JP2006327015A - Manufacturing system for precast concrete product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing system for a precast concrete product, capable of efficiently fabricating the same. <P>SOLUTION: The manufacturing system of the precast concrete product, in which form panels are circulated in the working yard divided into two stories, comprises a form cleaning step, a parts attaching step wherein the parts are attached, a reinforcing mesh installation step wherein the reinforcing mesh is installed in the form, a PC steel wire laying step wherein the PC steel wire is laid on the form, a PC steel wire straining step wherein the PC steel wire is tensed, a buffering step wherein a plurality of the forms are collected temporarily, a descending step wherein the form is conveyed to the lower working yard, a concrete placing step wherein concrete is placed, a finishing step wherein metal fittings are furnished for the body formed by the placing, a curing step, a removing step after the cure, a prestress introducing step wherein prestress is introduced, a demolding and product taking-out step, and a lifting step wherein the form is conveyed to the upper working yard. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a manufacturing apparatus suitable for mass production of precast concrete products.

  Pre-tensioned precast concrete products need only be provided with holes to allow PC steel wires to pass through on-site, so the factory can be easily manufactured. However, pre-tensioned precast concrete products can be used before placing concrete on the formwork. The PC steel wire must be tensioned to maintain the tension until the concrete hardens. Therefore, it is necessary to provide a tension holding force to the mold itself or to provide a tension holding mechanism on the outside of the mold.

The manufacturing method in which the formwork itself has tension holding power is called an Individual Mold Method (IM method), and is known as an industrially impractical one. All the production methods that have been put to practical use in the past are made of a long pretensioned concrete slab by using a long PC steel wire tensioning equipment called a long bench, and divided into the required length, or a mold of the required length. The frames were arranged in series on the bench. The applicant has disclosed Japanese Laid-Open Patent Publication No. 62-264913 “Method and apparatus for producing PC concrete slab”, and has proposed a regeneration means for the IM method.
Further, the applicant has proposed Japanese Patent Laid-Open No. 5-208409 as a precast concrete product manufacturing apparatus which is an improved version of this.
Japanese Patent Laid-Open No. 62-264913 Japanese Patent Laid-Open No. 5-208409

Although the above-described method using a long bench has continued as the only means for producing pretensioned concrete slabs for several decades, the productivity improvement has reached its limit and no further improvement can be expected. The new IM method developed by the applicant earlier is the idea of circulating the lower formwork, but the lower formwork is moved indefinitely mainly by the overhead traveling crane, and the movement by the rail is performed on the lower formwork. In order to proceed in the longitudinal direction, an extremely long site and a large transport facility were required. In addition, there is a problem that labor productivity is reduced due to a wide range of labor of workers.
Furthermore, even in the precast concrete product manufacturing apparatus improved as described above, it is necessary to manually perform the scoring operation, the part insertion operation, and the like, resulting in poor productivity.

  This invention is proposed in view of the above, and it aims at providing the manufacturing system of the precast concrete product which can improve productivity.

  In order to achieve the above object, the present invention is a precast concrete product manufacturing system for manufacturing a precast concrete product by circulating a formwork in a work yard divided into two layers. A mold cleaning process for removing concrete pieces attached to the frame and applying a release material; a component mounting process for positioning a part to be mounted in the mold by an insert mechanism; At the end of the formwork, a mesh reinforcement installation process for installing mesh reinforcement in the formwork, a PC steel wire laying process for drawing the wound PC steel wire, cutting it to a predetermined length, and laying it on the formwork PC steel wire tensioning process that attaches a tension jack and tensions the PC steel wire, and a buffer that attaches various metal fittings and temporarily stores multiple molds After that, a lowering process for conveying the formwork to the lower work yard, a concrete placing process for placing concrete by a placing machine after fixing the upper formwork on the formwork, and after placing the concrete, The finishing process of removing the upper mold and attaching the back metal fitting to the concrete casting body, the curing process for curing the concrete casting body together with the mold in the curing room, and the concrete casting body from the curing room with the mold Curing and removing process to be taken out, pre-stress introduction process to introduce prestress into concrete product by cutting the end of PC wire that is strained through the formwork, demolding to remove the hardened concrete product from the formwork, It is characterized by comprising a product taking-out process and an ascending process for conveying the formwork to the upper work yard.

  In the present invention, the work yard is provided with a drive mechanism for conveying the formwork.

  Further, in the present invention, the processing steps from the mold cleaning process to the buffing process and the concrete placing process to demolding and product taking-out process are performed in different work yards, and the molds are moved between the work yards by a lifting mechanism. It is characterized by conveying.

