JP2678968B2 - Large ALC panel manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a large ALC panel, and more particularly to a method for manufacturing a wide large ALC (steam curing lightweight cellular concrete) panel having a width of 600 mm or more.

[0002]

2. Description of the Related Art Conventionally, as a method for manufacturing a large ALC panel of this type, an ALC panel precured by a mold is
At least placed on the surface plate (bottom plate) of the formwork, it is loaded on a trolley and subjected to autoclave curing.

[0003]

In the conventional example, the mold surface plate is repeatedly heated and cooled each time the autoclave is cured. As a result, the mold surface plate is distorted due to thermal expansion and cooling contraction. Occurs. For this reason, it is necessary to replace the surface plate, which is a large flat steel plate, relatively frequently, resulting in high cost. In addition, a release agent is applied on the surface plate to facilitate the separation of the surface plate and the finished product, but since this release agent is also heated during autoclave curing, the release agent burns onto the surface plate. It may end up. Also, since the ALC material on a large flat steel plate is autoclaved, steam is difficult to reach the inside of the material due to being blocked by the surface plate.

Therefore, it is an object of the present invention to provide a method for manufacturing a large ALC panel which solves the above-mentioned problems.

[0005]

In order to achieve the above-mentioned object, the present invention prepares a slurry as an ALC raw material,
Create a reinforcing bar cage to be built in the LC panel, assemble the base plate and side plate of the separable formwork to create a formwork that can create one ALC panel in a horizontal state, and reinforce the created formwork. Set the rebar cage, cast the slurry into the mold with the reinforcing rebar cage set, and foam and harden the slurry cast as pre-curing to create a semi-plastic body, separate the mold and remove the side plate from the surface plate. Remove, transfer the semi-plastic material from the surface plate to the wagon frame and place it horizontally, stack multiple semi-plastic materials via the wagon frame, and place the semi-plastic materials on the wagon frame and autoclave the stacked semi-plastic materials. Large AL, characterized by being carried into an autoclave and curing
The C panel manufacturing method is adopted.

[0006]

Next, an embodiment of the present invention will be described with reference to the drawings.

FIG. 1 is a flow chart showing all the steps of manufacturing the large ALC panel of the present invention. 2 to 6 are
It is a figure for explaining an assembling process of a reinforced rebar cage,
7 to 14 are views for explaining the mold, and FIG.
5 to 18 are diagrams for explaining the mold frame attaching / detaching device, and FIGS. 19 and 20 are diagrams for explaining the wagon frame.

(1) All steps of manufacturing method of large ALC panel: First, referring to FIG. 1, all steps of manufacturing method of large ALC panel will be described. ) ALC raw material slurry preparation process, (b) Reinforcing steel bar cage assembly and rustproofing process, (c) Formwork surface plate and side plate cleaning, assembly process, (d) pre-curing process, and (e) Since it can be roughly divided into the autoclave curing step, it will be described below in this order.

(A) ALC raw material slurry preparation process: A
The LC raw material slurry preparation process prepares each raw material and water,
The slurry is prepared by weighing so as to have a predetermined ratio, mixing the weighed ratios, and adding and kneading aluminum powder as a foaming agent (steps 1 to 4). This ALC
The process of preparing the raw material slurry is the same as the conventional process, and thus detailed description thereof is omitted in this specification.

(B) Reinforcing Reinforcing Bar Basket Assembly and Anticorrosion Treatment Process: For assembling the reinforcing reinforcing bar cage, the reinforcing bars for the main reinforcing bars and the transverse reinforcing bars are cut into desired lengths, respectively, and these are assembled in a predetermined arrangement. A basket is created (steps 5 to 7) (details of assembling this reinforced rebar cage will be described later). Then, the reinforced cage is subjected to rust prevention treatment (step 8). In this anticorrosion treatment, a bogie that suspends the rebar cage horizontally, a mechanism that vertically raises and lowers the bogie, a mechanism that horizontally moves the bogie, a storage tank that stores the anticorrosive liquid, and a coated anticorrosive liquid A drying chamber for drying the is used. The trolley for horizontally suspending the rebar cage is a horizontal grid, and is a suspender that can be stretched by a spring, and is configured to suspend a desired portion of the rebar cage.

