JP7373961B2 - Reinforced concrete column manufacturing equipment and manufacturing method - Google Patents

Description

The present invention relates to an apparatus and method for manufacturing reinforced concrete columns such as RC columns.

In structures such as buildings, concrete columns with embedded steel such as reinforced concrete columns (RC columns), steel reinforced concrete columns (SRC columns), and steel frame columns (S columns) (also referred to herein as reinforced concrete columns) are used.

Reinforced concrete columns are formed to a predetermined length (for example, 4 to 5 meters) corresponding to each floor, and are extended to the desired height by connecting them vertically. Reinforced concrete columns are manufactured using conventional construction methods, precast construction methods, and the like (for example, see Patent Document 1).

In the case of conventional construction methods, reinforcing bars and steel frames are assembled at the construction site at the construction site. After that, the surrounding area is covered with a formwork such as a control panel, and concrete is poured into it to form a reinforced concrete column (so-called formwork support). In the case of the precast construction method, hollow pillars made of reinforcing bars and concrete shells are formed in advance at a location different from the construction site. Then, by assembling the hollow pillar material at the construction site and pouring concrete into it, a reinforced concrete pillar is formed.

In any of these construction methods, when manufacturing reinforced concrete columns, formwork is used to shape the concrete, which requires time and effort to install and recover.

In contrast, in recent years, attempts have been made to utilize three-dimensional printer technology for construction (Patent Documents 2 and 3). Patent Document 2 and Patent Document 3 disclose devices in which a nozzle is supported by a robot arm. By using this device, it becomes possible to manufacture columnar structures without using formwork.

Specifically, a robot arm repeatedly moves the nozzle along the outline of the columnar structure while pushing out mortar and other materials from the nozzle. Then, by stacking the mortar to a predetermined height, a hollow columnar structure is formed. In Patent Document 2, a solid columnar structure is formed by subsequently pouring concrete into the columnar structure.

Japanese Patent Application Publication No. 2017-179841 JP2019-147338A JP2018-69661A

The hollow or solid columnar structures formed in Patent Document 2 and Patent Document 3 do not have steel materials such as reinforcing bars embedded therein, and therefore do not have the strength of reinforced concrete columns. Therefore, it cannot be used as is for pillars in buildings, etc.

By using steel materials, it is possible to manufacture reinforced concrete columns with the apparatus of Patent Document 2 or Patent Document 3.

However, when manufacturing reinforced concrete columns, a hollow columnar structure must be formed around a frame made of reinforcing bars or steel frames of a predetermined length. To do this, it is necessary to layer the mortar while rotating the nozzle around the outer circumference of the framework. In particular, in the case of RC columns, in order to ensure an appropriate cover thickness, the reinforcing bars must be located close to the outer surface of the reinforced concrete column (about a few centimeters), and the nozzle must be moved along the reinforcing bars. Must be.

To do this, the robot arm must make a large turn around the skeleton, and control the nozzle's posture so that the nozzle discharge port faces in the appropriate position and in the appropriate direction. It is necessary to raise the robot arm until Therefore, its control becomes extremely complicated.

Furthermore, in the case of a robot arm, its structure makes it difficult for the arm to reach the opposite side of the skeleton, which limits its movement there. If the nozzle could be moved properly on the other side of the skeleton, the robot arm would be huge. As described above, there are many problems in manufacturing reinforced concrete columns using the apparatus of Patent Document 2 and Patent Document 3, and it is difficult to put it into practical use.

The purpose of the technology disclosed therein is to provide a manufacturing apparatus and a manufacturing method that can manufacture reinforced concrete columns such as RC columns without using formwork, at a level that can be put into practical use.

One of the disclosed techniques relates to an apparatus for manufacturing reinforced concrete columns in which steel is embedded. The manufacturing apparatus includes a discharge device that discharges a molding material formed by adding water to a cement-based material, a material supply mechanism that supplies the molding material to the discharge device, and a material supply mechanism that supplies the molding material to the discharge device in a horizontal direction and a vertical direction. and a control device that controls each of the discharge device, the material supply mechanism, and the three-dimensional movement mechanism.

