ES2764387T3 - Support method to support an armor construction - Google Patents

Abstract

Support method (21) to support a reinforcement construction (1, 2) in the manufacture of precast concrete parts, where - in a first method step (23) data are prepared for the reinforcement construction (1, 2 ) designed for the precast concrete part to be manufactured, - in a second method step (24), in a programmable electronic calculation facility (3), positions (33, 34) are calculated to support the reinforcement construction ( 1, 2) based on the prepared data of the truss construction (1, 2), - in a third method step (25), for the support of the truss construction (1, 2) in the positions (33 , 34) calculated, spacer supports (4) are placed, characterized by the step: - in a fourth method step (26) on the spacer supports (4) a reinforcement construction (1, 2) manufactured according to the data is placed.

Description

DESCRIPTION

Support method to support an armor construction

The invention relates to a bearing method for supporting a reinforcement construction and to a manufacturing method for manufacturing precast concrete parts.

In order to ensure that the reinforcement elements inserted therein have sufficient concrete cover, in the manufacture of precast concrete parts, spacer supports in the form of, for example, plastic rings or strips of different sizes are placed manually on a lower floor and on them, then, the armor elements. With this, the manual placement of the spacer supports is produced based on experience values, which results in part from using too many spacer supports. This increases the risk of formation of hollow spaces, since the spacer supports together with the reinforcement elements are covered with concrete, which acts disadvantageously on the quality of the precast concrete part. Furthermore, this results in higher costs because, on the one hand, unnecessary spacer supports are used and, on the other hand, when recycling the precast concrete parts, a greater investment is needed to extract the spacer supports from the precast concrete part again.

DE 3420806 A1 relates to the manufacture of a reinforcement from several intersecting wire rods.

DE 4031 384 C1 publishes a method for securely ordering mounting parts on a pallet in place.

Document DE 41 35 581 A1 publishes the claim for an armature construction by means of expandable or foaming tracks, where different separations are carried out by influence of the expansion or foaming process.

DE 1918965 A1 publishes a device for attaching anchor lugs.

EP 1273407 A1 publishes a robot for attaching a magnet. DE 19651 933 C1 publishes a formwork robot.

The mission of the present invention is to present a support method, improved with respect to the state of the art, of a reinforcement construction and a manufacturing method for the manufacture of precast concrete pieces that takes advantage of this support method, where the The support method according to the invention is particularly notable for better quality of precast concrete parts, cost savings as well as environmentally friendly recycling of precast concrete parts.

This mission will be solved by the characteristics of claims 1 and 9.

According to them, it is foreseen that in the support method to support a reinforcement construction in the manufacture of precast concrete parts:

- in a first method step, data is prepared from a reinforcement construction designed for the precast concrete part to be manufactured,

- in a second method step, in a programmable electronic calculation facility, positions are calculated to support the reinforcement construction, based on the prepared data of the reinforcement construction,

- in a third method step, to support the reinforcement construction, spacer supports are placed on the calculated positions,

- in a fourth method step on the spacer supports the reinforcement construction manufactured according to the data is placed.

With this, because in the course of the second method step the positions are calculated to support the reinforcement construction and then in the course of the third method step the spacer supports are placed in the calculated positions, it is ensured that a quantity is used optimal spacer supports and that these are placed in the optimal positions. This enables precast concrete parts to be manufactured in units with a suitable concrete coating and fewer voids, reducing costs and protecting the environment by recycling at the end of the useful life of precast concrete parts.

On the data prepared in the course of the first method step of a reinforcement construction designed for the precast concrete part to be manufactured, it may be for example the construction, the geometry and the weight of the reinforcement construction. Typically the reinforcement constructions used are constructed from longitudinal bars, cross bars and / or mesh supports, where depending on the precast concrete part can be provided with castings for eg windows or doors. The outer contours of the reinforcement construction can reproduce the outer contours of the precast concrete part to be manufactured, that is, for example, inclined surfaces or the like. The mesh supports that are usually used generally have an upper and a lower arrangement and, between them, straps that run diagonally. The exact construction of the mesh support may also form a part of the data presented. The diameter and material composition of the longitudinal and transverse bars or of the mesh support used as well as the relative arrangement of these elements also play a role.

All these data can be prepared in the course of the first method step, specifically in the form of a CAD file. But the expression "prepare" also includes solutions in which the data is generated in the course of the first method step from a programmable electronic calculation facility or obtained from a data bank. In addition, it can be the same programmable electronic calculation facility that is also used in the second method step.

