EP2255938A2 - Automatic cutting assembly of a casting station - Google Patents

Abstract

The apparatus is designed such that sheathing gaps remain on a sheathing support during positioning sheathing elements (4a-4d) and special sheathing elements (5). Data of the sheathing gaps is supplied to an automated cutting equipment by a control device, where the cutting equipment cuts the special sheathing elements for filling the sheathing gaps. The control device includes an electronic data processing equipment, and the sheathing plan is stored in the processing equipment. The processing equipment calculates the sheathing gaps as a function of the plan. An independent claim is also included for a method for applying a sheathing on a sheathing support for prefabricated concrete components.

Description

The invention relates to a device for use in a formwork station for a precast concrete element, in particular in the context of a pallet circulation system, wherein in the positioning of formwork elements on a formwork support formwork gaps remain, comprising a control device and a Zuschneidanlage.

In the case of automatic laying of formwork for precast concrete components, in particular in a formwork station of a pallet circulation system, formwork gaps inevitably remain. Such formwork gaps arise because the existing formwork elements, which often have standardized dimensions, are not so arranged that exactly the outer shape of the concrete precast element to be produced can be delimited. The contour line to be covered with formwork elements therefore does not match exactly with the existing lengths of the formwork elements or their combinations. The formwork elements are mostly made of metal. It may also happen that the contour line to be shuttered is shorter than the shortest existing shuttering element.

Another reason for the emergence of such formwork gaps is that the end profile of the formwork elements does not match in shape to the lateral profile of the adjacent formwork or the lateral profile of the adjacent fixed pallet edge formwork. Even contour corners that protrude into the precast concrete component, usually can not be covered with standardized formwork elements, as these shuttering elements frontally not have the necessary shape to demarcate the cast concrete in the correct form. Usually, the shuttering elements made of metal are open at the front, but even in the event that one would close these formwork elements end side, they would still not have the desired line-dependent profile there. Such contour corners may include concave or convex corners of the element border or recesses.

Overall, this results in particular in precast concrete components which are produced by automatic shuttering robots and complicated contours have a number of such formwork gaps that can not be covered by the normal formwork elements.

To avoid such formwork gaps, it would in principle be possible to tailor a wooden formwork, as e.g. is realized in the form of a wooden box for shuttering a window. Such a measure is very laborious and therefore costly and time consuming.

Another possibility would be to use special Eckschalungselemente, but only provide a satisfactory result when the recesses have only fixed predetermined shapes and dimensions. However, this is generally not the case, so that this possibility can provide a satisfactory result only with strong restrictions on the concrete precast components to be produced.

So far, the method of choice has been to lay the standardized formwork elements made of metal as far as possible along the contour line, while at the same time minimizing the formwork gaps. Subsequently, the formwork gaps of Styrofoam (polystyrene) fittings were filled. This method offers the greatest flexibility. In the past, the procedure was such that the formwork gaps were measured manually. Subsequently, the Styrofoam was cut by hand and appropriately inserted into the formwork gaps.

The manual cutting and measuring of Styrofoam pieces is very time consuming and therefore costly. However, the resulting extension of the production cycle time does not fit with the increasingly demanded assembly-friendly and rapid delivery of the construction sites, which has led to a paradigm shift in the production processes, which is characterized by an increasing degree of automation and a significant expansion of flexibility.

Furthermore, it is difficult to manually trim the styrofoam pieces in the case of corner elements in such a way that the corner element has the correct profile resting against the concrete on all sides. This leads to significant loss of quality in the manual production of styrofoam fittings.

The object of the invention is therefore to avoid the above-mentioned disadvantages and to provide a device which allows a further automation of the production of precast concrete components, whereby the time required to produce the formwork is reduced. At the same time, the quality of the precast concrete components to be produced is to be improved.

This is achieved by a device having the features of claim 1.

The inventive measure to provide a useable in a station for precast concrete components device to be provided with a control device from the data of the placement of formwork elements remaining Schalurigslücken a Zuschneidanlage can be fed, the manual steps of measuring the formwork gaps and the cutting can be largely automated since the trimming unit can automatically cut special chattering elements according to the data transmitted by the control device data of the formwork gaps for filling these formwork gaps.

