EP2119542B1 - Method and apparatus for producing pre-fabricated concrete elements using pallets - Google Patents

Description

The invention relates to a method for producing precast concrete elements, in which the production of the components takes place on pallet forms, the pallet shapes successively through several stations of a production line in particular circulating and the advance of the pallet forms from one to the next station depending on a predetermined maximum time per power stroke, in particular synchronously, takes place.

There are already methods for the production of precast concrete elements, in which the manufacture of the components takes place on pallet shapes and the pallet shapes successively pass through several stations of a production line, known. In the demoulding station, the precast concrete element is lifted and the formwork elements are removed from the pallet form, after which the pallet forms are cleaned in another station before they are fitted with new formwork at the formwork station. Then in the new formwork, the reinforcement and the concrete, or vice versa introduced and the pallet shapes of a curing chamber, in which the setting of the concrete takes place.

In the previously known methods, in particular the application and lifting of the formwork elements and the insertion of the reinforcement mat before concreting by hand, making it at the corresponding stations of the production line - namely at the Endschalstation, the Schalstation and the reinforcement station - can always come back to traffic jams so that the palette cycle time is delayed.

To remedy this problem, it has hitherto been customary to use more personnel at the critical stations in order to be able to maintain an economically acceptable pallet cycle time even in the case of precast concrete elements which require complex formwork or complex reinforcement.

• a) Abheben der ausgehärteten Betonfertigbauelemente und Abheben der Schalelemente, oder umgekehrt,
• b) Reinigen der Palettenformen in der Reinigungsstation,
• c) Automatisches Aufbringen von zumindest einem Schalelement auf die Palettenform für das nächste herzustellende Betonfertigbauelement,
• e) Automatisches Einbringen von Bewehrungselementen in die Schalung,
• d) Automatisches Einbringen des Betons in die Schalung und
• f) Transportieren des noch nicht ausgehärteten Betonfertigbauelementes zu einer Härtekammer

The FR 1 447 898 A discloses a plant for the production of precast concrete elements according to the preamble of claim 15 and a method in which the production of precast concrete elements is carried out on pallet forms, the pallet shapes successively through several stations of a production line in particular circulating and the advance of the pallet forms from one to the next station in dependence a predetermined maximum time per power stroke, in particular synchronously, takes place with the following steps:

• a) lifting the hardened precast concrete elements and lifting the formwork elements, or vice versa,
• b) cleaning the pallet molds in the cleaning station,
• c) automatic application of at least one formwork element to the pallet form for the next concrete precast element to be produced,
• e) Automatic introduction of reinforcement elements into the formwork,
• d) Automatic introduction of the concrete into the formwork and
• f) transporting the not yet cured precast concrete element to a curing chamber

The DE 37 14 581 A1 shows a method and an apparatus for placing a prefabricated reinforcement in a reinforced concrete slab plate in a position, in which a device for pressing or Einrütteln the reinforcement in the still liquid concrete is also used to lift the finished concrete element, whereby a shorter production time is achievable.

Based on this prior art, the invention has set itself the task of a new process for the production of precast concrete elements create, with which the above-described disadvantages can be avoided and which in particular allows the maintenance of a short pallet cycle time with little staffing.

A method according to the invention is provided in claim 1 or claim 2, wherein claim 2 is an alternative to the method of claim 1.

So that the precast concrete elements actually have the desired dimensions and to avoid edge breakouts during production, can be provided according to a further embodiment of the invention that at least one shell element, preferably all shell elements, after application in step c) at least until leaving the curing chamber the pallet shape remains.

A preferred embodiment of the invention provides that at least one of the steps a), b) or f) is performed at least partially automatically, wherein it has been found to be particularly advantageous if all steps a), b) and f) carried out automatically become.

The fact that the necessary steps for the production of a precast concrete element in a production line of removing the hardened precast concrete element on the cleaning of the pallet form, the application of the new formwork and the introduction of the concrete and the reinforcement, up to the transport of pallet shapes in the curing chamber automatically, One can realize a total of a fully automated system for the production of precast concrete elements, which on the one hand, the maintenance of a fixed, short pallet cycle time is made possible and on the other a reduction of the required personnel, which also has to fulfill primarily monitoring tasks, can be achieved. It is understandable for everyone that cost savings and higher production time result from these advantages.
Further automation can be achieved if, according to an embodiment of the method according to the invention, the stacking of the precast concrete elements takes place automatically after leaving the curing chamber. For this purpose, according to a preferred embodiment of the invention can be provided that the precast concrete elements by means of a lifting device, preferably a lift-off from the (the) pallet form (s) are lifted, the lifting device the precast concrete elements on the concrete protruding handle elements, preferably reinforcing elements engages and the positions of the grip elements relative to the pallet shapes of the lifting device are transmitted by a control device.

