CN108890850B - Intelligent production line and production process capable of producing various standard PC components - Google Patents

Intelligent production line and production process capable of producing various standard PC components Download PDF

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Publication number
CN108890850B
CN108890850B CN201810649223.9A CN201810649223A CN108890850B CN 108890850 B CN108890850 B CN 108890850B CN 201810649223 A CN201810649223 A CN 201810649223A CN 108890850 B CN108890850 B CN 108890850B
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China
Prior art keywords
mold
die
station
machine
template
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CN108890850A (en
Inventor
刘纪祥
胡水兵
周健
陈智
涂继开
倪华中
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Meihao Building Assembly Technology Co ltd
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Meihao Building Assembly Technology Co ltd
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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B15/00General arrangement or layout of plant Industrial outlines, plant installations
    • B28B15/007Plant with two or more identical shaping or moulding devices
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B21MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21FWORKING OR PROCESSING OF METAL WIRE
    • B21F27/00Making wire network, i.e. wire nets
    • B21F27/08Making wire network, i.e. wire nets with additional connecting elements or material at crossings
    • B21F27/10Making wire network, i.e. wire nets with additional connecting elements or material at crossings with soldered or welded crossings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00Producing shaped prefabricated articles from the material
    • B28B1/04Producing shaped prefabricated articles from the material by tamping or ramming
    • B28B1/045Producing shaped prefabricated articles from the material by tamping or ramming combined with vibrating or jolting
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/24Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
    • B28B11/245Curing concrete articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B13/00Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
    • B28B13/02Feeding the unshaped material to moulds or apparatus for producing shaped articles
    • B28B13/0215Feeding the moulding material in measured quantities from a container or silo
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B13/00Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
    • B28B13/02Feeding the unshaped material to moulds or apparatus for producing shaped articles
    • B28B13/0215Feeding the moulding material in measured quantities from a container or silo
    • B28B13/023Feeding the moulding material in measured quantities from a container or silo by using a feed box transferring the moulding material from a hopper to the moulding cavities
    • B28B13/0235Feeding the moulding material in measured quantities from a container or silo by using a feed box transferring the moulding material from a hopper to the moulding cavities the feed box being provided with agitating means, e.g. stirring vanes to avoid premature setting of the moulding material
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B13/00Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
    • B28B13/04Discharging the shaped articles
    • B28B13/06Removing the shaped articles from moulds
    • B28B13/065Removing the shaped articles from moulds by applying electric current or other means of discharging, e.g. pneumatic or hydraulic discharging means
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/02Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
    • B28B23/022Means for inserting reinforcing members into the mould or for supporting them in the mould
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/38Treating surfaces of moulds, cores, or mandrels to prevent sticking
    • B28B7/382Devices for treating, e.g. sanding
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/38Treating surfaces of moulds, cores, or mandrels to prevent sticking
    • B28B7/386Cleaning

Abstract

The invention provides an intelligent production line and a production process capable of producing various standard PC components, wherein two intelligent production lines are respectively arranged on an axis A to an axis C and an axis C to an axis E, are symmetrical about the axis C and are arranged between 1-28 axes of each span; the single production line comprises a die placing device, a mesh sheet rib processing device, a truss rib processing device, a concrete mixing station, a distributing machine, a turnover machine, a curing kiln, a stacking machine and a tipping machine; the invention can realize that a single production line can simultaneously produce three standard PC components, namely a laminated slab, a laminated shear wall without heat insulation, a laminated shear wall with a heat insulation plate and the like, and utilizes an informatization system to realize the whole process control of design, production and transportation, thereby further reducing the labor, wherein the intelligent production line only needs 18 persons to operate on the production line for one shift, only is 1/4 persons for one shift of the traditional PC production line, avoiding the current labor shortage, reducing the labor intensity, improving the product quality and the production efficiency, and reducing the production cost of enterprises.

Description

Intelligent production line and production process capable of producing various standard PC components
Technical Field
The invention relates to the field of automatic production lines of precast concrete components, in particular to an intelligent production line and a production process capable of producing various standard PC components.
Background
With the large-scale development of the urbanization of China, the construction industry is also greatly changed. The defects of more construction wastes, high labor cost, more sewage, time consumption, energy consumption and the like in the traditional construction are gradually shown. In the process, the assembly type building meets the development opportunity.
Various incentive policies are continuously issued, and the rapid development of the assembly type building is promoted. This is because compared with traditional building construction, this trade has energy-conservation, water conservation, economize on manpower, production efficiency is high, advantages such as product reliability height. Especially, the development of intellectualization and informatization also enables the assembled building to have the characteristic of high automation degree, which meets the overall requirements of the industry 2025. In combination with policy incentives, Precast Concrete units (PC units for short) in fabricated buildings have been rapidly developed. The prefabricated member in the form is used as a novel green building product, is widely applied to the fields of buildings, traffic, water conservancy, nuclear power and the like, and plays an important role in national economy. The intelligent concrete prefabricated part production line is core production equipment of a concrete prefabricated part assembly factory, realizes unattended operation, production automation, scheduling intellectualization and management informatization of prefabricated parts, reduces labor cost to the maximum extent, improves production efficiency, is a development direction of modern PC (personal computer) component production enterprises, and is also an important ring of the building industry in the industry 2025.
At present, most of products produced by PC production lines in China have limitations, low yield and high energy consumption, and the information technology and the intelligent manufacturing technology are not fully utilized to realize the whole process control of design, production and transportation, so that the labor intensity is high, the production cost is high, the product quality is uneven, and the traceability, report management, remote management and enterprise ERP interactive docking of the production process cannot be completely realized.
Disclosure of Invention
The invention aims to solve the problems and provides an intelligent production line and a production process capable of producing various standard PC components, so that the production efficiency is improved, the labor intensity of workers is reduced, and the traceability, report management, remote management and enterprise ERP interactive docking of the production process are realized.
The technical scheme of the invention is as follows:
an intelligent production line capable of producing various standard PC components is characterized in that two intelligent production lines are respectively arranged on an axis A to an axis C and an axis C to an axis E, are symmetrical about the axis C and are arranged between 1-28 axes of each span, and a single production line comprises a die placing device, a mesh rib processing device, a truss rib processing device, a concrete mixing station, a distributing machine, a turnover machine, a curing kiln, a stacking machine, a tipping machine and a crown block;
the mold placing device comprises a mold removing mechanical arm, a mold table cleaning device, a side mold cleaning device, a storing and taking mechanical arm and a side mold warehouse, and is used for disassembling and cleaning the side molds of the empty mold table rotated from the tipping machine, storing the cleaned side molds into the side mold warehouse and taking out the required side molds from the side mold warehouse to form the mold table;
the mesh rib processing device is arranged at the rear end of the die placing device and is used for automatically blanking and welding mesh ribs required by a PC (personal computer) component and arranging the mesh ribs into corresponding side die areas on a die table rotated from the die placing device;
the truss rib processing device is arranged at the rear end of the mesh rib processing device and used for automatically blanking and welding truss ribs required by a PC (personal computer) component and arranging the truss ribs in corresponding side die areas turned from mesh rib wheels;
the concrete mixing station is arranged at the outer sides of the shaft A and the shaft E of the production line and is positioned near the distributing machine, and is used for producing self-compacting concrete and conveying the mixed concrete to the distributing machine through a torpedo tank;
the distributing machine is arranged beside the concrete mixing station and is used for receiving concrete conveyed by the concrete mixing station, distributing the concrete to the die table and compacting the concrete by vibration;
the turnover machine is arranged at the rear end of the distributing machine and is used for turning over the first layer of the die platform A and superposing the second layer of the die platform B when the shear wall is produced;
the stacking machine and the curing kiln are arranged at the rear end 7-14 spans of the turnover machine and are used for stacking laminated slabs or laminated shear walls into the kiln and curing the laminated slabs according to an MES instruction;
the tilting machine is arranged at the outlet of the curing kiln and is used for tilting the cured shear wall to separate the shear wall from the die table and hoisting the shear wall into a goods shelf by using a crown block; the laminated floor slab is horizontally lifted by a crane and separated from the mould platform;
the mould placing device, the mesh rib processing device, the truss rib processing device, the concrete mixing station, the distributing machine, the turnover machine, the curing kiln, the stacking machine and the tipping machine rotate the mould platform through the transverse ferry vehicle; the overhead travelling crane is used for hoisting the component;
and a heat-insulation plate cutting device is also arranged near the distributing machine, and the heat-insulation plate is arranged on the first layer A plate of the superposed shear wall with heat insulation and then rotates the die table through a stacker crane and a transverse ferry vehicle.
