CN111941626A - Design method of environment-friendly intelligent production system for concrete prefabricated part - Google Patents
Design method of environment-friendly intelligent production system for concrete prefabricated part Download PDFInfo
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
- B28B11/245—Curing concrete articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
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- G05B19/4183—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by data acquisition, e.g. workpiece identification
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- G05B19/41835—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by programme execution
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- G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by quality surveillance of production
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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Abstract
The invention discloses a design method of an environment-friendly intelligent production system of a concrete prefabricated part. The method comprises the following steps: the system comprises a totally-enclosed gravel aggregate storage and transportation system, a totally-enclosed concrete mixing and conveying system, an integrated gravel separation and filter pressing workshop, an environment-friendly up-to-standard reinforcing steel bar framework processing workshop, an environment-friendly up-to-standard prefabricated part pouring and forming workshop, an intelligent steam curing system, an intelligent water curing system, an intelligent finished product stacking and delivering system, an information and intelligent management system and an auxiliary production facility system. The invention provides a highly integrated, intelligent, systematic and environment-friendly factory comprehensive solution for producing concrete prefabricated parts and a design method based on the solution; the method comprises the steps of comprehensively treating pollution sources such as noise, dust, solid waste and waste water, fusing technologies such as the Internet of things, big data and cloud computing, and meeting the environmental protection and the secondary utilization of various materials by using technical means such as an Application Programming Interface (API), thereby realizing the environmental protection requirement of circular green.
Description
Technical Field
The invention belongs to the technical field of building industrialization, particularly belongs to the technical field of factory production of component parts in building industrialization, and particularly relates to a design method of an environment-friendly intelligent production system for a whole set of environment-friendly standard concrete prefabricated parts.
Background
In 1974, "building industrialization" was defined as follows in "government policy and measure guidance for gradually realizing building industrialization" published by the united nations: the construction industry is reformed according to the large-scale industrial production mode, so that the process gradually changes from handicraft industry production to social large-scale production.
The building industrialization of China is gradually replacing the scattered, low-level and low-efficiency handicraft industry production mode in the traditional building industry by the symbolic building design standardization, the component production industrialization, the construction mechanization and the organization management scientization, and the labor-intensive industry is steadily transformed to the technology-intensive industry.
In the aspect of component production industrialization, China realizes component production industrialization in the fields of building engineering, highway engineering, railway engineering, municipal public engineering, water conservancy and hydropower engineering and the like to different degrees, and covers large and medium-sized concrete prefabricated components such as assembly type building components (PC components), prefabricated beams (road bridges), track plates, prefabricated sleepers, shield segments, prefabricated comprehensive pipe galleries, prefabricated water pipelines, water supply and drainage pipe culverts and various small-sized concrete prefabricated components such as assembly type inspection wells, subway evacuation platforms, prefabricated sound barriers, prefabricated well covers and prefabricated trench covers.
At present, the production technology of concrete prefabricated parts tends to be mature and cured, and comprises the working procedures of manufacturing a steel reinforcement framework, pre-stress tensioning and releasing, mixing concrete, pouring and forming the prefabricated parts, steam curing, water curing, natural curing, anti-corrosion treatment and the like. Except for the prefabricated parts for large roads and bridges produced by adopting a long-line method or a short-line method, the industrialized automatic/semi-automatic assembly line production is adopted on the basis of realizing the factory production of the parts of the concrete prefabricated parts. The existing concrete prefabricated part production has the problems of dust pollution, noise pollution, solid waste, wastewater treatment and the like; the further development of the concrete prefabricated part production factory and the building industrialization is severely restricted by the bottlenecks of low equipment integration and intelligence degree and the like.
Disclosure of Invention
The invention discloses a design method of an environment-friendly intelligent production system of a concrete prefabricated part according to the defects of the prior art. The invention aims to provide a highly integrated, intelligent, systematic and environment-friendly concrete prefabricated part production factory comprehensive solution and a concrete prefabricated part environment-friendly intelligent production system based on the design method.
The invention is realized by the following technical scheme:
the design method of the environment-friendly intelligent production system of the concrete prefabricated part is characterized by comprising the following steps of: the production system comprises: the system comprises a totally-enclosed gravel aggregate storage and transportation system, a totally-enclosed concrete mixing and conveying system, an integrated gravel separation and filter pressing workshop, an environment-friendly up-to-standard reinforcing steel bar framework processing workshop, an environment-friendly up-to-standard prefabricated part pouring and forming workshop, an intelligent steam curing system, an intelligent water curing system, an intelligent finished product stacking and delivering system, an information and intelligent management system and an auxiliary production facility system.