The discharge device includes a material introduction section that introduces the molding material from the material supply mechanism, and a nozzle that is rotatably supported by the material introduction section and discharges the molding material from a discharge port that is open at its tip. It has a section and. The control device controls the material supply mechanism so that the molding material is supplied to the discharge device, and at the same time, the discharge device ascends while going around the outside of the steel material. An outer shell portion of the reinforced concrete column is formed by controlling the three-dimensional movement mechanism and controlling the discharge device so that the nozzle portion rotates and the discharge port circulates along the steel material. .

According to this reinforced concrete column manufacturing apparatus, the outer shell of the reinforced concrete column can be appropriately formed from the outside of the steel material with a relatively simple structure and control, so there is no need to use formwork. , reinforced concrete columns such as RC columns can be manufactured.

Preferably, the three-dimensional movement mechanism includes a vertical movement section that supports the ejection device at a lower end and displaces the ejection device in a vertical direction, and a vertical movement section that supports the vertical movement section and moves the vertical movement section in a horizontal direction. It has a lateral movement part that causes displacement.

Preferably, the lateral moving part includes a fixed mast, a rotating mast installed on the fixed mast so as to be rotatable around a vertical axis, and installed so as to extend horizontally from an upper part of the rotating mast. and a rotating arm, the vertical moving unit having an elevating arm installed to extend vertically at the tip of the rotating arm, and under the control of the control device, the rotating mast rotates. , the pivot arm slides horizontally, and the lifting arm slides vertically.

Another disclosed technique relates to a method of manufacturing a reinforced concrete column in which steel is embedded. a first step of arranging the steel material in a predetermined position in an upright state, and a second step of forming an outer part of the reinforced concrete column around the steel material using the manufacturing device as described above; and a third step of pouring a concrete material into the outer shell portion.

According to the disclosed technology, reinforced concrete columns such as RC columns can be manufactured without using formwork.

FIG. 1 is a schematic diagram showing a reinforced concrete column manufacturing apparatus. FIG. 2 is a block diagram showing the relationship between a control device and its related devices. It is a schematic perspective view which shows the process of forming the outer part of a reinforced concrete column. FIG. 3 is a schematic diagram showing a movement path of the discharge device. It is a flowchart showing the main steps of a method for manufacturing a reinforced concrete column.

Hereinafter, embodiments of the disclosed technology will be described in detail based on the drawings. However, the following description is essentially just an example, and does not limit the present invention, its applications, or its uses.

<Configuration of reinforced concrete column manufacturing equipment>
FIG. 1 shows a reinforced concrete column manufacturing apparatus (column frame manufacturing apparatus 1) disclosed in this embodiment. This column frame manufacturing apparatus 1 is used in the manufacturing process of reinforced concrete columns such as RC columns, SRC columns, and S columns (RC columns are exemplified in this embodiment).

That is, conventionally, when molding an RC column into a predetermined shape, a formwork such as a control panel is used, but in this column frame manufacturing apparatus 1, the outer part of the RC column is used instead of the formwork. form. Therefore, by using this column frame manufacturing apparatus 1, the work of installing and recovering the formwork becomes unnecessary, so that the effect of reducing the number of man-hours and shortening the construction period can be obtained.

Moreover, the strength required by the Building Standards Act, etc., is the same as in the past, where RC columns are formed by pouring concrete material into the outer shell of the RC columns, and steel is embedded in them. ensured by the core of Therefore, the outer part of the RC column formed by this column frame manufacturing apparatus 1 only needs to have the same strength as the formwork.

FIG. 1 shows an example of a case where an RC column 100 is formed on each floor F of a building, etc., by adding to the RC column 100 formed on the floor below it. . FIG. 1 shows a state in which the frame of the RC column 100 to be constructed is formed by adding reinforcing bars 101 to the upper end of the RC column 100 on the lower floor exposed above the floor F.

Generally, the RC pillar 100 is formed into a prismatic shape with rounded corners. Usually, the height of the RC pillars 100 formed in each floor is about 3 m to 5 m, and the width is about 1 m. The column frame manufacturing apparatus 1 is installed on the floor F while being positioned at a predetermined position adjacent to the RC column 100 to be constructed. The column frame manufacturing apparatus 1 includes a three-dimensional movement mechanism 2, a material supply mechanism 4, a discharge device 6, a control device 8, and the like.

