EP1892069A2 - Production line for making a prefabricated panels for building walls - Google Patents

Abstract

A fabrication plant has a number of discrete assembly frames (5) for construction the individual panel elements, and has an opening station (1) for discrete assembly frames and a first horizontally arranged station (3) for the lower wall faces of the panel elements. Each individual assembly frame (5) is mounted on a trolley for transporting in turn to the opening station (1), that is, for opening the first assembly station (3) for reinforcement iron, the second station for the upper wall face of the panel element, and a closure station (2) for closing the assembly frames (5).

Description

The present invention relates to a system for the production of prefabricated board elements for the production of inner or outer walls of buildings according to the preamble of patent claim 1.

Fabrication in fixed and mobile factories for prefabricated panel elements for residential buildings, industrial buildings, private and public buildings (schools, hospitals, etc.) has undergone great development of technology and applications over the last decades.

In particular, the designers sought to rationalize the fabrication of the panel elements and to broaden the range of applications, with multilayer panel elements being proposed for a wide variety of applications. In general one can say that the rationalization efforts have been directed to a very specific aspect, namely to cheapen the fabrication of the panel elements as much as possible. Two approaches were followed for this purpose. On the one hand, fabrication has been limited to a few types of panel elements, or even more so to a single type, in order to obtain large quantities of always identical products. Of course, this allows the highest possible degree of rationalization, and thus the greatest possible cost reduction, to be achieved, although the flexibility of the system is lost. Wall elements of the same type always produce monotonous monotony of the constructed structures, ie architectural monotony, and the need to produce very large wall surfaces. These are major drawbacks that limit, above all, the freedom of creativity of architects and which lead to dull suburban landscapes of many cities.

The other approach of the planners was to create versatile fabrication facilities for prefabricated panel elements, on which a larger Number of types (two- or multi-layered, with integral coating on one or both sides, in different dimensions and different designs of structural design according to intended application, etc.) could be fabricated with a minimum of modifications on the same installation. In this case, the rationalization efforts were directed not to the production of the largest possible series of the same panel elements, but to the establishment of manufacturing facilities, which allowed as much as possible adjustments to the properties of the panel elements to be produced. It is therefore about optimizations whose goals are completely different and sometimes quite opposite to those of the aforementioned first example.

As a typical example of this second thrust direction is certainly the European patent application of 19.7.2006 with the number EP-06405314.3 entitled 'Fabbrica mobile per la fabbricazione di elementi prefabbricati (mobile plant for the manufacture of prefabricated elements)', which describes a manufacturing plant consisting of a number of facilities (mounting frame, equipment for processing rebar, concrete mixing plant, etc .), which are mounted on trolleys or in transportable containers that can be transported on the road or by rail, so that the entire manufacturing plant - as a mobile plant - can be moved to where the prefabricated elements to be installed, the whole System is provided with a roof that can also be transported. The purpose of this system is therefore to create a mobile manufacturing plant, the mounting frame for the panel elements are mounted in straight-line manufacturing process on trailers of a truck. This design, which is based on the idea that the panel elements are to be produced at the point of use, so that the transport costs can be reduced, but has the disadvantage that the versatility of the system is very limited, since just the portability of the manufacturing plant size and thus the Production capacity and diversity limited to the producible types of panel elements. In particular, there is a lack of possibility to set up a storage space for curing the panel elements produced, which is an indispensable prerequisite for increasing the production capacity of a plant. The mobile factory according to this proposal is therefore suitable when in very remote areas (for example in the desert or in inaccessible mountain country) entire settlements or quarters prefabricated buildings are to be created, all the same, with the transport problems, which bring prefabricated panel elements with it , outweigh those of production capacity and versatility.

Purpose of the present invention is to provide a production line for the production line prefabricated panel elements, which allows to produce large daily production quantities of prefabricated panel elements of various kinds with only minor adjustments of the actual fabrication facilities, the constraints on portability of the fabrication facility are overcome in accordance with the aforementioned patent application, which The present invention is closest to the state of the art.