The totally enclosed grit aggregate storage and transportation system includes: the device comprises a receiving pit, a finished aggregate bin, a belt conveyor, feeding equipment, weighing equipment, high-efficiency automatic dust collecting equipment and a totally-enclosed dustproof enclosure structure;
the totally enclosed concrete mixing and conveying system comprises: a concrete mixing plant or station, a cementing material tank, a finished concrete conveying line, high-efficiency automatic dust collecting equipment and a totally-enclosed dustproof enclosure structure;
the grit separation and filter-pressing workshop that integrates includes: a sand-stone separator, a filter press, a slurry stirring pool or tank, a clean water pool, a circulating pipeline and a totally-enclosed dustproof noise-reducing enclosure structure;
the up-to-standard framework of steel reinforcement processing workshop of environmental protection includes: the system comprises a steel structure factory building, an industrial fresh air system, reinforcing steel bar framework processing supporting equipment, welding equipment, negative pressure dust collecting equipment, spraying dust settling equipment and active noise reduction equipment; the spraying dust-settling equipment is used for non-live working;
the up-to-standard prefabricated component of environmental protection pours the forming shop and includes: the system comprises a steel structure factory building, an industrial fresh air system, a concrete prefabricated part production line, a central control room, a prefabricated part pouring forming area noise reduction and sound insulation room, negative pressure dust collection equipment, spraying dust settling equipment and active noise reduction equipment; the spraying dust-settling equipment is used for non-live working;
the intelligent steam curing system comprises: the system comprises a steam curing kiln, a boiler system, a closed-loop circulating heat exchange pipeline, a steam pipeline and a temperature and humidity control system;
the intelligent water system of supporting includes: the system comprises a maintenance water pool, a maintenance water circulation pipeline, a temperature monitoring system and a maintenance water pH value monitoring system;
the intelligent finished product stacking and shipping system comprises: a finished product storage yard, an automatic spraying system, a rainwater collection system and an intelligent comprehensive compound flow management platform;
the information and intelligent management system comprises: an enterprise resource planning system (ERP), a Manufacturing Execution System (MES), a Management Information System (MIS), a Building Information Model (BIM), various data acquisition sensors, an input/output terminal and a computer;
the production sub-facility system includes: the system comprises a power supply and distribution system, a box-type transformer, a power distribution room, a factory fire-fighting system, a fire pump room, an air compression station, a warehouse, a test room, a guard room, a truck scale, a full-automatic car washer, a finished product prefabricated part type inspection area and a fire pool.
The operation process flow of the production system comprises two process technical routes of concrete mixing and prefabricated part production;
firstly, feeding the sandstone aggregate raw material entering a field into a mixing plant through a totally enclosed sandstone aggregate storage and transportation system according to the design mixing proportion of concrete, mixing the concrete in a totally enclosed concrete mixing and transportation system, and transporting the mixed concrete to a specified pouring station to wait for pouring of the prefabricated part. Solid waste and waste water generated in the concrete production process enter an integrated sand-stone separation and filter pressing workshop for treatment, and clear water meeting the environmental protection standard and sand-stone aggregate meeting the process requirements can be recycled again;
on the other hand, raw materials such as steel bars entering the field are stored in a steel bar framework processing workshop with the environment-friendly standard to wait for processing, the processed steel bar framework is transported to a prefabricated part pouring forming workshop with the environment-friendly standard, and the prefabricated part pouring forming workshop is hoisted at a preset station to enter a prefabricated part production line. And after the steam curing is finished and the die is demolded, the prefabricated part is transferred to an intelligent water curing system for water curing if needed. And after the water culture meets the technical requirements of the process, the water culture is finally transferred to an intelligent finished product stacking and shipping system, natural maintenance is carried out on a finished product storage yard, and storage scheduling and logistics management are unified.
In the operation process of the production system, the informatization and intelligent management system is deeply embedded comprehensively to assist production management, so that the management efficiency, the decision sensitivity, the accuracy and the foresight are greatly improved, and the quality, the safety, the environmental protection and the professional health of personnel in the whole process of production management of the prefabricated parts are ensured to reach the standard.
According to the totally-enclosed sandstone aggregate storage and transportation system, incoming sandstone aggregates are fed from a receiving pit, conveyed by a belt conveyor, classified and stored in a finished aggregate bin, weighed according to a designed mixing ratio, and fed to a mixing plant for concrete mixing.
According to the totally-enclosed concrete mixing and conveying system, cement, fly ash and other cementing materials entering a field are stored in a cementing material tank, and concrete mixed by a mixing plant according to a designed mixing ratio is conveyed to a prefabricated part pouring station by a conveying line. The solid waste and waste water produced in the concrete mixing process are treated in a centralized way by an integrated sand-stone separation and filter pressing workshop.
In the integrated sand-stone separation and filter pressing workshop, solid waste is separated from sand and stone by the sand-stone separator, sand, slurry and wastewater are discharged into the slurry stirring pool, and then the slurry is subjected to filter pressing by the filter press, so that clear water, sand and stone can be recycled, and zero emission of the solid waste and the wastewater is achieved.