  Further, the present invention is characterized in that, in the component attaching step, a partition formwork is further installed in the formwork so that a plurality of concrete products can be manufactured.

  Further, the present invention is characterized in that, in the PC steel wire laying step, a supply arm for laying a PC steel wire cut to a predetermined length on a mold is provided.

  A precast concrete product manufacturing system according to the present invention is a precast concrete product manufacturing system for manufacturing a precast concrete product by circulating a formwork in a work yard divided into two layers. A mold cleaning process for removing concrete pieces attached to the frame and applying a release material; a component mounting process for positioning a part to be mounted in the mold by an insert mechanism; At the end of the formwork, a mesh reinforcement installation process for installing mesh reinforcement in the formwork, a PC steel wire laying process for drawing the wound PC steel wire, cutting it to a predetermined length, and laying it on the formwork PC steel wire tensioning process that attaches a tension jack and tensions the PC steel wire, and attaches various metal fittings and multiple molds once A buffering process, a lowering process for transporting the formwork to the lower work yard, a concrete placing process for placing concrete by a placing machine after fixing the upper formwork on the formwork, and concrete After placing, the upper mold is removed, and a finishing process for attaching the post-fill metal fitting to the concrete casting body, a curing process for curing the concrete casting body together with the mold in the curing room, and a concrete casting body from the curing room. A curing and taking out process together with the formwork, a prestressing process for cutting the end of the PC wire that is strained through the formwork and introducing prestress into the concrete product, and a hardened concrete product from the formwork It consists of a demolding and removal process to remove, and an ascending process to transport the formwork to the upper work yard. It can be improved.

  A precast concrete product manufacturing system for manufacturing a precast concrete product by circulating a formwork in a work yard divided into two layers, including positioning of parts to be mounted in the formwork by an insert mechanism, scoring work, and We realized a precast concrete product manufacturing system that can automatically perform the component mounting process for mounting components.

  Hereinafter, the present invention will be described in detail with reference to the drawings illustrating an embodiment. FIG. 1 is a layout view showing a second layer portion F2 of the precast concrete product manufacturing system according to the present invention, and FIG. 2 is a layout view showing the first layer portion F1 of the manufacturing system. Here, the manufacturing system of the precast concrete product of a present Example manufactures a precast concrete product by circulating the formwork 10 in the work yard divided into two layers. By making the work yard into two layers, the work space can be effectively used. In the present embodiment, the precast concrete product manufacturing system removes the concrete pieces and the like attached to the mold 10 by the keren operation and the suction operation, and also applies the release material, and the insert mechanism 12. The component mounting step 14 for positioning the component to be mounted in the mold, scoring and mounting the component, the mesh bar installation step 16 for installing the mesh bar 15 in the mold, and the rolled PC steel A PC steel wire laying step 18 for drawing the wire 17 and cutting it to a predetermined length and then laying it on the mold, and a PC steel wire tensioning step 19 for attaching a tension jack to one end of the mold 10 and tensioning the PC steel wire, A buffer process 20 for attaching various metal fittings and temporarily storing a plurality of molds, a lowering process 21 for transporting the molds 10 to a lower work yard, and a mold After the upper mold 22 is fixed on the concrete, a concrete placing process 24 in which concrete is placed by the placing machine 23, and after the concrete is placed, the upper mold 22 is removed and a back-filling metal fitting is attached to the concrete placing body. A finishing step 25, a curing step 27 for curing the concrete placement body together with the mold 10 in the curing room 26 for a predetermined time, a curing removal step 28 for removing the concrete placement body together with the mold from the curing chamber 26, and the mold 10 A pre-stress introduction step 29 for cutting the end of the PC wire 17 that is strained through the pre-stress to introduce pre-stress into the concrete product, and a demolding and product removal step 30 for removing the hardened concrete product from the mold 10. The ascending step 31 for conveying the mold 10 to the upper work yard.

  As shown in FIG. 1, the mold cleaning process 11 scrapes off a large concrete lump adhering to the mold 10 by the worker's keren work, and sucks the concrete pieces and dust scraped by the kelen by the suction work. Suction work is intensively performed by a central cleaning system, and concrete pieces, garbage, etc. are transported to the tank on the first floor.

