EP3089853B1

EP3089853B1 - Side element for forming a casting mould

Info

Publication number: EP3089853B1
Application number: EP14876782.5A
Authority: EP
Inventors: Timo Suutarinen
Original assignee: Sora Ja Betoni V Suutarinen Oy
Current assignee: Sora Ja Betoni V Suutarinen Oy
Priority date: 2014-01-03
Filing date: 2014-12-31
Publication date: 2022-08-24
Anticipated expiration: 2034-12-31
Also published as: EP3089853A4; LT3089853T; EP3089853A1; WO2015101719A1

Description

The present invention relates to a side element for forming a casting mould according to the wording of claim 1.
In the concrete industry, such as, for example, in the manufacture of prefabricated wall panels, casting moulds are used. In the prior art, the casting mould is formed on a steel table at least partly from side elements that can be freely placed. Thus the casting mould can be formed as desired. In the attachment of the side elements, powerful magnets can be used, by means of which the side element will remain precisely in place on the steel table during casting. In practice, the thickness of the cast products being manufactured varies. For example, in wall panels insulation of different thicknesses can be used between cast shells. Thus a known side element includes one or more additional elements, by means of which the height of the casting mould can be altered. In other words, at least one additional element is attached on top of the basic element.
The known system and the side elements used in it are complicated. In practice the additional elements must be of many different heights. This leads to many different additional elements, which require a great deal of storage space. Particularly with the additional element the side element becomes heavy, so that overhead cranes or robots are needed to move the side element. In addition, the system is inflexible in terms of manufacturing. Only rarely does the height of a side element exactly match the desired thickness of the wall panel. Thus, plywood, for example, must be used to increase the height of the casting mould. This slows down the making of the mould and leads to additional costs. On the other hand, an excessively high side element prevents, or at least hinders the mechanical floating of the cast surface.
DE application publication number 102011010931 discloses a side element according to the preamble of claim 1, the height of which can be altered. A spacer plate, the height of which can vary, is installed between the basic element and additional element belonging to the side element. In practice, the height of the spacer plate is selected according to the height of the required side element. There must be numerous spacer plates in storage, so that the desired height of the side element can be achieved. Thus, in practice the height of the side element can only be set in steps. In addition, the spacer plate is subject to great strain, because most of the height of the side element is the spacer plate. There are grooves in the basic element and additional element for the spacer plate, in order to hold the spacer plate in place. The casting mass, and particularly its fines, i.e. cement paste, enters these grooves, leading to very labourious cleaning. At the same time, shoulders form at the joints between the spacer plate and the basic element and additional element. It then becomes impossible to make the cast product straight at the sides. In addition, the basic element and the additional element are heavy pieces.
EP2821193A1 is a prior art document under Article 54(3) EPC and discloses a side element for forming a casting mould with adjustment means for adjusting the height of the side element. JPH02293104A and KR20090013653A disclose metallic side elements with adjustment means for adjusting the height of the side element.
The invention is intended to create a new type of side element, which would not only be more versatile but also lighter than previously. The characterizing features of the side element according to the present invention are stated in the accompanying Claims. The construction and operating principle of the side element according to the invention are of a new type. The side element is suitable for forming various kinds of flat moulds and is easy to handle. The side element is suitable for both single castings and for automated series production. In addition, the side element is durable and gives a good surface quality. Further, the side element can easily be attached and detached without damaging the casting.
In the following, the invention is described in detail with reference to the accompanying drawings showing some embodiments of the invention, in which

Figure 1a: shows schematically the forming of a casting mould,
Figure 1b: shows a second embodiment of the forming of a casting mould according to Figure 1a,
Figure 2a: show an end view of the side element not according to the invention at its maximum height,
Figure 2b: shows the side element of Figure 2a at its minimum height,
Figure 2c: shows the side element not according to the invention, with the longitudinal structural components detached from each other,
Figure 2d: shows the side element with the vertical structural components detached from each other,
Figure 3: shows a rear view of the side element,
Figure 4: shows a second embodiment of the side element according to Figure 3,
Figure 5: shows the application in casting of the side element according to the invention,
Figure 6: shows a third embodiment of the side element according to Figure 3,
Figure 7a: shows an end view of the side element according to Figure 6 and according to the invention at its maximum height,
Figure 7b: shows the side element of Figure 7a and according to the invention at its minimum height,
Figure 8a: shows a rear view of the side element not according to the invention,
Figure 8b: shows a front view of the side element of Figure 8a,
Figure 9: shows a rear view of the side element of Figure 8a, with the addition element detached,
Figure 10: shows a front view of the side element of Figure 9,
Figure 11a: shows the beam of the side element before and after bevelling,
Figure 11b: shows the attachment of the side element before and after bevelling,
Figure 11c: shows a schematic end view of the side element not according to the invention.