In the environment-friendly steel reinforcement framework processing workshop, the industrial fresh air system is started in the whole process in the steel reinforcement framework processing process; when the reinforcing cage processing supporting equipment and the welding equipment are used, corresponding negative pressure dust collecting equipment and non-live working spraying dust settling equipment are started; the operating personnel are equipped with active noise reduction equipment and personal labor protection supplies.
In the environment-friendly up-to-standard prefabricated part pouring forming workshop, an industrial fresh air system, negative pressure dust collecting equipment and non-live working spraying dust settling equipment are started in the whole process of the prefabricated part pouring forming process; the noise pollution of the prefabricated part pouring forming area is controlled within a relatively small range by means of a sound insulation room; the central control room remotely monitors and remotely controls the operation of the production line; the operating personnel are equipped with active noise reduction equipment and personal labor protection supplies.
In the intelligent steam curing system, in the steam curing process of the prefabricated part, the temperature and humidity control system controls the boiler system, the circulating heat exchange pipeline and the steam pipeline to ensure that technical indexes of the steam curing temperature and humidity process meet the standard requirements; and the recorded temperature and humidity change curve is fed back to the informatization and intelligent management system in time so as to be convenient for reference decision making when manual intervention is needed.
In the water curing process of the prefabricated part, the temperature monitoring system and the PH value monitoring system for the maintenance water monitor the temperature and the change condition of the PH value of the maintenance water in real time, and the technical indexes of the maintenance water meet the standard requirements; and the recorded temperature change curve and the pH value change curve are fed back to the informatization and intelligent management system so as to be convenient for reference decision making when manual intervention is needed.
According to the intelligent finished product stacking and delivering system, when the prefabricated parts are naturally maintained and stacked in a finished product storage yard, the automatic spraying system regularly sprays water according to the program setting, and the spraying water is supplied by the rainwater collecting system and the municipal water supply pipe network; the intelligent comprehensive compound flow management platform uniformly schedules and manages the storage, delivery and transportation of the prefabricated parts, and establishes real-time communication with the informatization and intelligent management system, so that managers can retrieve the storage and logistics information of the prefabricated parts at any time to assist decision making.
The information and intelligent management system and an enterprise resource planning system (ERP) realize integrated management of enterprise-level material resources, capital resources and information resources; a Manufacturing Execution System (MES) realizes intelligent workshop production management and scheduling execution; a Management Information System (MIS) implements Office Automation (OA); the Building Information Model (BIM) realizes the sharing and transmission of data in the whole life cycle of the design, construction, operation and demolition (reconstruction) of a production system.
The information and intelligent management system highly integrates various information fed back in the operation and maintenance processes of the production system, such as equipment monitoring, environmental protection monitoring, security monitoring, process technical parameter acquisition, warehouse logistics data, finished product prefabricated part type inspection data and the like, and records, stores and shares the information.
Compared with the prior art, the invention has the following beneficial effects:
1. a highly integrated, intelligent, systematic and environment-friendly up-to-standard concrete prefabricated part production factory comprehensive solution and a complete design method based on the solution are provided.
2. The technical means of comprehensive treatment is considered in the process design stage for pollution sources such as noise, dust, solid waste, waste water and the like generated in the production process of the concrete prefabricated part. The pollution prevention facility and the main engineering of the production system are designed, constructed and put into operation simultaneously, so that the noise and dust meet the requirements of national standard limit values, the solid waste and wastewater are zero-discharged, and the occupational health of operators is comprehensively guaranteed.
3. The intelligent manufacturing method is characterized in that technical means such as the Internet of things, big data and cloud computing are fused, single machines of a traditional concrete prefabricated part production factory are intelligently connected in series to form an intelligent factory by means of an informatization and intelligent management system, and intelligent manufacturing of concrete prefabricated part production is achieved by means of an Artificial Intelligence (AI) auxiliary decision-making mechanism and an artificial intervention decision-making mechanism.
4. By using technical means such as Application Programming Interfaces (API) and the like, data information sharing and interconnection among hardware and software systems such as an enterprise resource planning system (ERP), a Manufacturing Execution System (MES), a Management Information System (MIS), a Building Information Model (BIM), various types of data acquisition sensors, various types of equipment facility input (output) terminals, a public computer and the like are realized, and data support is provided for manual intervention decision making.
5. After the solid waste and waste water produced in the concrete mixing process are subjected to sand-stone separation and filter pressing processes, clear water and sand-stone aggregate can be reused.
6. The maintenance water of the prefabricated part can be recycled by the maintenance water circulation pipeline under the condition of meeting the requirements of technological parameters such as PH value and the like.
7. Rainwater in the rainwater collection system can be used for spraying, site washing, vehicle washing and other operations in the natural maintenance process of the prefabricated part.