The automatic side mold cleaning device is characterized in that a mold removing mechanical arm is mounted on a first mold station of the mold placing device, an assembling mechanical arm is mounted on a second mold station, a side mold transmission track is arranged on one side of the first mold station and one side of the second mold station, a side mold warehouse is arranged at the tail end of the second mold station, a storage mechanical arm is erected on the side mold warehouse, a side mold returning track extending into the area of the second mold station is arranged on the side mold warehouse, an automatic mold cleaning device is arranged between the first mold station and the second mold station, and an automatic side mold cleaning device is mounted on the side mold transmission track.
The mesh sheet rib machining device comprises a feeding working platform, a welding bracket and a discharging working platform, wherein the feeding working platform and the discharging working platform are arranged at the same height through a rack; the feeding device is characterized in that a longitudinal bar feeding mechanism and a transverse bar feeding mechanism are arranged on the feeding working platform, a discharging mechanism is arranged on the discharging working platform, the longitudinal bar feeding mechanism and the transverse bar feeding mechanism respectively convey longitudinal bars and transverse bars to the position of the positioning welding die, and the welding machine head is used for welding to form a reinforcing mesh.
The turnover machine comprises a rack arranged on the ground, a bridge machine arranged on the rack, a hoisting device arranged on the bridge machine and turnover equipment connected below the hoisting device, wherein the bridge machine moves along a track on the rack to move the hoisting device and the turnover equipment to corresponding stations; the lifting device comprises a lifting sling and a lifting frame connected with the lifting sling, wherein overturning equipment is arranged on the lifting frame and used for lifting and overturning a wallboard A and a wallboard A mould table which are maintained by the maintenance kiln and stored in an overturning station, and the wallboard A is placed on the wallboard A mould table; the turnover equipment comprises a turnover frame and a die table clamping device, wherein the die table clamping device clamps and fixes a wallboard A die table in the turnover frame, and a turnover motor drives the turnover frame to turn over for 180 degrees; the turnover frame is provided with a centering device, the centering device and a wallboard B die table realize centering operation when the bridge crane drives the lifting frame to reach a superposition station, the wallboard B is placed on the wallboard B die table, and the wallboard A is superposed on the wallboard B after being turned for 180 degrees; the wallboard folding device is characterized in that limit switches are arranged on the lifting frame and the overturning frame, the limit switches, the bridge crane, the lifting device and the overturning motor are connected to a control box arranged on the rack through wires, and the control box controls the bridge crane to move, the lifting device to lift and descend and the overturning device to overturn, so that the wallboard A and the wallboard B are folded.
Put mould device, net piece muscle processingequipment, truss muscle processingequipment, concrete mixing plant, cloth machine, upset machine, curing kiln, hacking machine and the quick-witted department of tipping all install corresponding control box, install the PLC controller in the control box, the control box all is connected to the industrial switch through the wire, and the industrial switch is connected to MES system, cloud platform and database server, and MES system, cloud platform and database server are connected to enterprise ERP system.
An intelligent production process capable of producing various standard PC components comprises the intelligent production line, the specific process flow is as follows,
s1, an empty mold platform wheel is rotated to a mold placing device, a mold removing manipulator of the mold placing device is used for side mold removing, a removed side mold is conveyed to a side mold warehouse through a side mold conveying rail, and a storing and taking manipulator erected on the side mold warehouse automatically stores the removed side mold to the side mold warehouse in a classified mode according to the length of the side mold;
s2, the enterprise ERP system makes a production plan according to order requirements and sends the production plan to the MES system, the MES system controls the access manipulator to take out the side die from the side die library through the control box of the industrial exchanger control die placing device and assemble the die table, and meanwhile, the MES system controls the control boxes of the mesh rib machining device and the truss rib machining device to automatically weld and produce mesh ribs and truss ribs through the industrial exchanger;
s3, turning the mold table wheel assembled by the mold placing device to a mesh rib placing station and a truss rib placing station, adding mesh ribs and truss ribs or only adding mesh ribs according to instructions of an MES system, and then turning to a distributing station below a distributing machine;
s4, the MES system sends an instruction to the concrete mixing station, the mixed concrete is conveyed to the upper part of a mould table of a distributing station through a torpedo tank to distribute the material on the mould table, and a vibrating device at the distributing machine vibrates and compacts the concrete distributed on the mould table to form a wet template;
s5, controlling the wet template to ferry to a curing kiln through a transverse ferry vehicle by the MES system, and stacking the wet template into the curing kiln for curing by a stacker crane;
s6, producing the superposed shear wall or the superposed floor with heat preservation by the template which is cured by the curing kiln according to a control instruction of an MES system;
s7, finishing production of the superposed shear wall or the superposed shear wall with heat preservation, performing maintenance in a curing kiln, performing 75-degree tipping on the product by using a tipping machine, and demolding by using a crown block; horizontally hoisting the laminated floor slab, and then demoulding by using a crown block;
s8, conveying the demolded overlapped shear wall or overlapped shear wall with heat insulation or overlapped floor slab to a storage yard or an outward transportation site, and rotating the demolded die table wheel to a die placing device for next production;
in the step S1, an automatic side mold cleaning device for cleaning the side mold is installed on the side mold conveying track, and a mold table cleaning device for uniformly spraying a mold release agent on the empty mold table is installed between the first mold table station and the second mold table station; the tipper in said step S7 is disposed at the exit of the curing kiln and near the entrance of the mold placement device so that the product is demolded with two parallel lines.
The production process of the composite floor slab comprises the following specific steps,
(1) the MES system controls a control box of the die placing device to control the access manipulator to take out the side die from the side die warehouse and assemble the die table, and simultaneously controls a control box of the mesh rib processing device and the truss rib processing device to automatically feed and weld mesh ribs and truss ribs through an industrial exchanger;
(2) turning the mold table wheel assembled by the mold placing device to a mesh rib placing station and a truss rib placing station, adding mesh ribs and truss ribs according to instructions of an MES system, and turning to a distributing station below a distributing machine;
(3) the MES system sends an instruction to the concrete mixing plant, the mixed concrete is conveyed into a distributing hopper of a distributing machine through a torpedo tank, the distributing machine distributes the material to the die platform turned by the wheel, and a vibrating device at the distributing machine vibrates and compacts the concrete distributed on the die platform to form a wet template;
(4) the MES system controls the wet template to be ferred to the curing kiln through the transverse ferry vehicle, and the stacker crane stacks the wet template into the curing kiln for curing;
(5) the production of the laminated floor slab is finished by the template cured by the curing kiln;
(6) after the production of the laminated floor slab is finished, hoisting by using a horizontal multi-hook to carry out demoulding;
(7) and conveying the demolded composite floor slab to a storage yard or transporting the demolded composite floor slab to a construction site, and rotating the demolded die table to a die placing device for next production.
The production process of the superposed shear wall comprises the following specific flows,
1) the MES system controls a control box of the die placing device to control the access manipulator to take out the side die from the side die warehouse and assemble the die table, and simultaneously controls a control box of the mesh rib processing device and the truss rib processing device to automatically feed and weld mesh ribs and truss ribs through an industrial exchanger;
2) turning the mold table wheel assembled by the mold placing device to a mesh rib placing station and a truss rib placing station, adding mesh ribs and truss ribs to the mold table of the first layer A of the superposed shear wall according to instructions of an MES system, and turning to a distributing station below a distributing machine;
3) the MES system sends an instruction to the concrete mixing plant, the mixed concrete is conveyed into a distributing hopper of a distributing machine through a torpedo tank, the distributing machine distributes the material to the die platform rotated by the wheel, and a vibrating device at the distributing machine vibrates and compacts the concrete distributed on the die platform to form a first layer A wet template of the superposed shear wall.