With regard to the types of panel elements to be produced, the reference to another European patent application of 13.2.2006 under the number suffices EP-06405065.1 entitled 'Elementi in laterizio per la costruzione di pannelli prefabbricati per l'edilizia'('bricks' material used in the manufacture of prefabricated building panel elements)', which in turn constitutes an improvement to a previous European patent application, numbered 08.01.2003 EP-1273729 was submitted.

These documents give an overview of the different types of panel elements, and their practical applications, which are ultimately to form the finished product, which are based on the manufacturing plant according to the present invention Invention are produced. An indispensable prerequisite for achieving this great variety is above all the possibility of adapting the mounting frame of the type of panel element to be produced, or the availability of specific mounting frames for the individual types of panel elements. Both of these possibilities are provided in the manufacturing plant for the production line, which is the subject of the present invention.

The above-mentioned objects are achieved by means of a plant for production line production of panel elements according to the preamble of claim 1 having the properties according to the characterizing part of claim 1.

The novelty of the plant according to the invention is mainly based on the provision of a predefined production run, according to which each assembly frame is brought back to the starting point of the run after completion of the manufacturing process, where the work cycle can start again, all this with simple transport systems that allow a fast and efficient work schedule for the workforce.

Fig. 1

einen Grundriss und einen Aufriß einer erfindungsgemässen Fabrikationsanlage mit drei Stationen, wo die Elemente für die Tafelelemente in die Montagerahmen eingelegt werden, eine Station, wo die Montagerahmen geöffnet werden und eine Station, wo sie geschlossen und verfüllt werden, und 24 Stationen für die Aushärtung des Zementmörtels;

Fig. 2

einen Schnitt längs der Linie A-A der Fig. 1, welcher die Station zeigt, wo die Montagerahmen geöffnet werden;

Fig. 3

einen Schnitt längs der Linie B-B der Fig. 1, welcher die Station zeigt, wo die Konstruktionselemente (Backsteine oder Ziegelstein-Platten) sowie die Armierungseisen eingelegt werden;

Fig. 4

einen Schnitt längs der Linie C-C der Fig. 1, welcher die Station zeigt, wo die Montagerahmen geschlossen werden und mit Zementmörtel verfüllt werden;

Fig. 5

einen Schnitt längs der Linie D-D der Fig. 1, welcher die Verschiebung, eines geschlossenen Montagerahmens zur Zone der Zementmörtel-Aushärtung zeigt;

Fig. 6

eine Ansicht von oben (Grundriss) des Transportwagens für den Montagerahmen, wobei eine der Wände des Montagerahmens in horizontaler und die andere in vertikaler Stellung gezeigt sind;

Fig. 7

ein Detail der Einrichtung für den Richtungswechsel der Montagerahmen zwischen der Herstellzone und der Aushärtungszone bzw. der Auspackzone, und der Rückführung der leeren Montagerahmen zur Herstellzone.

The present invention will be described below in detail with reference to the drawings. The figures show in the:

Fig. 1

a plan and an elevation of an inventive plant with three stations, where the elements for the panel elements are inserted into the mounting frame, a station where the mounting frame are opened and a station where they are closed and filled, and 24 stations for the curing of cement mortar;

Fig. 2

a section along the line AA of Figure 1, showing the station where the mounting frame are opened.

Fig. 3

a section along the line BB of Figure 1, showing the station where the construction elements (bricks or brick slabs) and the reinforcing bars are inserted.

Fig. 4

a section along the line CC of Figure 1, showing the station where the mounting frame are closed and filled with cement mortar.

Fig. 5

a section along the line DD of Figure 1, which shows the displacement of a closed mounting frame to the zone of cement mortar curing.

Fig. 6

a top view (floor plan) of the transport carriage for the mounting frame, wherein one of the walls of the mounting frame in horizontal and the other are shown in a vertical position;

Fig. 7

a detail of the device for the change of direction of the mounting frame between the manufacturing zone and the curing zone or the Auspackzone, and the return of the empty mounting frame to the manufacturing zone.

In Fig. 1 is shown - in plan and in elevation - an example of a manufacturing plant according to the present invention comprising a station 1 where the mounting frames are opened, and a station 2 where the mounting frames are closed and filled, and four Stations 3, 3 ', 3 ", 3"', where elements are designed and assembled, which form the panel element, and 24 stations 4 - 4 ^xxlv for the curing of the cement mortar.