Neither the measurement of the formwork gaps nor the cutting of the special formwork elements must therefore be carried out manually. Data is automatically generated on these formwork gaps, namely on their position in the formwork, their dimensions and their shape. By means of a control device, these data are transmitted to a trimming unit, which can then automatically trim the right special formwork elements. As Zuschneidanlagen come to known devices, such as. Computer-controlled sawing machines, in question.

Further advantageous embodiments of the invention are defined in the dependent claims.

In a particularly preferred embodiment of the invention, the control device comprises an electronic data processing system in which a formwork plan is stored. This formwork plan contains information about the concrete precast element to be produced, in particular about the size and shape of the contour line. In addition, in the formwork plan or in the electronic Data processing system further data on the formwork elements to be used, with which the formwork is to be performed. The electronic data processing system can now calculate through the data of the existing formwork elements and the data of the contour line, the formwork gaps remaining in the formwork depending on the formwork plan. From this, the special shuttering elements necessary for the elimination of the formwork gaps are calculated and the corresponding data is transmitted to the cutting machine by means of the control device.

The formwork elements for the formwork plan can be selected so that the remaining formwork gaps have a size that they can be filled as simple as possible by special formwork elements. In particular, this can be prevented that special formwork elements are needed that are so short that they are no longer automatically handled or fixed. In the computational determination of the special formwork elements, with which the remaining formwork gaps can be filled, the shape of the adjacent formwork elements is taken into account. In particular, this relates to the profile of the formwork elements, with which they rest on the formwork support.

The previously calculated special formwork elements are then subsequently cut automatically by the trimming unit.

It is preferably provided that the formwork plan is created as a function of existing in a shuttering formwork elements. Thus, in the formwork plan, the contour line of the precast concrete component to be produced is covered as well as possible with formwork elements. The remaining formwork gaps should be minimized as far as possible. It can be provided, however, not to create this formwork plan already in the preparation of the laying plan or production plan, but only in the context of the production of Betonfortigbautells or the formwork itself, as can be considered for the formwork plan existing in a shuttering formwork elements. Namely, different sizes of formwork elements may be present in a formwork store, so that the formwork gaps depend on the formwork element present in the formwork store. In this case, the remaining formwork gaps can not be planned in advance, but the Product of the calculation of the electronic data processing system. But it can also be provided that the preparation of the formwork plan and the calculation of Schalurigslücken already in advance in the planning of production, where beispielswelse a production and installation plan is created is performed.

In one embodiment of the invention, the apparatus is associated with a formwork robot, for example, part of the formwork station, in particular in the context of a pallet circulation system. Such a pallet circulation system, are created in the precast concrete components on pallet shapes in a production line, for example, in the Austrian patent application AT 506 748 A1 described. The formwork robot has the task of positioning the formwork elements in dependence on the formwork plan on the formwork support, wherein the formwork gaps to be filled with special formwork elements remain.

If the formwork gaps are determined during the preparation of the formwork plan, it is preferably provided that the cutting of the special formwork elements for filling the Schalurigslücken and the positioning of the formwork elements, for example by a formwork robot, substantially simultaneously takes place. While the formwork robots or persons assigned to them are busy laying the formwork elements, the previously calculated special formwork elements are automatically cut to size, so that the cutting of the edge formwork elements does not cause a noticeable loss of time.

In a further embodiment of the invention, a measuring device is provided, from which the formwork gaps can be determined. In this case, the formwork gaps do not have to be calculated by the electronic data processing system depending on the formwork plan, but can be measured automatically. This can already take place in the course of the positioning of the formwork elements or after the positioning of the formwork elements. This measuring device has, for example, optical measuring sensors or a scanning device which scans the scarf support during or after the positioning of the formwork elements. The formwork gaps determined by the measuring device are then fed to the control device, which forwards these data to the cutting machine.