The fact that the precast concrete elements already leave the curing chamber in the desired stacking order and the position of the handle elements on which the precast concrete elements are lifted from the pallet shapes, the lifting device are known, the lifting and stacking of precast concrete elements in contrast to the state with the inventive method The technique, in which the grippers have been set by hand, done automatically.

It does not matter whether the positions of the gripping elements projecting from the concrete in a reinforcement station, either during or immediately after the insertion of the reinforcement, are determined and passed on to the control device or whether the positions of the gripping elements projecting from the concrete by means of a Course of the production line arranged or arrangeable scanning device can be determined and passed on to the control device.

In any case, it is essential to the invention that the lifting device of the lifting station knows the positions of the grip elements projecting from the concrete, which are advantageously formed by parts of the reinforcement. In the second case, that is, when the positions of the grip elements are detected by means of a scanning device, it has been found to be favorable according to a further embodiment of the invention, when the scanning device between the curing chamber and the Abhebestation is arranged or can be arranged.

According to a further embodiment of the invention, it has proven to be advantageous if after removing the precast concrete elements before the automatic lifting of the at least one formwork element according to step a) the pallet shapes are scanned for determining the positional position of the scarf elements to be removed, wherein a preferred embodiment of the invention provides that the lifting and / or the application of the formwork elements according to step a) or step c) takes place by means of a shuttering robot.

In order to achieve a fully automatic process sequence or a fully automated plant for the production of prefabricated concrete elements, a further embodiment of the method according to the invention provides that the sequence of the automatically performed process steps a) to f) is centrally controlled by a control device, wherein it has proven to be favorable, if the control device comprises a master computer.

In the prior art, in particular the introduction of the reinforcing elements is done manually. Reinforcement mats are inserted into the formwork by means of spacers, whereby the spacers are to prevent the reinforcing mats from being pushed onto the formwork floor by the latter when subsequently introducing the concrete. In order to perform the introduction of the reinforcing elements automatically now, provides a further embodiment of the invention, that connect automatically to be inserted reinforcing elements in a reinforcement preparation station computer-aided by, preferably welded, made of several individual elements and preferably formed three-dimensional.

This ensures that the individual elements are connected to each other exactly at the designated places. To ensure that the lattice girders, reinforcing baskets and other individual elements are connected to each other exactly at the designated places with each other or with one or more reinforcement mat (s), the three - dimensional reinforcement elements are manufactured in the reinforcement preparation station CADICAM - supported. This accuracy is advantageous both for receiving the reinforcing elements by means of the insertion traverse and in later consequence when lifting the hardened precast concrete elements of the pallet shape by means of a Entschaltraverse advantage.

In general, therefore, a three-dimensional reinforcing element is produced, which according to a further exemplary embodiment of the invention can be formed by a bent and / or curved reinforcing mat or is produced by connecting a plurality of lattice girders to at least one reinforcing mat, thereby achieving that the introduction of the Reinforcement elements, for example by means of a crossbar, which engages the reinforcing elements on the lattice girders, for example with special pliers, can be done. In this case, the concrete cover required when introducing the reinforcing elements after concreting is made by correspondingly deep impressions or shaking the reinforcing elements by means of the insertion traverse, so that no or only a very few spacers are needed.

To ensure that the predetermined maximum time per stroke can be met, provides a further embodiment of the invention, that on a pallet form a formwork for a concrete precast element to be produced is preferably arranged centrally.

With the previously known shuttering methods, as many forms as possible were placed on a pallet in order to maximize the utilization of the pallets. The first element was usually placed in a corner, the second adjacent to it, etc. This method, however, has the disadvantage that the Depending on the formwork, the working cycle at the formwork station takes up a variable amount of time, which can considerably increase the maximum time at the formwork station. The preferred arrangement of exactly one formwork per pallet shape improved automation is achieved because only one element must be edited. If the arrangement of precisely one formwork is also centered, the working distances are shortened and the central position of the formwork can serve as a fixed reference point for a shuttering robot.

Thus, the necessary manipulation work can be minimized with the finished precast concrete elements after removal from the production line to the removal to the site, can further be provided that the components according to a production plan, based on a laying plan or multiple installation plans to produce the number of individual Fertigfertigteileiemente and / or the occupancy of the pallet shapes are defined, manufactured and grouped after passing through the production line to loading grouped, the precast concrete elements in one of the set in the installation plan or the installation plans assembly sequence corresponding or fallen order of the production line and per installation plan be stacked grouped.

