RU2464392C1 - Method to erect walls, plant for automatic erection of walls from building modules and set of equipment for mechanised erection of walls from building modules - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: method to erect walls from face (facade) and ordinary building modules, every of which comprises upper and lower bed surfaces, and at least two pairs of coaxial holes arranged perpendicularly to bed surfaces, where fixing elements are placed, including layer installation of modules into a wall and application of a binder between modules. After installation of each new layer of building modules, they are exposed to vibration, and a binder is arranged to seal connecting seams between the modules. A plant for automatic erection of walls in accordance with the specified method comprises a mobile device to locate building modules, a facility for their gripping, movement to a wall and further installation in the specified order, and also a reservoir with a binder and device for its supply and application, besides, the plant additionally comprises a device for vibratory action at a masonry mortar, a device to remove detachable process gaskets, and a unit of plant control. A set of equipment for mechanised erection of walls in accordance with the proposed method includes a facility for modules gripping, their displacement and further arrangement in the specified order, a device of supply and application of a binder, consisting of a pump connected by hoses with a reservoir with a binder, and the pump is located near the reservoir, and a nozzle installed on guides as capable of movement along them with the help of a drive, and a device of vibration exposure comprising a vibration site with a spring-loaded electric motor installed on it with an eccentric weight or a vibrator, for instance, of magnetostrictive type.

EFFECT: higher efficiency and quality of building modules installation during wall erection.

10 cl, 14 dwg

Description

The invention relates to the field of construction, and more specifically to technical means for the construction of walls of building elements (bricks, blocks) of civil and industrial applications.

Since the construction of walls from building elements stacked in rows is associated with high manual labor in construction, attempts are constantly being made to mechanize these works, both regarding the laying of building elements on the wall and the application of cementitious mortar by creating appropriate devices.

A known method of laying a wall of brick, including moving it from the supply line to the masonry line along a curved path and treating it with a knitting material, the brick is moved by rotating in a horizontal plane along an arc of a circle to the masonry line, while supplying the required amount of knitting material to the free the end face of the brick, exert pressure on the brick sufficient to evenly distribute the binder material between the ends of the bricks, and during the laying of each ednogo brick in the wall of the center of rotation is moved along the line of masonry by an amount equal to the length of a brick (RF patent №2250324, IPC E04G 21/22, published 2005).

There is also a method of erecting walls from blocks made with through vertical holes arranged to accommodate vertical rods in adjacent holes in a staggered manner, and containing central and additional longitudinal grooves, the method including laying blocks in rows with offset holes and placing them in the holes of the rods whereby horizontal rods are initially laid in the central and additional longitudinal grooves, and then vertical rods are inserted into the holes in a checkerboard pattern the order with the alternation of the rods in front of the central bar, and in the adjacent hole behind the bar, the rods are fastened with rods, after which the holes are filled either with insulation, or light concrete, or heavy concrete (RF patent No. 2289660, IPC E04B 2/14, B28B 7/16, E04B 2/26, 2006 publication).

The disadvantages of the known methods include their low productivity.

A well-known machine for masonry walls made of brick, containing the supporting-running device with a supporting movable console, a device for feeding, orienting and laying bricks and a device for feeding and laying mortar (AS USSR No. 952551, IPC E04G 21/16, 1982 publication )

A disadvantage of the known machine is the complexity of the design of the device for orienting and laying bricks with disabilities. There is no guarantee of high-quality filling of vertical joints with mortar, there is no supply of bricks directly from the package to the machine feeder; the running gear does not allow the machine to maneuver horizontally and produce masonry from any position.

A known installation for the erection of walls, containing a vertical guide mounted on it with the possibility of axial movement and rotation of 180 ° around the horizontal axis of the table with clamps for fixing the building blocks, a means for supplying mortar, storage and stacker of building blocks, the installation is equipped with a device for assembling building blocks in groups and an additional vertical rail with a device for moving and rotating 180 ° around the horizontal axis laying building blocks from the device for assembling them onto the table with the main vertical guide, moreover, the device for shifting building blocks is made in the form of a clamping frame or in the form of a table with clamps for fixing building blocks, and the device for assembling building blocks in groups is in the form of a conveyor belt program management (RF patent No.2019655, IPC E04G 21/16, 1994 publication).