8. The automatic reading and collection of the data are realized through the type inspection of the concrete prefabricated part, the data acquisition sensor establishes real-time communication with the information and intelligent management system, the process data of the test is recorded, stored and shared, the test detection report is automatically generated, the interference of artificial factors in the test process is avoided, and the true and objective test detection result is ensured.
Drawings
FIG. 1 is a plan layout view of an embodiment of the present invention;
in the figure, 1 is a receiving pit, 2 is a finished aggregate bin (with a gallery), 3 is a belt conveyor, 4 is a totally-enclosed dustproof enclosure structure, 5 is a concrete mixing plant, 6 is a gelled material tank, 7 is a finished concrete conveying line, 8 is a sand-stone separator, 9 is a filter press, 10 is a slurry stirring pool, 11 is a clean water pool, 12 is a totally-enclosed dustproof and noise-reducing enclosure structure, 13 is a steel structure factory building, 14 is a steel reinforcement framework processing area, 15 is a steel reinforcement framework conveying track, 16 is a concrete prefabricated component production line, 17 is a central control room, 18 is a noise-reducing and sound-insulating room, 19 is a steam-curing kiln, 20 is a boiler room, 21 is a prefabricated component conveying track, 22 is a curing water pool, 23 is a finished product yard, 24 is an automatic spraying system, 25 is a gantry track beam, 26 is a gantry rainwater collecting system, 27 is a gantry crane, 28 is a box-type transformer, 29 is a power distribution room, 30 is a fire pump room, 31 is an air compression station, 32 is a warehouse, 33 is a laboratory, 34 is a finished prefabricated part type inspection area, 35 is a truck scale, 36 is a guard room, 37 is an inlet and an outlet, 38 is a full-automatic car washer, 39 is an office building, 40 is a worker dormitory, 41 is a worker entertainment facility, 42 is a finished aggregate bin, 43 is a prefabricated part anticorrosion area, 44 is a small prefabricated part production area, and 45 is a fire pool.
Detailed Description
The present invention is further described below in conjunction with the following detailed description, which is intended to further illustrate the principles of the invention and is not intended to limit the invention in any way, but is equivalent or analogous to the present invention without departing from its scope.
With reference to the attached drawings.
Referring to the drawings, as shown in fig. 1, the concrete prefabricated part factory production comprehensive solution has both the production capacity of large, medium and small concrete prefabricated parts, and the complete design method of the environment-friendly intelligent concrete prefabricated part production system comprises the following steps:
1. the entrance 37 and the exit 36 should be separately installed according to different use functions of the production area and the office living area.
2. At least two inlets and outlets 37 of the production area are arranged, so that raw materials can enter the production area and prefabricated part finished product delivery streamline organizations are relatively independent, and each inlet and outlet 37 in the production area is provided with a full-automatic car washing machine 38 for automatically washing vehicles which are delivered from the production area.
3. Before main and auxiliary materials such as sand aggregate, steel bar, cement, fly ash, silica fume, concrete admixture, anticorrosive paint and the like enter a field, the metering is finished by the truck scale 35, and metering data is automatically recorded into the informatization and intelligent management system.
4. For the storage and transportation of the sandstone aggregate produced by large and medium-sized concrete prefabricated components, a totally-enclosed sandstone aggregate storage and transportation system is designed, and a totally-enclosed dustproof enclosure structure 4 is used as an outer peripheral protection system of the whole system. The sand aggregate entering the field is unloaded to a receiving pit 1, is transported to a finished aggregate bin (with a gallery) 2 by a belt conveyor 3 (B1-B2), is transported to a concrete mixing plant 5 by the belt conveyor 3 (B3-B4) and the belt conveyor 3 (B5-B6) in the gallery, and waits for mixing of concrete.
5. For the storage and transportation of the sandstone aggregate produced by the small concrete prefabricated part, the engineering economy and daily peak requirements are comprehensively considered, and a common sandstone aggregate storage and transportation system can be designed. The sand aggregate entering the field is directly discharged to a finished aggregate bin (without gallery) 42, the sand aggregate is transported and fed by a loader, and then is transported to a concrete mixing plant 5 by a belt conveyor 3(B7) to wait for mixing of concrete. Each monomer structure of the sandstone aggregate storage and transportation system is independently sealed, and the totally-closed dustproof enclosure structure 4 is used as an outer enclosure structure.
6. A totally enclosed concrete mixing and conveying system is designed for mixing and conveying concrete, and a totally enclosed dustproof enclosure structure 4 is used as an outer enclosure system of the whole system. And (3) storing the cementing material in a cementing material tank 6 for later use, feeding the cementing material into a concrete mixing plant 5 by a screw conveyor during use, and conveying the mixed concrete to a specified pouring station by a finished concrete conveying line 7 to wait for pouring of the prefabricated part.