(Three-dimensional movement mechanism 2)
The three-dimensional movement mechanism 2 includes a vertical movement section 10 and a lateral movement section 20. The vertical movement section 10 supports the discharge device 6 at its lower end, and displaces the discharge device 6 in the vertical direction (Z direction in FIG. 1). The horizontal moving unit 20 supports the vertical moving unit 10, and displaces the vertical moving unit 10 in the horizontal direction (a direction including the X direction in FIG. 1 and a Y direction component perpendicular to the plane of the paper perpendicular to the X direction). let

By operating the vertical movement section 10 and the horizontal movement section 20 in cooperation with each other, the three-dimensional movement mechanism 2 moves the discharge device 6 horizontally and Displace each in the vertical direction. Since the movement of the discharge device 6 can be controlled in both the horizontal direction and the vertical direction, control can be simplified.

The lateral movement section 20 includes a fixed mast 21, a rotating mast 22, a swing arm 23, a mast motor 24, a slide motor 25, and the like. Each of the fixed mast 21 and the rotating mast 22 is made of a cylindrical member. The fixed mast 21 extends vertically and is removably fixed at a predetermined position on the floor F by fastening bolts or the like.

The rotating mast 22 is installed on the fixed mast 21 so as to be rotatable about the first vertical axis J1 (an axis extending in the Z direction) via a bearing 26 or the like. Mast motor 24 is installed between fixed mast 21 and rotating mast 22. By driving the mast motor 24, the rotating mast 22 rotates in both forward and reverse directions within a predetermined range corresponding to the RC pillar 100.

The swing arm 23 is composed of a slide guide 23a, a slider 23b, etc., and is installed so as to extend horizontally from the top of the rotating mast 22. The slide guide 23a is composed of a pair of elongated rail-shaped members (rail members) that are parallel to each other.

The slide guide 23a has one end fixed to the upper part of the rotating mast 22, and extends horizontally from there. The rigidity of the cantilevered slide guide 23a is strengthened by ribs, beams, braces, and the like.

The slider 23b consists of a pair of members supported by each rail member. The slider 23b is slidably installed on the tip side of the slide guide 23a. The slide motor 25 is installed on the slide guide 23a. By driving the slide motor 25, the slider 23b slides in the X direction in a predetermined range r1 corresponding to the RC pillar 100.

The vertical moving section 10 is installed at the tip of the slider 23b, which constitutes the tip of the swing arm 23, so as to extend in the vertical direction.

The vertical movement unit 10 includes a lifting arm 11, a lifting motor 12, and the like. The lifting arm 11 has a support pipe 11a and a slide pipe 11b. The support pipe 11a is made of a cylindrical member and is fixed to the tip of the slider 23b so that its center coincides with the second vertical axis J2 (an axis extending in the Z direction) and extends in the vertical direction.

The slide pipe 11b is made of a cylindrical member having a smaller diameter and longer than the support pipe 11a, and is coaxially and slidably inserted into the support pipe 11a. A discharge device 6 is installed on the slide pipe 11b, and the slide pipe 11b also constitutes a part of the material supply mechanism 4. The lifting motor 12 is installed at the tip of the slider 23b, and by driving the lifting motor 12, the slide pipe 11b slides in the Z direction in a predetermined range r2 corresponding to the RC pillar 100.

(Material supply mechanism 4)
The material supply mechanism 4 includes a hopper 40, a feed pump 41, a transfer hose 42, and the like in addition to the slide pipe 11b described above. The hopper 40 of this embodiment is installed on the floor F to make it easier for workers to work there. Materials for the column frame manufacturing apparatus 1 are charged into the hopper 40 . For example, a material (molding material) prepared by adding an appropriate amount of water to a cement-based material containing mortar, chemicals, etc. and kneading it to have an appropriate viscosity (molding material) is put into the hopper 40 .

A feed pump 41 is attached to the hopper 40. The molding material is sent out from the hopper 40 by this feed pump 41. One end of a transfer hose 42 is connected to the outlet of the feed pump 41 . The other end of the transfer hose 42 is connected to the upper end of the slide pipe 11b.

A buffer tank 43 is installed on the slider 23b in the middle of the transfer hose 42. The molding material put into the hopper 40 is supplied to the discharge device 6 via the transfer hose 42, buffer tank 43, and slide pipe 11b. Note that the buffer tank 43 is not essential. It may be supplied to the discharge device 6 from the hopper 40 via the transfer hose 42 and the slide pipe 11b.