The disadvantages of the known device include the complexity of the design of the device and its low productivity.

Known equipment for the erection of brick walls, containing a cassette filled with brick to be laid, a conductive grate, the cells of which correspond to standard brick sizes and are arranged together in the order corresponding to the row laid in the wall, a tick grip acting on the brick placed in the cassette and in contact with a bin for a binder mortar with a device for filling vertical seams in the masonry with templates, while the grid-conductor is autonomous, the tick-borne gripper affects the WTO oh cassette bottom row of bricks, and the device for filling the vertical joints comprises forcibly rotationally synchronously with forward movement of the hopper mounted on its output auger oriented transversely to the direction of laying (patent №79597, MIC E04G 21/00, publication 2009 YG).

Known equipment allows you to provide a group method of laying bricks in the wall, which increases the productivity of a bricklayer. However, in the equipped cassette, the bricks are tightly packed, and they should be laid with a gap in the wall. Accuracy of laying is not guaranteed, and bricking is carried out manually. The quality of filling the vertical joints in the layer with a binder is also ensured manually.

It is known to use for erection of walls of building modules connected to each other by means of fixing elements installed in coaxially arranged holes made in building modules perpendicular to their bed surfaces (for example, Duplex building modules according to RF patent No. 75204).

The fixing elements are preliminarily inserted into the part of the holes located on one of the sides of the building modules with the formation of conical protrusions on their surface. In the process of laying the wall after applying a binder to the surface of one building module from above, the protrusions of the second building module connected to it are introduced from above. The centering of two adjacent building modules is achieved by the conical shape of the protrusions. In this case, the excess solution is squeezed out and between the two wall building modules fastened during installation, a uniform gap is ensured.

The objective of the proposed technical solution is to create such a method of erecting walls from building modules that are connected to each other by means of fixing elements installed in holes made in building modules, which would reduce labor costs when erecting walls, simplifying and facilitating the work of masons when erecting walls from blocks , created the reliability of fixing the blocks together, i.e. increased the strength of the walls.

Another objective of the proposed technical solution is the creation of an automated installation for masonry walls of building modules that are connected to each other by means of fixing elements installed in the recesses made in the building modules.

Another objective of the proposed technical solution is the creation of a set of equipment for mechanized masonry of walls from building modules that are connected to each other by means of fixing elements installed in the recesses made in the building modules.

The technical result of the proposed technical solutions is to increase the productivity and quality of laying of building modules during the construction of walls.

The essence of the proposed technical solutions is as follows.

The method of erecting walls from front (front) and ordinary building modules, each of which contains upper and lower bed surfaces and at least two pairs of coaxial holes located perpendicular to the bed surfaces in which the fixing elements are placed, includes layering the modules in a wall and applying a binder between the modules. The fixing elements are made in the form of straight cone inserts provided with collars and reverse cone inserts, which are placed in the module holes coaxially located during the laying process, while during the laying of the next layer of modules the straight cone inserts are inserted into the reverse cone inserts of the underlying layer modules, thus connecting every two layers of modules located one above the other with a constant gap between them, determined by the height of the shoulder of the insert of the straight cone. Before applying the binder to the bed surfaces of the building modules, removable technological gaskets are placed in the inserts of the inverse cone, which, after applying the binder, are removed together with the binder that fell on them, and after laying each next layer of building modules, they vibrate and the binder is used to seal and harden the connecting seams between modules.

The front (facade) building modules are equipped with cladding elements with heat-insulating liners embedded in them on the front side of the wall, and heat-insulating linings embedded on the opposite side, while the cladding elements are installed on the modules with the possibility of their partial closure into the wall and are equipped with protrusions and bevels forming seamless "wall facade system (SPS).