4) And the MES system controls the first layer A of wet templates of the superposed shear wall to be ferred to the curing kiln through the transverse ferry vehicle, and the stacking machine stacks the first layer A of wet templates of the superposed shear wall into the curing kiln for curing.
5) When the first layer of template A of the superposed shear wall is cured and taken out of the kiln, only net reinforcements are added to a mold platform of the second layer of template B according to the instruction of an MES system, then the mold platform rotates to a material distribution station below a material distributor, the material distributor distributes the second layer of template B, and then the second layer of template B flows to a station to be superposed with the first layer of template A;
5) turning a first layer of template A of the laminated shear wall cured by the curing kiln to a station of a turning machine, turning the first layer of template A by 180 degrees by the turning machine, then stacking the first layer of template A on a second layer of wet template B below the turning station, vibrating and compacting the laminated shear wall by a medium-low frequency vibrating system, and then transferring the laminated shear wall into the curing kiln for secondary curing, and simultaneously turning the first layer of template A to a mold placing device for next production;
6) after the production of the superposed shear wall is finished, a product is tipped by 75 degrees by using a tipping machine, and then the product is demoulded by using a crown block and is placed on a goods shelf;
7) and conveying the demolded superposed shear wall to a storage yard or an external construction site, and turning the demolded die table wheel to a die placing device for next production.
The production process of the superposed shear wall with heat insulation comprises the following specific steps,
a, a control box of a MES system control mold placing device controls an access manipulator to take out a side mold from a side mold warehouse and assemble a mold table, and meanwhile, the MES system controls a control box of a mesh rib machining device and a truss rib machining device through an industrial exchanger to automatically feed and weld mesh ribs and truss ribs;
b. turning the mold table wheel assembled by the mold placing device to a mesh rib placing station and a truss rib placing station, adding only mesh ribs to the mold table with the first layer A of the thermal insulation laminated shear wall template according to an instruction of an MES system, and turning to a distributing station below a distributing machine;
c, the MES system sends an instruction to the concrete mixing station, the mixed concrete is conveyed into a distributing hopper of a distributing machine through a torpedo tank, the distributing machine distributes the material to the die platform turned by the wheel, and a vibrating device at the distributing machine vibrates and compacts the concrete distributed on the die platform to form a first layer of template A;
the MES system controls the first layer of template A of the superposed shear wall with heat insulation to rotate to a heat insulation plate adding station to place the heat insulation plate, the first layer of template A of the superposed shear wall with heat insulation rotates to a mesh rib placing station again to place a second layer of mesh ribs B on the heat insulation plate after the heat insulation plate is placed, the second layer of mesh ribs B are inserted into the heat insulation plate and wet concrete through U-shaped cards, a connecting piece is manually inserted according to a design drawing, then the first layer of template A of the superposed shear wall with heat insulation rotates to a curing kiln, and a stacker crane stacks the first layer of template A of the superposed shear wall with heat insulation into the curing kiln for curing;
e. b, repeating the steps B and c to produce a second layer of template B (a mesh rib and a truss rib are required to be added to a mold table of the second layer of template B according to an instruction of an MES system), scheduling and rotating the template to a station of a turnover machine through the MES system, simultaneously rotating the first layer of template A with the heat-insulating superposed shear wall cured by a curing kiln to the station of the turnover machine, turning the first layer of template A by the turnover machine for 180 degrees and then superposing the template on the second layer of template B, vibrating and compacting the superposed shear wall with the heat-insulating superposed shear wall by a medium-low frequency vibrating system, then transferring the superposed shear wall to the curing kiln for secondary curing to complete production, and simultaneously rotating the mold table of the first layer of template A to a mold placing device;
f. after the production of the laminated shear wall with the heat preservation is finished, a product is tipped for 75 degrees by using a tipping machine, and then demoulding is carried out by using a crown block;
g. and (4) conveying the demolded overlapped shear wall with the heat preservation function to a storage yard or an external construction site, and rotating the demolded die table wheel to a die placing device for next production.
The invention has the beneficial effects that: the production diversification production of the concrete prefabricated part is realized, the whole process control of design, production and transportation is realized by utilizing an informatization system, the labor is further reduced, the labor intensity is reduced, the current labor shortage is avoided, the product quality and the production efficiency are improved, and the production cost of enterprises is reduced.
Drawings
FIG. 1 is a schematic diagram of two exemplary embodiments of the present invention;
FIG. 2 is a schematic view of a single line construction of the present invention;
FIG. 3 is a schematic structural diagram of a mold placing apparatus according to the present invention;
FIG. 4 is a schematic structural view of a mesh reinforcement welding device according to the present invention;
FIG. 5 is a schematic view of the construction of the tilter of the present invention;
FIG. 6 is a network topology diagram of the MES system of the present invention.
The reference numbers in the figures denote: 1-a die placing device, 2-a mesh rib processing device, 3-a mesh rib placing station, 4-a truss rib processing device, 5-a truss rib placing station, 6-a concrete mixing station, 7-a distributing machine, 8-a heat insulation board installing station, 9-a turnover machine, 10-a stacker, 11-a tipping machine, 12-a crown block, 13-a curing kiln, 100-a die removing mechanical arm, 101-a die platform cleaning device, 102-a side die conveying track, 103-a side die cleaning device, 104-a side die returning track, 105-an assembly mechanical arm, 106-a side die warehouse, 107-an access mechanical arm, 20-a loading working platform, 21-a blanking working platform, 22-a welding bracket, 23-a welding head, 24-a longitudinal rib feeding mechanism, 25-a transverse rib feeding mechanism, 26-a positioning welding die, 30-a rack, 31-a bridge crane, 32-a hoisting device, 33-a turnover frame, 34-a lifting frame, 35-a wallboard A die platform, 36-turnover equipment, 37-turnover motor, 38-lifting sling and 39-mould table clamping device.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1 to 6, the technical solution of the present invention:
an intelligent production line capable of producing various standard PC components is symmetrically arranged on an axis A to an axis E about an axis C, and spans from 1 to 28, wherein the single production line from the axis C to the axis E comprises a mold placing device 1, a mesh reinforcement processing device 2, a truss reinforcement processing device 4, a concrete mixing station 6, a distributing machine 7, a turnover machine 9, a curing kiln 13, a stacking machine 10, a tipping machine 11 and a crown block 12;
the mold placing device 1 comprises a mold removing mechanical arm 100, a mold table cleaning device 101, a side mold cleaning device 103, an access mechanical arm 107 and a side mold library 106, and is used for removing the side molds of the empty mold table turned from the tipper 11 and storing the side molds into the side mold library 106 after cleaning and taking out the required side molds from the side mold library 106 to form a mold table;
the mesh reinforcement processing device 2 is arranged at the rear end of the die setting device 1 and is used for automatically welding mesh reinforcements required by PC component production and processing and arranging the mesh reinforcements to a die table rotated from the die setting device;
the truss rib processing device 4 is arranged at the rear end of the mesh rib processing device 2 and is used for automatically welding truss ribs required by processing PC components;
the concrete mixing station 6 is arranged outside the production line and at the rear end of the truss rib processing device 4 and is used for mixing concrete and conveying the mixed concrete to the distributing machine 7;
the distributing machine 7 is arranged beside the concrete mixing station 6 and is used for receiving concrete conveyed by the concrete mixing station 6, distributing the concrete to the mould platform and compacting the concrete by vibration;
the turnover machine 9 is arranged at the rear end of the distributing machine 7 and is used for laminating the templates during production of the shear wall;
the curing kiln 13 and the stacker crane 10 are arranged at the rear end of the turnover machine 9 and are used for stacking, placing and curing the stacked shear walls or stacked floor slabs;
the tipping machine 11 is arranged at a demoulding station at an outlet of the curing kiln 13 and the stacking machine 10 and is used for tipping the cured shear wall so as to separate the shear wall or the laminated floor slab from the mould platform; the laminated floor slab is positioned at a demoulding station, and a special hanging scaffold is adopted to hook 6 lifting hooks on the exposed truss ribs to horizontally and stably lift and separate from a mould platform;
the mould placing device 1, the mesh reinforcement processing device 2, the truss reinforcement processing device 4, the concrete mixing station 6, the distributing machine 7, the tilter 9, the curing kiln 13, the stacker crane 10 and the tilter 11 are rotated by a transverse ferry vehicle and a crown block;
and a heat insulation plate mounting station 8 is further installed at the distributing machine 7, and the heat insulation plate mounting station 8, the curing kiln 13 and the stacker crane 10 realize the rotation of the die table through the transverse ferry vehicle.