In contrast to the prior art, in one exemplary embodiment of the method according to the invention, therefore, not the maximum pallet utilization is the highest priority; rather, during the preparation of the production plan, care is taken to ensure that the assembly order defined in the laying plan is maintained. This ensures that the precast concrete elements of the production line can be removed in the same or in the fallen order, so that the concrete precast elements after lifting from the pallet form directly to a stack that includes the required in a laying plan precast concrete elements in the desired order can be summarized , This means that over the known from the prior art method, the step of intermediate storage is omitted, resulting in both a savings in terms of the required storage space and a reduction in working time.

According to a preferred embodiment of the invention, the method according to the innovation, ie the steps: IV) comprises the production plan and a pile plan as a function of at least one laying plan, V) subsequent production of the precast concrete elements according to the production plan created in step IV) and VI) subsequent stacking of the precast concrete elements according to the pile plan created in step IV).

Thus, while in the prior art, the production plan was created primarily depending on the available formwork surface of the pallet forms, the method according to the innovation follows a completely new approach by the set in the laying plan mounting sequence is maintained in the same or fallen order in the preparation of the production plan and, depending on the installation plan, a batch plan that takes into account the production process and the installation plan is created even before the start of production.

In this case, it does not matter whether the precast concrete elements produced in an order overturned to the assembly order specified in the laying plan or laying plans and after removal from the production line according to order in a stack in one of the arranged in the laying plan or laying plans order be arranged or whether the precast concrete elements produced according to order in one of the set in the laying plan or laying plans assembly sequence and arranged after removal from the production line in an order to the laid down in the laying plan or installation plans sequence sequence in a stack.

In any case, one aspect of the invention consists in considering or maintaining the assembly order of the precast concrete elements in the production plan as well as in the stacking plan so that the precast concrete elements are removed from the production line in the same or in the toppled order and without interim storage directly to a stack per Laying plan can be summarized.

In this case, a sequence that corresponds to the set assembly order is understood to mean that the component marked in the installation plan as the first seton ready component to be mounted in accordance with the production plan of the Production line is removed as the first component or is removed, which has the consequence that this first precast concrete element in the laying plan corresponding stack finished concrete precast elements represents the lowest element. This variant will therefore be selected when the precast concrete elements for transport to the construction site individually on the means of transport, such as a low loader, charged, since in this case the order in the stack is again toppled, that is after completion of the loading is the Stack lowest element, which is formed by the first to be assembled on the construction site precast concrete element to lie on top of the transport so that the ranking of precast concrete elements on the transport from top to bottom corresponds to the installation order specified in the laying plan.

Conversely, under the order of sequence of installation sequence overturned is understood that in the laying plan specified last assembly to be assembled precast element of the production line as the first finished precast concrete element is removed or removed and therefore subsequently forms the lowest component in the stack of finished precast concrete elements so that the order of precast concrete elements in the stack already corresponds to the set assembly order according to the laying plan. This variant will then be selected when loading the concrete prefabricated components onto the means of transport of the entire, the laying plan corresponding stacks of precast concrete elements at once, for example by means of a lifting device loaded.

Of course, it would also be possible to supply the precast concrete elements after removal from the production line prior to the formation of a stack of further processing. This measure is primarily suitable for the production of double wall elements. The hardened precast concrete elements could be supplied directly to a turning device, for example by means of the lifting beam after lifting from the pallet form and connected in known per se with a not yet cured precast concrete element to a double wall element, which subsequently passes through the production line to the end. It is preferred, although these double wall elements from the production line in one of the fixed assembly order appropriate or fallen order and be summarized without intermediate storage directly to a stack per installation plan.

In addition, it should be noted at this point that the term stack does not refer exclusively to a series of stacked precast concrete elements, but all includes the summarized in a laying plan precast concrete elements, that is, a plurality of juxtaposed stack of stacked precast concrete elements that a laying plan In other words, assigned to a job are also included in the term stack.

It is preferred if in a series of stacked precast concrete elements only concrete prefabricated elements that a laying plan - in the same or fallen order as the fixed mounting order - belong together.

According to a further embodiment, it is further provided that the creation of the production plan and the stack plan according to step IV) takes place as a function of exactly one laying plan.

In this case, a further embodiment of the invention provides that the precast concrete elements after removal from the production line according to step VI) are arranged in one of the arranged in the laying plan assembly sequence or fallen order in exactly one stack.

