by In order to meet the requirements of production process, considering the characteristics of the original production workshop, an expandable combined long line pedestal prefabricated component production line was developed, and the structural requirements of movable equipment such as vibrating and overturning integrated equipment, movable equipment ferry equipment, self-propelled side formwork, and reinforcement transportation and installation integrated equipment were emphasized, It is expected to provide reference for the research, development and application of prefabricated component production line and equipment.
Keywords can be expanded; Combined type; Long line pedestal; Production equipment; Prefabricated components Prefabricated components factory production, as the key link of industrial construction, plays a vital role in improving the efficiency of engineering construction, improving the quality of construction, and reducing energy consumption.
With the vigorous development of building industrialization, the production line and production equipment of prefabricated components are gradually moving towards automation, intelligence and digitalization, and the production equipment of prefabricated components is constantly improving.
Some traditional production methods are gradually being replaced by intelligent production lines, such as the expandable digital production line of formwork, mobile digital production line of formwork, and digital production line of long line formwork, The intelligent production line makes the production of prefabricated components more reliable and efficient.
The transformation of the prefabricated component production line shall meet the requirements of the production process, make full use of the existing workshop and facilities, and make clear the functional zoning and reasonable layout in combination with the characteristics of the workshop, and meet the requirements of relevant environmental protection and safety.
In addition, it is necessary to ensure the smooth transportation route of components and reduce the lifting operation of components.
In the original production workshop, through the introduction, digestion and absorption of foreign production line technologies, this paper develops an expandable combined long line pedestal method prefabricated component production line, with a view to achieving flexible combination and two-way expansion of equipment through the production mode of fixed formwork and mobile equipment, so as to achieve efficient production of prefabricated components.
1.
The layout design of the production line uses the automatic distribution technology to reform the distribution system of the fixed mold table.
The traditional lifting hopper is replaced by the lifting conveying system and the spiral distribution system, so as to improve the distribution efficiency of the prefabricated component production.
Layout of production line 3.7m × There are 30 9m fixed mold tables.
Two longitudinal production lines are arranged in 3 groups, with 5 mold tables in each group.
Each production line is arranged with 15 mold tables.
The connection between the two production lines can be completed by transporting key equipment through the horizontal ferry rail.
Two longitudinal rails are arranged at the bottom and both sides of the formwork of each production line.
After the concrete pouring of the formwork is completed, the vibration equipment at the bottom of the formwork can move longitudinally to the designated formwork to complete the vibration compaction of the components; The left and right rails of the mold table can be used for moving production equipment; The outer rails of the two longitudinal production lines are used for the movement of the bridge type concrete tanker.
Figure 1 shows the plane layout of the production line equipment.
2 Research and development of production line equipment In this paper, the industrial optimization design theory and modular and standardized design methods are used to design and develop the following production line equipment: vibration rollover integration equipment, low energy consumption in-situ maintenance equipment, cleaning, demoulding and scribing integration equipment, mobile equipment ferry equipment, self-propelled side formwork and reinforcement transportation and installation integration equipment.
2.1 Integrated vibrating and side tipping equipment The vibrating and side tipping equipment of the formwork platform that can move vertically and horizontally by itself mainly includes: frame, turnover frame, hydraulic device, vibration device, etc., as shown in Figure 2.
For the compaction process, it is necessary to lift the turnover frame vertically so that the vibrator can directly apply the force on the pallet.
The allowable load of the equipment platform is 4500kg, the frequency of a single vibration motor is 50Hz, the maximum traveling speed is 10m/min, the power of a single motor is 0.75kW, and the maximum total operating weight is 10000kg.
2.2 Low energy consumption in-situ curing equipment Low energy consumption in-situ curing equipment includes fixed thermal formwork and troweling and covering equipment.
The fixed hot formwork platform includes the concrete bottom frame and the formwork platform used for the installation and fixation of prefabricated component side formwork.
The inside of the concrete bottom frame is pasted with thermal insulation plates and provided with two hollow openings.
Positioning FRP bars are arranged at the bottom of the hollow openings, color steel plates are arranged at the top, and mesh sheets are laid above them.
By pouring foam concrete, the color steel plates, mesh sheets and foam concrete form an insulation layer.
The insulation layer divides each hollow opening into two upper cavities (3625mm) × 3100mm × 130mm) and two lower cavities (3625mm × 3100mm × 40mm), the formwork platform is welded and installed on the steel plate bottom frame through embedded parts.
A hollow insulation layer is formed between the panel and the hollow hole, as shown in Figure 3.
The plastering and covering equipment is based on the expandable combined prefabricated component production line, integrating the surface plastering function and maintenance tarpaulin covering function of prefabricated components into a mobile intelligent device, as shown in Figure 4.
2.3 Formwork preparation during the production of prefabricated components of cleaning, release agent and scribing integrated equipment, including formwork cleaning, release agent spraying and side formwork installation.
The vertical and horizontal self-propelled cleaning, mold release agent spraying and scribing integrated machine device based on the expandable prefabricated component production line developed in this paper can integrate the functions of template cleaning, mold release agent spraying and scribing positioning into an intelligent device, which includes the frame, scraper, roller brush, disc brush and other components.
The device can clean the formwork surface through the falling scraper and brush, spray the release agent through the rotary nozzle, and realize the drawing of the geometric data of the prefabricated components, the installation parts and other supplementary information, as shown in Figure 5..