The calculation of the positions to support the reinforcement construction performed in the course of the second method step may also take into account other parameters in addition to the reinforcement construction data prepared in the course of the first method step, for example, the load capacity of spacer supports used to support reinforcement construction.

The calculation of the positions can be done in different ways:

For example, it is possible for different types of precast elements to be handled in a diversified manner. For example, based on simplified static models made to measure for each type of element, an algorithm could be developed that is suitable for calculating position.

Specifically it is possible in the course of the calculation, firstly to place the spacer supports in positions that appear appropriate to each type of element, then to determine the warping behavior of the reinforcement construction depending on the data prepared from that reinforcement construction. and check if this warping behavior corresponds to the default limit values. Depending on the result of this check, the positions of the spacer supports are displaced iteratively, and the warping behavior is again calculated and compared with the limit values. These steps are carried out until no substantial improvement can be obtained, that is, reduction in the number of spacer supports and at the same time armor construction buckling behaviors still tolerable.

During the calculation based on the warping behavior of the reinforcement construction, it was also highlighted as favorable to calculate the torques exerted and compare them with the predetermined limit values.

As a complement or as an alternative, during the calculation of the positions to support the reinforcement construction in the course of the second method step, the reinforcement construction can be divided into support zones, where each support zone is associated exactly a spacer. Thus, it has been shown to be advantageous to iteratively shift the boundaries of the support zones during position calculation to support reinforcement construction in the course of the second method step.

As regards the positioning of the spacer support in the positions calculated in the course of the third method step, the following solutions have been declared as advantageous:

On the one hand, the placement can be carried out manually, where a marking device can be used to mark the positions. In this case it may be for example a plotter or a modulated paint laser or the like.

On the other hand, placement can be carried out automatically, for example, by means of a placement automat. Then, in the course of the fourth method process on a placed spacer supports a precast reinforcement construction is deposited according to the data.

This essentially ends the support method for supporting an armor construction. To now manufacture a precast concrete part in another sequence, in a next method step the reinforcement construction deposited on the spacer supports is embedded in a concrete mass together with the spacer supports.

Preferably, in the course of the third method step, the spacer supports are placed on a pallet provided with formwork elements and the manufacturing method is carried out on a circulating installation on pallets. Advantageous embodiments are defined in dependent claims 2 to 8.

Other details and advantages of the present invention are explained in more detail below, on the basis of the description of the figures and with reference to the drawings. It shows:

Figure 1, a flow chart to represent each of the steps of the support method or the manufacturing method,

Figure 2a, an exemplary reinforcement construction, based on which a possible calculation strategy for calculating the positions for the spacer supports is described.

Figure 2b, the reinforcement construction according to figure 2a supported by a row of spacer supports,

Figure 3a, another example of an armature construction supported with a row of spacer supports,

Figure 3b, an extract of the reinforcement construction according to figure 3a,

Figure 4, a separation device for the intermediate feeding of the spacer supports to be placed,

Figures 5a-5d, a sequence of positions of the separation device to illustrate its way of acting,

Figure 6a, a preferred embodiment of a stationary positioning automaton for carrying out the support method according to the invention,

FIG. 6b shows an exemplary embodiment of a moveable positioning automat for carrying out the support method according to the invention,

FIG. 7 shows a preferred construction of a charging station for a positioning automat; FIG. 8 a centering bolt for storing spacer supports placed one on top of the other, as can be provided in the charging station according to FIG. 7.

Figure 1 schematically shows, on the basis of a flow diagram, the development of the support method 21 to support a reinforcement construction during the manufacture of precast concrete parts, where:

- in a first method step 23, data of a reinforcement construction designed for the precast concrete part to be manufactured are prepared,

- in a second method step 24, in a programmable electronic calculation facility, positions are calculated to support the reinforcement construction, based on the prepared data of the reinforcement construction,

- in a third method step 25, to support the reinforcement construction, spacer supports are placed on the calculated positions, and

- in a fourth step of method 26, on the spacer supports the reinforcement construction manufactured according to the data is placed.

The supporting method 21 for supporting a reinforcement construction can be integrated into the manufacturing method 22 for the manufacture of precast concrete parts, wherein in a method step 27 which is joined following the method steps 23 to 26 of support method 21, the reinforcement construction placed on the spacer supports is embedded in a concrete mass.