In other words, according to this embodiment of the invention, a production plan and a stacking plan are prepared for a single job involving the precast concrete elements drawn in a laying plan, and the precast concrete elements are placed in exactly one stack after removal from the production line. That is, in this embodiment of the method according to the invention exactly one production plan and exactly one stack plan is created based on exactly one installation plan, the production plan and the stack plan correspond to the installation plan, that is, it can be dispensed with the preparation of a separate pallet allocation plan. It is quite conceivable to arrange on a pallet form two or more formwork for precast concrete elements of a laying plan, it is important that the lifting of the finished precast concrete elements of the pallet shape is guaranteed in the correct stacking order.

Alternatively, however, it is also possible for the production plan and the stack plan to be created according to step IV) as a function of a plurality of installation plans.

In this case, a further embodiment of the invention provides that the production of at least two precast concrete elements according to step V) takes place on a common pallet form, wherein at least two of the arranged on a common pallet form precast concrete elements are assigned to different installation plans.

In this embodiment, as in the prior art, a mixing of several orders, in order to achieve a better utilization of the pallet shapes in this way can be done. In contrast to the prior art but fixed in the laying plan assembly order is maintained in the same or in a fallen order, so according to a further embodiment of the invention, the precast concrete elements after removal from the production line according to step VI) respectively in one of the set in the installation plans assembly sequence or fallen order in multiple stacks, each of which is assigned to exactly one layout plan, can be arranged.

In other words, in this embodiment of the method according to the invention, precisely one production plan is created on the basis of x installation plans, and subsequently either exactly one stacking plan, which includes the division of the manufactured precast structural elements into x stacks, or x stacking plans is created.

With the embodiment of the method according to the invention, the production of precast concrete elements follows a completely new logic. While according to the state of the art as many precast concrete elements as possible were produced on a production pallet, usually only one more is used Prefabricated concrete element produced per pallet form. The poorer utilization of the individual pallet shapes brings with it the advantage of a fixed, maximum working time per working cycle, which allows consistent automation up to a full automation of the production line, as a result of which the manufacturing costs can be reduced considerably due to the enormous personnel savings and the shorter pallet cycle time. In addition, the maximum time per power stroke allows a predeterminable lead time for a pallet form through the production line, whereby production jams can be avoided.

Furthermore, a plant for the production of precast concrete elements according to the teaching of claim 15 is to be specified.

A disadvantage of the previously known systems, in addition to the very difficult or even unpredictable total working time for the passage of a pallet form the occurrence of production jams, as a result of uneven work cycles at the individual stations of the production line and the associated irregular feeds of the pallet forms may be problematic.

To avoid this problem, the plant according to the innovation for the production of precast concrete elements therefore provides that at least three stations are automated from the group of the demolition, the cleaning station, the station, concreting and reinforcement station, where it is in the sense of consistent automation as particularly advantageous has been identified, if all stations are automated from the group of the demolition station, the cleaning station, the sheathing station, the concreting station and the reinforcement station.

It is advantageous if the automated stations of the plant for the production of precast concrete elements with a central control device, preferably comprises a host computer, for data transmission either via data lines or wirelessly connected.
To increase the flexibility of the system according to the invention, for example, in order to produce special forms of precast concrete elements, provides a further embodiment of the invention that the system has one or more special stations that are excluded from the clocked circulation of the pallet shapes in the production line. It is expedient if the pallet forms taken at these special stations from the circulation line of the production line and at the same time another pallet shape is placed in the circulation line to hold the fixed cycle.

Special stations can e.g. for the manufacture of special parts such as e.g. Balcony slabs, which are also included in the installation plan, may be necessary as these special parts require a high manual workload. If necessary, the reinforcement with spacers can be introduced before concreting, if e.g. Parts such as pipes or insulation should be integrated into the reinforcement.

For this purpose, it has proved to be advantageous if a special station is arranged between the station and the concreting station and / or in the area of the take-off station.

Fig. 1

eine Anlage zur Herstellung von Betonfertigbauelementen,

Fig. 2

schematisch den Ablauf der Schritte III) bis VIII) eines Ausführungsbeispiels des erfindungsgemäßen Verfahrens,

Fig. 3a

die Schritte I) bis VI) eines ersten Ausführungsbeispieles eines erfindungsgemäßen Verfahrens,

Fig. 3b

die Schritte I) bis VI) eines zweiten Ausführungsbeispieles,

Fig. 4a und 4b

zwei unterschiedliche Produktionsabläufe im Schritt V) eines Ausführungsbeispiels des erfindungsgemäßen Verfahrens,

Fig. 5a

den Produktionsablauf und die Stapelbildung auf Basis genau eines Verlegeplanes,

Fig. 5b

den Produktionsablauf und die Stapelbildung auf Basis von zwei Verlegeplänen,

Fig. 6a bis 6d

das Einbringen des Betons und der Bewehrungselemente in die Schalung gemäß den Verfahrensschritten d) und e) und

Fig. 7a bis 7d

das Abheben und Stapeln der Betonbauelemente an der Abhebe-und Stapelstation der Anlage.