(C) Cleaning and assembling process of mold surface plate and side plate: The mold used last time is separated into the surface plate and the side plate for the next use and brought to the cleaning station. The platen is washed and a release agent is applied (steps 9 to 11). Also, the side plate is washed and a release agent is applied (steps 12 to 14). The surface plate coated with the release agent and the side plate are assembled to form a mold (steps 15 and 16). The details of the mold and the details of the mold assembly performed by the mold detaching device will be described later.

(D) Pre-curing step: As a pre-step of the pre-curing step, a mold made by washing, applying a release agent and assembling in steps 9 to 16 and forming a rebar cage in steps 5 to 8 are assembled. After the steel is created, a rustproof steel basket is set (step 17). In this setting process, insert a mounting jig of a predetermined size in the corner between the reinforcing cage and the side plate of the form,
In the positioned state, the rebar cage parallel to the side plate of the rebar cage is clamped from above at each one position in the longitudinal direction and the right angle direction of the rebar cage, and the flat base is fastened to the side plate. Then, the set is completed by removing the mounting jig.

Next, step 1 is carried out on the formwork in which the rebar cage is set.
Cast the slurry created in ~ 4. (Step 18). The slurry is poured into a mold to a predetermined level, and allowed to stand to be reactively foamed and cured (Step 1
9). After the foaming is completed, the fixing jig is removed before completely solidifying. This creates the semi-plastic of the ALC panel.

Next, the frame is removed (step 20).
That is, the mold surface plate and the side plate are separated. The molds are separated by a mold attaching / detaching device, the details of which will be described later. The side plate of the separated form, as shown by the solid line A,
Moved to wash station for next use.

After separating the side plates, the side plates are contacted and shaped (step 21). In this step, the surface of the semi-plastic material is cut with a horizontal cutting blade to a desired thickness. Next, the two surfaces on the partition plate side (which will be described later) and the opening are vertically cut into desired dimensions. At this time, the cutting debris remaining on the surface is removed by a screw conveyor that cooperates with the cutting blade, and the opening is left with a break.

(E) Autoclave curing step: As a pre-step of the autoclave curing step, the semi-plastic panel is transferred from the surface plate of the mold to the wagon frame (step 22). This wagon frame is a panel transfer / curing frame for transferring the panel to the autoclave and placing the panel during curing in the autoclave, and in the present specification, for convenience of explanation, it is simply a "wagon frame". Say. The mold surface plate with the semi-plastic panel removed is for next use as shown by the solid line B.
Moved to wash station. A vacuum suction device is used for transfer to the wagon frame. The outer shape of the suction chamber of this vacuum suction device is almost the same as the outer shape of the side plate of the form, the inside is divided into a plurality of suction chambers, and each of these suction chambers is capable of sucking independently. It is configured to detect the atmospheric pressure of the chamber and control it so as to reach the set pressure. The wagon frames on which the panels are placed are stacked (step 23). The stacked wagon frames are loaded into the autoclave, and the panels are autoclaved (step 24). After curing the autoclave, the panel and wagon frame are removed from the autoclave. The wagon frame is separated from the carriage and is moved to the panel transfer station for next use, as shown by the dotted line C for the wagon frame and the dotted line D. Also, the panel is transferred to the roller conveyor using another vacuum device and moved to the finishing station (step 25).

The autoclaved panel is finished by finishing (step 26). The finishing process is performed as follows. First, the four facets are cut to accurately machine the desired dimensions. Next, for those having an opening, the edge face of the opening is cut to accurately machine it to a desired size. If necessary, tiles are attached to the surface of the panel, painted, or patterned.

(2) Details of the process for assembling the reinforcing reinforcing bar cage:
Next, with reference to FIGS. 2 to 6, the assembly of the reinforcing reinforcing bar cage will be described. In assembling the reinforcing bar cage, the reinforcing bars for the main bars and the horizontal bars are cut into desired lengths respectively, and the main bars 11 in the longitudinal direction are cut.
1s are arranged one by one at desired intervals. And each of these main lines 1
The roller 11 is moved horizontally by a desired distance to perform positioning in the lengthwise direction, but when it is necessary to form an opening, the stopper 116 is operated to open a space corresponding to the opening.

