EP1881130A1 - Mobile factory for making prefabricated elements - Google Patents

Abstract

The factory has a removable canopy (A) as a protective roof, and rotatable assembly tables (1, 1.2, 1.3) for manufacturing individual building units from brick material and cement mortar. A container processes reinforcement iron for the building units, and a concrete batching plant prepares cement mortar for filling the building units on the tables. A service container is provided for an office, sanitary facility and a canteen. Individual installations of the factory are assembled on trolleys and/or in containers that are transported on a roadway or track till to a construction site.

Description

The present invention relates to an autonomous factory for prefabricated elements, hereinafter referred to as "mobile factory" for producing prefabricated components according to the preamble of claim 1.

The term "prefabricated elements" is understood here in particular elements of brick or cement mortar for the creation of panels for the construction industry (housing and industrial building), such as in the European patent application EP-01810973.6 , published under the number EP-1273729A2 on 21.08.2003. described.

In the present case, these elements are made of brick material that can be assembled with cement mortar by means of reinforcing iron and potting to produce various types of prefabricated components (box elements, walls, floor plates, etc.).

It should be emphasized that the mobile factory described and claimed herein is generally suitable for making any prefabricated "on-site" components that consist of bricks (or brick) elements joined together with reinforced cement mortar to form a rigid structure for any shapes and uses.

The "mobile factory" arises due to the work requirements and is able to produce a large number of prefabricated components within a short time and to reduce the material transport costs.

It is a new, high-quality technology capable of putting a door-to-door industrial process directly on the site into operation.

This plant represents the realization of experiences that matured in the field of prefabrication, for the benefit of users, manufacturers and technicians.

The substance of the inventive idea is also evident from the fact that the hitherto common practice of producing prefabricated elements applied structures were within fixed and permanent work places (floor plates, for example), with the only advantage in the repeatability of the production of the same elements was without the Problems of transport and assembly could be addressed. The present invention, on the other hand, aims to resolve once and for all problems associated with transportation and assembly for on-site prefabricated elements where the proposed building is to be erected.

These objects are achieved with the inventive mobile factory, which is characterized in that it comprises a whole series of working elements, which combine with each other form the characterizing part of claim 1. In the general concept, the mobile factory includes a provisionally mounted canopy, namely, for the time required to produce the prefabricated elements, in the immediate vicinity of the building site where the intended building is to be erected, under which cover necessary for the production of the elements Facilities are set up. These devices comprise according to the present invention at least one mounting plate for producing the individual components of brick and reinforced cement mortar, a plant for preparing the reinforcing bars, a concrete mixing plant, an energy center (for generating electricity, steam, compressed air, etc.) and possibly service containers for the offices and the needs of the staff.

The present invention is characterized in that the individual workstations are mounted on trolleys and / or in containers, which can be transported on the road or by train to the building site, where the building or buildings should arise as planned and where Workstations according to a favorable investment plan that meets the requirements for more efficient production, can be assembled and assembled.

• Mit den gleichen Montagetischen können verschiedene Element-Typen hergestellt werden;
• Tafelelemente verschiedener Dicke könne hergestellt werden;
• Jeder Anhänger transportiert zwei Arbeitseinheiten mit dem Magazin für die Arbeit;
• Die Fabrikation erfolgt immer vom Boden abgehoben, wodurch feuchte und Umgebung vermieden wird;
• Flächen von 250 m² und von 400 m² von Elementen können pro Arbeitstag hergestellt werden;
• Mit den gleichen Einrichtungen können auch herkömmliche Arbeiten ausgeführt werden;
• Die Anlage ist besonders für umfangreiche Bauarbeiten angezeigt, beispielsweise für das Errichten ganzer Häusersiedlungen oder Quartier-Überbauungen;

The fabrication facilities are designed to serve multiple fabrication functions:

• With the same assembly tables different element types can be produced;
• Panel elements of different thicknesses can be produced;
• Each trailer transports two working units with the magazine for work;
• Fabrication is always off the ground, avoiding moisture and the environment;
• Areas of 250 m ² and 400 m ² of elements can be produced per working day;
• Conventional work can also be carried out with the same equipment;
• The plant is particularly indicated for extensive construction work, for example, for the construction of entire housing estates or neighborhood complexes;

The mobile factory can be controlled in terms of production technology also by computer, with special software for the organization on firm basis, not only for the planning, but also for the production control and the assembly of the elements.

The principles described for the present invention relate to an innovative technique in the field of building construction, based on the fabrication concept.

The main features of the novel method of assembly are known in the art, for example from an element of brick material (according to the cited) European patent application EP-12737729A2 ) by which it has already become possible to achieve a number of important benefits, which are described in detail in said document.

Practical experience has shown that these forms of assembly of all types of wall and ceiling elements are possible thanks to special facilities that can be easily transported to the construction sites where the construction work is to be undertaken and which can be made operational within a few hours.