In order to further increase the degree of automation, it can be provided that a positioning device, preferably a formwork robot, positions the special formwork elements in the formwork gaps. As a result, a manual insertion of the special formwork elements can be avoided. This positioning device can be connected to the control device in order to query the data of the formwork plan, in particular the position and position of the formwork gaps on the formwork support. This filling of the formwork gaps can be done in the formwork station or in another station of a production line for precast concrete components, in particular in a pallet circulation system.

The blanks of the special formwork elements can be made in 90 ° wnkeln, in miter or with curves. In principle, very diverse shapes are possible through an automatic trimming system.

In one embodiment of the invention, it is provided that at least one retaining element can be inserted into the special formwork elements. This insertion of the holding element, which has a magnet, is preferably carried out automatically. The holding element serves to hold the special lining element on the formwork support. Such a holding element is in the Austrian patent application AT 506 402 described.

When creating the formwork plan or when calculating the formwork gaps can be taken into account that the resulting special formwork elements are large enough that they can be fixed with such holding elements on the formwork support. Furthermore, it can be provided to arrange the necessary recesses for the holding elements, for example vertical holes, during automatic cutting of the special formwork elements, preferably also from the cutting machine. The position and number of these recesses may be selected depending on the dimensions of the special formwork elements. The holding element may have an activation device at its end remote from the formwork support, with which the holding element is activated after the positioning of the special formwork element and thus the fixation of the special formwork element on the formwork support takes place. The activation can in turn be done automatically, for example by the formwork robot.

In a further embodiment, it is provided that the holding element can be removed from the special formwork element, whereby the holding element is reusable. The special formwork elements are usually made individually for the respective formwork and are disposed of after the production of Betorifertigbautelles.

Instead of such a magnetic holding element in one embodiment of the invention, a fixation of the special formwork elements with adhesive is conceivable. For this purpose, the surface of the special formwork elements to be fastened to the formwork support can be provided with adhesive, for example with hot glue, so that the special formwork elements are glued to the formwork support with this surface. Of course, additionally or instead, the formwork support itself may be provided with adhesive, in particular in those areas on which formwork and / or special formwork elements are to be arranged, ie e.g. along the contour line. Additionally or alternatively, it can also be provided to hold the special formwork elements by negative pressure on the formwork support. For this purpose, the formwork support may be provided with holes, by means of which air is extracted, so that a negative pressure is created, which holds the special formwork elements on the formwork support.

Particular preference is given to special formwork elements made of polystyrene (polystyrene). But it is also possible to use special formwork elements made of wood or similar material. The formwork elements themselves are preferably made of metal.

In a preferred embodiment of the invention, the trimming unit is designed such that it can cut the basic material of the special formwork elements, for example wood or polystyrene three-dimensionally, so that overall the special formwork elements can be trimmed in three dimensions. In order to achieve this, the trimming unit can comprise, for example, vertically arranged cutting devices which can perform cuts in two directions, so that a three-dimensional cut is optionally made possible with an additional movement of the base material from which the special formwork element is to be cut. Particularly suitable as cutting devices are wires with a to correspondingly trained surface, which may be formed for this purpose, for example, serrated. With such wires can also be corners or round shapes, as they are needed in particular for the front-end profile and the side profile of the special formwork elements. This applies in particular to special formwork elements made of polystyrene.

The invention further relates to a Paleftenumlaufantage for the production of precast concrete components with a formwork station having a device as described above.

The invention further relates to a method for attaching a formwork on a formwork support for precast concrete components, wherein, at least one formwork element, preferably made of metal, is positioned depending on a formwork plan on the formwork support. Formwork gaps remain between the formwork elements and / or between a formwork element and the lateral edge of the scissor support. The remaining formwork gaps are calculated with an electronic data processing system or determined with a measuring device. The special formwork elements for filling the formwork gaps are automatically cut by a trimming unit depending on the formwork gaps. Subsequently, the special formwork elements are positioned in the respective formwork gaps.

It is particularly preferred that the positioning of the formwork elements and the automated cutting of the special formwork elements take place substantially simultaneously.

In one embodiment of the method according to the invention, it is provided that the determination of the formwork gaps and / or the positioning of the formwork elements and / or the positioning of the special formwork elements is automated. For positioning the formwork elements and the special formwork elements a shuttering robot can be provided.