Next, the transverse stripes 112 orthogonal to each other are supplied one by one at desired intervals and welded by the upper and lower electrodes 113 to form 1
The first wire mesh-shaped rebar mat 115 is manufactured. This rebar mat 115 is transferred to the next step by the roller conveyor 114a, and if the mounting bracket 117 is supplied to a desired position and welded during this time, the rebar mat 1 as shown in FIG.
It becomes 15. If the second rebar mat 115a is manufactured in the same manner, the lifter 114b rises when it is transferred to the next step by the roller conveyor 114a, and is transferred to the upper roller conveyor 114c. (See Fig. 3)

Then, the upper and lower roller conveyors 114a,
114c are started at the same time and two rebar mats 115, 1
15a is moved in parallel by a desired distance, and a plurality of united muscles 11
8 from above and two rebar mats 115, 115a
The main bar 111 is welded and then cut (see FIGS. 4 and 6). The horizontal reinforcement 112 of the rebar cage 110 thus assembled is fixed above the main reinforcement 111.
In addition, each of these devices is controlled by a sequence starting program based on the specifications of the manufacturing order input to the main computer and is operated fully automatically.

(3) Form: Next, the form will be described with reference to FIGS. FIG.
Is a plan view of the entire formwork in a state where a surface plate and side plates are combined and fixed, and FIG. 8 is a side view of the edge of the formwork,
9 is a front view of the mold, FIG. 10 is a plan view of the surface plate, FIG. 11 is a side view of the surface plate, and FIG. 12 is a line 12-12 of FIG. 7 showing the positioning means. 13 is a cross-sectional view taken along line 13--13 of FIG. 7 showing the clamping means.
FIG. 14 is a cross-sectional view taken along the line, and FIG. 14 is a side view of the partition plate clamping device.

First, referring to FIG. 7, the outline of the mold of the present invention will be described. The mold 210 has a surface plate 212 which serves as a horizontal bottom surface for supporting the slurry for ALC, and a surface plate 212. Four portions 214a to 21 that are detachably fixed
4d having a rectangular side plate 214. A partition plate 216 is arranged in parallel with long portions 214b and 214d in the longitudinal direction of the side plate 214, and the partition plate 216 is slidably attached to the short portions 214a and 214c of the side plate and the clamp device 230 ( It will be clamped at an appropriate position by (details will be described later). A scale plate 222 is fixed to the upper surfaces of the respective portions 214a and 214c of the side plate 214, and the partition plate 216
Can be positioned at a desired position based on the scales of the two scale plates 222.

The second partition plate 21 is provided between the partition plate 216 and one portion of the side plate 214 (portion 214b in FIG. 7).
8 is slidably arranged so that it can be clamped at an appropriate position by a clamp device 232 (described later in detail). The scale plate 224 is also fixed to the upper surfaces of the side plate 214b and the partition plate 216, and therefore, the second partition plate 2
18 is a part 21 of the side plate 214, similar to the partition plate 216.
4b scale plate 224 scale and partition plate 216 scale plate 2
It can be positioned at a desired position based on 24 scales.
The slurry 220 is introduced into a rectangular space having a desired size formed by the positioned partition plate 216, the positioned second partition plate 218, and the side plate 214 portion (214a, 214b in FIG. 1). It has been pre-cured. The portions 214a, 214 of the side plate 214 are
b is used as a reference plane in dimensions.

At the positions of the four corners of both the surface plate 212 and the side plate 214 of the mold 210, which face each other, the side plate 2 is attached to the surface plate 212.
Positioning means 234 (which will be described later in detail) for positioning 14 and clamping means 2 such as a cotter for clamping the side plate against the surface plate 212 after positioning.
36 (which will be described later in detail). The positioning means 234 and the clamping means 236 are provided at four positions near both ends of the short portions 214a and 214c of the side plate. In addition, a detaching device (FIG. 1) is used for transporting the surface plate to each of two longitudinal edges of the surface plate 212.
5) two locking parts 23 for lifting by
8 is provided, and the long part 214 of the side plate 214 is provided.
B and 214d are similarly provided with locking portions 240 for separating and lifting the side plate 214 from the surface plate by a detaching device. The surface plate 212 and the side plate 214 are formed in a U-shape in cross section so as to have a concave portion in a side portion thereof.

