (13) with two side edges are generated that are opposite to each other transversely to the direction of movement of the panel band (12), wherein each individual panel (13) has a length which is adapted individually to the respectively predetermined length of the shuttering panel (1, 2) to be produced, whereafter each individual panel (13) is chucked subsequently to the separating on a transport pallet (32) in an aligned way,
   characterized in that the individual panel (13), lying on the same transport pallet (32), is conveyed into and through working stations which successively follow each other along the main conveying line and in which the individual panels (13) are processed successively in a processing station (29) by their cutting into the respectively and individually predetermined geometry of the respective shuttering panel (1, 2), including a generation of provided cut-outs, and the shuttering panels (1, 2) generated by such processing are successively equipped with the fastening devices (3, 4) at predetermined positions in a fastening station (35) and subsequently with the reinforcement elements (5, 6) in at least one reinforcement station (37), wherein of two individual panels (13) subsequently conveyed into the processing station (29) one individual panel is cut as inner shuttering panel (2) and the other individual panel (13) is cut as an outer shuttering panel (1) depending on the condition that the one side edge of the one individual panel (13) is defined as a foot portion (13B) of the inner shuttering panel (2) and that side edge of the other shuttering panel, that is turned away from said one side edge, is defined as a foot portion (13A) of the outer shuttering panel (1), wherein both shuttering panels are fed into a tilting station (40) at the end of the conveyor line and are there erected around their respective foot portion by tilting the associated transport pallets (32) in opposite tilting directions.
2. Method according to claim 1, wherein the standard panels, before the lining-up, are guided on a feeding conveyor system (22) in their longitudinal direction through an edge processing station (24), in which an edge processing is carried out on the standard panels (11) during their passage, in which a longitudinal groove is milled on the one longitudinal edge of each standard panel (11) and a longitudinal tongue is milled on the other longitudinal edge of the standard panel (11).
3. Method according to claim 1 or 2, wherein the standard panels (11) are extracted individually in an extracting station (20) from a supply and are conveyed on a feeding conveyor system (22) in their longitudinal direction successively through a glue applying station (26), in which a glue is applied at least to one of their longitudinal edges during their passage, whereafter the standard panels (11) provided with glue are conveyed into a pressing station (28) transversely to their longitudinal direction, in which the assembling and gluing of the standard panels (11) is performed successively and in predetermined pressing steps.
4. Method according to claim 3, wherein the separation of each individual panel (13) is performed in a separating station (30) following the pressing station (28) during one of the pressing steps performed in the separating station.
5. Method according to claim 4, wherein each individual panel (13) is labeled in the separating station (30) during the pressing step in which the separating is carried out in a controlled manner and in adaptation to a further processing of the individual panel (13).
6. Method according to any one of claims 1 to 5, wherein one shuttering panel of the two shuttering panels (1, 2) which have successively been processed in the processing station (29) is displaced in a working station (38) downstream of the fastening station (35) laterally in a direction that is turned away from the foot portion of this one shuttering panel, and the other shuttering panel is disposed at the latest in the tilting station (40) next to said one shuttering panel in such a manner that in the tilting station (40) the foot portion of said one shuttering panel and the foot portion of the other shuttering panel are facing each other, whereafter the two shuttering panels (1, 2) are folded together in the opposite tilting directions.
7. Method according to any one of claims 1 to 6, wherein the separated individual panels (13) are each stacked before the processing station (29) in a buffer stack (33) successively one upon the other from top to bottom and are extracted successively from the buffer stack (33) from below and are transferred into the processing station (29).
8. Method according to any one of claims 1 to 7, wherein the processed shuttering panels are stacked one below the other from bottom to top in a buffer stack (34) between the processing station (29) and the fastening station (35) and are extracted from the buffer stack (34) from above and are transferred into the fastening station (35).

Images