Front (facade) building modules can be painted on the front side of the wall with hot curing paint,

The task is also achieved by the fact that the installation for the automated construction of walls in accordance with the specified method contains a mobile device for placing building modules, a means for capturing them, moving them to the wall and subsequent laying in a predetermined order, as well as a container with a binder and a device for supplying it and application, while the installation further comprises a device for vibration exposure to the stacked layer of modules and a binder, a device for removing removable process gaskets ok, mechanisms for extending the aforementioned devices to the working area and returning them to their original position and the unit control unit. Building modules laid in a block on at least one pallet, means for their capture, movement on the wall and their subsequent laying in the specified order, a container with a binder and a device for feeding and applying it, as well as a device for vibration exposure, a device for removing removable technological gaskets, mechanisms for extending the aforementioned devices to the working area and returning them to their original position and the installation control unit are placed on a cargo area installed on a mobile platform with the possibility of New vertical movement relative to it.

The means for gripping the modules, moving them to the wall and subsequent laying in the specified order is made in the form of a device containing means for creating a vacuum, for example, in the form of a vacuum pump, at least one cartridge with pneumosuckers that interact with each other over the block of building modules in the process of erecting a wall with building modules, and connected to a means for creating a vacuum through valve-controlled air ducts, such as hoses, and a device control unit connected to flush valves with a signal channel.

The binder feeding and applying device consists of a pump connected to each other and with a tank with a binder located next to the tank, and a nozzle mounted on the rails with the possibility of moving along them with the help of a drive.

A device for removing removable process gaskets consists of a movable holder with needle grips.

The vibration exposure device consists of a vibration platform with a spring-loaded electric motor mounted on it with an unbalance or vibrator, for example, a magnetostrictive type.

The cargo area is equipped with additional supports (outriggers) for supporting the wall being erected and is connected to the mobile platform by drives of the required power, for example hydraulic drives or screw-nut pairs.

The task is also achieved by the fact that a set of equipment for the mechanized erection of walls from building modules in accordance with the specified method is characterized in that it includes means for gripping the modules, moving them to the wall and subsequent laying in a predetermined order, which is made in the form of a device containing a means for creating a vacuum, for example, in the form of a vacuum pump, placed above the block of building modules, at least one cartridge with pneumosuckers that interact t during the construction of the wall with building modules and are connected to a means for creating a vacuum through valve-controlled air ducts, for example hoses, and a device control unit connected to the valve-controlled signal channel, as well as a binder feeding and applying device, consisting of hoses connected to each other and with a tank with a binder of a pump located next to the tank, and a nozzle mounted on rails with the ability to move along them, a device for removing removable technological rokladok consisting of a displaceable holder with needle grippers, and apparatus vibrational effects, consisting of a vibrating platform mounted thereon with a spring-loaded motor or vibrator unbalance, e.g., a magnetostrictive type.

The proposed technical solution is illustrated by drawings, where

figure 1 shows the connection of building modules with each other;

figure 2 is a section AA in figure 1;

figure 3 - schematically shows the proposed automated installation for the erection of walls from building modules (side view);

figure 4 - automated installation (top view);

figure 5 is a view a in figure 4;

figure 6 - section of the wall being built;

figure 7 - capacity with a binder and a pump;

on Fig - pallets with building modules;

figure 9 is a device for removing removable process gaskets;

figure 10 - a device for applying a binder;

figure 11 is a device for capturing and transferring building modules;

in Fig.12 is a view of B in Fig.11 (rotated);

in Fig.13 is a view In Fig.9 (rotated);

in Fig.14 is a view of G in Fig.10 (rotated).

The proposed method is designed for use in the construction of walls of building modules, for example, Duplex building modules, in which holes are made that are perpendicular to the bed surfaces.

As shown in figure 1, the building modules 1, made on the basis of any building materials (for example, brick, foam concrete, wood, etc.), are equipped with at least two pairs of inserts fixing building elements to each other: inserts of a straight cone 2, equipped with shoulders 3, and inserts of the inverse cone 4 located on the same axis. Facade modules are additionally equipped with cladding elements 5 on the front side with heat-insulating inserts 6 embedded in them, and on the opposite side with heat-insulating spacers 7. The cladding elements also have bevels and protrusions to form a viewer perception of a “seamless” wall, and are connected to the base element with the possibility of termination of part of the facing element in the wall.

The proposed method consists of a preparatory operation and the cyclic execution of the following technological operations: applying a binder, removing removable process gaskets, moving and installing a new layer of modules in their wall in the wall, vibration sealing and vibration strengthening of the formed binder joints. Subsequently, the cycle repeats.