(Discharge device 6)
The discharge device 6 includes a material introducing section 60, a nozzle section 61, a nozzle motor 62, and the like. The material introducing section 60 is installed at the lower end of the slide pipe 11b. A molding material is introduced into the material introduction section 60 from the slide pipe 11b. Although detailed illustrations are omitted, the material introduction section 60 incorporates a flow rate adjustment valve 60a that adjusts the discharge amount of the molding material by the opening degree, a rotary joint 60b, a slip ring 60c, and the like. A nozzle motor 62 is provided beside the material introduction section 60.

The nozzle portion 61 has a pipe-like member bent into a substantially L shape, and is composed of a short cylindrical portion 61a and a long cylindrical portion 61b continuous to one end of the short cylindrical portion 61a. The short cylindrical portion 61a is rotatably supported by the material introducing portion 60 (rotary joint 60b) about the second vertical axis J2. By driving the nozzle motor 62, the long cylinder portion 61b pivots around the second vertical axis J2.

A box-shaped discharge portion 61c is provided at the tip of the long cylindrical portion 61b. A discharge port 61d that opens laterally (horizontally) is formed at the lower end portion of the discharge portion 61c. The discharge port 61d is configured to be located sufficiently away from the center of the material introducing portion 60 in the radial direction thereof. The discharge port 61d communicates with the slide pipe 11b via the nozzle section 61 and the material introduction section 60. Note that the opening of the discharge port 61d is not limited to the horizontal direction, but may be opened in the vertical direction as long as it is not on the traveling direction side.

A shutter mechanism 61e that opens and closes the discharge port 61d is also installed in the discharge portion 61c. The discharge portion 61c is also provided with a position sensor 61f that detects the height of the discharge port 61d. The shutter mechanism 61e and the position sensor 61f are electrically connected to the control device 8 via the slip ring 60c.

(Control device 8)
The control device 8 is composed of hardware such as a CPU, memory, and interface, and software such as a control program implemented in the hardware, and controls each device and each mechanism that make up the column frame manufacturing device 1. comprehensively controls the operation of the The control device 8 is installed on the operation panel 1a together with an input/output device 1b, such as a monitor and operation buttons, which transmits and receives input signals and output signals to and from the control device 8.

FIG. 2 shows the control device 8 and its main related devices. The control device 8 has a three-dimensional position control section 80, a nozzle rotation control section 81, and a material supply control section 82 as its functional configuration. The three-dimensional position control unit 80 controls the driving of the mast motor 24, slide motor 25, and lifting motor 12 based on information such as the position, size, and shape of the RC pillar 100 inputted through the input/output device 1b. .

The nozzle rotation control section 81 controls the drive of the nozzle motor 62 based on information such as the horizontal position of the discharge device 6 and the rotational position of the nozzle section 61 obtained from the three-dimensional position control section 80 . The material supply control unit 82 controls the output of the feed pump 41 and the opening degree of the flow rate adjustment valve 60a based on information such as the discharge pressure and the output of the feed pump 41.

<Operation of reinforced concrete column manufacturing equipment>
The frame manufacturing apparatus rotates the nozzle part 61 that discharges the molding material as necessary, and raises the discharge device 6 from the lower end portion of the reinforcing bar 101 while going around the reinforcing bar 101 . Then, the outer part 100a of the RC column 100 is formed around the reinforcing bars 101.

Specifically, when the operation is started, the control device 8 (three-dimensional position control section 80, nozzle rotation control section 81) controls the three-dimensional movement mechanism 2 so that the discharge port 61d is located at the lower end of the reinforcing bar 101. The mast motor 24 is controlled to rotate the rotating mast 22, the slide motor 25 is controlled to slide the swing arm 23, and the nozzle motor 62 is controlled to move the nozzle part 61 to a predetermined starting position nearby. Swirl.

When the discharge port 61d is set to the starting position, the control device 8 (material supply control unit 82) controls the shutter mechanism 61e to open the discharge port 61d. At the same time, the molding material is supplied to the discharge device 6, and the output of the feed pump 41 and the opening degree of the flow rate adjustment valve 60a are controlled so that a predetermined amount of the molding material is discharged at a predetermined speed.