The number of stations 3, 3 ', ... 3 ⁿ , where elements are designed and assembled, which form the finished panel element is shown in the example in Fig. 1 with four stations, but may vary depending on the type of in the provided fabrication plant to be fabricated panel elements. The greater the number of stations for laying out and assembling, um the versatility of the manufacturing plant increases. With a larger number of stations for laying out and assembling, more or less "specialized" stations can be formed to carry out certain fabrication steps, which is to be understood in the sense that, for example, stations can be provided which are suitable for producing panel elements of a particular one Total thickness are suitable, without adjustment work on the construction elements would have to be made. Conversely, fewer stations to lay out and assemble require that the versatility of the fabrication facility decrease, or that adjustments or adjustments to the elements forming the station must be made to produce various types of panel elements, which reduces the productivity of the fabrication facility which causes higher production costs.

Compared to the prior art, especially compared to the EP-06405314.3 , the present invention is characterized in that each individual mounting frame 5, ... 5 ⁿ (visible in the various workstations 1 to 4 in Fig. 1) is constructed on a carriage 6, on which he successively from the Öffnüngsstation is brought to the mounting station 3 for the bottom wall of the panel element, and then to the second station where the reinforcing bars are installed and to the second mounting station 3 "for the top wall of the panel element, then to the station 3"'where the mounting frame is closed, to the filling station 2 and the curing station 4 ... 4 ⁿ for the cement mortar. The mounting frame 5 on the carriage 6, which rolls on suitable rails, thus completes a predetermined concentricity, which returns each mounting frame 5, ... 5 ⁿ after completion of the work with the curing phase to the starting station, ie to the station 1, where the mounting frame 5 is opened, the finished panel element is lifted out, and where after any cleaning operation of the open mounting frame (for example, at the station 1, where the mounting frame 5 is opened, can take place, or in one of the first stations 3, where the design and composition of the elements takes place, the lower wall of the new panel element is designed and assembled.

It should be noted here that the terms lower wall or upper wall of the panel element refer only to the position of the element during the fabrication process and not to the position that occupies the panel element after installation on the site. The lower side of the panel element can thus be after installation on site to the outer wall or the inner wall of the building so that its structure (for example, the interpretation of the reinforcement or the thermal insulation) is taken into account for the final orientation of the wall. However, this has no influence in the context of the present invention.

Regarding the rail system on which the carriages 6 move with the mounting frames 5... 5 ⁿ , further explanations of the details follow with reference to the corresponding figures.

It should also be noted here that the concept of the present invention readily, with the appropriate practical consequences, with that of the mobile factory according to the EP-06405314.3 can be combined. Of course, in combining the basic idea of the present invention, namely the circulation of the mounting frame on sliding carriage, with that of the mobile factory to make essential compromises in terms of flexibility and versatility of the manufacturing plant, as already mentioned above. However, the two concepts do not contradict each other in the execution and can therefore be combined.

According to a preferred embodiment of the present invention, which is not illustrated in detail, but which will be readily understood, it is envisaged that the station where the mounting frame 5 is closed and that where the filling with cement mortar takes place will be collapsed. These operations can be performed in two separate stations because it is clear that once the mounting frame 5 is closed and its Walls are secured, this is ready for filling with cement mortar, that is, this can be done "on the spot", provided that the necessary and known devices are available for it, without the mounting frame must be moved. This solution allows a workstation to be saved but, on the other hand, can slow down the work rhythm since two operations must be performed on a single station. This possibility will be applicable only where it allows a real optimization of the working cycle, taking into account the residence times of the mounting frame in the stations preceding the closing of the mounting frame.