7. The solid waste and waste water produced by mixing concrete should be treated by an integrated sand-stone separation and filter-pressing workshop, and special facilities for preventing and treating pollution should be designed. The solid waste is separated into sand and stone by a sand-stone separator 8, the sand, slurry and waste water are discharged into a slurry stirring tank 10, then the uniformly stirred slurry is subjected to pressure filtration by a pressure filter 9 and then is discharged, and clear water enters a clear water tank 11. The treated clean water, sand and stone can be recycled, and the zero discharge of solid waste and wastewater is realized.
8. The steel reinforcement framework processing should be designed into a special steel reinforcement framework processing workshop which is environment-friendly and reaches the standard. An industrial fresh air system is required to be configured in the steel structure factory building 13; a special steel reinforcement framework processing area 14 is required to be arranged, and processing equipment, welding equipment, negative-pressure dust collection equipment and spraying dust-settling equipment (non-live working) are planned in a unified way; the working personnel are equipped with active noise reduction equipment and personal protection articles. And the processed reinforcement cage is temporarily stored in a reinforcement cage processing workshop.
9. Big-and-middle-sized prefabricated component framework of steel reinforcement processing vehicle should independently set up, and when framework of steel reinforcement used, transport track 15 through framework of steel reinforcement, the framework of steel reinforcement of transport to concrete prefabricated component production water line 16 goes into by the mould station, waits to hoist and goes into the mould.
10. Small-size prefabricated component framework of steel reinforcement processing vehicle can pour the shaping workshop with the prefabricated component and set up together, and when framework of steel reinforcement used, by the framework of steel reinforcement income mould station of transporting to small-size prefabricated component production area 44 through fork truck or bridge crane, wait for hoist and mount to go into the mould.
11. A large and medium-sized prefabricated component is poured and formed, and a special and environment-friendly prefabricated component pouring and forming workshop up to the standard is designed. An industrial fresh air system is required to be configured in the steel structure factory building 13; a negative pressure dust collecting device and a spraying dust settling device (non-live working) are planned in a unified way in an operation area which is easy to generate dust in a workshop; a noise reduction and sound insulation room 18 is designed in the casting forming area of the prefabricated part; a central control room 17 is designed in the workshop for remotely monitoring and controlling the operation of the concrete prefabricated part production line 16; the operating personnel are equipped with active noise reduction equipment and personal labor protection supplies.
12. And (3) designing a special intelligent steam curing system for steam curing of the prefabricated parts. The steam curing kiln 19 needs to perform thermal calculation to meet the technical requirements of the steam curing process; the boiler room 20 should be designed with a closed-loop circulation heat exchange pipeline and a steam pipeline to supply heat and steam to the steam curing kiln 19; a temperature and humidity control system is installed in the boiler system to control the temperature and humidity change curve in the steam curing kiln 19 to meet the standard requirement, and data are recorded and fed back to the informatization and intelligent management system.
13. A special intelligent water culture system is designed for water culture of the prefabricated parts. After the casting and forming of the prefabricated parts are finished, the prefabricated parts are transported to the side of a maintenance water pool 22 through a prefabricated part transfer track 21, and the hoisting operation of the prefabricated parts in and out of the pool is finished through a portal crane 27 above the maintenance water pool 22; the maintenance water tank 22 should be designed with a maintenance water circulation pipeline to recycle the maintenance water meeting the technical indexes of the process; the maintenance water pool 22 should be equipped with a temperature monitoring system and a maintenance water pH value monitoring system, so as to monitor the temperature and pH value variation condition of the maintenance water in real time and feed back the recorded temperature variation curve and pH value variation curve to the informatization and intelligent management system.
14. The natural maintenance, storage, stacking and shipping of the prefabricated parts need to be designed with a special intelligent finished product stacking and shipping system. After the water curing of the prefabricated parts is finished, the gantry crane 27 is matched with a transfer trailer to transport the prefabricated parts to a finished product storage yard 23 for natural curing; an automatic spraying system 24 is designed on the inner side of the gantry crane track beam 25 to replace manual spraying operation; one end of the finished product storage yard 23 is covered with the blind area by the gantry crane 27, and a rainwater collecting system 26 can be designed to be matched with a municipal water supply pipe network to provide water source supply for spraying, site washing, vehicle washing and other operations.
15. And the corrosion prevention of the prefabricated parts is realized by designing a special corrosion prevention operation area. A prefabricated part anticorrosion area 43 can be designed in the finished product storage yard 23 at intervals of 60-80 m, so that the centralized management of anticorrosion operation and the prevention and control of pollution generated by operation are facilitated.
16. For the type checking of the prefabricated parts, a special finished prefabricated part type checking area 34 is designed. The equipment for testing the type of the prefabricated part has the functions of automatically acquiring, reading and recording data; the data acquisition sensor should establish real-time communication with the informatization and intelligent management system, record, store and share test process data, and automatically generate a test detection report.