Figures 1a and 1b show schematically the formation of a casting mould. This shows the manufacture of a sandwich-type prefabricated concrete panel at a factory, where plane moulds are used. Sandwich-type concrete panels are also referred to as double-shell panels. Before casting, the side elements are fitted to a planar casting table, situated in the manner required by the desired concrete panel. Usually, the concrete panels, and thus the plane moulds are rectangles. The casting table is usually of steel, so that the side elements can be attached with the aid of magnets. In practice, the inner and outer shells of a sandwich-type concrete panel are cast in the horizontal position. Other panels too than a sandwich-type panel can be cast using a plane mould. In sandwich panels, the outer shell is generally cast first in the plane mould, to which casting stiffeners and ties are attached. After this, one or more insulation layers are placed on top of the outer shell, on top of which the inner shell is cast. The inner shell also extends to the ties, so that the shell structures and insulation form a unified formed insulated concrete panel. The inner shell can be, for example, a 150-mm thick reinforced concrete casting, to which 180-mm thick polyurethane or mineral-wool insulation can be attached, followed by a 70-mm thick outer shell. In both casting stages, the concrete is spread using, for example, a casting machine moving above the plane mould. Once the cast has dried, the casting table is tipped to nearly a vertical position and, after removal of at least some of the side elements, the concrete panel can be removed and transferred from the casting table to finishing.
In practice, the dimensions of the concrete panels being manufactured vary. Thus, at least some of the side elements of the plane mould are able to be situated freely. Figure 1a shows a casting table 10, in which there are two fixed sides 11. In addition to these, the casting mould includes two side elements 12, which can be placed at the desired locations. Here, these freely placeable side elements 12 are attached to the casting table 10 with magnets and the uppermost of the side elements has still to be set in place. Figure 1b shows another casting mould 13 placed on the casting table 10, which is formed of four freely placeable side elements 12. Here the right-hand side element is not yet set in place. In both alternatives, there can be moulds formed with shorter side elements inside the plane mould, for example, for delimiting window and door openings in the concrete panel (not shown) . In addition, the side can be formed of several side elements placed end-to-end.
In addition to the width and height of the concrete panel, the thickness of the concrete panel varies. For example, the thickness of the insulation layer can vary in different production series, or even between individual concrete panels. In other words, after casting one kind of concrete panel a different concrete panel can already be cast. Thus, in manufacture according to the prior art, side elements of different heights are used, which are intended to form the casting mould. Generally, the side element 12 includes a basic element 14 and an additional element 15. The side element 12 also includes means 16 for attaching the basic element 14 and the additional element 15 to each other, in order to change the height of the side element 12 (Figures 2a and 2b). Here, the additional element 15 is arranged to form part of the side element 12. In other words, the additional element forms a permanent part of the side element. In addition, the means 16 are arranged as adjustment means 17 to adjust the height of the side element. Numerous separate additional elements are then unnecessary, as the basic element and the additional element are attached to each other the whole time. At the same time, the storage of different additional elements is avoided. In other words, concrete panels of different thicknesses can be cast using one and the same side elements according to the invention. The possibility to set the height of the side element precisely as desired thanks to the adjustment means is also important. It is thus possible, for example, to even the casting, using a compaction beam supported of the side elements, which simplifies and accelerates manufacture. In addition, the surface of the casting can be mechanically floated throughout, as the surface of the casting is on the level of the upper surface of the side element. This accelerates manufacture and creates a good surface quality for the concrete panel. At the same time, separate additional plywood sheets are not required to raise the plane mould.
The side elements have other properties, which are described with reference to Figures 2a-d and 3 - 7. First of all the adjustment means 17 are stepless. In other words, within certain limits the height of the side elements can be set steplessly as desired. Thus the alteration of production is easy and flexible. Even small production series can then be manufactured without time-consuming mould-making. It takes only a few minutes to adjust the height of one side element.
For example, the length of a side element can be 2500 - 3000 mm. In order to increase the flexibility of mould manufacture shorter side elements than this are used, in which case the length of the side element can be in the range 800 - 2000 mm, with side elements of different lengths being combined as required. Despite the length and height, even a single person can move the side elements according to the invention by hand.
Thanks to its new type of construction, the side element is considerably lighter than known side elements. It is considerably lighter than a known side element made from steel and lighter even than known side elements made from aluminium profiles. In addition to being moved by hand, the side element can of course be moved using an overhead crane, and also by a robot. Thus one and the same side element can be used in both automatic mould-making and in placing by hand.