  As shown in FIGS. 6 and 7, the mold frame 10 includes struts 102 on the outer sides of both side walls 101. The support column 102 is taller than the side wall 101, has an engaging projection 103 at the top, and has an engaging recess 104 at the bottom. A plurality of molds 10 can be stacked by the support column 102. At this time, the engagement protrusion 103 of the lower mold 10 is engaged with the engagement recess 104 of the upper mold 10. Moreover, the insertion groove | channel 105 which penetrates PC steel wire is formed in the end of the formwork 10, and the tension | tensile_strength part 106 for tensioning PC steel wire is formed in the other end. The mold 10 moves on the roller 32 installed in the work yard as shown in FIGS. 7 to 9 and is driven by the drive mechanism 33.

  As shown in FIGS. 1 and 4, the component mounting step 14 uses white ink using a computer-controlled robot arm 121 that can be moved in the X, Y, and Z directions in the mold 10 according to the CAD data by the insert mechanism 12. Perform marking and marking work for parts to be marked and mounted. The insert mechanism 12 pastes the parts stored in the insert stock 122, and then attaches polystyrene foam or the like to the position marked in the mold 10 according to the CAD data.

  The mesh streak installation step 16 installs the mesh streak 15 from the mesh streak place in the mold 10. Further, the mesh streaks 15 are arranged by a spacer so that a predetermined cover thickness can be secured from the bottom of the mold 10.

  As shown in FIGS. 1 and 5, the PC steel wire laying step 18 sets the types and lengths of a plurality of PC steel wires wound around the PC wire storage 34 and then draws them by the PC steel wire drawing device 35. Then, after cutting to a predetermined length, each one is laid on the mold 10 via the supply arm 181. One end of the laid PC steel wire 17 is fixed to the insertion groove 105 by a fixing tool (not shown), and the other end is fixed to the tension portion 106.

  In the PC steel wire tensioning step 19, as shown in FIG. 19, a tension jack (not shown) is attached to the end of the tension part 106 of the mold 10 to tension the PC steel wire 17.

  In the buffer process 20, as shown in FIG. 1, various metal fittings are attached and a plurality of molds 10 are temporarily stored in a work yard.

  In the descending step 21, the formwork 10 is conveyed to the lower work yard by the elevator 211. The elevator 211 accommodates and lowers the molds 10 one by one.

  In the concrete placing step 24, various metal fittings are attached and the upper mold 22 is fixed onto the mold 10 where the tension of the PC steel wire 17 is completed, and then the concrete is placed by the placing machine 23. As shown in FIG. 10, the placement machine 23 puts the concrete supplied from the hopper 36 from above the upper mold 22. The thrown-in concrete falls into a groove portion 22 a formed along the longitudinal direction of the upper mold 22. The bottom of the groove 22a corresponds to the rib surface of the product and is formed in a mesh shape. In addition, the concrete dropped into the groove 22a is leveled by the scraper 37 disposed in each groove, and the concrete is filled into the mold 10 from the mesh portion. Moreover, the placement machine 23 vibrates the mold 10 and repeats the placement of the concrete until there is no space in the mold. After the concrete is completely charged, the upper mold 22 is released from the clamp and the upper mold 22 is removed.

  In the finishing step 25, the backfill metal fitting is attached to the concrete casting body from which the upper mold 22 after the concrete casting is removed. Also, repair work is done by pulling out the product pulling wire, etc., and by hand-finishing the incomplete parts.

  In the curing step 27, the concrete placement body is cured together with the mold 10 for a predetermined time in the curing chamber 26 as shown in FIG. In the present embodiment, the curing room 26 is divided into six as shown in FIG. 2, and one room is always kept empty. Products are taken in and out using this empty space. The formwork 10 including the concrete placement body is sequentially stacked in the curing chambers 26 by the overhead crane 38, and the temperature is controlled after the ceiling gate 26a is closed. Curing time is managed for each room.

  In the curing and removing step 28, the concrete placement body stored in the curing room after a predetermined time has been taken out together with the mold 10 by the overhead crane 38 and transported to the curing and removal position.

  In the pre-stress introduction process 29, after releasing the tension of the PC wire 17 that is in tension via the formwork 10 with a jack or the like, the PC steel wire 17 is cut and pre-stress is introduced into the concrete product.

  In the demolding and product removal step 30, the hardened concrete product 39 is removed from the mold 10 while being suspended by the overhead crane 40 as shown in FIG. 12. The concrete product 39 taken out is carried out after product inspection.

  In the ascending step 31, only the mold 10 from which the concrete product 39 has been taken out is transported to the upper work yard F <b> 2 by the elevator 212, and then transported to the next mold cleaning process 11.