17. The special design of electrical engineering is required, and strong current and weak current meet the use requirements of equipment facilities such as a power supply of a production system, office and living electricity, network communication and the like.
18. Professional design of fire-fighting engineering, fire-fighting systems in production areas and fire-fighting systems in office living areas are required to meet relevant regulations of national mandatory standards.
19. The production auxiliary facility system is provided with buildings, structures and equipment facilities such as a box transformer 28, a distribution room 29, a fire pump room 30, an air compression station 31, a warehouse 32, a laboratory 33, a guard room 36, a truck scale 35, a full-automatic car washer 38, a fire pool 45 and the like according to actual use requirements.
20. The office living area should design buildings such as an office building 39, a worker dormitory 40 and the like according to the actual requirements of managers and operators; the facilities such as the employee entertainment facility 41 can be selected according to the enterprise standardization, the enterprise culture related requirements, and the actual conditions of the project and the site.
21. The production system should establish a complete informatization and intelligent management system to meet the basic conditions for realizing intelligent manufacture of intelligent factories and prefabricated parts.
The concrete prefabricated part production line 16 and the small prefabricated part production area 44 comprise stations of demoulding and hoisting, mould cleaning, steel bar framework mould entering, embedded part installation, pouring forming, water collecting and surface plastering, standing, steam curing and the like; the device also comprises a prestress tensioning station and a prestress releasing station which are arranged according to needs.
The intelligent steam curing system and the steam curing are used for improving the early strength of the prefabricated part, rapidly achieving the demolding condition and improving the turnover efficiency of the prefabricated part mold. When the requirement on the production flow rhythm is not high, the intelligent steam curing system can be closed, the production flow rhythm is prolonged, and the energy consumption is reduced.
The intelligent water culture system of the large and medium-sized prefabricated components is arranged in an outdoor open field, and the intelligent water culture system of the small prefabricated components can be arranged indoors or outdoors; when the water culture is not needed in the production process of some prefabricated parts, the design of the part can be eliminated, and the maintenance water pool 22 and the supporting equipment thereof are replaced by buildings and structures which are necessary for other production processes.
The anticorrosion of the prefabricated part is different in anticorrosion process and requirement according to different using functions and parts of the prefabricated part, and even anticorrosion treatment may not be needed. When the prefabricated parts do not need to be preserved, the prefabricated part preservation area 43 can be directly used as the finished product storage yard 23.
The type of the prefabricated part is inspected, and proper test detection equipment is configured according to different specifications and types of the prefabricated part, and the national mandatory standard and the technical requirements of a purchasing party are met.
The information and intelligent management system comprises but is not limited to the following platforms: an enterprise resource planning system (ERP) for realizing integrated management of enterprise-level material resources, capital resources and information resources; a Manufacturing Execution System (MES) for realizing intelligent workshop production management and scheduling execution; a Management Information System (MIS) implementing Office Automation (OA); the Building Information Model (BIM) realizes the sharing and transmission of data in the whole life cycle of the design, construction, operation and demolition (reconstruction) of a production system.
The informatization and intelligent management system is used for highly integrating various information fed back in the operation and maintenance processes of a production system, such as equipment monitoring, environmental protection monitoring, security monitoring, process technical parameter acquisition, warehouse logistics data, finished product prefabricated part type inspection data and the like, and recording, storing and sharing the information.
The informatization and intelligent management system has the auxiliary decision-making capability of Artificial Intelligence (AI) and the decision-making capability of artificial intervention, and realizes the intelligent manufacturing of the concrete prefabricated part.
The device configurations, including but not limited to: the system comprises a belt conveyor 3, concrete mixing equipment, weighing equipment, feeding equipment, a sand-stone separator 8, a filter press 9, reinforcing steel bar processing equipment, welding equipment, a concrete prefabricated part production line 16, a boiler, automatic spraying equipment, rainwater collecting equipment, a gantry crane 27, a bridge crane, a box-type transformer 28, an air compressor, testing equipment, type inspection equipment, a truck scale 35, prefabricated part anticorrosion equipment, a trailer, a forklift, a loader and the like, wherein adaptive equipment configuration is selected according to different prefabricated part production models and different processes.
Fig. 1 is a plan layout diagram of a process design of a track traffic supporting facility project in a metropolitan area, which is a comprehensive solution for the industrial production of a concrete prefabricated part based on the design method of the environment-friendly intelligent production system for the concrete prefabricated part. The production system has the production capacity of large and medium-sized concrete prefabricated parts such as track plates, prefabricated sleepers and shield segments, and small concrete prefabricated parts such as subway evacuation platforms, prefabricated sound barriers, prefabricated well covers and prefabricated trench cover plates. After technological transformation, concrete prefabricated components such as prefabricated building components (PC components), prefabricated beams (roads and bridges), prefabricated comprehensive pipe galleries, prefabricated water pipelines, water supply and drainage pipe culverts, prefabricated inspection wells and the like can also be produced.