The preparatory operation consists in laying the modules on transport pallets in the reverse order of their transfer for installation in the wall. At the same time, removable technological gaskets 8 are placed in the inserts 4 of the reverse cone of the modules, repeating the shape of these cones, and a “dry” laying of the modules is formed on the pallet, since the inserts 2 of the direct cone of each upper module are included in the removable technological gaskets made of material that facilitates removal top modules.

The operation of applying a binder can be performed in a known manner manually or using an auxiliary device placed on the wall either manually or using a special mechanism.

The operation of removing the protective technological gaskets 8 with a part of the binder that has fallen into them can be performed manually using a special device for gripping them or using a device that carries several such grippers placed on the wall either manually or using a special mechanism.

The operation of moving and installing the modules in their place in the wall in accordance with the thickness of the wall being built can be performed manually for one module (in this case, the pallet with the modules should be located next to the worker) or using a device for group capture, hold and release of the modules when installing them with using to move the device itself any of the general-purpose building mechanisms or a special mechanism. In this case, the modules of the new layer “sit” on the modules of the underlying layer until they stop in shoulder 3, the height of which determines the constant gap between the layers for the binder joint. The constancy of the lateral gaps between the modules of one layer is determined by the choice of the distance between the axes of the pairs of tabs of the forward and reverse cones.

The operation of vibration sealing and vibration hardening of the formed joints of the binder has become possible due to the formation of a stiffening lattice from the bodies of the base elements 1 and inserts of the forward 2 and reverse 4 cones. The operation consists in transferring vibrations from a special device placed on the modules, installed manually on the layer wall, or using a special mechanism, as a result of which the “cement milk” penetrates the porous body of the base element to a greater depth, strengthening the joints.

When using all modules from the pallet (s), the empty pallet (s) are replaced with the pallet (s) with modules prepared for wall installation.

To automate the aforementioned cyclic technological operations, a complex of equipment is proposed, consisting of devices for the actually automated execution of each operation and the mechanisms of their movement mounted on a single loading platform, capable of changing its position in height and moving using a self-propelled chassis. The device of such a self-propelled automated installation of masonry walls (SAUKS) of building modules, such as modules "Duplex", is illustrated in figure 3, 4, 5.

A cargo platform 10 is mounted on a self-propelled chassis 9, moving vertically by means of, for example, threaded spindles 11 closed by casings 12 and driven by electric motors 13. The cargo area with pallets with modules located on it can rise to a height of 5-6 m.

Technological operations for laying the modules in the wall are carried out in the stationary position of the self-propelled chassis 9 and the loading platform 10 parallel to the wall being erected. In this case, the stable position of the platform 10 is provided by additional supports (outriggers) 14, for example, with a hydraulic drive, in the area of the wall being erected, mounted on a frame 15 mounted on the platform 10.

On the cargo platform 10 posted:

- pallet (s) 16 with building modules stacked in a given order;

- a tank 17 with a binder and with a pump 18 mounted above it, connected by a hose (not shown) to the tank;

- a device 19 for applying a binder containing guides 20 and transferred to the working area above the section of the wall being built by a sliding mechanism (not shown). The nozzle 21 of the device 19, the width of which corresponds to the thickness of the wall being built, is connected to the pump 18 with a flexible hose (not shown) and moves along the guides 22 using its own drive (not shown);

- a device for removing removable process gaskets of cassette type 23 with needle grips 24 and with a mechanism for its extension into the working area above the section of the wall being built (not shown). The removed protective pads together with the binder that got into them are discharged into the water bath 25 and can be reused;

- a device for capturing, holding and releasing cassette-type modules 26 with a control device 27 and guides 22 of the extension mechanism (not shown) from the area of the pallets into the working area above the section of the wall being built 28. The capture is carried out using suction cups 29 connected to the vacuum pump 30 through controlled valves 31 by flexible duct (not shown). The combination of suction cups 29 corresponds to the number and position of the modules laid in the wall in the current cycle, and is determined by the signals of the control device 27 connected to the controlled valves 31 of the cartridge 26 by a signal channel (not shown). The modules are released according to the signals of the control device 27 at the moment the inserts of the straight cone of the modules of the stacked layer are located above the inserts of the inverse cone of the modules of the underlying layer. Greater accuracy is not required, since the conical connection provides the only correct position under the action of the dead weight of the module;

- a device for vibration sealing and vibration strengthening 32 with a mechanism for moving it (not shown) along the guides 22 into the working area above the section of the wall being built 28. The device 32 is made in the form of a vibration plate 33 with a vibrator 34 mounted on it, for example, a magnetostrictive type.