Further advantages and details of the invention will be explained in more detail with reference to the following description of the figures with reference to the embodiments illustrated in the drawings. It shows

Fig. 1

a plant for the production of precast concrete elements,

Fig. 2

1 schematically the course of steps III) to VIII) of an embodiment of the method according to the invention,

Fig. 3a

the steps I) to VI) of a first embodiment of a method according to the invention,

Fig. 3b

the steps I) to VI) of a second embodiment,

Fig. 4a and 4b

two different production processes in step V) of an embodiment of the method according to the invention,

Fig. 5a

the production process and stacking on the basis of exactly one laying plan,

Fig. 5b

the production process and the stacking on the basis of two installation plans,

Fig. 6a to 6d

the introduction of the concrete and the reinforcing elements in the formwork according to the method steps d) and e) and

Fig. 7a to 7d

the lifting and stacking of the concrete components at the lifting and stacking station of the plant.

In the Fig. 1 illustrated plant 1 for the production of precast concrete elements 3 comprises several stations, which are arranged such that the pallet forms 20 on which the precast concrete elements 3 are produced, these stations in the sense of a production line 2 in particular circulating through.

The production line 2 comprises a lift-off station 16, in the region of which a lift-off traverse 17 is arranged. Directly following this, the stacking station 18 follows, so that the precast structural elements 3 removed in the lift-off station 16 can be transported directly to the stacking station 18 by means of the lift-off traverse 17 and stacked there.

After lifting off the precast concrete element 3, the feed of the pallet 20, on which is still the old formwork 29, the demolition station 4. It is scanned in the demoulding station 4 or on the way to this the pallet form by means of a scanning device 26 to a to determine the position of the formwork elements 9 and to determine the other, whether there are other parts on the pallet 20. In the demoulding station 4, the formwork elements 9 are then removed from the pallet form 20 by means of a scarf robot 8. Shuttering elements 9, which are not suitable for robots and other possibly on the pallet form parts can be removed manually.

The pallet form 20 subsequently passes through a cleaning station 6 in which the surface of the pallet form, ie the formwork surface, is cleaned and oiled. The formwork elements 9 are also supplied to a cleaning and oiling device and then either immediately used again for producing a new formwork in the subsequent Schalstation 7 or stored in a warehouse.

In the shell station 7, the required formwork elements 9 are placed by means of a scarf robot 8 and, for example, magnetically fixed. In this case, oblique parts, recesses, passages or even polygonal parts can be switched and manufactured. The data required for this purpose are transmitted to the shuttering robot 8 by a master computer 22.

Following the formwork station 7, a special station 10 is arranged in the system 1 shown, in which special formwork and residual formwork can be manually supplemented by an employee. Such special formworks are cut in the embodiment shown from Styrofoam of a Styrofoam cutting machine 11, wherein the corresponding data from shuttering robot 8 or from the host computer 22 are determined. Although it is provided in the embodiment shown that these special forms are manually set by a staff, it would be quite possible to also position the special formwork produced in the polystyrene cutting machine 11 by means of the shuttering robot 8 on the pallet 20 and fix.

Subsequently, the pallet 20, on which there is now a shutter 29 closed on all sides, moved to concreting station 12, in which by means of a preferably fully automatic concrete distributor 13 of the concrete 34 is introduced into the formwork 29. The thus applied to the scarf surface concrete 34 is subsequently compacted by shaking or shaking, before in the reinforcement station 14, the reinforcing elements 23 is pressed or vibrated by means of a cross member 15 from above into the not yet cured fresh concrete 34. The required concrete cover for the reinforcing elements 23 is made by correspondingly deep impressions, so that can be dispensed with the previously necessary use of spacers.

The reinforcement elements 23 to be introduced in the reinforcement station 14 are prepared in a reinforcement preparation station 27 that is excluded from the production line 2. For this purpose, the reinforcement preparation station 27 has a Welding device 28 for welding reinforcing mats 24 with lattice girders 23 on. In this reinforcement preparation station 27 all required for the precast concrete elements 3 reinforcing elements 23 are prepared, by cutting, bending, tying or welding of individual elements such as reinforcing mats, longitudinal and transverse bars and lattice girders. This production process is advantageously carried out automatically, which ensures that all reinforcing elements 23 can be made available for the concrete precast elements 3 to be produced in the correct time for circulation. If the production of the reinforcing elements 23 on the basis of data provided by the master computer of the control device 22, an exact positioning of the lattice girder 25 is achieved, which in particular for the gripping of the reinforcing elements 23 by means of the traverse 15 in the reinforcement station 14 and the lifting beam 17 in the Abhebestation 16 is advantageous.