Elastic sealing materials (not shown in FIG. 7) such as rubber packings are attached to the bottom surfaces of the side plate 214, the partition plate 216, and the second partition plate 218.
Is fixed to the surface plate 212, the surface plate 212
Since the space between the side plate 214 and the partition plate 216 can be kept in a watertight state, and the surface plate 212 and the partition plate 218 can be kept in a watertight state when the second partition plate 218 is attached. It is held in the square and does not leak out. In addition, the inner surface of the side plate 214 is formed by a tapered surface that is inclined so as to spread downward,
The surfaces of the partition plate 216 and the second partition plate 218 into which the slurry is introduced are formed as tapered surfaces that are inclined so as to spread downward. Therefore, the pre-cured semi-plastic material can be easily separated from the side plate 214 and left on the platen 212 by separating and lifting the side plate 214 from the platen by the desorption device after the slurry 220 is pre-cured. . The taper surfaces on the four sides of this semi-plastic material are vertically cut and removed with a predetermined dimension in the next step.

Next, referring to FIGS. 8 and 9, FIG.
FIG. 9 is a side view of an edge portion of the mold 210, and FIG. 9 is a front view of the mold 210. As is clear from FIGS. 8 and 9, the mold 2
At the opposite positions near both ends of the shorter edge of 10,
Positioning means 234 and clamp means 236 are provided, and a long plate edge is provided with a platen locking portion 238 and a side plate locking portion 240. Next, FIG. 10 and FIG.
1, FIG. 10 is a plan view of the surface plate 212, and FIG. 11 is a side view thereof. As shown in FIGS. 10 and 11, the surface plate 212 is formed with a guide hole 234a that constitutes the positioning means 234, and the clamp lever 236c of the clamp means 236 (see FIG. 13).
And a semi-circular cutout 236a for passing the clamp lever shaft 236d (see FIG. 13) downward from above.
An engagement member 236b is provided which engages with 36c to securely clamp the surface plate 212 and the side plate 214.

Referring now to FIG. 12, FIG. 12 is a cross-sectional view of the positioning means taken along line 12-12 of FIG. A guide pin 234b is provided outside the lower end of the side plate 214, and the guide pin 234b is tapered downward. Therefore, the guide hole 2 of the surface plate 212
34a, the side plate 214 is positioned with respect to the surface plate 212 when fully inserted. In addition,
When the side plate 214 is mounted on the surface plate 212, it is performed in the mounting station, and the surface plate 212 is mounted (assembled).
Since the side plate 214 is transported to the station and pre-positioned within a certain allowable range at the mounting station, and the side plate 214 is also transported and mounted at that position within the certain allowable range, the side plate 214 is mounted to the guide hole 234a at the time of mounting. Since the guide pin 234b is conveyed to a position where it can be guided,
The problem of not being able to position does not occur. FIG.
As is clear from FIG. 2, the inner surface 215 of the side plate 214 is formed into a tapered surface, and the elastic seal member 21 is formed at the lower end.
7 is attached.

Referring now to FIG. 13, FIG. 13 is a sectional view taken along line 13-13 of FIG. 7 showing the clamping means. The guide hollow member 237 is provided outside the lower end of the side plate 214.
g is fixed, and a clamp lever shaft 236d is inserted into the guide hollow member 237g, and is arranged so as to be vertically movable and rotatable. A clamp lever 236c is fixed to the lower end of the clamp lever shaft 236d so as to project outward, and a flange portion at the upper end of the clamp lever shaft 236d and the guide hollow member 23.
A spring 236e for urging the clamp lever 236c upward via the clamp lever shaft 236d is arranged between 7g. Further, the upper end 236f of the clamp lever shaft 236d is formed in a hexagonal shape such as a bolt head. For this reason, for example, a hexagonal wrench (see FIG. 18) provided in the attachment / detachment device (see FIG. 15) is clamped. By fitting and rotating the upper end 236f of the lever shaft,
The clamp lever 236c is rotated by 90 ° in the direction perpendicular to the paper surface from the position shown in the drawing, and 236b provided on the surface plate 212 is rotated.
It can be clamped by tightly engaging (see FIG. 5).