The plants can accommodate a number of brick construction elements, which are provided with the inserted reinforcements and cement mortar fillings which are panel elements ready for installation (transport and assembly).

The assembly methods presented here are designed to eliminate the difficulties of transport and the absence of specialized professionals.

The aim of the present invention is therefore to be understood as an improvement of the known techniques, as they are used in construction and in the manufacture of prefabricated elements in stationary equipment as traditional techniques.

Thanks to the application of said design concept, according to the prior art and in the EP-1273729A2 For example, the result achieved enables, for example, the assembly of up to 15 types of panel elements which are not only different from one another but may also have different thicknesses.

This has been achieved thanks to the study of the particular devices which are also used in the context of the present invention and an appreciation of the use of the commonly used known materials and the reduction of costs through the introduction of a new design process.

The mobile factory according to the present invention therefore represents the logical improvement of the concept of rationalized assembly of the individual elements forming the prefabricated component.

The execution times are optimized and are not dependent on weather related inconveniences, especially in winter, eliminating the problems caused by the construction site and the transports.

The present invention thus makes it possible, directly in the field, to create a plurality of panel elements, all of which are produced in better quality, inexpensively and quickly.

The "mobile" factory is preferably set up in the sense of a one-way traffic, with the starting materials coming in on one side and the assembled product coming out on the other side.

• Standardisierung des Herstellprozesses für alle Typen vorfabrizierter Bauelemente (beispielsweise die in der EP-1273729A2 beschriebenen);
• Möglichkeit, grössere Abmessungen der Tafelelemente in der Länge und in der Breite zu erreichen, wobei alle Transportschwierigkeiten entfallen;
• Herstellung von tragenden Strukturen oder Trennwände oder homogene Zwischenwände in hoher Qualität mittels eines einzigen Zusammenbauprozesses;
• Herstellung einer grossen Zahl von ebenen Tafelelementen ohne spezialisierte Arbeitskräfte mittels eines geordneten Herstellprozesses;
• Vollständige Kontrolle des Herstellprozesses und der Qualität aller zusammengebauten Produkte.

The application of the proposed manufacturing system and equipment brings the following major benefits of the "mobile" factory:

• Standardization of the manufacturing process for all types of prefabricated components (for example, those in the EP-1273729A2 described);
• Possibility to achieve greater dimensions of the panel elements in length and width, eliminating all transport difficulties;
• Production of supporting structures or partition walls or homogenous partitions in high quality by means of a single assembly process;
• Production of a large number of flat panel elements without specialized workers by means of an orderly production process;
• Complete control of the manufacturing process and the quality of all assembled products.

Fig. 1

Eine Überdachung (Zelt, transportierbare Abdeckung aus Stahl und Blech, usw.) zum Schutz der im Folgenden beschriebenen Einrichtungen vor Witterungs-Unbilden, von oben und von der Seite gesehen;

Fig. 2

Die Auslegung der mobilen Fabrik mit den hauptsächlichsten Einrichtungen;

Fig. 3

Die Auslegung der mobilen Fabrik mit den hauptsächlichsten Einrichtungen, im Schnitt gesehen;

Fig. 4

Das Grundschema des Transports der Einrichtungen;

Fig. 4.1

Das Grundschema der Einrichtungen für den Betrieb der Anlage;

Fig. 5

Das Schema der Herstellung in der mobilen Fabrik;

Fig. 6

Grundriss, Ansicht und Schnitt eines Montage-Tisches für die Herstellung von Wandelementen mit doppelten Elementen aus Backsteinmaterial auf einem Wagen während des Transportes;

Fig. 6.1

Grundriss, Ansicht und Schnitt eines Montage-Tisches für die Herstellung von Wandelementen mit doppelten Elementen aus Backsteinmaterial auf einem Wagen während des Arbeitsprozesses am Boden;

Figuren 7 und 7.1

Grundriss, Ansicht und Schnitt eines Containers für die Bearbeitung der Armierungseisen;

Fig. 8

Grundriss, Ansicht und Schnitt der vollständigen Anlage für die Herstellung des Zementmörtels (Betonmischanlage).

The present invention will be described below in detail with reference to some illustrated examples. The pictures show in the:

Fig. 1

A shelter (tent, transportable cover made of steel and sheet metal, etc.) for the protection of the facilities described below against the weather, seen from above and from the side;

Fig. 2

The design of the mobile factory with the main facilities;

Fig. 3

The design of the mobile factory with the main facilities, seen on average;

Fig. 4

The basic scheme of transportation of the facilities;

Fig. 4.1

The basic scheme of facilities for the operation of the plant;

Fig. 5

The scheme of manufacture in the mobile factory;

Fig. 6

Floor plan, view and section of an assembly table for the production of wall elements with double brick elements on a cart during transport;

Fig. 6.1

Layout, view and section of a mounting table for the production of wall elements with double elements made of brick material on a trolley during the working process on the ground;

FIGS. 7 and 7.1

Layout, view and section of a container for processing the reinforcing bars;

Fig. 8

Layout, view and section of the complete plant for the production of the cement mortar (concrete mixing plant).