After the reinforcement station 14, the pallet shape is supplied to the curing chamber 21 for drying. After leaving the curing chamber 21, the pallet molds 20 are supplied with the cured precast concrete elements 3 thereon the Abhebestation 16.

The plant 1 shown is particularly suitable for the production of precast concrete elements 3, as they are needed in the production of floor elements or double walls.

Fig. 2 shows individual steps of a first embodiment of a method according to the invention, in which - starting from the laying plan provided in step III) - created in step IV) a fixed in the laying plan mounting order production plan 30 and subsequently a stacking plan 32 is prepared, the a target stack, which also takes into account the set in the laying plan assembly order for the concrete components 3 includes

In step V) then the precast concrete elements 3 according to the elaborated in step IV) production plan 30 in the in Fig. 1 illustrated Appendix 1 produced and in the subsequent step VI) to a stack corresponding to the target stack 33 is grouped.

The actual stack 33 produced in this way can subsequently be loaded directly onto a means of transport (step VII), whereupon the precast concrete elements 3 are mounted on the construction site following transport to the assembly sequence prescribed in the laying plan.

The process according to the invention thus allows the grouped stacking of precast concrete elements 3 already in the assembly sequence required on the construction site directly after removal from the lift-off station 16, ie. without a prior intermediate storage, as was previously required in the known from the prior art method.

Fig. 3a shows an embodiment in which the production plan 30 and the stacking plan 32 is created based on exactly one laying plan 31. In this case, in a first step I) the architect or the structural engineer produces the blueprint for an element ceiling to be produced, for example. Based on this blueprint, the vertege plan 31 resulting in step III) is then compiled in a computer-assisted manner according to step II). In step IV) the production plan 30 and the stacking plan 32 are then created on the basis of the laying plan 31, whereupon in step V) the concrete prefabricated elements 3 required according to the laying plan 31 are produced according to steps a) to f) of the method according to the invention and subsequently in step VI) in a stack 33, in one of the order of installation 31 provided in the installation order corresponding or fallen order.

The embodiment according to Fig. 3b differs from the embodiment according to Fig. 3a merely in that the production plan 30 and stacking plan 32 created in step IV is created on the basis of two installation plans 31, 31 'so that after production according to step V) in the following steps VIa), VI) a separation of the arranged on the pallet forms Prefabricated concrete elements 3 in two separate stacks 33, 33 ', which in turn correspond to the installation plans 31, 31', takes place.

Fig. 4a shows an embodiment in which the production of precast concrete elements 3a-3g according to step V) of an embodiment of the method according to the invention is carried out in an order supported for the assembly order of the laying plan 31 order. After removal from the production line, the production order in the lift-off station 16 is then reversed in step VI) by stacking the precast concrete elements 3g-3a, so that the precast concrete elements 3g-3a are arranged in the resulting stack 33 in an order corresponding to the assembly order provided in the installation plan 31 That is, the concrete prefabricated element 3a to be mounted on the construction site as the first to be mounted is arranged at the top in the stack 33. This embodiment will be used when the resulting stack 33 is loaded as a whole, for example by means of a lifting device on the means of transport, so that when loading the order of precast concrete elements 3a-3g no longer changes.

An alternative embodiment is in Fig. 4b shown. In this case, the production sequence according to step V) is carried out in accordance with the installation sequence provided in the laying plan 31, so that the precast concrete elements 3a-3g are arranged in the resulting stack 33 in an order that has been overturned in the laying plan 31 in the laying plan. This exemplary embodiment will be used when, when loading the stack 33 onto the means of transport, the precast concrete elements 3a-3g are lifted individually onto the means of transport, whereby the order of the precast concrete elements 3a-3g in the stack 33 changes, ie after being loaded on the means of transport The order of precast concrete elements 3a-3g again corresponds to the assembly order provided in the laying plan 31.

Fig. 5a shows step V) and step VI) according to the embodiment according to Fig. 3a , In this embodiment, based on exactly one laying plan, exactly one production plan and exactly one stack 33 corresponding to the laying plan 31 are created.