Next, referring to FIG. 14, FIG. 14 is a side view of the partition plate clamping device. The partition plate 216
Since the clamp device 230 and the clamp device 232 of the second partition plate 218 have almost the same configuration, only the clamp device 230 will be described. The partition plate 216 includes a partition plate body 216a and a portion that slidably supports the partition plate body toward the side plate 214 to be clamped.
That is, in the partition plate body 216, the two bolts 216b are mounted side by side horizontally, while the L-shaped member 216 serving as a guide portion when sliding with respect to the side plate 214.
An oval hole 216c is formed in the horizontal portion 216d supporting e.
Is formed, and a plate member protruding from the lower end is attached. The bolt 216b is guided by the oval hole 216c so that it can be slid horizontally for a short distance. A clamp lever 230 is provided above the horizontal portion 216d.
A support member 230a that rotatably supports b around the pivot 230d is provided. Clamp lever 230
When b is rotated in the direction of arrow A, for example, the tension member 23
0c moves in the direction of arrow C. The bolt 230e connected to the rear end of the tension member is connected to the projecting portion 216f of the partition plate 216, and therefore the partition plate body 21
6a is moved in the direction of the arrow B, and the end face thereof is the side plate 21.
4, the partition plate 216 is clamped to the side plate 214.

Finally, the structure of the second partition plate 218 will be described with reference to FIG. 7 again. Second partition plate 218
Is different from the partition plate 216 in which the partition plate body is composed of one long plate, and the short partition plates 218a which are arranged at both ends and are clamped to the side plates 214 and the partition plates 216, respectively, and the partition plates 218a are covered. And a cover plate 218b for partitioning between the two partition plates 218a. As the cover plate 218b, for example, three types of lengths are prepared depending on the size of the ALC to be manufactured.

The method of using the ALC manufacturing form of the present invention will be briefly described below. First, the partition plate 216 and the second partition plate 218 are slid and clamped according to the size of the ALC to be manufactured. Clamp using devices 230,232. Next, the side plate 214 with respect to the surface plate 212
Are positioned using the positioning means 234 and clamped using the clamping means 236. Then slurry 22
0 is poured into the partitioned space, pre-cured until foamed and solidified in a semi-plastic state. After that, by separating the side plate 214 from the surface plate, the material that has been pre-cured can be conveyed to the next step of cutting the excess portion, for example. The separated surface plate 212 and side plate 214 are, for example, cleaned and then assembled again for the next ALC production.

(4) Form removing / attaching device: Next, the form removing / attaching device will be described with reference to FIGS. FIG.
FIG. 17 is a front view schematically showing a mold removing / attaching device of the present invention, FIG. 16 is a plan view of the mold removing / attaching device, and FIG.
[Fig. 18] is a partial front view showing a main part of a mold removing / attaching device, and Fig. 18 is a side view showing a clamp device and a lifting device of the mold removing / attaching device in an enlarged manner.

First, with reference to FIG. 15 and FIG. 16, a schematic structure and an overall operation of the mold frame attaching / detaching device will be described. A mold attaching / detaching device (hereinafter, simply referred to as an attaching / detaching device) 350 has a carriage 352 having wheels 352a. The carriage 352 is configured so that the wheels 352a allow the form 21 to move.
It is possible to travel on a rail 360 between a separation station A for separating the surface plate 212 and the side plate 214 of 0 and a mounting (assembly) station D for mounting the side plate on the surface plate. Between the separation station A and the mounting station D, a spare station B and a maintenance station C for performing maintenance such as cleaning of the separated side plate, application of a release material, adjustment of a partition plate, and the like are provided. The detaching device 350 includes a lifting device (see FIGS. 17 and 18) and a clamping device (see FIG. 1).
No. 7, FIG. 18) for supporting a sprocket 35, which is hung by a chain 355 hung on a sprocket 357.
7 is driven by a motor 361 via a speed reducer 359 so that it can be vertically moved up and down.