Figure 2a schematically shows in an upper plan view an example of a reinforcement construction 1 which is built for the manufacture of a precast concrete part in the form of a polystyrene roof. The reinforcement construction 1 is composed of several longitudinal bars 28, essentially oriented perpendicular to the transverse bars 29 as well as mesh supports 30, which for example can be constructed from an upper belt arrangement and a lower belt and belt arrangement diagonals running between them. The data of this armature construction 1 is prepared in the course of the first step of method 23. In a second step of method 24, in a programmable electronic computing facility they are calculated, based on the data of the armature construction 1 prepared , positions 33 and 34 (see figure 2b) to support reinforcement construction 1.

In the specific case, the type of element is dominated by the five longitudinal lines in which the longitudinal reinforcement is concentrated and in which the mesh supports 30 are located. A logical assumption as a starting point for the calculation is to locate the Spacer supports exclusively along these five main lines in the longitudinal direction 33. Then several spacer supports 4 are distributed by way of test along these longitudinal lines and the warping behavior of these longitudinal lines is calculated in approximation mode, disregarding the cross bars 29, and are compared with the predetermined limit values. Subsequently, positions 33 and 34 of the spacer supports 4 are iteratively displaced, the warping behavior is calculated again and compared with the limit values, and so on until the maximum separation 31 of the first spacer support 4 has been calculated from the start of the reinforcement construction 1 as well as the maximum spacing 32 of the spacer support 4 one below the other along the longitudinal line, with a still tolerable buckling behavior. Values 31 and 32 are therefore calculated with a certain tolerance that depends on the spacing 44 of the crossbars 29, since for reasons It is logical not to place the spacer supports 4 exactly on the positions given by 31 and 32, but to move them to the closest crossing point.

On the basis of this calculation method it is possible to calculate a set of positions 33, 34 essentially optimal to support the reinforcement construction 1 based on the prepared reinforcement construction 1 data, where this set of positions 33, 34 ensures a minimum number of spacer supports 4 for at the same time a tolerable warping behavior of the reinforcement construction 1, which consequently acts on the quality of the precast concrete part to be manufactured.

In a third method step 25, the spacer supports 4 are now placed at positions 33 and 34 to support the calculated reinforcement construction 1. In a fourth method process 26, an armature construction 1 calculated according to the data is deposited on the spacer supports 4. The result of these third and fourth method steps 25 or 26 is schematically represented in Figure 2b, in where additionally the internal contours of the formwork elements 10 are also exposed, which correspond to the external contour of a prefabricated concrete part manufactured by embedded in a concrete mass of the reinforcement construction 1 deposited on the spacer supports 4 and the hardening of the concrete mass.

Figure 3a shows another example of a truss construction 2 in the form of a mat that is constructed from longitudinal bars 28 and transverse bars 29. The mat has a recess 35 for a window and a recess 36 for a door as well as a inclined surface 43.

In the course of the first method step 23 the data from this reinforcement construction 2 is prepared in the form of CAD data.

In a second method step 24, positions 33 and 34 are calculated for the support of reinforcement construction 2 in a programmable electronic calculation facility based on these data prepared from reinforcement construction 2.

For this, as shown in Figure 3b, the mat is divided into support areas 5, where each support area 5 is associated exactly with a spacer support 4 which at least supports a longitudinal bar 28 or a cross bar 29. Each of these supported bars buckles down from a fulcrum. This buckling essentially depends on the proper weight of the supported bar and the weight of the welded supported bars. In the course of the calculation, it is required that a maximum parameterizable moment of rotation cannot be exceeded, where the moment of rotation depends on the diameter of the supported bar. The load of the supported bars is distributed over all the supported bars. Each supported bar that rests on a spacer support is calculated. In other steps each supported bar is considered in turn as a support bar and calculated until all bars are supported. The buckling of the supported bars depends on their diameter and on the weight of the welded bars and on the resulting moment of rotation.

This calculation is performed for support zones 5 in each of which a spacer support 4 is located. The distribution in the support zones 5 is carried out, for example, starting from one side of the reinforcement construction 2. The initial size of each Support zone 5 is parameterizable. Depending on the calculation result for a bar of a support area 5, during the calculation the size of the support area 5 is iteratively modified to get as close as possible to the limit of the predetermined torque. The limits 16 of each support zone 5 are predetermined on the one hand by the limits of the exterior and interior reinforcement construction 2 (recesses for windows, doors or the like) and on the other hand by the calculated loads and the resulting limits for them other support areas 5.

Furthermore, it should be noted that the maximum load capacity of the spacer support 4 is taken into account when calculating positions 33 and 34.