The lightness is achieved by using a plate material together with bendings. In addition, lightening openings are utilized in the construction (Figures 2d and 3). More generally, the side element 12 is of a plate material equipped with bends, in which there are lightening openings 19. Figures 2a and 2b show an end view of one side element 12 not according to the invention, in different extreme positions, more specifically at its maximum and minimum heights. The plate material is preferably steel or a corresponding material. Various surface treatments can also be used. The use of plywood is also possible in the side element.
The lightness and sturdiness of the side element is largely achieved by utilizing a plate material. First of all, the longitudinal structure components 20 of the side element are pieces bent from a plate material (Figure 2c). In the embodiment shown, these are four pieces, two in the basic element and in the additional element. In each longitudinal structural component 20 there is at least one bend, but there are preferably more. The bends are easy to make mechanically and by means of them considerable additional stiffness is obtained in the structural components. In addition, in the invention the structural components are attached to each other, in this case by welding. Thus the structural components together form a rigid totality. In the embodiment shown, the longitudinal structural components 20 of the additional element 12 form together a casing structure, which is extremely rigid.
The stiffness is achieved, even though lightening openings are used in each structural component. In practice, the lightening openings can be formed at the same time as the plate material is cut, after which the necessary bends are made. After bending, the structural components are ready for assembly.
Figure 2d shows the vertical structural components 21 separated from each other. These too are plate pieces and there are lightening openings 19 in them. In the vertical structural component 21 belonging to the basic element there is a recess 22, into which the longitudinal structural components fit. Thus the greatest possible contact surface is formed between the various components. At the same time, long welded joints can be used. There can be bends in the vertical structural components 21, but these are not essential, as the vertical structural components corresponds at several points to the longitudinal structural components and they are welded onto them.
The plate-like vertical structural components 21 also simplify the construction of the side element. That is because the adjustment means include guide means 23, which in this case are arranged as part of the vertical structural components 21. The guide means permit the basic element and the additional element to move relative to each other. Thus it is possible to alter the height of the side element. Here the guide means include bolts 25, equipped with nuts 24, fitted to the vertical structural component 21 of the additional element 15. A slot 26 corresponding to the bolts is arranged in the vertical structural component 21 of the basic element 14. The pair of bolts keeps the mutual position of the basic element and the additional element constant, permitting only a vertical movement.
The guide means 23 also include locking means 27. Thus, the desired height will remain unaltered, despite the pressure caused by the concrete. In the embodiment shown, the pairs of bolts that are part of the guide means 23 act at the same time as the locking means 27. This simplifies the construction of the side element and accelerates the adjustment of the height. In practice, it is sufficient if each bolt is loosened, after which the height of the side element can be changed. At a suitable point the bolts are tightened and the side element is ready for use.
Figure 3 shows a rear view of the side element. This position corresponds to the situation in Figure 2a, in which the side element is at its maximum height. A gap then remains between the basic element and the additional element, at which the insulation comes in the casting (Figure 5). Thus there is an even steel surface at the castings of the inner shell 38 and the outer shell 39. In the embodiment shown, between the basic element 14 and the additional element 15 there is a gap 40, which is arranged to be adjusted by means of the adjustment means 17 according to the insulation 42 belonging to the double-shell panel 41 being manufactured in the casting mould. Thus the basic element 14 and the additional element 15 limit the casting while the insulation closes the gap 40. In practice, the insulation 42 is supported by both the basic element 14 and the additional element 15, closing the gap 40. More generally, the gap 40 is smaller than the thickness 47 of the insulation 42. The spacer plates according to the prior art are then entirely unnecessary. In addition, the thinnest fines, i.e. cement paste, cannot flow out of the casting mould to the wrong side of the side element. At the same time, the side element is easy to clean, as there are no open grooves that collect fines and the surfaces to be cleaned are straight and flat. More specifically, the surfaces of the basic element 14 and the additional element 15 on the side facing the casting are essentially on the same plane. Thus the edges of the cast panel are even.
In the embodiments of Figures 3 and 4, the adjustment means 17 are formed by two jacks 28, which are situated between the basic element 14 and the additional element 15 separately from the guide means 23. Using the two jacks, the height can be altered evenly. The jacks are, in addition, attached with bearings, so that the ends of the side element can be lifted at a slightly different rate independently of each other. Thus, even one person can, with little effort, change the height of the side element. In addition, the jacks are separate from the guide means, to that each can be operated independently of each other. In other words, the tightening of the bolts does not interfere with the jack and vice versa. At the same time, the construction of the side element remains compact. In other words, the thickness of the side element remains reasonable. In the embodiment shown, each jack 28 is formed by a scissors jack. A scissors jack is light, but by means of it sufficient force is achieved, as well as rapid and precise adjustment. At the same time, a scissors jack has a long movement.