The front end of the mold placing device 1 is also provided with a tipping machine 11, and the intelligent production line is arranged in a two-span workshop and is provided with a crown block for hoisting on the intelligent production line. .
The mold unloading device is characterized in that a mold removing manipulator 100 is installed on a first mold station of the mold placing device 1, an assembling manipulator 105 is installed on a second mold station, side mold conveying rails 102 are arranged on one sides of the first mold station and the second mold station, a side mold warehouse 106 is arranged at the tail end of the second mold station, an access manipulator 107 and a side mold returning rail 104 extending into the second mold station are erected on the side mold warehouse 106, an automatic mold cleaning device 101 is arranged between the first mold station and the second mold station, and an automatic side mold cleaning device 103 is installed on the side mold conveying rail 102.
The mesh sheet rib machining device comprises a feeding working platform 20, a welding support 22 and a discharging working platform 21, wherein the feeding working platform 20 and the discharging working platform 21 are arranged at the same height through a rack, the welding support 22 is arranged between the feeding working platform 20 and the discharging working platform 21 and connects the two working platforms, a welding head 23 and a positioning welding mold 26 are arranged on the welding support 22, and the positioning welding mold 26 is arranged right below the welding head 23; be equipped with on material loading work platform 20 and indulge muscle feeding mechanism 24 and horizontal muscle feeding mechanism 25, be equipped with unloading mechanism on unloading work platform 21, indulge muscle feeding mechanism 24 and horizontal muscle feeding mechanism 25 and deliver to the position of fixed-position welding mould 26 with vertical reinforcing bar defeated respectively with horizontal reinforcing bar to form the reinforcing bar net piece through welding head 23 welding.
The turnover machine comprises a frame arranged on the ground, a bridge machine 31 arranged on the frame 30, a lifting device 32 arranged on the bridge machine 31 and turnover equipment 36 connected below the lifting device 32, wherein the bridge machine 31 moves along a track on the frame 30 to move the lifting device 32 and the turnover equipment 36 to corresponding stations; the lifting device 32 comprises lifting slings 38 and a lifting frame 34 connected with the lifting slings 38, wherein overturning equipment 36 is arranged on the lifting frame 34 and used for lifting and overturning the wallboard A and the wallboard A mold table 35 which are maintained by the maintenance kiln and stored in an overturning station, and the wallboard A is placed on the wallboard A mold table 35; the overturning equipment comprises an overturning frame 33 and a die table clamping device 39, the die table clamping device 39 clamps and fixes the die table 35 of the wallboard A in the overturning frame 33, and an overturning motor 37 drives the overturning frame 33 to overturn for 180 degrees; the turnover frame 33 is provided with a centering device, the centering device is aligned with a die table of a wallboard B when the bridge crane 31 drives the lifting frame 34 to reach a superposition station, the wallboard B is placed on the die table of the wallboard B, and the wallboard A is superposed on the wallboard B after being turned for 180 degrees; limit switches are installed on the lifting frame 34 and the overturning frame 33, the limit switches, the bridge crane, the hoisting device and the overturning motor are connected to a control box installed on the rack 30 through wires, and the control box controls the movement of the bridge crane 31, the lifting and descending of the hoisting device 32 and the overturning of the overturning equipment 36, so that the wallboard A and the wallboard B are overlapped.
Put mould device 1, net piece muscle processingequipment 2, truss muscle processingequipment 4, concrete mixing plant 6, cloth machine 7, upset machine 9, maintenance kiln 13, hacking machine 10 and 11 departments of tipping machine and all install corresponding control box, install the PLC controller in the control box, the control box all is connected to the industry switch through the wire, and the industry switch is connected to MES system, cloud platform and database server, and MES system, cloud platform and database server are connected to enterprise ERP system.
An intelligent production process capable of producing various standard PC components comprises the intelligent production line, the specific process flow is as follows,
s1, an empty mold platform wheel is rotated to a mold placing device, a mold removing manipulator of the mold placing device is used for side mold removing, a removed side mold is conveyed to a side mold warehouse through a side mold conveying rail, and a storing and taking manipulator erected on the side mold warehouse automatically stores the removed side mold to the side mold warehouse in a classified mode according to the length of the side mold;
s2, the enterprise ERP system makes a production plan according to order requirements and sends the production plan to the MES system, the MES system controls the access manipulator to take out the side die from the side die library through the control box of the industrial exchanger control die placing device and assemble the die table, and meanwhile, the MES system controls the control boxes of the mesh rib machining device and the truss rib machining device to automatically weld and produce mesh ribs and truss ribs through the industrial exchanger;
s3, turning the mold table wheel assembled by the mold placing device to a mesh rib placing station and a truss rib placing station, adding mesh ribs and truss ribs or only adding mesh ribs according to instructions of an MES system, and then turning to a distributing station below a distributing machine;
s4, the MES system sends an instruction to the concrete mixing station, the mixed concrete is conveyed to the upper part of a mould table of a distributing station through a torpedo tank to distribute the material on the mould table, and a vibrating device at the distributing machine vibrates and compacts the concrete distributed on the mould table to form a wet template;
s5, controlling the wet template to ferry to a curing kiln through a transverse ferry vehicle by the MES system, and stacking the wet template into the curing kiln for curing by a stacker crane;
s6, producing the superposed shear wall or the superposed floor with heat preservation by the template which is cured by the curing kiln according to a control instruction of an MES system;
s7, finishing production of the superposed shear wall or the superposed shear wall with heat preservation, performing maintenance in a curing kiln, performing 75-degree tipping on the product by using a tipping machine, and demolding by using a crown block; horizontally hoisting the laminated floor slab, and then demoulding by using a crown block;
s8, conveying the demolded overlapped shear wall or overlapped shear wall with heat insulation or overlapped floor slab to a storage yard or an outward transportation site, and rotating the demolded die table wheel to a die placing device for next production;
in the step S1, an automatic side mold cleaning device for cleaning the side mold is installed on the side mold conveying track, and a mold table cleaning device for uniformly spraying a mold release agent on the empty mold table is installed between the first mold table station and the second mold table station; the tipper in said step S7 is disposed at the exit of the curing kiln and near the entrance of the mold placement device so that the product is demolded with two parallel lines.
The production process of the composite floor slab comprises the following specific steps,
(1) the MES system controls a control box of the die placing device to control the access manipulator to take out the side die from the side die warehouse and assemble the die table, and simultaneously controls a control box of the mesh rib processing device and the truss rib processing device to automatically feed and weld mesh ribs and truss ribs through an industrial exchanger;
(2) turning the mold table wheel assembled by the mold placing device to a mesh rib placing station and a truss rib placing station, adding mesh ribs and truss ribs according to instructions of an MES system, and turning to a distributing station below a distributing machine;
(3) the MES system sends an instruction to the concrete mixing plant, the mixed concrete is conveyed into a distributing hopper of a distributing machine through a torpedo tank, the distributing machine distributes the material to the die platform turned by the wheel, and a vibrating device at the distributing machine vibrates and compacts the concrete distributed on the die platform to form a wet template;
(4) the MES system controls the wet template to be ferred to the curing kiln through the transverse ferry vehicle, and the stacker crane stacks the wet template into the curing kiln for curing;
(5) the production of the laminated floor slab is finished by the template cured by the curing kiln;
(6) after the production of the laminated floor slab is finished, hoisting by using a horizontal multi-hook to carry out demoulding;
(7) and conveying the demolded composite floor slab to a storage yard or transporting the demolded composite floor slab to a construction site, and rotating the demolded die table to a die placing device for next production.