The sequence of actuating mechanisms for moving devices for the automated execution of cyclic technological operations from the starting position to the working area above the section of the wall being erected and vice versa is determined by the signals of the device for numerical program control of the installation (programmer) 35, also located on the loading platform 10 and connected to the mechanisms and control device 27 signal channels (not shown).

All devices are protected by dust and water proof housings. The power of all energy-consuming devices (engines, controlled valve actuators, control devices, etc.) is provided from a common switchboard 36 on a cargo platform 10.

Lowering and raising the outriggers is carried out by hydraulic cylinders 37, and technological operations are performed by pneumatic cylinders 38, 39, 40, 41.

After laying all the modules of the working area, all devices are brought to their original position and the self-propelled chassis 9 is moved to service the next working area.

All these actions are performed by a 3-person SAUKS installation maintenance team.

For many typical methods of laying modules, the use of such an automated installation can provide a ten-fold increase in labor productivity with absolute quality of work.

The proposed method of walling can also be carried out using a set of equipment for mechanized walling of building modules, shown in Fig.6-14.

A set of equipment for mechanized erection of walls from building modules is located directly on the construction site near the wall being built 42 (Fig.6). It also contains:

- two pallets 43 with building modules stacked in a given order;

- a tank 44 with a binder and with a pump 45 installed on it;

- a device 46 for applying a binder with guides 47, moved to the working area by crane or manually. The nozzle 48 of the device 46, the width of which corresponds to the wall thickness and does not reach the required size to the surface of the masonry, is connected to the pump 45 by a flexible hose through a quick connection (not shown). The nozzle 48 is moved along the guides 47 manually;

- a device for removing removable process gaskets of cassette type 49 with needle grippers 50 and with a removal plate 51. Technological gaskets are removed from needle grips by a removal plate in a bath of water 52 and can be reused. The movement of the device into the working area is carried out using a crane or manually;

- a device for gripping, holding and releasing modules consists of two cassettes 53, 54, which are used to carry modules stacked both along (pos. 53) and across the wall (pos. 54);

- transfer of cartridges with modules from pallets to the working area is carried out using general construction mechanisms, for example, a crane with a traverse 55;

- capture of the modules is carried out using vacuum suction cups 56 connected to the vacuum pump 57 through controlled valves with flexible hoses (not shown). All commands, including lowering the modules, are made according to the commands of the control device 58 (programmer);

- the vibrocompaction device of the binder 59 is also transferred to the working area by crane or manually.

The device 59 is made in the form of a vibration plate 60 with a vibrator 61 mounted on it, for example, a magnetostrictive type.

Devices 45 and 59 may be placed on rack 62.

The commands from the control device 58, for example, when grabbing or lowering the modules, can be replaced by signals from buttons pressed by the workers.

A set of equipment for mechanized erection of walls from building modules is served by a team of three people.

Labor productivity when using the proposed set of equipment increases several times.

Using the proposed technical solutions can improve the quality of walling and ensure that when laying building modules a new facade system is created that is not created by additional insulation and decoration of already erected walls of a building (for example, using a curtain wall system), but directly in the process of erecting walls of a building, for example, using a wall facade system (SFS).

In this case, the facing elements, already fixed together with the insulation on the building modules forming the building’s facade, partially enter their protrusions into the wall and are held in it by the weight of the building modules located above them. As a result, the basic elements of the building modules that make up the facade of the building are located between the shell with the heat-insulating liner located in it and the second heat-insulating liner on the other side of the module, which is located in the wall in the gap between adjacent modules. This design of the wall facade system (SPS) provides enhanced thermal characteristics of the walls of the building and the durability of its facade.