In the embodiment shown, the height of the side element can be varied in the range 320 - 520 mm. Here, 320 mm corresponds to the situation in Figure 2b and 520 mm to the situation in Figure 2a. Thus the adjustment range is 200 mm. More generally, the adjustment range of the adjustment means 17 is 40 - 70 % of the total height of the basic element 14 and the additional element 15. The adjustment range is indeed considerable, so that concrete panels of nearly all thicknesses can be manufacture using only a single side element. Manufacture is also facilitated by the fact that the basic element 14 is lower than the additional element 15. If panels of very different thicknesses are manufactured at the panel factory, the side element according to the invention can be scaled, for example, to form a series of three side elements. Using the smallest side element the thinnest panels can be cast, and correspondingly using the largest side element the thickest panels can be cast. In the largest side element the other structures of the side element are also scaled, so that it will withstand the pressure caused by a thick casting.
Figures 2b and 3 show the magnetic attachment 29 belonging to the basic element 14, which is fitted inside the basic element 14. The magnetic attachment is then firmly attached and will always travel with the side element. At the same time, the magnetic attachment is well protected from breakage and dirtying. Thus it is possible to use magnetic attachments of a light construction, as the side element acts as its shell structure. In addition to magnetic attachments, additional attachments can also be used if necessary.
There is a robot grip 30 in the magnetic attachment 29. The magnetic attachment acts as a robot grip. Figure 4 shows a side element 12 intended for robotic operation. Here there are four magnetic attachments 29 at 400-mm intervals. Thus the side elements can be used with a robot with 400-mm wide jaws (not shown). More specifically, the outermost magnetic attachments 29 are at a distance of 200 mm from the ends of the side element 12. Thus a robot can use its jaws to grip two side elements set end-to-end and thus position the side elements precisely on the same line. After this, the magnetic attachments of both side elements are released. The other two magnetic attachments are each at a distance of 200 mm from the centre point of the side element. Thus the side element will be balanced when being handled by the robot. The innermost magnetic attachments are released after the outermost magnetic attachments. Differing from Figures 1a and 1b, two or more side elements can thus be set end-to-end to form one side of a plane mould. In addition, the placing of the magnetic attachments particularly in manual-operation side elements can be chosen freely.
Figure 2b shows the rear support 31 attached to the guide means 23, which prevents the side element 12 from falling over due to the pressure of the concrete. In the rear support 31, there is, in addition, an adjustment screw 32, by means of which the side element 12 is made vertical. In terms of its default position, the side element is made in such a way that the adjustment screw is required only in special cases. Normally, the side element takes up naturally a vertical attitude on a flat casting table.
Correspondingly, Figure 2a shows a detaching buffer 33, which includes a lever arm 34. The detaching buffer 33 is mounted on bearings on a longitudinal shaft 35 in the side element. In the detaching buffer 33, there is a rounded head, which extends through the longitudinal structural component 20. Correspondingly, the lever arm 34 points upwards at a slant. An extension arm can then be placed on the lever arm, by turning which the side element will detach from the casting without breaking the casting. The extension arm can be part of the tool, with which the attachment magnet is opened. For opening, there is a pin 36 in the attachment magnet 29, which can be lifted using a tool like a jemmy (Figure 2b) . The pin lifts the magnet off the casting table. It is precisely the pin that the robot also grips with its jaws and by pressing the pin the magnetic attachment is released, when the magnet attaches to the casting table, holding the side element in place.
Figure 6 shows an embodiment, from which the jacks have been entirely eliminated. By loosening the locking means 27, the height of the side element can be adjusted manually. Eliminating the jacks lightens the side element. In addition, in this embodiment each robot grip 30 extends above the additional element 15. There is then no obstacle to the robot attaching itself to the robot grips 30 and thus moving the side element and using the magnetic attachments 29. The robot grip 30 and the attachment magnet 29 are connected by a link rod 43, which is formed of two parts threaded together. The length of the link rod can then be altered according to the height of the side element. The link rod can also be used as a jack.
In robot operation, the side elements are preferably stored on top of each other. In order to permit this, the robot grip is antimagnetic. This avoids a robot grip lower down in the stack from attaching to a higher magnetic attachment.
Figures 7a and 7b show an embodiment of the side element according to the invention, in which the additional element 15 is formed of a metal body 44 and a non-metallic sheet piece 45, which is attached to the metal body on the side next to the casting. In addition, the metal body 44 extends to less than half the height of the additional element 15. One or more holes can then, if required, be drilled in the sheet piece at a desired location, through which a lifting hook 46 or other grip, which extends outside the casting of the inner shell 38, can be brought to the casting (Figure 5). The sheet piece is preferably of sturdy plywood. Plywood is also used in the embodiment of Figure 5. The sheet piece can be changed when necessary, but the holes made in it can be blocked, for example, with tape. When the number of holes becomes great, the sheet piece is changed.