For the support of the reinforcement constructions 1, 2 it is possible to use spacer supports 4 with a support surface 40 of the mesh type in which steps are provided, and with several supports 42 that protrude from the support surface 40 that may be located both at the outer edge and also in the central area on the bearing surface 40, whereby the bearing surface 40 and the outer bearings 42 define a dummy volume of the spacer holder 4 (see also FIG. 4). Some of the passages are located in the support surface 40 in such a way that at least they offer space for supports 42 of another spacer support 4 of the same construction and with this, at least two spacer supports 4 can be stacked on each other and the dummy volume common of the stacked spacer supports 4 increases insignificantly with respect to the dummy volume of a spacer support 4, where the stacked spacer supports 4 are, in principle, in the same position and are only rotated or displaced relative to each other so that their surfaces bearing 40 rest parallel to one another.

In this way it is possible to place numerous spacer supports 4 next to each other saving space. In the present case, the mesh-shaped support surface 40 is circular. The supports 42 form the dimension that defines the concrete cover. Depending on the concrete cover of the reinforcement construction 1, 2 that is needed, the supports 42 can be longer or shorter.

In FIG. 4 a stack constructed in such a way with spacer supports 4 positioned one above the other or one inside the other is shown. To place the spacer supports 4 in the positions calculated in the course of the third method step 25, the stacked spacer supports 4 can be stored in an intermediate step in a differentiating device 8. This differentiating device 8 consists of a centering tube 37 with the that the spacer supports 4 are kept centered. The spacer supports 4 are lifted upwards by a stop 39.

In the starting position shown in FIG. 4 or 5a, the stack of spacer supports is supported on the stop 39. A differentiator 38 further separates the lower spacer support 4 from the second spacer support 4 from below. In order to be able to fit in the stop 39 or in the differentiator 38, the spacer supports 4 have an annular cantilever 45.

To now release the lower spacer bracket 4 to a calculated position 33, 34, the stop 39 is moved radially outward so that the spacer bracket 4 with the overhang 45 is no longer supported on the stop 39 (see Figure 5b). After the release of this spacer support 4, the stop 39 is brought back to its original position again (see figure 5c). The differentiator 38 is then moved radially outward. The stack of spacer supports thereby falls down onto the stop 39 (see FIG. 5d). finally the differentiator 38 is brought back to its original position according to figure 5a.

In order to facilitate the positioning of the spacer spacer 4 in the calculated positions 33, 34 in the course of the third method step 25, a marking device may be provided, for example a plotter which points to the spacer support 4 the calculated positions 33, 34 on a pallet. As an alternative, the marking device may also comprise a modular laser with which the positions 33, 34 calculated for the spacer support 4 are indicated, either sequentially one after the other or simultaneously. In another sequence a service person can place the spacer support 4 at the calculated positions 33, 34, which have been marked by means of the marking device.

As an alternative or as a complement to it, the positioning of the spacer support 4 in the positions 33, 34 calculated in the course of the third method step 25 can be carried out by means of a positioning automaton. Figure 6a shows an example of such a positioning automat 6, which is built stationary. This means that a pallet on which spacer supports 4 must be placed at the calculated positions 33, 34 is displaced with respect to the stationary positioning automat 6.

It is also possible to provide a stationary positioning automaton 6 of this type on a station of a circulating pallet installation. For this, the pallets 11 move along or transversely from one station to the next of the installation of circulating pallets. In the example shown, the displacement of the pallet 11 occurs in the longitudinal direction 33.

To place the spacer supports 4 in the previously calculated positions 33, 34, two positioning devices 19 are provided, each of which has one of the prescribed differentiating devices 8. For the control of a certain position 33, 34 the pallet 11 moves in the longitudinal direction 33 and one of the positioning devices 19 moves in the transverse direction 34 along a transverse beam 17. For this purpose, a unit for control 20 for controlling the movements of the positioning devices 19. According to a preferred embodiment, this control unit 20 can also control the movement of the pallet 11. Furthermore, the control unit 20 can be an electronic computing installation 3 programmable which in the course of the second method step 24 calculates the positions 33, 34 for the support of the reinforcement construction 1, 2 based on the prepared data of the reinforcement construction 1, 2.

Depending on the power required, a positioning automat 6 such as this may be provided, to which several beams parallel to each other may be associated, which are located transversely to the direction of travel of the pallet 11 and on which they rest, and one or more of them can be moved. positioning devices 19.

Figure 6b schematically shows an example of a positioning automaton 7 built to be able to move. In this case the pallet remains in a certain position during the placement of the spacer supports 4 in the calculated positions 33, 34 and the positioning devices 19 move both in the longitudinal 33 and in the transverse 34 direction with respect to the pallet 11. Also in this case, depending on the laying power, several parallel beams may be provided in which one or more laying devices 19 are located.