Positioning means 363, 3 for positioning the carriage 352 are provided inside one of the rails 360.
65, 367, 369 (described in detail later) are provided in each station. Further, in the separation station A and the mounting station D, positioning means (not shown) for positioning the surface plate 212 is provided, and the positioning means includes a width direction positioning means and a movement direction positioning means. The widthwise positioning means comprises guide rollers for guiding both sides of the surface plate, and the movement direction positioning means presses the stopper against the stopper that stops the tip of the surface plate that is arranged in front of the movement direction. After that, the clamping device is arranged at the rear end position so as to clamp the rear end of the surface plate.

Next, with reference to FIGS. 17 and 18, the lifting device 360 and the clamping device 36 of the detaching device 350.
2 will be described. Each part of the lifting device 360 and the clamp device 362 is provided symmetrically in the front-rear direction and the left-right direction of the detaching device 350. The mechanism for moving the gantry in the up-down direction, which will be described later, is also symmetrical in the front-rear and left-right directions except for the motor that is the driving source. 17 and 1
8 shows only one symmetrical part. The lifting device 360 and the clamp device 362 are attached to the pedestal 354 as described above, and as described above, by the motor (not shown in FIG. 17) via the chain 355, the sprocket 357, and the speed reducer 359. It is configured to be movable in the vertical direction.

The lifting device 360 includes a lever 370.
The lever 370 is rotated by a cylinder (not shown) via a link mechanism. Further, the lever 370 has a lifting arm 376.
Has been fixed. Therefore, when the cylinder 374 is operated, for example, the cylinder 374 is rotated in the direction of the arrow X and the lifting arm 376 can be engaged with the side plate locking portion 240 of the side plate 214. Further, the lifting arm 276 can be rotated in the direction opposite to the arrow X to separate it from the side plate locking portion 240 of the side plate 214.

The clamp device 362 itself is a cylinder 358.
Is configured to move in the vertical direction. The clamp device 362 is, for example, a hexagon head 2 above the clamp shaft 236 of the side plate 214 such as a hexagon wrench 390.
This hexagon wrench 3 has an engaging tool that can engage with 36f.
90 is supported by the lower end of the shaft 380, and the shaft 380 is supported by another shaft 384 via an elastic coupling 382. The coupling 382 is for swinging the shaft 380 with respect to the shaft 384 to some extent, and for adjusting and engaging even if the positions of the hexagon head 236f and the hexagon wrench 390 are displaced to some extent. The shaft 384 is rotated by the cylinder 386, so that the hexagon wrench 390 can be rotated.

Referring again to FIG. 17, the positioning means of the carriage will be described.
A bracket 371 having 73 formed therein is attached to the inside of the rail 360 (see FIG. 16). A protrusion (not shown) that moves in the vertical direction is attached to the carriage by a cylinder (not shown). When the carriage is transported to each station and rough positioning is performed, the protrusion comes almost above the groove 373. Thereafter, when the cylinder is operated, the protrusion is fitted into the groove, and precise positioning and clamping are performed.

Next, the operation of the mold attaching / detaching device will be outlined.
First, the operation of separating the side plate 214 from the surface plate 212 will be described. The surface plate 21 clamped at the separation station A is
The formwork 210 of the two and the side plates 214 is brought, positioned and clamped in that position. Next, the desorption device 350
Carriage 352 is moved over rail 360 to the separation station where it is positioned and clamped in place. By driving the motor 361, the pedestal 354 is lowered by the chain 355. The lifting arm 376 of the lifting device 360 is attached to the cylinder 37.
8 engages with the locking portion 240 of the side plate 214, and then the operation of the cylinder 358 lowers the clamp device 362, and the hexagon wrench 3 of the clamp device 362 moves.
90 engages with the hexagonal head 236f of the side plate 214. After that, the cylinder 386 is operated, the hexagon wrench 390 is rotated, and the side plate 214 is unclamped from the surface plate 212 to be in a separable state. Then, the cylinder 358
Reversely activates and pulls up the clamp device 362. next,
The pedestal 354 is lifted by the chain by driving the motor, and the side plate 214 is separated from the surface plate. In addition,
Since the platen 212 is also separated and the locking portion 238 is provided, the platen can also be lifted and transported by this attachment / detachment device.