At the same time, the control device 8 (three-dimensional position control section 80) rotates the rotary mast 22 or slides the swing arm 23 so that the discharge device 6 goes around a predetermined course outside the reinforcing bars 101. . As a result, a bank-like structure is formed around the reinforcing bars 101 by the discharged molding material.

Then, the control device 8 (three-dimensional position control section 80) slides the lifting arm 11 so that it rises by the height of the discharged molding material every time the discharge device 6 goes around the framework. By repeating such operations, as shown in FIG. 3, bank-like structures made of molding materials are laminated to form the outer part 100a of the RC pillar 100.

As described above, according to this column frame manufacturing apparatus 1, the pivoting arm 23 is simply rotated or slid, and the lifting arm 11 is slid, so that it can be moved to any position around the reinforcing bar 101 with relatively simple control and structure. The discharge device 6 can be moved.

At this time, the position sensor 61f measures the distance from the discharge port 61d to the upper surface of the laminated molding material, and outputs the measured value to the control device 8. The laminated molding materials tend to be compressed and become lower as the height increases. The control device 8 (three-dimensional position control unit 80) corrects the sliding amount of the lifting arm 11 based on the measurement value input from the position sensor 61f. Therefore, the outer part 100a of the RC pillar 100 can be formed with high precision.

Furthermore, in the case of the RC pillar 100, the reinforcing bars 101 must be located near the outer surface (about several cm), and the discharge port 61d must be moved along the reinforcing bars 101. On the other hand, since the discharge device 6 and the elevating arm 11 have a certain width, it is necessary to take a course so that the discharging device 6 and the lifting arm 11 orbit at a certain distance from the reinforcing bar 101.

On the other hand, in this column frame manufacturing apparatus 1, the discharge device 6 is provided with a nozzle portion 61 that can be rotated. By rotating the nozzle portion 61, the discharge port 61d provided at the tip of the nozzle can be rotated to a position sufficiently away from the discharge device 6.

Therefore, as shown in FIG. 4, the control device 8 (nozzle rotation control section 81) can rotate the discharge port 61d along the reinforcing bar 101 by rotating the nozzle section 61. Thereby, the lifting arm 11 and the material introduction part 60 can continuously discharge the molding material to an appropriate position near the reinforcing bar 101 while rotating along a predetermined course.

The column frame manufacturing apparatus 1 repeatedly performs such operations until reaching a predetermined end position near the upper end of the reinforcing bar 101. Thereby, the outer shell portion 100a of the RC pillar 100 can be formed while discharging the molding material without interruption from the start position to the end position. Since no seams are formed, cracks caused by seams can be prevented.

<Method for manufacturing reinforced concrete columns>
FIG. 5 illustrates the main flow of the method for manufacturing reinforced concrete columns. Reinforced concrete columns are manufactured through two steps: a step of placing steel members in a predetermined position in an erected state (first step S1), and a step of forming an outer shell of the reinforced concrete column around the steel members using the column frame manufacturing apparatus 1 (first step S1). It is manufactured through a second step S2), a step of pouring a concrete material into the formed outer shell portion (third step S3), and the like.

For example, when manufacturing an RC column 100 at a construction site, as shown in FIG. 1, reinforcing bars 101 are placed in an upright position at a location where a new RC column 100 is to be formed. Although only one reinforcing bar 101 is shown in FIG. 1, it is usually arranged at multiple locations. After that, as shown in FIG. An outer portion 100a of the pillar 100 is formed.

After the molding material is cured for a predetermined period of time, a material made by adding an appropriate amount of water to a mixture of gravel, sand, cement, additives, etc. is placed inside the outer part 100a of these RC pillars 100. (concrete-based material) is poured.

According to this manufacturing method, it is not necessary to install or recover formwork such as a control panel, so it is possible to reduce the number of man-hours and shorten the construction period.

Note that the disclosed technology is not limited to the embodiments described above, and includes various other configurations. For example, in the embodiment, RC columns are illustrated, but the target reinforced concrete columns are not limited to RC columns. Its shape is also not limited to a prismatic shape.