The production process of the superposed shear wall comprises the following specific flows,
1) the MES system controls a control box of the die placing device to control the access manipulator to take out the side die from the side die warehouse and assemble the die table, and simultaneously controls a control box of the mesh rib processing device and the truss rib processing device to automatically feed and weld mesh ribs and truss ribs through an industrial exchanger;
2) turning the mold table wheel assembled by the mold placing device to a mesh rib placing station and a truss rib placing station, adding mesh ribs and truss ribs to the mold table of the first layer A of the superposed shear wall according to instructions of an MES system, and turning to a distributing station below a distributing machine;
3) the MES system sends an instruction to the concrete mixing plant, the mixed concrete is conveyed into a distributing hopper of a distributing machine through a torpedo tank, the distributing machine distributes the material to the die platform rotated by the wheel, and a vibrating device at the distributing machine vibrates and compacts the concrete distributed on the die platform to form a first layer A wet template of the superposed shear wall.
4) And the MES system controls the first layer A of wet templates of the superposed shear wall to be ferred to the curing kiln through the transverse ferry vehicle, and the stacking machine stacks the first layer A of wet templates of the superposed shear wall into the curing kiln for curing.
5) When the first layer of template A of the superposed shear wall is cured and taken out of the kiln, only net reinforcements are added to a mold platform of the second layer of template B according to the instruction of an MES system, then the mold platform rotates to a material distribution station below a material distributor, the material distributor distributes the second layer of template B, and then the second layer of template B flows to a station to be superposed with the first layer of template A;
5) turning a first layer of template A of the laminated shear wall cured by the curing kiln to a station of a turning machine, turning the first layer of template A by 180 degrees by the turning machine, then stacking the first layer of template A on a second layer of wet template B below the turning station, vibrating and compacting the laminated shear wall by a medium-low frequency vibrating system, and then transferring the laminated shear wall into the curing kiln for secondary curing, and simultaneously turning the first layer of template A to a mold placing device for next production;
6) after the production of the superposed shear wall is finished, a product is tipped by 75 degrees by using a tipping machine, and then the product is demoulded by using a crown block and is placed on a goods shelf;
7) and conveying the demolded superposed shear wall to a storage yard or an external construction site, and turning the demolded die table wheel to a die placing device for next production.
The production process of the superposed shear wall with heat insulation comprises the following specific steps,
a, a control box of a MES system control mold placing device controls an access manipulator to take out a side mold from a side mold warehouse and assemble a mold table, and meanwhile, the MES system controls a control box of a mesh rib machining device and a truss rib machining device through an industrial exchanger to automatically feed and weld mesh ribs and truss ribs;
b. turning the mold table wheel assembled by the mold placing device to a mesh rib placing station and a truss rib placing station, adding only mesh ribs to the mold table with the first layer A of the thermal insulation laminated shear wall template according to an instruction of an MES system, and turning to a distributing station below a distributing machine;
c, the MES system sends an instruction to the concrete mixing station, the mixed concrete is conveyed into a distributing hopper of a distributing machine through a torpedo tank, the distributing machine distributes the material to the die platform turned by the wheel, and a vibrating device at the distributing machine vibrates and compacts the concrete distributed on the die platform to form a first layer of template A;
the MES system controls the first layer of template A of the superposed shear wall with heat insulation to rotate to a heat insulation plate adding station to place the heat insulation plate, the first layer of template A of the superposed shear wall with heat insulation rotates to a mesh rib placing station again to place a second layer of mesh ribs B on the heat insulation plate after the heat insulation plate is placed, the second layer of mesh ribs B are inserted into the heat insulation plate and wet concrete through U-shaped cards, a connecting piece is manually inserted according to a design drawing, then the first layer of template A of the superposed shear wall with heat insulation rotates to a curing kiln, and a stacker crane stacks the first layer of template A of the superposed shear wall with heat insulation into the curing kiln for curing;
e. b, repeating the steps B and c to produce a second layer of template B (a mesh rib and a truss rib are required to be added to a mold table of the second layer of template B according to an instruction of an MES system), scheduling and rotating the template to a station of a turnover machine through the MES system, simultaneously rotating the first layer of template A with the heat-insulating superposed shear wall cured by a curing kiln to the station of the turnover machine, turning the first layer of template A by the turnover machine for 180 degrees and then superposing the template on the second layer of template B, vibrating and compacting the superposed shear wall with the heat-insulating superposed shear wall by a medium-low frequency vibrating system, then transferring the superposed shear wall to the curing kiln for secondary curing to complete production, and simultaneously rotating the mold table of the first layer of template A to a mold placing device;
f. after the production of the laminated shear wall with the heat preservation is finished, a product is tipped for 75 degrees by using a tipping machine, and then demoulding is carried out by using a crown block;
g. and (4) conveying the demolded overlapped shear wall with the heat preservation function to a storage yard or an external construction site, and rotating the demolded die table wheel to a die placing device for next production.
Example one (production of laminated floor):
empty mould platform wheel is to putting mould device station, the position of side forms is discerned through machine vision device automatic identification to form removal manipulator 100, and transport to side forms transmission track 102 after dismantling the side forms, when side forms transmission track 102 passes through side forms self-cleaning device 103, side forms self-cleaning device 103 accomplishes the side forms clean, the side forms continue to transmit to side forms storehouse 106 along side forms transmission track 102 and snatch the region, access manipulator 107 passes through machine vision system discernment side forms length, and look for suitable vacant position through machine vision system is automatic, with the categorised warehouse entry of side forms. The empty mold table rotates from the mold table station I to the mold table station II, passes through the mold table automatic cleaning device 101 in the middle, automatically finishes mold table cleaning and uniformly sprays a release agent. And automatically selecting a side die combination with a proper length according to data issued by the MES system, and placing the side die on the side die returning track 104 by the access manipulator 107 to convey the side die to the assembly manipulator 105. And at a second mold station, the assembling manipulator 105 automatically and reasonably places the side molds and the reserved hole positions according to data sent by the MES system, completes the mold placement of the mold station, rotates to the buffering station through the transverse ferry vehicle wheel, continues to rotate to the steel bar protection block station and places the steel bar protection block. The mould platform wheel is rotated to net piece muscle and is placed station 3, is placed the net piece muscle by net piece muscle processingequipment 2 is automatic. And the mould wheel rotates to a truss rib placing station 5, the truss rib is automatically placed by the truss rib machining device 4, and the embedded part is placed. The mould platform continues to rotate through the cross-sliding ferry vehicle to reach the material distribution station, a torpedo tank of the concrete mixing station feeds concrete to the material distribution hopper through a rail, and the material distributor 7 distributes the material uniformly and vibrates and compacts through the low-frequency vibration system. After the vibration is finished, the mould platform is sent to a curing kiln for hot air curing through a hacking machine after galling. And taking out the cured and formed composite floor slab from the curing kiln through a stacker crane, rotating to a demolding station at a tipper, horizontally hoisting the composite floor slab by adopting a special hoisting plate with 6 hoisting point hooks on the exposed truss ribs, demolding the composite floor slab by utilizing a crown block, and conveying the composite floor slab to an outdoor stacking area by transversely moving a ferry vehicle and the crown block. And rotating the demolded empty mold table to a mold table station for removing the mold, and entering the next production cycle.
Example two (superposed shear wall production):
empty mould platform wheel is to putting mould device station, the position of side forms is discerned through machine vision device automatic identification to form removal manipulator 100, and transport to side forms transmission track 102 after dismantling the side forms, when side forms transmission track 102 passes through side forms self-cleaning device 103, side forms self-cleaning device 103 accomplishes the side forms clean, the side forms continue to transmit to side forms storehouse 106 along side forms transmission track 102 and snatch the region, access manipulator 107 passes through machine vision system discernment side forms length, and look for suitable vacant position through machine vision system is automatic, with the categorised warehouse entry of side forms. The empty mold table rotates from the mold table station I to the mold table station II, passes through the mold table automatic cleaning device 101 in the middle, automatically finishes mold table cleaning and uniformly sprays a release agent. And automatically selecting a side die combination with a proper length according to data issued by the MES system, and placing the side die on the side die returning track 104 by the access manipulator 107 to convey the side die to the assembly manipulator 105. And at a second mold station, the assembling manipulator 105 automatically and reasonably places side molds according to data sent by the MES system, plots the positions of doors, windows and reserved holes, completes mold placement of the mold station, rotates to a buffering station through a transverse ferry vehicle, continues to rotate to a steel bar protection block station and places the steel bar protection block. And the mesh ribs are automatically placed at the mesh rib placing station 3 by the mesh rib processing equipment 2. For a first layer A of wallboard of the superposed shear wall, placing a steel bar truss at a truss rib placing station 5 by truss rib processing equipment 4; the second layer of wallboard B of the superposed shear wall does not need to place a steel bar truss at the truss rib placing station 5. For the first layer A of wallboard of the superposed shear wall, the first layer A of wallboard continues to rotate to reach the material distribution station through the transverse ferry vehicle, the torpedo tank of the concrete mixing station feeds materials to the material distribution hopper through the rail, the material is uniformly distributed by the material distributor 7, and the material is vibrated and compacted through the low-frequency vibration system. After the vibration is finished, the mould platform is sent to a curing kiln for hot air curing through a hacking machine after galling.