More importantly, the highly integrated, intelligent, systematic and environment-friendly industrial comprehensive solution for producing the precast concrete components which reach the standard and the complete design method of the environment-friendly intelligent production system for the precast concrete components based on the solution can provide reference and reference for the factory production of structural parts in the subsequent building industrialization, particularly the factory production of the precast concrete components.
Claims (10)
1. The design method of the environment-friendly intelligent production system of the concrete prefabricated part is characterized by comprising the following steps of: the method comprises the steps of designing a production system and designing an operation process flow;
the production system comprises: the system comprises a totally-enclosed gravel aggregate storage and transportation system, a totally-enclosed concrete mixing and conveying system, an integrated gravel separation and filter pressing workshop, an environment-friendly standard reinforcement framework processing workshop, an environment-friendly standard prefabricated part pouring and forming workshop, an intelligent steam curing system, an intelligent water curing system, an intelligent finished product stacking and delivering system, an information and intelligent management system and a production auxiliary facility system;
the design of the operation process flow comprises the following steps: the technological route of concrete mixing and prefabricated member production.
2. The design method of the environment-friendly intelligent production system for the concrete precast element according to claim 1, is characterized in that:
the totally enclosed grit aggregate storage and transportation system includes: the device comprises a receiving pit, a finished aggregate bin, a belt conveyor, feeding equipment, weighing equipment, high-efficiency automatic dust collecting equipment and a totally-enclosed dustproof enclosure structure;
the totally enclosed concrete mixing and conveying system comprises: a concrete mixing plant or station, a cementing material tank, a finished concrete conveying line, high-efficiency automatic dust collecting equipment and a totally-enclosed dustproof enclosure structure;
the grit separation and filter-pressing workshop that integrate includes: a sand-stone separator, a filter press, a slurry stirring pool or tank, a clean water pool, a circulating pipeline and a totally-enclosed dustproof noise-reducing enclosure structure;
the up-to-standard framework of steel reinforcement processing workshop of environmental protection includes: the system comprises a steel structure factory building, an industrial fresh air system, reinforcing steel bar framework processing supporting equipment, welding equipment, negative pressure dust collecting equipment, spraying dust settling equipment and active noise reduction equipment;
the up-to-standard prefabricated component of environmental protection pours the forming shop and includes: the system comprises a steel structure factory building, an industrial fresh air system, a concrete prefabricated part production line, a central control room, a prefabricated part pouring forming area noise reduction and sound insulation room, negative pressure dust collection equipment, spraying dust settling equipment and active noise reduction equipment;
the intelligent steam curing system comprises: the system comprises a steam curing kiln, a boiler system, a closed-loop circulating heat exchange pipeline, a steam pipeline and a temperature and humidity control system;
the intelligent water culture system comprises: the system comprises a maintenance water pool, a maintenance water circulation pipeline, a temperature monitoring system and a maintenance water pH value monitoring system;
the intelligent finished product stacking and shipping system comprises: a finished product storage yard, an automatic spraying system, a rainwater collection system and an intelligent comprehensive compound flow management platform;
the information and intelligent management system comprises: an enterprise resource planning system (ERP), a Manufacturing Execution System (MES), a Management Information System (MIS), a Building Information Model (BIM), various data acquisition sensors, an input/output terminal and a computer;
the production sub-facility system includes: the system comprises a power supply and distribution system, a box-type transformer, a power distribution room, a factory fire-fighting system, a fire pump room, an air compression station, a warehouse, a test room, a guard room, a truck scale, a full-automatic car washer, a finished product prefabricated part type inspection area and a fire pool.
3. The design method of the environment-friendly intelligent production system for the concrete prefabricated parts according to claim 2 is characterized in that:
the technical route of the concrete mixing production process is that the sand aggregate raw material entering the field is fed into a mixing plant through a totally enclosed sand aggregate storage and transportation system according to the design mixing proportion of the concrete, the mixing of the concrete is completed in the totally enclosed concrete mixing and transportation system, and the mixed concrete is transported to a specified pouring station to wait for pouring of the prefabricated part; solid waste and waste water generated in the concrete production process enter an integrated sand-stone separation and filter pressing workshop for treatment, and clear water meeting the environmental protection standard and sand-stone aggregate meeting the process requirements can be recycled again;
the production process of the prefabricated part comprises the following technical route: raw materials such as steel bars entering a field are stored in an environment-friendly standard-reaching steel bar framework processing workshop for waiting for processing, the processed steel bar framework is transported to an environment-friendly standard-reaching prefabricated part pouring forming workshop and is hoisted at a preset station to enter a prefabricated part production line; and after the steam curing is finished and the die is demolded, the prefabricated part is transferred to an intelligent water curing system for water curing if needed. And after the water culture meets the technical requirements of the process, the water culture is finally transferred to an intelligent finished product stacking and shipping system, natural maintenance is carried out on a finished product storage yard, and storage scheduling and logistics management are unified.