In Fig. 1 a removable roof in the form of a large tent 1 is shown. One can think of a circus tent, but of course, according to the present invention, any kind of more demountable Cover just as conceivable (for example, a framework with steel girders and cover elements).

The shape and dimensions of the canopy A are chosen as a function of the size of the mobile factory to be set up. The only important thing is that it can be easily disassembled and transported.

• 1. Klappbarer Schwenk-Drehtisch,
• 1.1. Tisch für Tunnel-Elemente,
• 1.2. Tisch für Stützen und Pfeiler,
• 1.3. Tisch für Treppen,
• 1.4. Tisch für die Herstellung verschiedener Produkte,
• 1.5. Elektrische Hebewinde.

FIG. 2 shows a conceivable layout of the mobile factory according to the invention in a practical embodiment. The reference numerals in the figure denote the following device elements:

• 1. Folding swivel turntable,
• 1.1. Table for tunnel elements,
• 1.2. Table for columns and pillars,
• 1.3. Table for stairs,
• 1.4. Table for the production of various products,
• 1.5. Electric windlass.

Already here it should be noted that in Fig. 2, a mobile factory is shown, which is able to produce a whole range of different components of brick material. The required arrangement of the tables 1 to 1.3 according to the invention depends on the type of building to be built and can be easily adapted to the needs. Also, the size of the canopy A must be selected according to the particular needs, which may vary depending on whether an industrial building (hall), a city building, a multi-storey building, etc., should be built.

With 2 a water tank is designated (always necessary, except where a sufficient local water supply is available), and with 3 a concrete mixing plant is designated.

FIGS. 3.1 and 3.2 each show a bearing for the starting materials and a mortar distribution device, ie the elements useful in the mobile factory for the rationalization of work. In Fig. 4 the storage space for the brick elements is indicated, for the production of simple panel elements made of brick material and cement mortar (see the description in the cited EP-1273729A2 ) are needed; 5 denotes an office and magazine, and 5.1 denotes a device for processing reinforcing iron for the components of brick and cement mortar. Reference numeral 6 denotes a facility for providing working utilities (steam, electric power, compressed air, etc.) and 7 denotes containers for offices, sanitary facilities, sleeping quarters for workers, canteen, etc.

It goes without saying that these systems are set up according to the local requirements for the orders or not. Wherever conditions permit, no sleeping quarters for workers, etc., are set up, but one relies on what is available on the jobsite. But in any case, the mobile factory can also provide such services, so that it can be operated completely autonomously and independently of the external working conditions. It should also be noted that in the practical embodiment according to FIG. 2, also transportable footboards 10 are provided so that the manufactured brick components can be transported more easily, as well as a lifting device 11 in order to facilitate the internal transport. Of course, such transport aids are adapted to the individual order for the mobile factory, of which Fig. 2 should give only a practical example. Any change in the mobile factory fabrication plan described herein for the manufacture of prefabricated components is to be understood as being within the scope of the present invention, the individual elements constituting the mobile factory being mounted on carriages and / or in containers placed on the street or by train to the workplace can be transported. This is the actual characterizing feature of the present invention.

In Fig. 3, the investment plan of the factory according to FIG. 2 is shown schematically in section to show that the individual parts of the system 1, 1.1, 1.2, 1.3 are mounted on cars and therefore can be easily transported on the road. In Fig. 4 the basic scheme of the transport of the facilities is shown as the assembly tables 1, ... 1.3 can be transported in the transport state on the road. Of course, an analog solution for rail transport is easy to imagine.

In Fig. 4.1 a preferred particular embodiment of the present invention is shown in which the assembly table 1 is mounted on a trailer 12 (see also Fig. 4) of a truck (not shown) and provided with a horizontal hinge 13, that allows the pivoting of the table 1 from a vertical filling position (see Fig. 4) in an open horizontal unpacking position, which is also indicated in Fig. 4.1. It is a system that facilitates work in the mobile factory.

FIG. 5 then shows a conceivable block diagram of the mobile factory according to the invention. This illustration is self-explanatory and shows the basic design of the inventive mobile factory.

In Fig. 6 are plan, side view and section of a mounting table 1 on a carriage 12 for the production of double-layered brick wall elements shown during the phase of transport, while in the Fig. 6.1 Floor plan, side view and cross section of a mounting table 1 on a Cart for the production of wall elements with double-layered elements in the working position is shown.