For the second layer B of the wallboard of the superposed shear wall, the cycle time is calculated through an MES system, the first layer A of wallboard is accurately matched with the cycle time of the first layer A of wallboard out of the curing kiln, and the cycle time of the curing kiln to the turnover machine 9 and the cycle time of the second layer B of wallboard to the turnover machine 9 are matched. The second layer of wallboard B is transferred to the station of the turnover machine from the empty mould platform through demoulding, clearing, placing the mould and transferring by the transverse transfer vehicle (the same process flow as the first layer of wallboard A). The first layer of wallboard A of the shear wall is taken out of the curing kiln by a stacker crane after curing is completed, then the first layer of wallboard A is rotated to a turnover machine station, a turnover machine 9 clamps, lifts and turns 180 degrees the die table loaded with the first layer of wallboard A of the superposed shear wall, and conveys the die table to the turnover machine station to be superposed with the second layer of wallboard B of the superposed shear wall after distribution is completed, and the second layer of wallboard B of the superposed shear wall is vibrated and compacted by a medium-frequency vibrating system after superposition is completed. And unloading the empty mould table of the first layer A of wallboard of the superposed shear wall, and continuously rotating the empty mould table to a station of the mould placing device for mould removal. And conveying the die table wheel loaded with the superposed shear wall into a curing kiln by a stacker crane for hot air curing. And taking out the cured superposed shear wall from the curing kiln by a stacker crane, turning the superposed shear wall to a station of a tipper by a transverse ferry vehicle, tipping the mould platform by the tipper 11, demoulding the superposed shear wall by a crown block, and moving the superposed shear wall into an intelligent storage yard by a trolley and a crown block. And rotating the demolded empty mold table wheel to a mold placing device station for demolding, and entering the next production cycle.
Example three (superposed shear wall with insulation board):
empty mould platform wheel is to putting mould device station, the position of side forms is discerned through machine vision device automatic identification to form removal manipulator 100, and transport to side forms transmission track 102 after dismantling the side forms, when side forms transmission track 102 passes through side forms self-cleaning device 103, side forms self-cleaning device 103 accomplishes the side forms clean, the side forms continue to transmit to side forms storehouse 106 along side forms transmission track 102 and snatch the region, access manipulator 107 passes through machine vision system discernment side forms length, and look for suitable vacant position through machine vision system is automatic, with the categorised warehouse entry of side forms. The empty mold table rotates from the mold table station I to the mold table station II, passes through the mold table automatic cleaning device 101 in the middle, automatically finishes mold table cleaning and uniformly sprays a release agent. And automatically selecting a side die combination with a proper length according to data issued by the MES system, and placing the side die on the side die returning track 104 by the access manipulator 107 to convey the side die to the assembly manipulator 105. And at a second mold station, the assembling manipulator 105 automatically and reasonably places side molds according to data sent by the MES system, plots the positions of doors, windows and reserved holes, completes mold placement of the mold station, rotates to a buffering station through a transverse ferry vehicle, continues to rotate to a steel bar protection block station and places the steel bar protection block. The mesh ribs are automatically placed on the first layer of wallboard A with the heat-insulation superposed shear wall by the mesh rib processing device 2. For the first layer A of wallboard with the heat-insulation superposed shear wall, a steel bar truss does not need to be placed, and then an embedded part is placed. For the first layer of wallboard with the heat-preservation superposed shear wall, the first layer of wallboard continues to rotate to reach a material distribution station through a transverse ferry vehicle, a torpedo tank of a concrete mixing station carries out concrete feeding on a material distribution hopper through a rail, the material distribution machine 7 distributes the material uniformly and vibrates compactly through a low-frequency vibration system, high-pressure water-cutting heat-preservation board equipment is further installed near the material distribution machine, a die table rotates to a heat-preservation board installation station 8 to place heat-preservation board materials, and a mesh rib machining device 2 places a second layer of mesh ribs at a mesh rib placement station 3. And installing fasteners, and then conveying the fasteners into a curing kiln for hot air curing through a stacker crane in a rotating mode.
For the second layer of wallboard B with the heat-preservation superposed shear wall, the rotation time is calculated through an MES system, the first layer of wallboard A is accurately matched with the time of the first layer of wallboard B out of the curing kiln and the time of the second layer of wallboard B rotating to the turnover machine 9 from the curing kiln. And the second layer of the B wallboard is demoulded, cleared, placed in a mould, arranged with mesh ribs and truss ribs from the empty mould platform and then rotated to the station of the tilter through a cloth rear wheel. The first layer A wallboard of the shear wall is taken out of a curing kiln by a stacker crane after being cured, then is rotated to a turnover machine station, a mold platform carrying the first layer A wallboard of the laminated shear wall with the heat insulation plate is clamped, lifted and turned for 180 degrees by a turnover machine 9, and is conveyed to the turnover machine station to be superposed with the second layer B wallboard of the laminated shear wall which just completes the distribution, and the second layer B wallboard of the laminated shear wall is vibrated and compacted by a medium-frequency vibrating system after the superposition is completed. And unloading the empty mould table of the first layer A of wallboard of the superposed shear wall, and continuously rotating the empty mould table to a station of the mould placing device for mould removal. And conveying the die table wheel loaded with the superposed shear wall into a curing kiln by a stacker crane for hot air curing. And taking out the cured superposed shear wall from the curing kiln by a stacker crane, turning the superposed shear wall to a station of a tipper by a transverse ferry vehicle, tipping the mould platform by the tipper 11, demoulding the superposed shear wall by a crown block, and moving the superposed shear wall into an intelligent storage yard by a trolley and a crown block. And rotating the demolded empty mold table wheel to a mold placing device station for demolding, and entering the next production cycle.
The intelligent production line comprises a field device control system and an informatization management system, wherein a network structure of the industrial field device control system comprises sensors (digital quantity and analog quantity), board cards and instruments of a mixing station system, a curing kiln system, a mesh steel processing system, a truss rib processing system, a heat insulation board processing system, a mould platform rotation system, a mould placing system, a material distribution system, a tipping device, a safety protection system and the like. The field device control system is connected with the industrial switch through an industrial network interface, control is achieved through a PLC of the subsystem, the PLC drives a controlled object on the field through I/0, signal collection is achieved through RS485 communication and analog quantity signals of the transmitter, and the motion control portion is achieved through a robot.
The information system, namely MES (manufacturing enterprise production process execution system), realizes the functions of manufacturing data management, drawing splitting management, planning and scheduling management, production scheduling management, inventory management, quality management, equipment management, subsystem management, cost management, production process control, bottom layer data integration analysis, upper layer data integration decomposition and the like, and creates a solid, reliable, comprehensive and feasible manufacturing cooperation management platform for the whole production line.
The MES system can be implemented to provide a standard interface to general purpose software (such as Oracle, SAP or Microsoft) to exchange data with the accounting system and is easily incorporated into existing corporate structures.
The MES system support is a data format comprising PXML, Unitechnik and BVBS, and is provided with a central database and a server component, visualization and management of production lists, three-dimensional visualization of production data and a high-performance 3D editor for data visualization and PTS connection.