Each of the positioning automata 6, 7 represented in Figures 6a and 6b may also comprise a charging station for filling the spacer supports 4 to be placed in the course of the third method step 25. The charging station it can also be used to have prepared different types of spacer supports 4 so that a change between two different types of spacer supports 4 is simply possible.

A loading station 9 of this type is shown in FIG. 7. The loading station 9 comprises a warehouse with several, in this particular case three, turntables 12 each of which has a filling area 13 and a loading area emptying 14. For this reason, the warehouse can at the same time be filled with new spacer supports 4 by a service person through the filling area 13 of the turntable 12, while the other half of the warehouse, that is to say the emptying area 14 of the turntable 14 is arranged for the extraction of the spacer support 4. The warehouse is advantageously constructed so that a sufficient number of spacer supports 4 are stored for the day's production. In order to extract new spacer supports 4, the positioning device 19 moves on a stack of spacer supports prepared in the warehouse and houses one in the differentiating device 8. The loading station 9 can be constructed so that spacer supports 4 with different heights can be available in warehouses located next to each other.

Instead of turntables, for example, one or more drawers can also be used.

Centering bolts 15 can be provided to store the stack of spacer supports 9 in the loading station 9, which can fit into a corresponding central opening 41 in the bearing surface 40 of the spacer support 4 (see FIG. 4). In this way a stack of spacer supports can be stored in a predetermined warehouse position.

Basically it can be thought that the positioning device 19 takes a certain stack of spacer supports, uses a part of the spacer supports 4 of the stack, that is, in the course of the third step of method 25 it places them in positions 33, 34 previously calculated and the unused spacer supports 4 places them back in a warehouse position to take another type of spacer support, for example with a different height.

Claims (9)

1. Support method (21) to support a reinforcement construction (1, 2) in the manufacture of precast concrete parts, where - in a first method step (23) data is prepared for the reinforcement construction (1, 2) designed for the precast concrete part to be manufactured, - in a second method step (24), in a programmable electronic calculation facility (3), positions (33, 34) are calculated to support the reinforcement construction (1, 2) based on the prepared construction data armor (1,2), - in a third method step (25), to support the reinforcement construction (1, 2) at the calculated positions (33, 34), spacer supports (4) are located, characterized by the step: - in a fourth method step (26) on the spacer supports (4) a reinforcement construction (1, 2) manufactured according to the data is placed. 2. Support method (21) according to claim 1, wherein in the course of the third method step (25) the spacer supports (4) are placed on a pallet (11) with formwork elements (10). 3. Support method (21) according to claim 1 or 2, wherein the positions (33, 34) on which the spacer supports (4) have been placed in the course of the third method step (25) are marked by a marking device, which at least comprises a laser. 4. Support method (21) according to one of claims 1 to 3, wherein in the course of the third method step (25) the spacer supports (4) to be placed in the calculated positions (33, 34) to support the reinforcement construction (1, 2) they are extracted as a minimum of a differentiating device (8) preferably automated. 5. Support method (21) according to one of claims 1 to 4, wherein during the calculation of the positions (33, 34) for supporting the reinforcement construction (1,2) in the course of the second step of method (24), the reinforcement construction (1, 2) is divided into support areas (5), where each support area (5) is assigned exactly one spacer support (4). 6. Support method (21) where during the calculation of the positions (33, 34) for the support of the reinforcement construction (1,2) in the course of the second method step (24), the limits of the support areas (5) are moved iteratively. 7. Support method (21) according to one of claims 1 to 6, wherein the calculation of the positions (33, 34) for the support of the reinforcement construction (1,2) in the course of the second method step (24) is done taking into account - the construction of the armature construction (1, 2), - the geometry of the reinforcement construction (1, 2), - the weight of the armor construction (1, 2), - the buckling behavior of the reinforcement construction (1, 2), - the turning moments exerted as a function of the warping behavior of the reinforcement construction (1, 2), and / or - the load capacity of the supports (4) used to support the reinforcement construction (1, 2) in the consecutive method steps. 8. Support method (21) according to one of claims 1 to 7, wherein the positioning of the spacer supports (4) in the positions (33, 34) calculated in the course of the third method step (25) is carried out by means of a placement automat (6. 7). 9. Manufacturing method for the manufacture of precast concrete parts, wherein firstly the support method (21) for supporting the reinforcement construction (1, 2) is carried out according to one of claims 1 to 8, and in a subsequent method step (27) the reinforcement construction (1, 2) placed on the spacer supports (4) is embedded in a concrete mass, where preferably the manufacturing method (22) is carried out in an installation of circulating pallets.