Since the lateral movement part 20 only needs to be able to move the vertical movement part 10 in the X and Y directions within a predetermined range, it is not limited to the dragonfly crane shape as described above, but may be in the form of a bridge crane. The vertical movement unit 10 also only needs to be able to move in the Z direction within a predetermined range, so it is not limited to the form in which a single pipe is raised and lowered as described above, but may be in a form in which a plurality of multistage pipes are extended and contracted. .

1 Column frame manufacturing device 2 Three-dimensional movement mechanism 4 Material supply mechanism 6 Discharge device 8 Control device 10 Vertical movement section 11 Lifting arm 20 Lateral movement section 21 Fixed mast 22 Rotating mast 23 Swivel arm 40 Hopper 42 Transfer hose 60 Material introduction section 61 Nozzle part 61d Discharge port 100 RC pillar (reinforced concrete pillar)
101 Rebar (steel material)
F Floor J1 First vertical axis J2 Second vertical axis

Claims (4)

A manufacturing device for reinforced concrete columns in which steel is embedded,
a discharge device that discharges a molding material formed by adding water to a cement-based material;
a material supply mechanism that supplies the molding material to the discharge device;
a three-dimensional movement mechanism that displaces the discharge device in each of a horizontal direction and a vertical direction;
a control device that controls each of the discharge device, the material supply mechanism, and the three-dimensional movement mechanism;
Equipped with
The discharge device includes:
a material introduction part that introduces the molding material from the material supply mechanism;
a nozzle part that is rotatably supported by the material introduction part and that discharges the molding material from a discharge port that opens at the tip;
has
The control device controls the material supply mechanism so that the molding material is supplied to the discharge device, and at the same time controls the tertiary material supply mechanism so that the discharge device ascends while going around the outside of the steel material. Laminating the structure of the molding material by controlling the original moving mechanism and controlling the discharge device so that the nozzle part turns and the discharge port goes around the steel material. An apparatus for manufacturing a reinforced concrete column, which forms an outer part of the reinforced concrete column. The reinforced concrete column manufacturing apparatus according to claim 1,
The three-dimensional movement mechanism is
a vertical movement part that supports the discharge device at a lower end and displaces the discharge device in a vertical direction;
a lateral movement section that supports the vertical movement section and displaces the vertical movement section in a horizontal direction;
Reinforced concrete column manufacturing equipment. A manufacturing device for reinforced concrete columns in which steel is embedded,
a discharge device that discharges a molding material formed by adding water to a cement-based material;
a material supply mechanism that supplies the molding material to the discharge device;
a three-dimensional movement mechanism that displaces the discharge device in each of a horizontal direction and a vertical direction;
a control device that controls each of the discharge device, the material supply mechanism, and the three-dimensional movement mechanism;
Equipped with
The discharge device includes:
a material introduction part that introduces the molding material from the material supply mechanism;
a nozzle part that is rotatably supported by the material introduction part and that discharges the molding material from a discharge port that opens at the tip;
has
The control device controls the material supply mechanism so that the molding material is supplied to the discharge device, and at the same time controls the tertiary material supply mechanism so that the discharge device ascends while going around the outside of the steel material. The outer shell portion of the reinforced concrete column is formed by controlling the original moving mechanism and controlling the discharge device so that the nozzle part turns and the discharge port goes around the steel material. It is configured,
The three-dimensional movement mechanism is
a vertical movement part that supports the discharge device at a lower end and displaces the discharge device in a vertical direction;
a lateral movement section that supports the vertical movement section and displaces the vertical movement section in a horizontal direction;
has
The lateral movement section is
a fixed mast;
a rotating mast installed on the fixed mast so as to be rotatable about a vertical axis;
a swing arm installed to extend horizontally from the top of the rotating mast;
has
The vertical movement unit has a lifting arm installed to extend vertically at the tip of the swing arm,
A reinforced concrete column manufacturing apparatus, wherein the rotating mast rotates, the swing arm slides horizontally, and the elevating arm slides vertically under the control of the control device. A method for manufacturing a reinforced concrete column in which steel is embedded, the method comprising:
a first step of placing the steel material in a predetermined position in an upright state;
a second step of forming an outer part of the reinforced concrete column around the steel material using the manufacturing apparatus according to any one of claims 1 to 3;
a third step of pouring a concrete material into the outer shell portion;
A method for manufacturing reinforced concrete columns, including:

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