The MES system compatible subsystem comprises a mixing station system, a curing kiln system, a mesh steel processing system, a truss rib processing system, a heat insulation plate processing system, a mould platform rotation system, a mould placing system, a material distributing system, a tipping device and a safety protection system, and self-defined manual and automatic data import, and comprises a database such as oracle and MySQL connection, production data modification and storage, historical alarm information tracing and image and table unit processing.
The MES system self-defines an operation mode and visualization, comprises network integration, supports remote maintenance integration and remote access, defines management authorities of operators, managers and engineers, supports remote modification and local modification, diagnoses faults, processes alarm information and achieves event traceability.
In conclusion, the intelligent production line can simultaneously produce three standard PC components such as a laminated slab, a laminated shear wall without heat insulation, a laminated shear wall with a heat insulation plate and the like on a single production line, and utilizes an informatization system to realize the whole process control of design, production and transportation, so that the labor is further reduced, the intelligent production line only needs 18 persons to operate on the production line for one shift, and is only 1/4 persons for one shift of the traditional PC production line, the current labor shortage is avoided, the labor intensity is reduced, the product quality and the production efficiency are improved, and the production cost of enterprises is reduced.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents.

Claims (9)

1. An intelligent production line capable of producing various standard PC components is characterized in that: the two production lines are respectively arranged on the shafts A to C and the shafts C to E, are symmetrical about the shaft C and are arranged between the 1-28 axes of each span, and the single production line comprises a die placing device, a mesh rib processing device, a truss rib processing device, a concrete mixing station, a distributing machine, a turnover machine, a curing kiln, a stacking machine and a tipping machine;
the mold placing device comprises a mold removing mechanical arm, a mold table cleaning device, a side mold cleaning device, a storing and taking mechanical arm and a side mold library, and is used for removing the side molds of the empty mold table rotated from the tipping machine, cleaning the side molds, storing the side molds into the side mold library in a classified manner according to different lengths, and automatically taking out the required side molds from the side mold library to form the side molds of the new PC component;
the mesh rib processing device is arranged at the rear end of the die placing device and is used for automatically blanking and welding mesh ribs required by a PC (personal computer) component and arranging the mesh ribs into corresponding side die areas on a die table rotated from the die placing device;
the truss rib processing device is arranged at the rear end of the mesh rib processing device and used for automatically blanking and welding truss ribs required by a PC (personal computer) component and arranging the truss ribs in corresponding side die areas turned from mesh rib wheels;
the concrete mixing station is arranged at the outer sides of the shaft A and the shaft E of the production line and is positioned near the distributing machine, and is used for producing self-compacting concrete and conveying the mixed concrete to the distributing machine through a torpedo tank;
the distributing machine is arranged beside the concrete mixing station and is used for receiving concrete conveyed by the concrete mixing station, distributing the concrete to the die table and compacting the concrete by vibration;
the turnover machine is arranged at the rear end of the distributing machine and is used for turning over a first layer of die platform A and superposing a second layer of die platform B when the shear wall is produced, so that the wallboard A and the wallboard B in the die platforms are superposed together according to the technical requirements;
the stacking machine and the curing kiln are arranged at the rear end of the turnover machine and are used for stacking laminated slabs or laminated shear walls into the kiln and curing according to an MES instruction;
the tilting machine is arranged at the outlet of the curing kiln and is used for tilting the cured shear wall to separate the shear wall from the die table and hoisting the shear wall into a goods shelf by using a crown block; the laminated floor slab is horizontally lifted by a crane and separated from the mould platform;
the mould placing device, the mesh rib processing device, the truss rib processing device, the concrete mixing station, the distributing machine, the turnover machine, the curing kiln, the stacking machine and the tipping machine rotate the mould platform through the transverse ferry vehicle; the crown block is used for hoisting a finished PC component;
the material distributing machine is also provided with insulation board cutting equipment beside, the insulation boards are arranged on the superposed shear wall board A with insulation and then are rotated by the die table through the transverse ferry vehicle, and a second piece of net sheet rib is placed and sent into the curing kiln through the stacker crane;
put mould device, net piece muscle processingequipment, truss muscle processingequipment, concrete mixing plant, cloth machine, upset machine, curing kiln, hacking machine and the quick-witted department of tipping all install corresponding control box, install the PLC controller in the control box, the control box all is connected to the industrial switch through the wire, and the industrial switch is connected to MES system, cloud platform and database server, and MES system, cloud platform and database server are connected to enterprise ERP system.
2. The intelligent production line of claim 1, which can produce various standard PC components, characterized in that: the front end of the die placing device is also provided with a tipping machine, the single production line of the intelligent production line is arranged in a two-span workshop, and the workshop is internally provided with a crown block for demoulding and hoisting of the PC component.
3. The intelligent production line of claim 1, which can produce various standard PC components, characterized in that: the automatic side mold cleaning device is characterized in that a mold removing mechanical arm is mounted on a first mold station of the mold placing device, an assembling mechanical arm is mounted on a second mold station, a side mold transmission track is arranged on one side of the first mold station and one side of the second mold station, a side mold warehouse is arranged at the tail end of the second mold station, a storage mechanical arm is erected on the side mold warehouse, a side mold returning track extending into the area of the second mold station is arranged on the side mold warehouse, an automatic mold cleaning device is arranged between the first mold station and the second mold station, and an automatic side mold cleaning device is mounted on the side mold transmission track.
4. The intelligent production line of claim 1, which can produce various standard PC components, characterized in that: the mesh sheet rib machining device comprises a feeding working platform, a welding bracket and a discharging working platform, wherein the feeding working platform and the discharging working platform are arranged at the same height through a rack; the feeding device is characterized in that a longitudinal bar feeding mechanism and a transverse bar feeding mechanism are arranged on the feeding working platform, a discharging mechanism is arranged on the discharging working platform, the longitudinal bar feeding mechanism and the transverse bar feeding mechanism respectively convey longitudinal bars and transverse bars to the position of the positioning welding die, and the welding machine head is used for welding to form a reinforcing mesh.
5. The intelligent production line of claim 1, which can produce various standard PC components, characterized in that: the turnover machine comprises a rack arranged on the ground, a bridge machine arranged on the rack, a hoisting device arranged on the bridge machine and turnover equipment connected below the hoisting device, wherein the bridge machine moves along a track on the rack to move the hoisting device and the turnover equipment to corresponding stations; the lifting device comprises a lifting sling and a lifting frame connected with the lifting sling, wherein overturning equipment is arranged on the lifting frame and used for lifting and overturning a wallboard A and a wallboard A mould table which are maintained by the maintenance kiln and stored in an overturning station, and the wallboard A is placed on the wallboard A mould table; the turnover equipment comprises a turnover frame and a die table clamping device, wherein the die table clamping device clamps and fixes a wallboard A die table in the turnover frame, and a turnover motor drives the turnover frame to turn over for 180 degrees; the turnover frame is provided with a centering device, the centering device and a wallboard B die table realize centering operation when the bridge crane drives the lifting frame to reach a superposition station, the wallboard B is placed on the wallboard B die table, and the wallboard A is superposed on the wallboard B after being turned for 180 degrees; the wallboard folding device is characterized in that limit switches are arranged on the lifting frame and the overturning frame, the limit switches, the bridge crane, the lifting device and the overturning motor are connected to a control box arranged on the rack through wires, and the control box controls the bridge crane to move, the lifting device to lift and descend and the overturning device to overturn, so that the wallboard A and the wallboard B are folded.