In the following, FIGS. 2 to 5 will be briefly described, which correspond to the sections along the lines AA, BB, CC and DD of FIG. 1, ie the sections through the work stations, which are shown only in the sense of exemplary embodiments, but in no way as complete Exploitation of all possibilities to train such stations. Anyone skilled in the art will be aware of the problems of opening and cleaning the mounting frame, laying out and assembling the elements (brick material, reinforcing bars, etc.) on one wall of the mounting frame 5 in its horizontal position, closing the mounting frame to the other Wall in vertical position to form the gap to be filled. These are operations known in the fabrication technique for prefabricated walls and panel elements, which are performed with different, sometimes quite similar, but different devices. The illustrated system of the lockable mounting frame is therefore not to be regarded as essential in the context of the present invention, the novelty of which lies rather in the displaceability of the mounting frame 5 ... 5 ⁿ along a predetermined concentricity

In FIG. 2 is a section along the line AA shown according to FIG. 1 with the station at which the assembly frame 5 5 ⁿ open '.... There is a horizontal wall 7 of the open mounting frame 5 and a vertical Wall 8 of the mounting frame 5 shown. The open horizontally placed wall 7 is articulated at one point by means of a hinge 9, about which a pivoting upwards to a position can be performed, in which the mounting frame 5 is closed (shown in Fig. 5). For this purpose, a mechanism 10 is provided, with which the wall 7 is lifted, and which consists of a series of rods and pistons, which corresponds to all the common facilities in this field and therefore requires no further description. The carriage 6 is provided with wheels 11 which roll on the rails 12, 12 'which are arranged along the whole route connecting the station 1 to the filling station 2 for the mounting frames. Three such Schienengeleise 12, 12 'are provided, namely to carry the carriage 6 itself, and a rail (12') (left in Fig. 2 shown) to support the free end of the open wall 7 of the mounting frame 5, the otherwise stored cantilever on one side and thus would be insufficiently guided. However, the design and the number of rails 12, 12 'and the wheels 11 may vary depending on the requirements and do not themselves constitute an essential object of the present invention. It is only important that the mounting frame 5 in its open state (ie one of the Walls in a cantilevered position) can be displaced along a predetermined, preferably straight line between the stations for opening and closing and / or filling the mounting frame with cement mortar.

On the station shown in Fig. 2, the opening of the mounting frame 5 can take place, wherein the finished panel element is removed and where, if necessary, the cleaning of the mounting frame.

In Fig. 3 is a section along the line BB shown in FIG. 1, which shows an assembly station for laying out and assembling the structural elements of the panel element. These elements can form the bottom wall of the panel element and consist, for example, of a layer of brick or polystyrene, or of the reinforcing iron structure, as all this is shown in this figure. From this figure it can be seen how provisional guards 13 are used as protection for the workers.

In Fig. 4 is a section along the line C-C shown in FIG. 1, which shows the carriage 6 in the position in which the mounting frame 5 is closed, but here still shown in its open position. In the illustration, the lower layer denoted by 14 are the elements of the panel element, the reinforcing bars 15 (summarily indicated) and the upper layer of the panel element 16, which lies on the reinforcement 15. The lower layer 14 and the upper layer 16 of the panel member 17 may be made of bricks or tile, slate or polystyrene panels or other insulating material (for example, wood). The height of the panel member 17 is generally variable, but this height must be taken into account when arranging the linkage 9 with respect to the vertical fixed wall. For this purpose, reference is made to FIG. 5, in which the closed mounting frame 5 is shown from the side opposite to that shown in FIG. 4, and where the already filled filling of the gap between the layers 14 and 16 of the panel element 17 with cement mortar 18 can be seen. Whether the filling of the mounting frame 5 has been made in a filling station or in a combined closing and filling station is not important, but can be considered as a preferred feature of the present invention.