Figures 8a and 8b shows a side element not according to the invention, which is also intended to form a casting mould. In general, here too the side element 12 includes a basic element 14 and an additional element 15. The side element 12 also includes means 16 for attaching the basic element 14 and the additional element 15 to each other. In this case, the additional element 15 extends to the height of the basic element 14 and above it. In addition, the additional element 15 includes a wearing component 48, to which the means 16 are attached. The construction is simple and the wearing component 48 forms an even surface to the side element against the casting. In addition, the wearing component 48 is against the basic element 14, so that the addition element 15 is well supported and the side element will be certain to remain straight.
The height of the wearing component 48 is 2 - 5 times that of the basic element 14. The low basic element can then be utilized for casting concrete panels of many thicknesses. In the embodiment shown, the height of the basic element is about 50 mm, when the height of the wearing component can altered between, for example, 100 - 250 mm, by choosing an additional element of a suitable height. The detachable additional element thus varies according to the height. In addition, the wearing component 48 is of an easily machined material, such as wood, especially plywood. Thus, when assembling the casting mould, grip holes and other feed-throughs can be drilled above the basic element through the wearing component very freely at the necessary locations. The means take up a small space, so that the free drilling area is considerable. Reinforcement, for example, can be attached to the grip holes. The additional element is assembled in a jig, so that the side element will be precise dimensionally and in shape. The thickness of the plywood is selected to be such that it will remain straight. The higher the plywood is, the thicker it is. For example, a height of 100 mm can be made from 20-mm thick plywood.
The plywood can be machined to the desired height. Then, for example, the casting can be evened with a compaction beam supported on the side elements, which will simplify and accelerate manufacture. In addition, the surface of the casting can be floated mechanically throughout, as the casting's surface is on the level of the upper surface of the side element. This accelerates manufacture and creates a good surface quality in the concrete panels.
The means 16 include attachments 49, to which corresponding shape-locked counter-pieces 50 are arranged in the basic element 14. A secure attachment is then achieved, which can be detached and attached. In practice, it takes only a few minutes to detach the additional element. In the embodiment shown, there are three attachments 49, in each of which there are two attachment claws 51. Openings 52 corresponding to the attachment and its attachment claws are arranged in the base material of the basic element. The construction is simple, but sturdy and durable. The attachment claws are shaped in such a way that the additional element is set parallel to the basic element and the attachment claws are fed into the openings. After this, the additional element is pushed against the basic element, when the additional element locks into its final position and attitude. During casting, the pressure of the casting presses against this locking position. In one or more attachments, there can be locking, which prevents the additional element from being unintentionally detached, for example, when handling the side element. The wearing component is attached to the attachments, for example, using bolts, so that the wearing component can be easily replaced. The wearing component is replaced when required, not necessarily after each casting. The attachments are preferably of two or three different heights. Additional elements of different heights can then be attached to one kind of basic element. The higher the additional element, the higher the attachment. This ensures the sturdiness of the additional element.
In the embodiment not according to the invention shown, the length of the side element can be 800 mm. 1600-mm and 2400-mm long side elements can also be advantageously manufactured. Besides being moved by hand, the side element can, of course, be moved and placed using a gantry crane, and also a robot. Thus, the side element can be used in both automatic mould manufacture and in hand placing.
The basic element includes a magnetic attachment, which is fitted inside the basic element. The magnetic attachment is then securely fixed and always travels along with the side element. At the same time, the magnetic attachment is well protected against breakage and dirtying. Thus, a magnetic attachment of light construction can be used, as the side element acts as its shell structure. In addition to the fixed magnetic attachments, extra attachments can also be used if necessary.
There is a robot grip 30 in the magnetic attachment. In this case, there are two magnetic attachments spaced 400-mm apart. Thus, the side elements can be used with a robot with 400 mm between its jaws (not shown). In manually used side elements, the location of the magnetic attachments can be chosen freely. For opening, there is a pin 36 in the attachment magnetic, which can be lifted using a tool like a jemmy. The pin lifts the magnet off the casting table. It is precisely the pin which the robot grips with its jaws and by pressing the pin the magnetic attachment is released, so that the magnet attaches to the casting table, holding the side element in place.
The basic element and the attachment are preferably made from high-strength thermo-mechanically rolled cold-formed structural steel. Two commercial names are Optim MC and Domex MC. The bending, welding, and cutting properties of these steels are excellent. The surface quality of these steels and their dimensional and shape permanence is excellent. The basic element and attachments are of bevelled plate material. The components are easy to shape from plate material and the necessary openings can be easily machined prior to bevelling. After bevelling and surface treatment the components are ready for use.