In contrast, shows Fig. 5b Steps V) and VI) of the embodiment according to Fig. 3b , ie in the embodiment according to Fig. 5b If, on the basis of two laying plans 31, 31 ', in turn only exactly one production plan 30 is created, it will be but ultimately two, the installation plans 31, 31 'corresponding stack 33, 33' formed. In this case, it does not play a significant role whether a separate stacking plan is created for each stack 33, 33 'or whether only a stacking plan is created, which contains the two stacks 33, 33' to be formed.

In any case, one aspect of the invention is to create a corresponding production plan for a plant for the production of prefabricated concrete elements on the basis of the installation sequence specified in a laying plan 31, 31 and the concrete prefabricated elements thus produced after removal from the production line immediately in a mounting sequence of the laying plan or to dispose of the stacks which take into account the laying plans without prior temporary storage.

The Fig. 6a shows a pallet 20, on which by means of several formwork elements 9 a formwork 29 is designed for a concrete precast element 3 to be produced, in this formwork concrete is introduced in a further step in the concreting station 12 34 ( Fig. 6b ). Thereafter, the pallet 20 is moved to the reinforcement station 14 and - as in Fig. 6c shown - a reinforcing element 23 introduced from above into the not yet cured concrete 34. The reinforcing element 23 is formed three-dimensionally in the illustrated embodiment and comprises a reinforcing mat 24 which is fixedly connected to a plurality of lattice girders 25, preferably welded, and may for example be bent or cranked.

The fact that the reinforcing element 23 is introduced from above into the not yet cured concrete 34, can - as in Fig. 6d shown - the necessary concrete cover done by engagement or shaking, which can be dispensed with the use of spacers.

The Fig. 7a-7c show the process at the Abhebestation 16 and the stacking station 18. The manipulation of the precast concrete elements 3 between these two stations 16 and 18 by means of a Abhebetraverse 17 which is arranged both vertically and horizontally movable and which has a plurality of gripping elements 35 at its lower end , The gripping elements 35 are hook-shaped for engagement with the lattice girders 25 of the reinforcing elements 23.

The pallet molds 20 with the hardened precast concrete elements 3c, 3d are supplied to the lifting station 16 after leaving the curing chamber 21 ( Fig. 7a ). Then according to Fig. 7b lowered the lift-off traverse 17 in order to grip the precast concrete element 3d located on the pallet mold 20 and to move it into the stacking station 18 ( Fig. 7c ) and there stack on the stack 33 in one of the planned or fallen in the laying plan sequence. During stacking ( Fig. 7d ), the pallet 20, on which only the old formwork elements 9 are moved from the Abhebestation 16 further to the cleaning station 6 and the lifting process now again - as in Fig. 7a presented - start again.

The illustrated embodiments of a plant for the production of precast concrete elements and the described examples of possible manufacturing processes are of course not to be understood in a limiting sense but just a few examples of numerous ways to realize the inventive idea of an automated pallet circulation system for the production of precast concrete elements.

Claims (17)

1. A process for the production of precast concrete components in which production of the precast concrete components is effected on pallet moulds, wherein the pallet moulds successively pass in particular in a circulating flow through a plurality of stations of a production line and the advance of the pallet moulds from one station to the next is effected in particular synchronously in dependence on a predetermined maximum time per working cycle, comprising the following steps:

   a) lifting the set precast concrete components (3) and lifting off the shell elements (9), or vice-versa,

   b) cleaning the pallet moulds (20) in the cleaning station (6),

   c) automatically applying at least one shell element (9) to the pallet mould (20) for the next precast concrete component (3) to be produced,

   d) automatically introducing the concrete (34) into the formwork (29),

   e) automatically introducing reinforcing elements (23) by pressing or shaking into the concrete (34) which has not yet set from above, and

   f) transporting the precast concrete component (3) which has not yet set to a hardening chamber (21),

   g) ascertaining positions of gripping elements projecting from the concrete (34), preferably reinforcing elements (23), and

   h) communicating the ascertained positions of gripping elements projecting from the concrete (34), preferably reinforcing elements (23), to a control device (22) for automatically lifting off the hardened precast concrete components.
2. A process for the production of precast concrete components in which production of the precast concrete components is effected on pallet moulds, wherein the pallet moulds successively pass in particular in a circulating flow through a plurality of stations of a production line and the advance of the pallet moulds from one station to the next is effected in particular synchronously in dependence on a predetermined maximum time per working cycle, comprising the following steps:

   a) lifting the set precast concrete components (3) and lifting off the shell elements (9), or vice-versa,