FIG. 7 then shows a plan view, side view and section of a container 14 for the machining of reinforcing iron for the production of the components made of brick material and cement mortar. Also this container is provided with hinged walls and includes, for example, the following facilities: iron bending machine (left) 15, workbench 16, iron bending machine (right) 17, Armierungsnetzschneider 18, Netzbiegegerät 19, etc. In Fig. 8 finally in the plan and in the side view of the complete plant for the production of cement mortar (concrete mixer 3) shown, also transportable, mounted on a trailer 12, which facilitated transport to the workplace in accordance with the specifications of the present invention. In the figure, a possible installation site of the concrete plant 3 under the canopy A is indicated on the top right.

According to a preferred embodiment of the present invention it is provided that the working devices 1 to 6 are placed under the canopy A in such a way that the production of the components of brick material and cement mortar are arranged in the sense of a one-way street, the starting materials on the one hand Enter the roof and the finished components will come out on the other side of the A roof. This is apparent, for example, from the block diagram of Fig. 5, where the starting materials (brick elements, etc.) in the illustration come in on the left, while the finished components emerge after a straight pass on the right (towards the construction site). This is a procedure to rationalize production, which is certainly not new in itself, but novel in its use in a mobile factory according to the present invention.

The advantages of the mobile factory according to the invention relate mainly to the rationalization in the construction of large-scale residential and industrial buildings (for example, new housing developments for tourism or natural disasters, etc.) with a corresponding reduction in construction costs thanks to the fact that the factory is easily completed after completion of the works dismantled and transported to another site. Not to be neglected are also the ecological advantages, which arise because of the omission of the otherwise necessary transports, to personnel and elsewhere To bring prefabricated components to the assembly site, sometimes over hundreds of kilometers.

List of reference numerals used in the figures

A

Roofing (tent)

1, 1.1, 1.2, 1.3

Swivel mounting table

2

Water tank, water reservoir

3

Concrete plant

4

Storage area for brick elements for assembly

5

Office and magazine

5.1

Device for processing the reinforcing iron

6

Container for the provision of work aids

7

service container

10

transportable floor

11

hoist

12

trailer car

13

Hinge of the assembly table

14

Container for reinforcement machining

15

Bending device (left) for reinforcing iron

16

Workbench

17

Bending device (right) for reinforcing iron

18

Reinforcing cutter

19

Reinforcing bender

20

Storage space for completed components

Claims (9)

Mobile factory for the manufacture of prefabricated bricks and cement mortars for the construction of residential and industrial buildings comprising at least the following working facilities: - A removable roof (A) as a protective roof, - one or more assembly tables (1, 1.1, 1.2, 1.3) for the manufacture of individual bricks and cement mortar components, - a plant (14) for the machining of rebar for the brick and cement mortar components, - a concrete mixing plant (3) for the treatment of the cement mortar to fill the building elements on one or more assembly tables (1,1,1,1,2,1.3), - A plant for the production of working aids such as steam, electricity, compressed air, etc., with the appropriate pumps, - A service container (7) for offices, sanitary facilities, workers' dormitories and canteens, the individual facilities being constructed on wagons and / or in containers which can be transported on the road or by rail to the construction site, where they can be set up in accordance with a favorable site plan for the manufacture of the prefabricated building elements. Mobile factory according to claim 1,
characterized,
that the roof is designed as a large tent. Mobile factory according to claim 1,
characterized,
that the roof is designed as a construction with steel columns and cover plates. Mobile factory according to claim 1,
characterized,
that the working means (1 to 6) of the enclosure (A) are arranged in such a way that the production of the components of brick material and cement mortar in the sense of a one-way street is carried out, it being provided that the starting materials on the one side of the canopy (A ) come in and come out of the ready assembled brick and cement mortar components on the other side of the canopy (A). Mobile factory according to claim 1,
characterized,
in that the assembly table (1) is mounted on a truck trailer carriage (12) and is provided with a horizontal hinge (13) by means of which the worktable (1) can be folded out of a vertical transport and filling position into a horizontal working position. Mobile factory according to claim 5,
characterized,
that on a truck-trailer car (12) two mounting tables (1, 1 '), which can each be folded on one side of the trailer vehicle (12) and each a corresponding horizontal hinge (13) from a transport and filling position into a working position , Mobile factory according to claim 5 or 6,
characterized,
that the filling working position of the assembly table is also its transport position on the truck trailer (12). Mobile factory according to claim 1,
characterized,
that the system includes different kinds of work tables, such as: - mounting tables for flat wall elements (1, 1.1), - assembly tables for columns and pillars (1.2), - mounting tables for stairs (1.3), - Other types of assembly tables for different types of components (1.4). Mobile factory according to claim 1,
characterized,
that under the roof (A) or in its immediate vicinity, a storage space for starting materials (4) is provided and a storage space for completed individual components (20) made of brick material and cement mortar.

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