In one embodiment, it is further provided that in the special Scholungselemente at least one holding element is introduced, with which the special formwork elements are held on the formwork support. Preferably can be provided that the holding elements are automatically inserted. It can also be provided that the removal of the holding elements takes place automatically during the demoulding.

The invention further relates to a method for producing a precast concrete component on a formwork support, wherein a formwork is mounted on the formwork support in a method as set out above. Subsequently, concrete is poured into at least one space between the formwork elements. After the concrete has hardened, the precast concrete element is deactivated, i. the formwork elements and the special formwork elements are removed from the Schalurigsauflage. It can be provided that one or more of these steps take place automatically.

In addition, it can be provided that before pouring the concrete reinforcement elements, such as lattice girder structures are inserted into the formwork. These reinforcing elements can also be shaken or pressed from above into the already cast-in but still at least partially liquid concrete.

Fig. 1

ein Beispiel eines zu schalenden Betonfertigbauteiles in Form einer Wand mit einem Fenster,

Fig. 2

eine schematische Draufsicht auf die entlang der Konturlinie verlegten Schalungselemente, wobei Schalungslücken verbleiben,

Fig. 3

die schematische Draufsicht der Fig. 2, wobei die Schalungslücken mit Sonderschalungselementen ausgefüllt sind,

Fig. 4

eine Draufsicht eines zugeschnittenen Sonderschalungselementes.

Fig. 5a und 5b

eine Seiten- und eine Vorderansicht eines Sonderschalungselementes mit darin angeordnetem Halteelement,

Fig. 6

ein Halteelement,

Fig. 7

eine perspektivische Ansicht einer Schalungsauflage mit darauf angeordneten Schalungselementen und Sonderschalungs- elementen,

Fig. 8

eine schematische Darstellung einer Schalstation einer Palettenumlaufanlage und

Fig. 9

eine schematische Darstellung einer Ausführungsform einer Zuschneidanlage.

Further details and advantages of the present invention will be explained in more detail below with reference to the description of the figures with reference to the drawings. It shows:

Fig. 1

an example of a prefabricated concrete element to be shuttered in the form of a wall with a window,

Fig. 2

a schematic plan view of the laid along the contour line formwork elements, wherein formwork gaps remain,

Fig. 3

the schematic plan view of Fig. 2 , wherein the formwork gaps are filled with special formwork elements,

Fig. 4

a plan view of a tailored Sonderschalungselementes.

Fig. 5a and 5b

a side and a front view of a Sonderschalungselementes with arranged therein retaining element,

Fig. 6

a retaining element,

Fig. 7

a perspective view of a formwork support with thereon arranged formwork elements and Sonderschalungs- elements,

Fig. 8

a schematic representation of a formwork station a pallet circulation system and

Fig. 9

a schematic representation of an embodiment of a Zuschneidanlage.

Fig. 1 shows a manufactured in a pallet circulation plant precast concrete component 1, which has a window 2 and is bordered by a contour line 3. In Fig. 2 is shown in a schematic plan view, as have been laid on a formwork support 10 along the contour line 3 formwork elements 4a, 4b, 4c, 4d made of metal. These formwork elements 4a, 4b, 4c and 4d differ in their length. The formwork elements 4a have the shortest length in this embodiment, followed by the formwork elements 4c, 4d and 4b. The formwork elements 4a, 4b, 4c, 4d have been laid according to a formwork plan, which has been created such that the formwork gaps 9, which remain when laying the formwork elements 4a, 4b, 4c, 4d, are minimized as possible. It has been taken into account in the preparation of the formwork plan on existing in a formwork bearing 15 formwork elements 4a, 4b, 4c, 4d consideration. In another selection of existing formwork elements 4a, 4b, 4c, 4d, the formwork gaps 9 would have been different.

In Fig. 3 is the top view of Fig. 2 shown, wherein the shuttering gaps 9 were filled with special formwork elements 5. Each of the formwork gaps 9 has a different shape and size, so that each one of the special formwork elements 5 has been individually adapted for a special formwork gap 9. In this case, several special formwork elements 5 can be combined. The contour line 3 is thus completely covered by formwork elements 4 and special formwork elements 5, so that a pouring of the concrete into the formwork for the preparation of the precast concrete component 1 is possible.

