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▼ Source: Luban Alliance for Construction Engineering Figure 1 Jinan CSCEC Green Building Precast Concrete Component Production Factory CSCEC Green Building Industrial Park (Jinan) Co., Ltd.
was established in 2017, invested and constructed by China Construction Eighth Engineering Bureau Co., Ltd, The First Construction Co., Ltd.
of China Construction Eighth Engineering Bureau is responsible for operation management.
With the main direction of “research and development of green building products”, the company’s main business is the deepening design, production and processing of prefabricated concrete components.
It has developed a series of decorative products such as colored concrete, translucent concrete, image concrete, and new products such as imitation brick cladding, integrated insulation and decoration cladding.
The company has completed about 300000 cubic meters of supply of prefabricated components and about 150 service projects.
Case application scenario and technical product characteristics – key points of technical solution This case conducts systematic research around intelligent equipment, information technology and manufacturing process for prefabricated component production and manufacturing, introduces and develops a variety of intelligent production equipment and auxiliary equipment, develops an integrated workstation for prefabricated component production and manufacturing, and establishes an intelligent factory management platform integrating data collection, process transfer and comprehensive management, The system of automatic processing equipment for reinforcement, concrete curing equipment and concrete production and transportation equipment has been developed.
The case includes 6 prefabricated component production lines and 2 material processing lines, including 3 prefabricated component automatic production lines, 3 fixed formwork production lines, 1 reinforcement automatic processing line, and 1 concrete processing line.
The intelligent production equipment realizes the intelligence and automation of the whole production cycle of prefabricated concrete components.
Figure 2 Key technologies and innovations of prefabricated component production line 2.
1.
The intelligent factory information platform has been developed, which integrates Internet collaboration, two-dimensional code, data collection, big data processing and other functions, and can greatly improve the efficiency of information transmission and work collaboration.
Figure 3 Intelligent factory information platform 2.
Developed a complete set of prefabricated component production equipment, developed a variety of intelligent automation equipment, and formed an intelligent automatic production system for prefabricated component production through collaborative linkage.
Prefabricated component production line equipment mainly includes: (1) intelligent movable mold platform system.
The automatic assembly line is introduced, and the alarm system is set on the mold table, which can run along the track and warn the safety situation.
(2) Mobile vibrating platform.
After the concrete component is poured, it needs to be fully vibrated.
The traditional vibrating rod is prone to uneven vibration, insufficient or too long vibration time, resulting in unstable quality.
The mobile vibration platform can be developed and applied, which can be inserted into each fixed formwork along the track to assist in vibration.
The time is controllable, the amplitude is controllable, and the quality is stable.
(3) Intelligent steam curing kiln.
The curing of concrete components can affect the quality of components.
The traditional maintenance method has a long cycle, requires manual operation, and the maintenance environment is unstable.
With the introduction of intelligent steam curing kiln, automatic temperature control and tower storage, the maintenance quality is stable and the period is greatly shortened.
(4) Intelligent prestressed tensioning equipment.
With the introduction of intelligent prestressed tensioning equipment, digital control can automatically tension according to the setting parameters, ensuring the stability and reliability of the prestressed tensioning process.
Reinforcement processing equipment mainly includes: (1) Automatic straightening and cutting equipment for reinforcement.
The introduction of automatic steel bar straightening and cutting equipment can quickly and accurately straighten and cut the steel bars and place them in bundles.
(2) Automatic welding equipment for reinforcing mesh.
In order to solve the problem of slow manual binding speed and unstable accuracy of steel mesh, automatic welding equipment for steel mesh is introduced to replace binding with welding to improve the welding speed and accuracy of steel mesh.
(3) Truss bar automatic welding production equipment.
The structure of truss bars of composite plates for floor slabs is complex, and manual processing is difficult to meet the requirements.
The truss bar automatic welding production equipment is introduced, the parameters are set on the graphical interface, and the finished products are automatically processed to meet the application requirements, with high efficiency and good quality.
Concrete equipment mainly includes: (1) mixing plant.
DMPC convection planetary mixer is introduced, which can completely cover the bottom of the mixing tank every 5s after feeding, reducing dead space.
The concrete mixing is more uniform, which ensures the uniformity of the apparent color of the prefabricated component concrete to the greatest extent.
The daily output is 2000m ³， It can meet the concrete demand when the plant is operating at full load.
(2) Storage bin.
High level silo mode is adopted to reduce the use of loader.
(3) Dust removal equipment.
The storage bin is equipped with dedusting equipment to directly suck the dust into the deduster, so as to achieve the goal of environmental protection and energy conservation.
(4) Concrete transport crane.
The transport crane runs on two annular closed steel rails, which can transport concrete to each production line in the plant and achieve the goal of raw material transportation automation.
(5) Automatic concrete distribution and vibrating equipment.
The automatic distributor is used for concrete pouring, which is distributed by divisions and zones, and vibrated by the vibration table, speeding up the production rhythm and improving the production efficiency and component quality.
3.
The quality inspection system for prefabricated components has been developed.
In the production process of prefabricated components, if the cooperation between disciplines is not in place at the construction drawing stage, the refinement of the detailed design is not enough, and the production process is wrong, it will lead to the reserved holes, the missing embedded parts, or the position deviation on the laminated plate.
The application of prefabricated component quality inspection technology and system can greatly reduce the error rate and improve the quality of prefabricated components.
Figure 4 Application Scenario of Prefabricated Component Quality Inspection System III This production line is applicable to the production and manufacturing process in the field of prefabricated concrete components for prefabricated buildings.
It can realize “machine replacement” in some processes, reduce labor, improve factory information management and control, and improve the manufacturing quality of prefabricated components.
Case Implementation 1 Basic information of the case The factory is located in Zhangqiu District, Jinan City, and was officially put into operation in May 2018..