   b) cleaning the pallet moulds (20) in the cleaning station (6),

   c) automatically applying at least one shell element (9) to the pallet mould (20) for the next precast concrete component (3) to be produced,

   d) automatically introducing reinforcing elements (23) into the formwork (29),

   e) automatically introducing the concrete (34) into the formwork (29) and

   f) transporting the precast concrete component (3) which has not yet set to a hardening chamber (21),

   g) ascertaining positions of gripping elements projecting from the concrete (34), preferably reinforcing elements (23), and

   h) communicating the ascertained positions of gripping elements projecting from the concrete (34), preferably reinforcing elements (23), to a control device (22) for automatically lifting off the hardened precast concrete components.
3. A process according to claim 1 or claim 2 characterised in that at least one shell element (9) and preferably all shell elements (9) remains on the pallet mould (20) after application in accordance with step c) at least until leaving the hardening chamber (21).
4. A process according to one of claims 1 to 3 characterised in that in addition at least one of steps b) and f) is performed at least partially automatically.
5. A process according to claim 4 characterised in that all steps a), b) and f) are performed automatically.
6. A process according to one of claims 1 to 5 characterised in that stacking of the precast concrete components (3) after leaving the hardening chamber (21) is effected in automated fashion.
7. A process according to claim 6 characterised in that the precast concrete components (3) are lifted off the pallet mould or moulds (20) by means of a lifting device, preferably a lifting beam assembly (17), wherein the lifting device grips the precast concrete components (3) at gripping elements projecting from the concrete (34), preferably reinforcing elements (23), and the positions of the gripping elements relative to the pallet moulds (20) are communicated to the lifting device by a control device (22).
8. A process according to claim 7 characterised in that the positions of the gripping elements projecting from the concrete (34) are ascertained by means of a scanning device (36) which is or can be arranged in the course of the production line (1) or in a reinforcing station (14), either upon or immediately after introduction of the reinforcement, and are transmitted to the control device (22).
9. A process according to one of claims 1 to 8 characterised in that prior to lifting of the at least one shell element (9) according to step a) the pallet moulds (20) are scanned for determining the position of the shell elements (9) to be removed.
10. A process according to one of claims 1 to 9 characterised in that lifting and/or application of the shell elements (9) according to step a) or step c) respectively is effected by means of a formwork robot (8).
11. A process according to one of claims 1 to 10 characterised in that the implementation of the automatically performed process steps a) to f) is centrally controlled by a control device (22) which preferably includes a host computer.
12. A process according to one of claims 1 to 11 characterised in that the reinforcing elements (23) to be automatically introduced are produced in a reinforcement preparation station (27) in computer-aided fashion by joining, preferably welding, a plurality of individual elements.
13. A process according to one of claims 1 to 12 characterised in that precisely one formwork (29) for a precast concrete component (3) to be produced is arranged preferably centrally on a pallet mould (20).
14. A process according to one of claims 1 to 13 characterised in that the precast concrete components (3) are manufactured in accordance with a production plan (30) in which the number of the individual precast concrete components (3) to be produced and/or occupancy of the pallet moulds (20) are established on the basis of a layout plan (31) or a plurality of layout plans (31, 31') and after passing through the production line (2) are stacked in grouped relationship until the loading operation, wherein the precast concrete components (3) are taken from the production line (2) in a sequence which corresponds to the assembly sequence laid down in the layout plan (31) or the layout plans (31, 31') or which is based thereon and are stacked in grouped relationship per layout plan (31, 31').
15. An installation for the production of precast concrete components with a production line in which production of the precast concrete components is effected on pallet moulds in accordance with the process according to one of claims 1 to 14, wherein the pallet moulds successively pass, in particular in synchronously cycled relationship, through at least a shell removal station, a cleaning station, a shell station, a concreting station, a reinforcing station and a hardening chamber of the production line, wherein of the group of the shell removal station (4), the cleaning station (6), the shell station (7), the concreting station (12) and the reinforcing station (14) at least three stations (7, 12, 14) are automated, characterised in that the position of gripping elements projecting from the concrete (34), preferably reinforcing elements (23), can be ascertained, and there is provided a control device (22) to which the ascertained positions of gripping elements projecting from the concrete, preferably reinforcing elements (23), can be communicated to automatically lift off the hardened precast concrete components.
16. An installation according to claim 15 characterised in that of the group of the shell removal station (4), the cleaning station (6), the shell station (7), the concreting station (12) and the reinforcing station (14) all stations are automated.
17. An installation according to claim 15 or claim 16 characterised in that the installation (1) has one or more separate stations (10) which are excluded from the cyclic circulation of the pallet moulds (20) in the production line (2).

Images