Fig. 4 shows a plan view of a special formwork element 5, which has been made in this embodiment of polystyrene (Styrofoam) and thereby a larger polystyrene block 20 was cut. In the special formwork element 5, a recess 6 has been arranged, into which a holding element 7 can be inserted, with which the special formwork element 5 can be held on the formwork support 10.

Fig. 5a shows a side view of a further embodiment of a special formwork element 5 with it introduced holding elements 7. The heads of the holding elements 7 protrude beyond the top of the special formwork element 5. On the underside of the holding elements 7 each magnets 8 are arranged, which hold the special formwork element 5 on the formwork support as soon as the holding elements 7 have been completely pressed into the special formwork element 5. The special formwork element 5 has a convex corner 5 ', which is designed such that it fits to the respective adjacent formwork element 4a, 4b, 4c, 4d. This corner 5 'would be manually difficult to cut and with noticeable quality losses. In an automated trimming unit 17, this three-dimensional trimming is straightforward and can be carried out quickly.

In a front view of this special formwork element 5 it can be seen that a further convex corner 5 "is arranged on the front side of the special formwork element 5. It is particularly preferred that the special formwork elements 5 be made of polystyrene (polystyrene).

In Fig. 6 an example of a holding element 7 is shown, which can be inserted into recesses 6 of the special formwork element 5 and holds the special formwork element 5 on the formwork support with a magnet 8 arranged on the underside.

Fig. 7 shows a perspective view of a formwork support 10 with thereon arranged formwork elements 4c, 4d and special formwork elements 5. Together with lateral edge strips 11 form the formwork elements 4c, 4d and the special formwork elements 5 a space in which concrete can be poured. The standardized measures having shuttering elements 4c, 4d are not suitable to cover the entire contour line 3 of the precast concrete component 1 to be produced, so that a formwork gap 9 remains. In order to fill these accordingly, four individually tailored special formwork elements 5 are on the formwork support 10 been arranged. Both the formwork elements 4 c, 4 d and the special formwork elements 5 are held by one or two holding elements 7 on the formwork support 10.

Fig. 8 shows a schematic view of a formwork station 14, which is an element of a production line of a pallet circulation system. The possibly previously cleaned formwork support 10 is moved to the formwork station 14, wherein a formwork robot 12 according to a formwork plan formwork elements 4a, 4b, 4c, 4d on the formwork support 10 arranges. The shuttering elements 4 are thereby removed from the shuttering robot 12 a shuttering bearing 15 in which various shuttering elements 4a, 4b, 4c, 4d are mounted, which have standardized dimensions. The shuttering robot 12 may optionally also introduce holding elements 7 into the special openings of the shuttering elements 4a, 4b, 4c, 4d provided for this purpose.

According to the shuttering element 15 existing shuttering elements 4a, 4b, 4c, 4d and the contour line to be covered 3 calculates a control unit that includes an electronic data processing system 13, such as a PC, the remaining formwork gaps 9 and calculates depending on the zuzuschneidenden Sonderschalungselemente 5. The control unit also controls the formwork robot 12. From this control unit, the data is transmitted to an automatic Zuschneananlage 17, which removes the base material of Sonderschalungselemente 5 from a warehouse 16 and custom tailored special formwork elements 5, for example, with appropriate sawing devices, which serve as fittings for the formwork gaps 9. This base material of the special formwork elements 5 is preferably polystyrene, since this is characterized by a simple Schneidschneidung. Manually or automatically then the special formwork elements 5 are fitted or arranged in the formwork gaps 9 and held there eg with holding elements 7 or with adhesive or with negative pressure on the formwork support. Subsequently, the formwork support 10 provided with the now completed formwork for concreting station, where concrete in the space between the formwork elements 4a, 4b, 4c, 4d and special formwork elements 5 is filled, or to a reinforcement station, where reinforcing elements in the space between the formwork elements 4a, 4b , 4c, 4d and special formwork elements 5 are inserted, spent.