From Fig. 5 it is then seen how the trolley 6 of the mounting frame 5 is spent on the track 12 on a trolley 19, which is provided with wheels 20 (two wheels on each side), which roll on two rails 21, which in right angles to the rails 12, 12 'are arranged for the carriage 6. In other words, at the end of the production line of the panel elements between the station 1, where the mounting frame 5 is opened and the station 2, where it is closed, a direction change device 22 is installed, with which the direction of the Mounting frame 5 can be changed by 90 °. This direction change device 22 can be designed in various ways, among which the one illustrated in FIGS. 5 and 7 is merely a well-fitting solution, not the only one at all. According to this embodiment, two of the rails 12 which guide the carriage of the mounting frame 5 (the third rail 12 'is no longer needed after the mounting frame 5 has been closed) extend and terminate on the trolley 19, the wheels 20 of which at right angles to the rails 12 arranged rails 21 roll. The carriage 19 on which the carriage 6 has been brought can now be displaced in the direction of the arrow f (Figure 1), as far as one of the several parallel tracks 22 (four of which are shown in Figure 4), on which the carriages 6 are "threaded" by means of a same system, as described at 22, whereby the carriages 6 enter the hardening zone 4, which can receive a plurality of carriages and mounting frames. In Fig. 1 in the sense of an example on each track of the curing station 4 six cars 6 are housed, which in the case shown in the curing zone 4 (to understand as the entirety of ^{Aushärtestationen} 4 to 4 ^xxIv ) 26 mounting frame 5 during their Hardening phase find space. The total number of mounting frames 5 in the curing phase can vary considerably depending on the needs of the manufacturing plant, according to a preferred embodiment of the present invention provides that the total number of circulating mounting frame 5 is at least 12 (if only one to the track 12 parallel track in the curing zone 4 is available) and a maximum of 60 units. The maximum number results essentially, except for logistical reasons, from the maximum required curing time of the cement mortar in the mounting frame 5 before it can be opened. It would make no sense to keep the finished and hardened panel element longer in the mounting frame.

At the other end of the curing zone 4, that is shown in Fig. 1 on the right side, a second device for changing direction with tracks 21 'is provided, which is constructed in the same way and works the same as the device 22 to change direction, so they here does not need to be described again. With this device for changing direction, the cured panel elements are transported to the opening station 1, where the mounting frame are opened and the panel elements are removed and sent from there to the site, where they are installed.

In this way, the whole cycle is realized, is provided in accordance with the invention that the mounting frame complete a predetermined run, they get from point 1, where they are opened again to this opening point of the mounting frame 5.

According to a preferred embodiment of the present invention, it is provided that the manufacturing plant should have a plurality of rail tracks 23 (in FIG. 1, for example, four such procedures) and that in the same zone 4 at the same time a number of mounting frame 5 find their place during their curing phase, the Manufacturing time corresponds to the time required for curing the cement mortar of the first during a manufacturing cycle prefabricated panel element. In other words, cure zone 4 provides as many cure sites as are sufficient to fully cure the first panel element that was produced during a work cycle (which, of course, may last 24 hours, corresponding to continuous operation before the next work cycle begins), so what the next cycle begins with the opening of the above-mentioned first panel and the subsequent production of the first panel of the next cycle. In this way, it is possible to make best use of the curing zone 4 and to optimize its size. A less receptive cure zone would reduce the production capacity of the entire fabrication facility and cause time losses.

According to a further preferred embodiment of the present invention, it is provided that the individual mounting frames 5 are provided with devices (as shown in the figures, but in various ways available to the person skilled in the art) in order to adapt the mounting frame 5 to facilitate the type of panel element to be produced, in particular to the thickness of the panel element, which may vary from a few centimeters (for example, 15 cm) to 40 to 50 cm.

According to another preferred embodiment of the manufacturing plant according to the invention, it is then provided that different types of mounting frame 5 are simultaneously used therein, each of which is suitable for producing a specific type of panel elements. This is especially to sandwich panel elements with two sides of the wall with brick elements or on insulating panel elements with a wall side of brick elements and a wall side of polystyrene, etc., to think. More about it is in the already mentioned EP-A-06405065.1 to find.

In certain cases, however, it may prove useful to use instead of universally usable and adjustable mounting frame 5 to choose specifically designed mounting frame, which cost less and their handling is easier. This is ultimately a problem of economic acceptability.

The advantages offered by the present invention have been described in detail in the description, so that their repeated listing is unnecessary here.