4. The design method of the environment-friendly intelligent production system for the concrete precast element according to claim 3, is characterized in that: in the totally enclosed sandstone aggregate storage and transportation system, the incoming sandstone aggregate is fed by a receiving pit, conveyed by a belt conveyor, classified and stored in a finished aggregate bin, weighed according to a designed mixing proportion, and then fed to a mixing plant for concrete mixing; in the totally-enclosed concrete mixing and conveying system, incoming cement, fly ash and cementing materials are stored in a cementing material tank, and concrete mixed by a mixing plant according to a designed mixing proportion is conveyed to a prefabricated part pouring station by a conveying line; the solid waste and waste water produced in the concrete mixing process are treated in a centralized way by an integrated sand-stone separation and filter pressing workshop.
5. The design method of the environment-friendly intelligent production system for the concrete precast element according to claim 3, is characterized in that: in the integrated sand-stone separation and filter pressing workshop, solid waste is separated from sand and stone by a sand-stone separator, sand, slurry and wastewater are discharged into a slurry stirring pool, and then the slurry is subjected to filter pressing by a filter press, so that clear water, sand and stone can be recycled, and zero emission of the solid waste and the wastewater is achieved.
6. The design method of the environment-friendly intelligent production system for the concrete precast element according to claim 3, is characterized in that: in the environment-friendly steel reinforcement framework processing workshop, the industrial fresh air system is started in the whole process in the steel reinforcement framework processing process; when the reinforcing cage processing supporting equipment and the welding equipment are used, corresponding negative pressure dust collecting equipment and non-live working spraying dust settling equipment are started; the working personnel are provided with active noise reduction equipment and personal labor protection articles; in the environment-friendly up-to-standard prefabricated part pouring forming workshop, an industrial fresh air system, negative pressure dust collecting equipment and non-live working spraying dust settling equipment are started in the whole process of the prefabricated part pouring forming process; the noise pollution of the prefabricated part pouring forming area is controlled within a relatively small range by means of a sound insulation room; the central control room remotely monitors and remotely controls the operation of the production line; the operating personnel are equipped with active noise reduction equipment and personal labor protection supplies.
7. The design method of the environment-friendly intelligent production system for the concrete precast element according to claim 3, is characterized in that: in the intelligent steam curing system, in the steam curing process of the prefabricated part, the temperature and humidity control system controls the boiler system, the circulating heat exchange pipeline and the steam pipeline to ensure that technical indexes of the steam curing temperature and humidity process meet the standard requirements; the recorded temperature and humidity change curve is fed back to an informatization and intelligent management system in time so as to facilitate reference decision making when manual intervention is needed; in the water curing process of the prefabricated part, the temperature monitoring system and the PH value monitoring system for the maintenance water monitor the temperature and the change condition of the PH value of the maintenance water in real time, and the technical indexes of the maintenance water meet the standard requirements; and the recorded temperature change curve and the pH value change curve are fed back to the informatization and intelligent management system so as to be convenient for reference decision making when manual intervention is needed.
8. The design method of the environment-friendly intelligent production system for the concrete precast element according to claim 3, is characterized in that: according to the intelligent finished product stacking and delivering system, when the prefabricated parts are naturally maintained and stacked in a finished product storage yard, the automatic spraying system regularly sprays water according to the program setting, and the spraying water is supplied by the rainwater collecting system and the municipal water supply pipe network; the intelligent comprehensive compound flow management platform uniformly schedules and manages the storage, delivery and transportation of the prefabricated parts, and establishes real-time communication with the informatization and intelligent management system, so that managers can retrieve the storage and logistics information of the prefabricated parts at any time to assist decision making.
9. The design method of the environment-friendly intelligent production system for the concrete precast element according to claim 3, is characterized in that: the information and intelligent management system comprises: the enterprise resource planning system (ERP) is used for realizing integrated management of enterprise-level material resources, capital resources and information resources, the Manufacturing Execution System (MES) is used for realizing intelligent workshop production management and scheduling execution, the Management Information System (MIS) is used for realizing Office Automation (OA), and the Building Information Model (BIM) is used for realizing data sharing and transmission in the whole life cycle of design, construction, operation, demolition, reconstruction and extension of the production system.
10. The design method of the environment-friendly intelligent production system for the concrete precast element according to claim 3, is characterized in that: the information and intelligent management system is used for highly integrating information fed back by each production system in the running and maintenance processes of equipment monitoring, environmental protection monitoring, security and protection monitoring, process technical parameter acquisition, storage logistics data and finished product prefabricated part type inspection data, and recording, storing and sharing the information.
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