Fig. 9 shows a schematic perspective view of a Zuschneidanlage 17, which is particularly suitable for cutting polystyrene. The trimming unit 17 has two wires 18 and 19 arranged substantially perpendicular to one another. By a relative movement of the polystyrene block 20 to the wires 18, 19 in the direction of the double arrows A, B, C three-dimensional sections in the polystyrene block 20 can be made, whereby Sonderschalungselemente 5 can be prepared with corresponding front and side front. The Zuschneidanlage itself and / or the polystyrene block 20 can be moved. The three directions of movement allow any cutting directions and sectional shapes in the polystyrene block 20. By a relative rotational movement also round shapes are possible. The wires 18 and 19 are suitable for sawing and have a corresponding, for example, provided with teeth surface. It can also be provided that the wires are heated and / or at least along their longitudinal direction saw movements, ie back and forth movements perform.

Also, the location information chosen in the description, such as top, bottom, side, etc. related to the immediately described and illustrated figure and are to be transferred to the new situation mutatis mutandis when a change in position.

Claims (15)

Apparatus for use in a formwork station for a concrete precast component, in particular in the context of a pallet circulation system, wherein in the positioning of formwork elements on a formwork support formwork gaps remain, comprising a control device and a Zuschneidanlage, characterized in that from the control device data of formwork gaps (9) of the Zuschneidanlage (17) are fed, from which special formwork elements (5) for filling the formwork gaps (9) are cut to size. Apparatus according to claim 1, characterized in that the control device comprises an electronic data processing system (13) in which a formwork plan is stored, wherein the electronic data processing system (13) calculates the formwork gaps (9) as a function of the formwork plan. Apparatus according to claim 2, characterized in that the formwork plan in dependence on in a formwork bearing (15) existing formwork elements (4a, 4b, 4c, 4d) is created. Device according to one of claims 1 to 3, characterized in that the device is associated with a shuttering robot (12), of which the shuttering elements (4a, 4b, 4c, 4d) depending on the formwork plan on the formwork support (10) can be positioned, wherein Formwork gaps (9) remain. Device according to one of claims 1 to 4, characterized in that the positioning of the formwork elements (4a, 4b, 4c, 4d) and the cutting of the special formwork elements (5) takes place substantially simultaneously. Device according to one of claims 1 to 5, characterized in that a measuring device is provided, of which the formwork gaps (9) can be determined. Device according to one of claims 1 to 6, characterized in that a positioning device, preferably a shuttering robot, for positioning the Sonderschalungselemente (5) in the formwork gaps (9) is provided. Device according to one of claims 1 to 7, characterized in that in at least one of the special formwork elements (5) at least one holding element (7), preferably automated, is insertable, wherein the holding element (7) has a magnet (8) and the special formwork element (7). 5) stops at the formwork support. Apparatus according to claim 8, characterized in that the at least one holding element (7), preferably automatically, can be removed. Apparatus according to claim 8 or 9, characterized in that for receiving the at least one retaining element (7) necessary recesses (6) in the special formwork element (5), preferably by the Zuschneidanlage (17), are automatically created. Device according to one of claims 1 to 10, characterized in that the special formwork elements (5) by means of adhesive and / or negative pressure on the formwork support (10) are held. Pallet circulation plant for the production of precast concrete components comprising a shell station (14) with a device according to one of claims 1 to 11. Method for applying a formwork to a formwork support for precast concrete components (1), characterized by the steps: a) positioning of at least one formwork element (4a, 4b, 4c, 4d) in dependence on a formwork plan on the formwork support (10), wherein formwork gaps (9) remain, b) determination of the formwork gaps (9) with an electronic data processing system (13) or a measuring device, c) Automated cutting of special formwork elements (5) for filling the formwork gaps (9) of a trimming unit (17), d) positioning of the special formwork elements (5) in the respective formwork gaps (9), A method according to claim 13, characterized in that the steps a) and c) take place simultaneously and / or the steps a) and / or b) and / or d) are automated. Method according to one of claims 13 to 14, characterized in that in the at least one special formwork element (5) at least one holding element (7), preferably automated, is introduced, of which the special formwork element (5) is held on the formwork support (10).

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