Claims

Side element for forming a casting mould, which side element (12) includes,
- a basic element (14),

- an additional element (15), and

- means (16) for attaching the basic element (14) and the additional element (15) to each other, in order to alter the height of the side element (12),
in which side element (12), the additional element (15) is arranged to form part of the side element (12) and the means (16) are arranged to form adjustment means (17) for adjusting the height of the side element (12), and between the basic element (14) and the additional element (15) there is a gap (40), which is arranged to be adjustable using the adjustment means (17), according to the insulation (42) belonging to the double-shell panel (41) being manufactured using the casting mould, characterized in that the additional element (15) is formed of a metal body (44) and a non-metallic sheet piece (45), which is attached to the metal body (44) on the casting side,
and wherein the metal body (44) extends to less than half of the height of the additional element (15).
Side element according to Claim 1, characterized in that the surfaces of the basic element (14) and the additional element (15) on the casting side are essentially on the same plane.
Side element according to Claim 1 or 2, characterized in that the adjustment means (17) are stepless and the adjustment means (17) include guide means (23).
Side element according to Claim 3, characterized in that the guide means (23) include locking means (27).
Side element according to any of Claims 1 - 4, characterized in that the side element (12) is of a plate material equipped with bends (18), in which there are lightening openings (19).
Side element according to any of Claims 1 - 5, characterized in that the adjustment range of the adjustment means (17) is 40 - 70 % of the total height of the side element.
Side element according to any of Claims 1 - 6, characterized in that the basic element (14) is lower than the additional element (15).
Side element according to any of Claims 1 - 7, characterized in that the basic element (14) includes a magnetic attachment (29), which is fitted inside the basic element (14).
Side element according to Claim 8,
characterized in that there is a robot grip (30) in the magnetic attachment (29).
Side element according to Claim 9, characterized in that the robot grip extends above the additional element (15).
Side element according to Claim 9 or 10, characterized in that the robot grip (30) is anti-magnetic.