Claims (10)

1. A method of erecting walls from front (front) and ordinary building modules, each of which contains upper and lower bed surfaces and at least two pairs of coaxial holes located perpendicular to the bed surfaces, in which the fixing elements are placed, including layering of the modules into the wall and applying a binder between the modules, characterized in that the fixing elements are made in the form of inserts of a straight cone, provided with collars, and inserts of a reverse cone, which are placed in a coaxial the openings of the modules provided during the installation process, while during the installation of the next layer of modules the straight cone inserts are inserted all the way into the reverse cone inserts of the modules of the underlying layer, thus connecting every two layers of modules located one above the other with a constant gap between them, determined by the height of the insert flange a straight cone, while before applying the binder on the bed surface of the building modules, removable process gaskets are placed in the inserts of the reverse cone, which, after application the binder is removed together with the binder that has fallen on them, and after laying each next layer of building modules, a vibratory effect is applied to them and the binder is used to seal and harden the connecting seams between the modules. 2. The method according to claim 1, characterized in that the front (facade) building modules are equipped on the front side of the wall with cladding elements with heat-insulating liners embedded in them, and on the opposite side, with heat-insulating linings, while the cladding elements are installed on the modules with the possibility of partial wall embedment and have protrusions and bevels. 3. The method according to claim 1, characterized in that the front (facade) building modules are painted on the front side of the wall with hot curing paint. 4. Installation for automated erection of walls in accordance with the method according to claims 1 to 3, containing a mobile device for placing building modules, means for their capture, moving on the wall and subsequent installation in a predetermined order, as well as a container with a binder and a device for it supply and application, characterized in that the installation further comprises a device for vibration exposure to the stacked layer of modules and a binder, a device for removing removable process gaskets, mechanisms for sliding onto devices in the working area and returning them to their original position and the installation control unit, while the building modules previously laid in the unit on at least one pallet, means for their capture, movement on the wall and their subsequent installation in a predetermined order, the capacity of a binder and a device for feeding and applying it, as well as a device for vibration exposure and a device for removing removable process gaskets, mechanisms for pushing said devices into the work area and returning them to the original decomposition and installation of the control unit are placed on the load platform mounted on a mobile platform for vertical movement relative thereto. 5. Installation according to claim 4, characterized in that the means for gripping the modules, moving them to the wall and subsequent laying in the specified order is made in the form of a device including means for creating a vacuum, for example, in the form of a vacuum pump, placed above the block of building modules at least one cartridge with pneumatic suction cups, interacting during the construction of the wall with building modules and connected to means for creating a vacuum through valve-controlled air ducts, such as hoses, and a control unit a device connected to a valve-controlled signal channel. 6. Installation according to claim 4, characterized in that the supply and application of a binder consists of a pump connected to each other and a tank with a binder, located next to the tank, and a nozzle mounted on the rails with the possibility of moving along them using a drive . 7. Installation according to claim 4, characterized in that the device for removing removable process gaskets consists of a movable holder with needle grippers. 8. Installation according to claim 4, characterized in that the vibrating device consists of a vibration pad with a spring-loaded electric motor mounted on it with an unbalance or vibrator, for example, a magnetostrictive type. 9. The installation according to claim 4, characterized in that the cargo area is equipped with additional supports (outriggers) for supporting the wall being erected and connected to the mobile platform with drives of the required power, for example hydraulic drives or screw-nut pairs. 10. A set of equipment for mechanized walling in accordance with the method according to claims 1 to 3, characterized in that the kit includes means for gripping the modules, moving them to the wall and subsequent laying in a predetermined order, which is made in the form of a device containing means for creating a vacuum, for example, in the form of a vacuum pump, at least one cassette with pneumatic suction cups, which interact with the building modules during the construction of the wall and are connected to the means for creating a vacuum through valves controlled by air ducts, for example, hoses, and a device control unit connected to the valve-controlled signal channel, as well as a binder supply and deposit device, consisting of hoses connected to each other and with a tank with a pump binder located next to the tank, and a nozzle installed on guides with the ability to move along them, a device for removing removable process gaskets, consisting of a movable holder with needle grippers, and a vibrating device I, consisting of a vibration platform with a spring-loaded electric motor mounted on it with an unbalance or vibrator, for example, a magnetostrictive type.

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