  According to the precast concrete product manufacturing system as described above, since the component mounting step and the like are performed by a computer-controlled robot, the productivity can be significantly improved as compared with the conventional manufacturing system. In addition, it is possible to quickly respond to changes in attachment parts. Furthermore, since the work yard is divided into two layers, the site area can be efficiently used, and the maximum production efficiency can be achieved with the minimum site area.

  The present invention is not limited to the above embodiment, and a plurality of concrete products can be manufactured in one mold.

FIG. 1 is a layout view showing a second layer portion of a precast concrete product manufacturing system according to the present invention. FIG. 2 is a layout view showing the first layer portion of the precast concrete product manufacturing system according to the present invention. FIG. 3 is an explanatory view showing an elevating mechanism used in a descending and ascending process of the precast concrete product manufacturing system. FIG. 4 is an explanatory diagram showing a placing process, demolding, a product removing process, and the like of the production system for the precast concrete product. FIG. 5 is a plan view showing a mesh reinforcement installation process, a PC steel wire laying process, a curing process, and the like in the production system for the precast concrete product. FIG. 6: is the top view which notched the center part which shows the formwork used for the manufacturing system of the precast concrete product. FIG. 7 is a main part explanatory view showing the relationship between the formwork and the drive mechanism used in the precast concrete product manufacturing system. FIG. 8: is a side view which shows the drive mechanism of the formwork in the manufacturing system of the precast concrete product. FIG. 9 is a plan view showing a formwork driving mechanism in the precast concrete product manufacturing system. FIG. 10 is an explanatory view showing a concrete placing device used in the production system for the precast concrete product. FIG. 11 is explanatory drawing which shows the curing room used for the manufacturing system of the precast concrete product. FIG. 12 is an explanatory view showing a demolding and product removal process in the precast concrete product manufacturing system.

Explanation of symbols

F1 1st layer part F2 2nd layer part 10 Formwork 11 Formwork cleaning process 12 Insert mechanism 14 Component attachment process 15 Mesh reinforcement 16 Mesh reinforcement installation process 17 PC steel wire 18 PC steel wire laying process 19 PC steel wire tensioning process 20 Buffering process 21 Lowering process 22 Upper mold 23 Placing machine 24 Concrete placing process 25 Finishing process 26 Curing room 27 Curing process 28 Curing removal process 29 Prestress introduction process 30 Demolding and product removal process 31 Lifting process 32 Roller 33 Drive Mechanism 34 PC wire storage 35 PC steel wire drawing device 36 Hopper 37 Scraper 38 Overhead crane 39 Concrete product 40 Overhead crane

Claims (5)

  A precast concrete product manufacturing system for manufacturing a precast concrete product by circulating a formwork in a work yard divided into two layers, and removing concrete pieces adhering to the formwork by keren work and suction work Formwork cleaning process to apply release material, parts installation process to locate parts, crease work and parts installation by insert mechanism, and mesh lines to install mesh lines in the formwork An installation process, a PC steel wire laying process in which the wound PC steel wire is pulled out, cut to a predetermined length, and then laid on the mold, and a tension jack is attached to one end of the mold to attach the PC steel wire Steel wire tensioning process, buffer process for attaching various metal fittings and temporarily storing multiple molds, and transporting the molds to the lower work yard A lowering process, a concrete casting process in which concrete is cast by a placing machine after the upper mold is fixed on the mold, and after the concrete is cast, the upper mold is removed and the concrete casting body is A finishing process for attaching the metal fittings, a curing process for curing the concrete placement body together with the mold in the curing room for a predetermined time, a curing removal process for removing the concrete placement body together with the mold from the curing room, and tension through the mold Cutting the end of the PC wire and introducing prestress into the concrete product, removing the hardened concrete product from the formwork, taking out the product, and the work yard above the formwork A precast concrete product manufacturing system comprising an ascending process for transporting to a precast concrete product.   The precast concrete product manufacturing system according to claim 1, wherein a drive mechanism for transporting the formwork is disposed in the work yard.   The processing steps from the mold cleaning process to the buffing process, the concrete placing process, demolding, and the product taking out process are performed in different work yards, and the mold is transported between the work yards by a lifting mechanism. The manufacturing system of the precast concrete product of Claim 1 or 2.   The system for producing a precast concrete product according to any one of claims 1 to 3, wherein in the component attaching step, a partition formwork is further installed in the formwork so that a plurality of concrete products can be produced. .   The precast concrete product according to any one of claims 1 to 4, further comprising a supply arm for laying a PC steel wire cut into a predetermined length on a mold in the PC steel wire laying step. Manufacturing system.

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