List of reference numerals used in the figures

1

Station where the mounting frames are opened

2

Station where the mounting frames are closed and / or filled

3, 3 ', 3 ", 3' ''

Station for construction and assembly

4 '... 4 ^xxlv

Station for curing the cement mortar

5 ... 5 ⁿ

mounting frame

6

dare

7

open (horizontal) wall of the mounting frame 5

8th

vertical wall of the mounting frame 5

9

joint

10

lifting mechanism

11

Wheels of the trolley

12

track

13

temporary protection device

14

lower wall side of the panel element

15

rebar

16

upper wall side of the panel element

17

panel member

18

cement mortar

19

Transfer cars

20

Wheels of the transfer carriage

21

track

22

Device for changing direction

23

third track

Claims (9)

Fabrication plant for production line prefabricated panel element for creating outer and / or inner walls of buildings, with a plurality of individual mounting frame (5 ... 5 ⁿ ) for building the individual panel elements, with an opening station (1) for each mounting frame, a first horizontal arranged assembly station (3) for the lower wall side of the panel element, a mounting station (3 ') for the reinforcing bars of the panel element, a second horizontally arranged mounting station (3 ") for the upper wall side of the panel element, a closing station (2), where the Mounting frame (5 ... 5 ⁿ ) closed, a filling station for filling the gap between the two wall sides of the panel element with cement mortar and a curing zone (4 ... 4 ⁿ ) for curing the cement mortar,
characterized in that
each individual mounting frame (5 ... 5 ⁿ ) is mounted on a carriage (6) on which it is successively transported to the stations, namely for opening (1), the first assembly station (3) for the lower wall side of the panel element , the reinforcing bar mounting station (3 '), the second mounting station (3 "2) for the upper wall side of the panel element, the closing station (3"') for closing the mounting frames (5 ... 5 ⁿ ), to the filling station (2) for filling with cement mortar and to the curing zone (4 ... 4 ⁿ ), according to a pre-determined cycle, each assembly frame (5 ... 5 ⁿ ) after completion of the cycle with the curing phase to the starting point of the run returns. Fabrication plant for the production line of prefabricated panel elements according to claim 1,
characterized in that
the closing station (2) for the mounting frame (5) and the station for cementing with cement mortar are combined. Fabrication plant for the production line of prefabricated panel elements according to claim 1,
characterized in that
the opening station (1) for the mounting frame (5), the first assembly station (3) for the construction of the lower wall side of the panel element, the mounting station (3 ') for the reinforcing iron, the second assembly station (3 ") for the construction of the upper wall side of the panel element, the closing station (3 "'or 2) for the mounting frame (5) and the station (2) for filling with cement mortar along a straight line and with a first track (12, 12') with each other on which the carriages (6) on which the mounting frames (5) are displaced individually, while the access to the curing zone (4) by means of a second track (21) is at right angles to the first track (12, 12 ') is arranged. Fabrication plant for the production line of prefabricated panel elements according to claim 1,
characterized in that
the hardening zone (4) has at least one third track (23) arranged parallel to the first track (12, 12 ') on which the mounting frame (5) was transported during the preceding manufacturing stage of the panel element. Fabrication plant for production line of prefabricated panel elements according to claim 4,
characterized in that
the hardening zone (4) for the cement mortar comprises a plurality of strands of the third track (23), and that at the same time as many mounting frames (5) find room in their hardening phase, as required by the duration of the hardening phase, to allow the hardening of the hardening phase Cement mortar is ensured in the first prefabricated during a whole cycle work table element. Fabrication plant for the production line of prefabricated panel elements according to claims 1 and 5,
characterized in that
the number of mounting frames (5) in circulation is between a minimum of 12 units and a maximum of 60 units. Fabrication plant for the production line of prefabricated panel elements according to claim 3,
characterized in that
the transition of the trolley (6) for each mounting frame (5) from the first track (12, 12 ') to the second track (21) and from the second track to the third track (23) of the hardening zone (4) and from the third track (5) 23) back to the first track (12, 12 ') is accomplished by means (22) for changing direction, which are able to change the direction of displacement of the mounting frame (5) by 90 °. Fabrication plant for the production line of prefabricated panel elements according to claim 1,
characterized in that
each mounting frame (5) has devices which facilitate the adaptation to the type, in particular the thickness, of the panel element to be fabricated. Fabrication plant for the production line of prefabricated panel elements according to claim 1,
characterized in that
various types of mounting frame (5) are in use, each of which is suitable for the manufacture of a specific type of panel elements.

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