Next, the mounting operation will be described.
Are brought to the mounting station D, positioned and clamped in that position. A carriage 352 having a pedestal 354 holding the side plate 214 is moved on the rail 360 and brought to the mounting station D by the lifting arm 376 of the lifting device 360, and is positioned by the carriage positioning means 369 with respect to the clamped surface plate 212. Be positioned. The frame 354 holding the side plate 214 is lowered via the chain by the driving of the motor 361, and the side plate 214 is positioned by the positioning means 334 (see FIG. 1).
6) and is placed on the surface plate 212. Next, the operation of the cylinder 358 lowers the clamp device 362, and the hexagon wrench 390 of the clamp device 362 engages with the hexagon head 236f of the side plate 214. After that, the hexagon wrench 390 is rotated by 90 ° and clamped by the operation of the cylinder 386. Then, the cylinder 358 is reversely operated and the clamp device 362 is pulled up. Then, the lifting arm 376 is rotated in the direction opposite to the arrow X by the operation of the cylinder 374 and separated from the side plate. In this way, the clamped formwork 210 is then transported to another station (see FIG. 1) for slurry loading.

(5) Wagon frame: Next, the wagon frame will be described with reference to FIGS. 19 and 20. FIG.
Is a front view of a plurality of stacked wagon frames,
FIG. 20 is a front view showing an enlarged part A of FIG.

First, referring to FIG. 19, a wagon frame (hereinafter simply referred to as a frame) 411 is provided with wheels 420.
It is mounted on a carriage 422 having a frame, and another frame having the same structure can be mounted on one frame. In addition, a receiver for carrying a spacer attached to a frame body, which will be described later in detail, is also attached to the upper surface of the carriage itself.

The frame 411 has a frame body 412 having four sides (only one of which is shown in FIG. 20).
And a steel material 414 arranged on the longitudinal side portion of the frame main body 412 at a large number of intervals. The steel material 414 is formed so that the upper surface thereof has extremely high flatness, and the cross section thereof has a substantially square shape (FIG. 2).
0).

The steel materials 414 are arranged such that a large number of the steel materials 414 are arranged at intervals and their upper surfaces are in the same horizontal plane. For example, three of these steel materials 41
4a is strictly fixed to a standard height by, for example, welding, and the other steel materials 414 are adjusted to have the same height. Adjustments are made as shown in FIG.
The bolt 415 is attached to the bolt hole provided in the leg portion of and the adjustment is made by the screwing depth of the bolt 415. This allows for very large dimensions (for example, about 4.5
m: a flat surface having a width of about 2.6 m) and a height difference of 0.3 mm or less is obtained. If one plate such as a surface plate is used to obtain a highly flat surface with such a large size, it is extremely difficult, and if the plate is repeatedly used for steam curing, distortion ( Deformation) occurs, but if distortion occurs as described above, it is difficult to correct and it must be discarded.

The gap between the steel materials 414 has an opening ratio of 10 to 2
Selected to be 0%. If the opening ratio is too small, there is no problem in supporting the semi-plastic material (hereinafter sometimes simply referred to as the material), but there is a problem that water cannot be uniformly degassed from the material, and conversely, the opening ratio is large. If it is too much, moisture can be uniformly removed from the material, but there is a problem in supporting the material horizontally without distortion. Therefore, it is preferable to select a desired value of 10 to 20% as the aperture ratio.

Referring now to FIG. 20, a spacer member 416 that separates the two frames is shown. The spacer member 416 is attached to the lower portion of the frame body 412, and the lower end of the spacer member 416 has the lower end of the frame 41.
It is adapted to be mounted on one pair of reference steel materials 414a.
In addition, the guide protrusion 41 is provided at the lower end of the spacer member 416.
8 is provided, and the guide protrusion 418 is
Guided in the groove 414b formed at the tip of 14a,
Position the upper and lower frames. Spacer member 416
The height of is selected so that there is an appropriate clearance between the material and the upper frame with the material placed between the frames.

Although not shown in the figure, it is preferable to provide a cover below the steel material 414 so that water drops that may be dropped from between the steel materials and fall on the material below the wagon frame can be discharged.