6. An intelligent production process capable of producing various standard PC components is characterized in that: comprises the intelligent production line as claimed in any one of claims 1 to 5, and has the following specific process flow,
s1, an empty mold platform wheel is rotated to a mold placing device, a mold removing manipulator of the mold placing device is used for side mold removing, a removed side mold is conveyed to a side mold warehouse through a side mold conveying rail, and a storing and taking manipulator erected on the side mold warehouse automatically stores the removed side mold to the side mold warehouse in a classified mode according to the length of the side mold;
s2, the enterprise ERP system makes a production plan according to order requirements and sends the production plan to the MES system, the MES system controls the access manipulator to take out the side die from the side die library through the control box of the industrial exchanger control die placing device and assemble the die table, and meanwhile, the MES system controls the control boxes of the mesh rib machining device and the truss rib machining device to automatically weld and produce mesh ribs and truss ribs through the industrial exchanger;
s3, turning the mold table wheel assembled by the mold placing device to a mesh rib placing station and a truss rib placing station, adding mesh ribs and truss ribs or only adding mesh ribs according to instructions of an MES system, and then turning to a distributing station below a distributing machine;
s4, the MES system sends an instruction to the concrete mixing station, the mixed concrete is conveyed to the upper part of a mould table of a distributing station through a torpedo tank to distribute the material on the mould table, and a vibrating device at the distributing machine vibrates and compacts the concrete distributed on the mould table to form a wet template;
s5, controlling the wet template to ferry to a curing kiln through a transverse ferry vehicle by the MES system, and stacking the wet template into the curing kiln for curing by a stacker crane;
s6, producing the superposed shear wall or the superposed floor with heat preservation by the template which is cured by the curing kiln according to a control instruction of an MES system;
s7, finishing production of the superposed shear wall or the superposed shear wall with heat preservation, performing maintenance in a curing kiln, performing 75-degree tipping on the product by using a tipping machine, and demolding by using a crown block; horizontally hoisting the laminated floor slab, and then demoulding by using a crown block;
s8, conveying the demolded overlapped shear wall or overlapped shear wall with heat insulation or overlapped floor slab to a storage yard or an outward transportation site, and rotating the demolded die table wheel to a die placing device for next production;
in the step S1, an automatic side mold cleaning device for cleaning the side mold is installed on the side mold conveying track, and a mold table cleaning device for uniformly spraying a mold release agent on the empty mold table is installed between the first mold table station and the second mold table station; the tipper in said step S7 is disposed at the exit of the curing kiln and near the entrance of the mold placement device so that the product is demolded with two parallel lines.
7. The process according to claim 6, characterized in that: the production process of the composite floor slab comprises the following specific steps,
(1) the MES system controls a control box of the die placing device to control the access manipulator to take out the side die from the side die warehouse and assemble the die table, and simultaneously controls a control box of the mesh rib processing device and the truss rib processing device to automatically feed and weld mesh ribs and truss ribs through an industrial exchanger;
(2) turning the mold table wheel assembled by the mold placing device to a mesh rib placing station and a truss rib placing station, adding mesh ribs and truss ribs according to instructions of an MES system, and turning to a distributing station below a distributing machine;
(3) the MES system sends an instruction to the concrete mixing plant, the mixed concrete is conveyed into a distributing hopper of a distributing machine through a torpedo tank, the distributing machine distributes the material to the die platform turned by the wheel, and a vibrating device at the distributing machine vibrates and compacts the concrete distributed on the die platform to form a wet template;
(4) the MES system controls the wet template to be ferred to the curing kiln through the transverse ferry vehicle, and the stacker crane stacks the wet template into the curing kiln for curing;
(5) the production of the laminated floor slab is finished by the template cured by the curing kiln;
(6) after the production of the laminated floor slab is finished, hoisting by using a horizontal multi-hook to carry out demoulding;
(7) and conveying the demolded composite floor slab to a storage yard or transporting the demolded composite floor slab to a construction site, and rotating the demolded die table to a die placing device for next production.
8. The process according to claim 6, characterized in that: the production process of the superposed shear wall comprises the following specific flows,
1) the MES system controls a control box of the die placing device to control the access manipulator to take out the side die from the side die warehouse and assemble the die table, and simultaneously controls a control box of the mesh rib processing device and the truss rib processing device to automatically feed and weld mesh ribs and truss ribs through an industrial exchanger;
2) turning the mold table wheel assembled by the mold placing device to a mesh rib placing station and a truss rib placing station, adding mesh ribs and truss ribs to the mold table of the first layer A of the superposed shear wall according to instructions of an MES system, and turning to a distributing station below a distributing machine;
3) the MES system sends an instruction to the concrete mixing plant, the mixed concrete is conveyed into a distributing hopper of a distributing machine through a torpedo tank, the distributing machine distributes the material to the die platform rotated by the wheel, and a vibrating device at the distributing machine vibrates and compacts the concrete distributed on the die platform to form a first layer A wet template of the superposed shear wall;
4) the MES system controls the first layer A of wet templates of the superposed shear wall to be ferred to a curing kiln through the transverse ferry vehicle, and the stacking machine stacks the first layer A of wet templates of the superposed shear wall into the curing kiln for curing;
5) when the first layer of template A of the superposed shear wall is cured and taken out of the kiln, only net reinforcements are added to a mold platform of the second layer of template B according to the instruction of an MES system, then the mold platform rotates to a material distribution station below a material distributor, the material distributor distributes the second layer of template B, and then the second layer of template B flows to a station to be superposed with the first layer of template A;
5) turning a first layer of template A of the laminated shear wall cured by the curing kiln to a turning machine station, turning the first layer of template A by 180 degrees by the turning machine, then stacking the first layer of template A on a second layer of wet template B below the turning station, vibrating and compacting the laminated shear wall by a medium-low frequency vibrating system, then transferring the laminated shear wall into the curing kiln for secondary curing, and reversely turning the first layer of template A by 180 degrees to realize resetting and then turning the laminated shear wall to a mold placing device for next production;
6) after the production of the superposed shear wall is finished, a product is tipped by 75 degrees by using a tipping machine, and then the product is demoulded by using a crown block and is placed on a goods shelf;
7) and conveying the demolded superposed shear wall to a storage yard or an external construction site, and turning the demolded die table wheel to a die placing device for next production.
9. The process according to claim 6, characterized in that: the production process of the superposed shear wall with heat insulation comprises the following specific steps,
a, a control box of a MES system control mold placing device controls an access manipulator to take out a side mold from a side mold warehouse and assemble a mold table, and meanwhile, the MES system controls a control box of a mesh rib machining device and a truss rib machining device through an industrial exchanger to automatically feed and weld mesh ribs and truss ribs;
b. turning the mold table wheel assembled by the mold placing device to a mesh rib placing station and a truss rib placing station, adding only mesh ribs to the mold table with the first layer A of the thermal insulation laminated shear wall template according to an instruction of an MES system, and turning to a distributing station below a distributing machine;
c, the MES system sends an instruction to the concrete mixing station, the mixed concrete is conveyed into a distributing hopper of a distributing machine through a torpedo tank, the distributing machine distributes the material to the die platform turned by the wheel, and a vibrating device at the distributing machine vibrates and compacts the concrete distributed on the die platform to form a first layer of template A;
the MES system controls the first layer of template A of the superposed shear wall with heat insulation to rotate to a heat insulation plate adding station to place the heat insulation plate, the first layer of template A of the superposed shear wall with heat insulation rotates to a mesh rib placing station again to place a second layer of mesh ribs B on the heat insulation plate after the heat insulation plate is placed, the second layer of mesh ribs B are inserted into the heat insulation plate and wet concrete through U-shaped cards, a connecting piece is manually inserted according to a design drawing, then the first layer of template A of the superposed shear wall with heat insulation rotates to a curing kiln, and a stacker crane stacks the first layer of template A of the superposed shear wall with heat insulation into the curing kiln for curing;
e. b, repeating the steps B and c to produce a second layer of template B, adding mesh ribs and truss ribs to a mold table of the second layer of template B according to instructions of an MES system, scheduling and rotating the mesh ribs and the truss ribs through the MES system to a station of a turnover machine, simultaneously rotating the first layer of template A with the heat-insulating superposed shear wall which is well cured through a curing kiln to a station of the turnover machine, turning the first layer of template A by 180 degrees through the turnover machine and then superposing the template A on the second layer of template B, vibrating and compacting the superposed shear wall with the heat-insulating superposed shear wall through a medium-low frequency vibrating system and then transferring the superposed shear wall to the curing kiln for secondary curing to complete production, and reversely turning the mold table of the first layer of template A by 180 degrees to realize resetting and then rotating the superposed template to a mold;
f. after the production of the laminated shear wall with the heat preservation is finished, a product is tipped for 75 degrees by using a tipping machine, and then demoulding is carried out by using a crown block;
g. and (4) conveying the demolded overlapped shear wall with the heat preservation function to a storage yard or an external construction site, and rotating the demolded die table wheel to a die placing device for next production.
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