[0048]

As described above, according to the present invention,
The mold is used up to the pre-curing step, and since the autoclave curing is performed using the wagon frame, the life of the mold can be greatly extended, and the curing is also well around steam, and a large ALC that can shorten the time A method of manufacturing a panel is obtained.

[Brief description of the drawings]

FIG. 1 is a flow chart showing all the steps of manufacturing a large ALC panel of the present invention.

FIG. 2 is a diagram for explaining a process of assembling the reinforcing bar cage.

FIG. 3 is a diagram for explaining a process of assembling the reinforcing reinforcing bar cage.

FIG. 4 is a diagram for explaining a process of assembling the reinforcing bar cage.

FIG. 5 is a diagram for explaining a process of assembling the reinforcing bar cage.

FIG. 6 is a diagram for explaining an assembling process of the reinforcing bar cage.

FIG. 7 is a plan view of the entire formwork in a state in which a surface plate and side plates are combined and fixed.

FIG. 8 is a side view of the edge of the mold.

FIG. 9 is a front view of a mold.

FIG. 10 is a plan view of a surface plate.

FIG. 11 is a side view of a surface plate.

12 is a line 12 of FIG. 7 showing the positioning means.
FIG. 12 is a sectional view taken along line -12.

13 is a line 13 of FIG. 7 showing the clamping means.
FIG. 13 is a sectional view taken along line -13.

FIG. 14 is a side view of a partition plate clamping device.

FIG. 15 is a front view schematically showing a mold attaching / detaching device of the present invention.

FIG. 16 is a plan view of the mold attaching / detaching device.

FIG. 17 is a partial front view showing a main part of the mold attaching / detaching device.

FIG. 18 is an enlarged side view showing a clamp device and a lifting device of a mold attaching / detaching device.

FIG. 19 is a front view of a plurality of stacked wagon frames.

20 is an enlarged front view showing a portion A of FIG. 19. FIG.

[Explanation of symbols]

 1 ALC raw material 4 Slurry 5 Reinforcing bar 7 Reinforcing bar cage 8 Rustproofing 9 Formwork surface plate 12 Formwork side plate 15 Assembly 19 Foam hardening 22 Panel transfer 24 Autoclave curing 210 Formwork 212 Surface plate 214 Side plate 216 Partition plate 218 No. 2 Partition plate 220 Slurry 222 Scale plate 224 Scale plate 230 Clamping device 232 Clamping device 234 Positioning means 350 Form removing / attaching device 352 Carriage 354 Frame 360 Lifting device 362 Clamping device 411 Wagon frame 412 Frame body 414 Steel material 416 Spacer member 420

Continuation of the front page (56) Reference JP-A-5-84721 (JP, A) JP-A-5-177624 (JP, A) JP-A-1-139218 (JP, A) JP-A-3-284904 (JP , A) JP-A-5-261715 (JP, A) JP-A-62-87306 (JP, A)

Claims (4)

(57) [Claims] 1. A slurry as an ALC raw material is prepared and
Create a reinforcing bar cage to be built in the C panel, assemble the base plate and side plate of the separable formwork to create a formwork that can create one ALC panel in a horizontal state, and reinforce the created formwork. Set the rebar cage, cast the slurry into the mold with the reinforcing rebar cage set, and foam and harden the slurry cast as pre-curing to create a semi-plastic body, separate the mold and remove the side plate from the surface plate. Remove, transfer the semi-plastic material from the surface plate to the wagon frame and place it horizontally, stack multiple semi-plastic materials via the wagon frame, and place the semi-plastic materials on the wagon frame and autoclave the stacked semi-plastic materials. Large ALC characterized by being carried into an autoclave and cured.
Panel manufacturing method. 2. The method for manufacturing a large ALC panel according to claim 1, wherein the surface plate and the side plate of the separated mold are respectively washed, and after applying a release agent, the mold is assembled to form a mold. A method for manufacturing a large ALC panel. 3. The method for manufacturing a large ALC panel according to claim 1, wherein a plurality of wagon frames are stacked. 4. The method of manufacturing a large ALC panel according to claim 1, wherein the wagon frame is transferred to a wagon frame carriage, and after autoclaving, the wagon frame is removed from the carriage and individually brought to the panel transfer position. A method for manufacturing a large ALC panel, characterized by: