WO2016177272A1 - 墙板成型设备及其使用方法 - Google Patents

墙板成型设备及其使用方法 Download PDF

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Publication number
WO2016177272A1
WO2016177272A1 PCT/CN2016/079699 CN2016079699W WO2016177272A1 WO 2016177272 A1 WO2016177272 A1 WO 2016177272A1 CN 2016079699 W CN2016079699 W CN 2016079699W WO 2016177272 A1 WO2016177272 A1 WO 2016177272A1
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WO
WIPO (PCT)
Prior art keywords
wall panel
mold
eccentric
forming apparatus
folding
Prior art date
Application number
PCT/CN2016/079699
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English (en)
French (fr)
Inventor
王灿明
章亚
Original Assignee
中澳环球建筑工程(天津)有限公司
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Publication of WO2016177272A1 publication Critical patent/WO2016177272A1/zh

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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00Producing shaped prefabricated articles from the material
    • B28B1/14Producing shaped prefabricated articles from the material by simple casting, the material being neither forcibly fed nor positively compacted
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B13/00Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
    • B28B13/04Discharging the shaped articles
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/16Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes
    • B28B7/18Moulds for making shaped articles with cavities or holes open to the surface, e.g. with blind holes the holes passing completely through the article
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00Moulds; Cores; Mandrels
    • B28B7/28Cores; Mandrels
    • B28B7/30Cores; Mandrels adjustable, collapsible, or expanding

Definitions

  • the invention relates to a wallboard forming apparatus and a method of using same.
  • the inflated core inserting member only needs to be laterally expanded to make the cross section reach the set cavity; After that, the core inserting member needs to be deflated to reduce the core cavity until the core inserting member is separated from the inner wall of the wall plate, so as to reduce the outer diameter of the core pulling member when it is pulled upwards and detached from the inner wall of the wall. Friction between the holes.
  • the existing vertical mold inflation type insert member is usually made of natural rubber or synthetic rubber or other materials, when subjected to a certain air pressure, the core insertion member cannot be expanded only laterally or only longitudinally, but horizontally and vertically.
  • the core inserting member is an air bag composed of a plurality of gas hoses.
  • the actual expansion coefficient of the core inserting member is greatly reduced due to the leakage of the gas pipe and the joint, and the core inserting member is deflated.
  • the core inserting member can only be removed from its lifting frame, the wall panel is removed and the core insert member is removed, and the produced wall panel is scrapped.
  • the present invention provides a wall panel forming apparatus including a mold for forming a cavity, a mold driving mechanism for driving the mold to open/close a mold, and inserting into the cavity during wall forming.
  • a core pulling member defining a hollow structure of the wall panel, a core pulling member driving mechanism for driving the core pulling member to insert/extract the cavity and positioning the same, and a supporting device for supporting.
  • the mold comprises a pair of templates disposed oppositely and vertically, and the mold driving mechanism is symmetrically disposed outside the pair of templates.
  • the pair of templates are oppositely arranged and arranged in an upright manner, the two wall surfaces of the molded wall panel are made finer and flatter, and the flat mold apparatus is prevented from molding a flat and rough wall panel.
  • the mold driving mechanism includes an eccentric mechanism connected to an outer side of the template, and a driving motor that drives the eccentric mechanism to operate.
  • the driving motor drives the eccentric mechanism to perform an eccentric rotation toward the outer upper direction, thereby driving
  • the template connected to the eccentric mechanism is moved in the upward direction with respect to the wall panel, thereby releasing the mold and opening the mold.
  • the driving motor only needs to drive the eccentric mechanism to perform the reverse movement. It mainly uses the eccentric gear to classify the axial rotation to apply the template with large area adsorption force to a certain angle.
  • the outer upper direction moves, and the huge adsorption force formed during the pumping process of the pressure pump is statically offset, thereby achieving the purpose of completely separating the template from the wall panel, and avoiding damage to the wall panel during demolding, which is beneficial to ensure The smoothness of the outer surface of the wallboard, while also solving the demoulding problem of the prefabricated formwork of large vertical buildings at a low cost and effectively.
  • the eccentric mechanism comprises an eccentric gear, a support arm whose one end is fixedly connected with the eccentric gear and the other end is connected to the outside of the template, and the drive motor is drivingly connected with the eccentric shaft of the eccentric gear.
  • the mold needs to be demolded and the mold is opened, and the driving motor is driven to rotate the eccentric shaft connected with the driving, so that the eccentric gear drives the supporting arm connected thereto to make the eccentric rotation toward the outer upper direction. Further driving the template connected to the support arm to move toward the upper direction relative to the wall panel and simultaneously opening to the left and right direction, thereby releasing the mold from the mold and opening the mold, so that the newly formed and low strength wall panel is static. The ground successfully broke away from the mold.
  • the drive motor only needs to drive the eccentric mechanism to perform the reverse movement.
  • the eccentric mechanism on the same side is plural and spaced apart along the vertical direction of the template.
  • the large-sized upright stencil can be balanced by force, thereby facilitating the release effect and avoiding the uneven reception of the template.
  • the outer surface of the formed wallboard is detached or broken.
  • the support arms of the plurality of eccentric mechanisms on the same side and the corresponding eccentric gears are in the same vertical plane.
  • the force applied to the template by the eccentric mechanism on the same side is on the same straight line in the up and down direction, and the force applying effect on the template is ensured.
  • the eccentric mechanism on the same side comprises an upper eccentric turbine placed on the upper side a central eccentric mechanism disposed in the middle portion and a lower eccentric mechanism disposed in the lower portion, the drive motor being coupled to the middle eccentric shaft of the middle eccentric mechanism, the upper eccentric shaft and the upper eccentric of the upper eccentric mechanism
  • the lower eccentric shaft of the shaft and the lower eccentric mechanism is drivingly connected, and the rotations of the upper eccentric shaft, the middle eccentric shaft and the lower eccentric shaft are kept synchronized.
  • the mold is demolded and the mold is opened, the driving motor is operated to drive the middle eccentric shaft to rotate, and the middle eccentric shaft drives the upper eccentric shaft and the lower eccentric shaft to rotate synchronously through the conveying chain, which The eccentric gears of the three eccentric shafts are driven to rotate eccentrically toward the outer upper direction, and the stencils connected to the support arms are moved in the upward direction with respect to the wall panel and simultaneously open to the left and right directions.
  • the mold is demolded and opened, and the newly formed and low-strength wall panel is successfully and successfully separated from the mold.
  • the drive motor only needs to drive the eccentric mechanism to perform the reverse movement.
  • a column is symmetrically disposed on the support device on an outer side of the pair of templates, and the mold driving mechanism is mounted on the column.
  • the core pulling member comprises a hollow structure fixed on the core pulling member driving mechanism, inserted into the cavity during the forming process of the wallboard and in an open state to define the wall panel, and the wall panel is closed after being formed.
  • the state is a plurality of folded core members that are withdrawn from the cavity.
  • the plurality of folded core pulling members are inserted into the cavity and are in an open state to define a hollow structure of the wall panel, and the plurality of folded core pulling members are in the wall panel after forming
  • a gap is formed between the folded core member and the hole wall of the template, so that the outer surfaces of the plurality of folded core members are more easily separated from the wall of the wall plate to ensure that the plurality of folded core members smoothly pass through
  • the cavity is extracted to solve the core pulling problem of the insert member of the manufacturing equipment of the vertical prefabricated large-area building hollow wall panel.
  • each of the folded core-pulling members comprises a spindle mounted on the core-member driving mechanism, a top cover, and a folding sleeve fitted on the spindle by the bottom end of the spindle, a driving device on the main shaft, a plurality of sets of folding support rods disposed around the main shaft and connecting the driving device and the folding sleeve.
  • the driving device pushes the folding branch during the wall forming process
  • the struts slide down the main shaft to open the folding support rod, and the folding support rod pushes the folding sleeve to open to define the hollow structure of the wall panel, and the folding core pulling member is in an open state;
  • the driving device pulls the folding support rod to slide upward along the main shaft, so that the folding support rod is in a folded state, and the folding support rod drives the folding sleeve toward the main shaft, and the folding core pulling member is closed.
  • a gap is formed between the folded core member and the hole wall of the template, thereby achieving core pulling.
  • the folding sleeve comprises a plurality of folding baffles made of a rigid material, and the plurality of folding baffles are connected by a flexible connecting member.
  • the folding baffle is made of a rigid material, it can better resist the huge hydrostatic pressure formed by the slurry to better define the hollow structure of the wall panel; since the adjacent folding baffles are connected by flexibility Piece connection, which is more conducive to deformation or opening or folding of multiple folding baffles
  • a bottom plate is disposed at a bottom end of the main shaft, the folding baffle and the flexible connecting member are alternately arranged along a circumferential direction of the bottom plate, and the bottom plate, the folding baffle and the flexible connecting member are sealingly connected.
  • the hollow structure of the wall panel is jointly defined by the bottom plate, the folding baffle and the flexible connecting member.
  • the slurry is filled in the cavity wall of the mold and the hole wall of the hollow structure. Between the three seal connections, it is possible to prevent the slurry from which the wall panel is formed from entering the fold sleeve.
  • the folding sleeve is a soft sleeve made of a flexible non-elastic material.
  • the driving device is a hydraulic press, and the plurality of folding core pulling members are uniformly driven by the same hydraulic press.
  • the moving direction, speed, and the like of the plurality of folded core members can be kept consistent to ensure that the plurality of folded core members maintain synchronous operation.
  • each of the folded core pulling members further comprises a positioning plug disposed outside the bottom of the folding sleeve, the mold further comprising a wall forming platform disposed at the bottom, and the wall forming platform is provided with a seat The positioning holes that match the positioning plugs are described.
  • the positioning plug is matched with the positioning hole, and the positioning plug is inserted into the corresponding positioning hole to position each of the folded core pulling members.
  • the core pulling member driving mechanism comprises adjusting means for adjusting the position of the plurality of folding core pulling members to cooperate with the positioning holes, and the top end of the spindle is mounted on the adjusting device.
  • the adjustment means since the adjustment means is provided, the plurality of folded core members can be accurately positioned.
  • a wall panel removal device is further included, and the wall panel forming platform is disposed on the wall panel removal device.
  • a gantry extending above the mold is provided on the supporting device, and the core pulling member driving mechanism is mounted on the gantry.
  • a hose pump for feeding the cavity is also included.
  • the hose pumping machine can uniformly and continuously deliver the slurry into the cavity of the mold under the control frequency and pressure for a set time, so that the formed wall panel has the same function as the injection molded product.
  • a feed passage communicating with the hose pumping machine and the cavity is provided at the bottom of the mold.
  • the feed passage is disposed at the bottom of the mold so that the curable mixture is injected from the lower portion of the mold, the gravity and the center of gravity of the slurry itself can be fully utilized to make the molded wall panel denser. Uniform, effectively reducing the generation of bubbles.
  • the feed channels are a pair and are symmetrically disposed at the bottom of the mold.
  • the slurry can be symmetrically and uniformly entered into the mold cavity from the bottom of the mold to ensure uniformity of feeding, and the molded wall panel is more uniform and firm.
  • a discharge channel communicating with the feed passage is further provided at the bottom of the mold, and a feed valve is disposed in the feed passage.
  • the hose pumping machine can also pump the remaining or waste slurry through the discharge according to the instruction of the PLC.
  • the channel is sent to the waste pool for recycling.
  • the invention also proposes a method of using a wallboard forming apparatus, which has the structure described in any of the foregoing, comprising at least the following steps:
  • Step A Lowering the core pulling member to the mold by using the core pulling member driving mechanism Positioning and positioning, and then placing a plurality of the folded core pulling members in an open state;
  • Step B The driving motor drives the eccentric mechanism to perform an eccentric movement toward the inner lower direction, so that the template is closed to complete the mold clamping;
  • Step C pumping the mixed slurry into the cavity of the mold by using the hose pumping machine
  • Step D After the injected slurry reaches a solidified state, a plurality of the folded core pulling members are in a closed state, and the folded core pulling members are separated from the wall of the solidified wall panel;
  • Step E Using the core pulling member driving mechanism to lift the core pulling member upward from the cavity of the mold, and all the folding core pulling members are separated from the wall panel;
  • Step F The driving motor drives the eccentric mechanism to perform an eccentric movement toward the outer upper direction, and the template is statically separated from the outer surface of the wall panel to complete mold opening and demolding.
  • Figure 1 is a schematic overall view of a wallboard forming apparatus
  • FIG. 2 is a schematic view showing the assembly of a mold driving mechanism and a template
  • Figure 3 is a schematic view of a mold driving mechanism
  • Figure 4 is a schematic view of the core pulling member, which is a first embodiment
  • Figure 5 is a plan view of the core pulling member
  • Fig. 6 is a schematic view of the core pulling member, which is a second embodiment.
  • the wallboard forming apparatus mainly comprises a mold for forming a cavity, a mold driving mechanism 9 for driving the mold to open/close the mold, and a cavity inserted into the cavity during the forming of the wall panel to define a hollow of the wall panel.
  • the wallboard forming equipment further comprises a fully automatic batching system, a fully automatic feeding mixer 2, a hose pumping machine 3, and a feeding passage 4 connecting the hose pumping machine 3 and the cavity, and a feeding passage. 4 connected discharge passage 41, sewage collection and treatment device 13 communicating with the discharge passage 41.
  • the wallboard forming apparatus further includes a PLC automatic control system 12.
  • the mold comprises a pair of templates 6 disposed oppositely and vertically, and a wall forming platform 101 disposed between the pair of templates 6 at the bottom is placed at both ends of the pair of templates 6 and
  • the connecting members which are sealed at both ends of the template are realized, and the pair of the template 6, the wall forming platform and the connecting member together form a cavity corresponding to the outer dimensions of the prefabricated wallboard.
  • the wallboard forming platform 101 is mounted on the wallboard removing device 10, and a plurality of positioning holes 102 matching the positioning plugs 59 on the core pulling members 5 are provided on the wall forming platform 101.
  • the feed channels 4 are a pair and symmetrically disposed at the bottom of the aforementioned template 6. Accordingly, the discharge channels 41 are also a pair and symmetrically disposed at the bottom of the aforementioned template 6, and the feed channels 4 on the same side are The discharge channels 41 are in communication to form an entire passage.
  • the bidirectional feed valve 42 is provided on the feed passage 4, and the structure can be used when the molded wall panel has reached the set height or in an emergency state, the hose pumping machine 3 can also According to the instruction of the PLC automatic control system 12, the remaining or waste slurry is pumped through the waste pipe to the waste pool for recycling.
  • the curable slurry is injected from the lower portion of the mold during the wall forming process, and the gravity and the center of gravity of the slurry itself can be fully utilized to effectively reduce the generation of bubbles. Make the molded wall and floor more dense and even.
  • the supporting device 11 is symmetrically disposed on the outer side of the pair of templates 6.
  • the supporting device 11 is symmetrically provided with a column 111, and the mold driving mechanism 9 is symmetrically mounted on the column 111.
  • the mold driving mechanism 9 is symmetrically disposed outside the pair of templates 6, for example, a mold driving mechanism 9 disposed outside one of the templates 6, the mold driving mechanism 9 including the outer side of the template.
  • An eccentric mechanism and a drive motor 99 that drives the operation of the eccentric mechanism.
  • the plurality of eccentric mechanisms on the same side of the eccentric mechanism are spaced apart along the vertical direction of the template 6 to ensure that the template 6 is balanced.
  • the single eccentric mechanism includes an eccentric gear, a support arm whose one end is fixedly connected with the eccentric gear and the other end is connected to the outer side of the template.
  • a mount 113 is fixed on the column 111, and the mount is fixed.
  • 113 has a pair of mounting plates disposed opposite to each other, and a pair of mounting holes are formed on the pair of mounting plates, and a female connector of the eccentric gear is disposed at an end of the supporting arm opposite to the template 6.
  • An eccentric shaft (a male joint constituting the eccentric gear) matched with the female joint passes through the aforementioned mounting hole and the female joint of the eccentric gear, so that the support arm is rotatably coupled to the mounting seat 113, and is formed at one end of the support arm opposite to the template 6.
  • the female joint and the eccentric shaft matched thereto form the eccentric gear structure of the present invention, and it is understood that the eccentric connection can also be achieved by other alternative structures.
  • the driving motor 99 is drivingly connected with the eccentric shaft of the eccentric gear, and the supporting arms of the plurality of eccentric mechanisms on the same side and the corresponding eccentric gears are in the same vertical plane, so that the eccentric mechanism on the same side is applied to the template 6.
  • the force is on the same straight line in the up and down direction, ensuring the effect of applying force to the template 6.
  • the eccentric mechanism on the same side is an upper eccentric mechanism, a middle eccentric mechanism, and a lower eccentric mechanism
  • the upper eccentric mechanism includes an upper eccentric gear having an upper eccentric shaft 96 and an upper support arm 92.
  • the eccentric mechanism includes a center eccentric gear having a middle eccentric shaft 97, and a middle support arm 93.
  • the lower eccentric mechanism includes an upper eccentric gear having a lower eccentric shaft 98 and a lower support arm 94, wherein the drive motor 99 and the middle eccentric shaft 97 pass
  • the belt drive connection is connected to the upper eccentric shaft 96 and the lower eccentric shaft 98 via the transmission chain 910, and the rotations of the upper eccentric shaft 96, the middle eccentric shaft 97 and the lower eccentric shaft 98 are synchronized. It is to be noted that, as shown in FIG.
  • the upper eccentric shaft 96, the middle eccentric shaft 97 and the lower eccentric shaft 98 have a certain length in a direction parallel to the template 6, except that the middle portion of each eccentric shaft forms an eccentricity with the template 6.
  • the two ends of each eccentric shaft are also eccentrically connected with the template 6, so that the connection portion between the eccentric mechanism and the template 6 can be increased, which is advantageous for increasing the force receiving area of the template 6 and making the force more balanced. , to ensure the effect of the template 6.
  • the driving motor 99 is operated to drive the middle eccentric shaft 97 to rotate.
  • the middle eccentric shaft 97 drives the upper eccentric shaft 96 and the lower eccentric shaft 98 to rotate synchronously through the conveying chain 910.
  • the eccentric gears to which the three eccentric shafts belong The corresponding support arm is eccentrically rotated toward the outer upper direction, thereby driving the template 6 connected to the support arm to move in the upward direction with respect to the wall panel and simultaneously opening in the left-right direction, thereby releasing the mold from the mold.
  • the mold makes the newly formed and low strength wall panel statically and successfully detached from the mold.
  • the driving motor 99 only needs to drive the eccentric mechanism to perform the reverse movement.
  • a gantry 112 extending above the mold is provided on the supporting device 11, and the core pulling member driving mechanism 8 is mounted on the gantry 112, which is mainly composed of a positioning and lifting system, and the core pulling member is driven.
  • the mechanism 8 also includes adjustment means 51 for adjusting the position of the plurality of folded core members of the core member 5 described below.
  • the core pulling member 5 comprises a hollow structure fixed to the core pulling member driving mechanism 8 and inserted into the cavity during the forming process of the wallboard to be opened to define the wall panel, and the wall panel is closed after being formed to be extracted from the cavity. Multiple folding core members.
  • each of the folded core-pulling members includes a main shaft 52 whose top end is mounted on the adjusting device 51, a folding sleeve which is disposed at the top and is fitted on the main shaft 52 by the bottom end of the main shaft 52, and is fitted A drive unit 7 on the main shaft 52, a folding support rod 55 disposed around the main shaft 52 and connected to the drive unit 7 and the folding sleeve.
  • a bottom plate 58 is provided at the bottom end of the main shaft 52.
  • the folding sleeve includes a folding baffle 57 and a flexible connecting member 56 disposed around the bottom plate 58 and alternately disposed along the circumferential direction thereof, and the bottom plate 58, the folding baffle 57 and the flexible connecting member 56 these three are sealed.
  • the folding baffle 57 is made of a rigid material, which mainly serves as a supporting function for resisting the huge hydrostatic pressure formed by the slurry to better define the hollow structure of the wall panel, and the flexible connecting member 56 is mainly used for An adjacent folding baffle 57 is connected, which is made of a flexible material made of canvas and rubber.
  • the overall shape of the folding baffle 57 is similar to that of the longitudinal section of the cylinder, and the flexible connecting member 56 is elongated.
  • the strip shape, in the open state of the folding sleeve, the folding flap 57 and the flexible connecting member 56 together form a cylindrical shape for defining the hollow structure of the wall panel.
  • the driving device 7 is a hydraulic press, and the plurality of folding core-pulling members are uniformly driven by the same hydraulic press, and the driving device 7 is connected to the folding support rod 55 via a connecting plate 54.
  • Each set of folding support rods 55 is rotatably connected by a plurality of rod members, and one set of folding support rods 55 is exemplified, which comprises a first rod member 551 having one end connected to the connecting plate 54 and the other end abutting on the bottom plate 58, one end and one end a second rod member 552 connected to the lower portion of the first rod member 551 at the other end of the bottom plate 58 is connected to the main shaft 52 side, a third rod member 553 connecting the middle portion of the second rod member 552 and the bottom end of the first rod member 551, and
  • the first rod 551 is disposed in a "V" shape and the bottom end is connected to the first rod member 551 and the third rod member 553 at the bottom end of the sixth rod member 556, and the upper portion of the first rod member 551 is connected to the upper portion of the sixth rod member 556.
  • a fourth rod member 554 a fifth rod member 555 disposed under the fourth rod member 554 and connecting the first rod member 551 and the sixth rod member 556, between the plurality of rod members, the first rod member 551 Between the connecting plate 54 and the second rod 552 and the bottom plate 58 are connected together by a rotatable joint 557.
  • each of the folded core-pulling members further includes a positioning plug 59 placed at the bottom of the folding sleeve, and the positioning plug 59 is inserted into the positioning hole 102 on the forming platform 101, and the folding core-member is performed by the cooperation of the two. Positioning.
  • the core pulling member is moved downward relative to the mold under the driving of the core pulling member driving mechanism 8 until the plurality of folding core pulling members are inserted into the cavity of the mold, and then the respective folding core members are adjusted by the adjusting device 51.
  • the specific position is such that the positioning plug 59 on each of the folded core members is inserted into the positioning hole 102 on the molding platform 101.
  • the driving device 7 pushes the folding support rod 55 to slide down along the main shaft 52, so that the folding support rod 55 is in an open state, and the folding support rod 55 drives the folding sleeve to open, and the folding sleeve defines a hollow structure of the wall panel.
  • the folded core member is in an open state as shown in FIG.
  • the driving device 7 pulls the folding support rod 44 to slide upward along the main shaft 52, so that the folding support rod 55 is in a folded state, and the folding support rod 55 drives the folding sleeve toward the main shaft 52. Then, the folding core member is in a closed state, and a gap is formed between the outer surface of the folding sleeve and the wall of the template. Then, the core pulling member is moved upward relative to the mold by the driving of the core pulling member driving mechanism 8 to pull the positioning plug 59 out of the positioning hole 102 on the molding platform 101, and until the plurality of folding core members are from the cavity of the mold Extracted in the middle.
  • the automatic control system 12 is operated in accordance with a preset program.
  • Step 1 Lowering the core pulling member 5 into the mold by the core pulling member driving mechanism 8, and inserting the positioning plug 59 at the bottom of each folding core pulling member into the positioning hole 102 on the molding platform 101 for positioning, and then using the driving device 7 causing the plurality of folded core pulling members to be in an open state;
  • Step 2 The driving motor 99 drives the eccentric mechanism to make an eccentric movement toward the inner and lower directions, so that the pair of oppositely disposed and vertically arranged templates 6 are closed to complete the mold clamping;
  • Step 3 The automatic batching system 1 mixes the materials according to the required wallboard, and inputs the materials into the fully automatic feeding mixer 2 according to the loading procedure and speed to form a nano-scale fiber.
  • High-strength curable composite slurry where the raw material is a curable mixture composed of a gypsum-based composite or a cement-based mixture and nano-sized whisker fibers;
  • Step 4 After the mixing to the expected mixing effect, the hose pumping machine 3 receives the start pumping signal, opens the two-way feed valve 42 and discharges the waste valve to close;
  • Step 5 Using the hose pumping machine 3 to pump the mixed nano-fiber lightweight high-strength curable composite slurry into the mold cavity according to the set frequency and speed;
  • Step 6 After the injected nano-fiber lightweight high-strength curable composite slurry reaches a solidified state, the plurality of folded core-pulling members are closed by the driving device 7, so that the outer surface of the folded sleeve of the folded core-pulling member is The wall of the solidified wall panel is separated;
  • Step 7 Lifting the core pulling member 5 upward by the core pulling member driving mechanism 8, so that the positioning plug 59 at the bottom of each folding core pulling member is disengaged from the positioning hole 102 on the forming platform 101, and then continues to move up to the cavity. Extracted internally to disengage all folded core members from the wall panel;
  • Step 8 The driving motor 99 drives the eccentric mechanism to make an eccentric movement toward the outer upper direction, so that the pair of oppositely disposed and vertically arranged templates 6 are statically separated from the outer surface of the wall panel, and the mold opening and demoulding are completed. And the formed wall panel is erected on the wall panel removing device 10;
  • Step 9 Use the wall panel removal device 10 to remove the wall panel from the complete set of equipment to complete a production cycle of the wall panel. Each production cycle takes about 40 minutes.
  • a step of synchronizing with the remaining steps is further included, that is, after the slurry quantitative pumping is completed, the bidirectional feed valve 42 is closed and the waste valve port is opened, and the automatic feeding mixer 2 starts the water washing program.
  • the waste water in the hose pumping machine 3 is discharged into the sewage collecting and processing device 13 through the discharge passage 41 for filtration and reuse, thereby forming a perfect production cycle.
  • step 3 a step is also included in which a release agent is applied to the mold for easily removing the wallboard from the mold.
  • the above-mentioned wallboard forming equipment is suitable for manufacturing large-area hollow building load-bearing wallboards, and is capable of producing 30 pieces of 12m long*3m high*130-200mm thick lightweight high-strength water-resistant inner wall and outer wall structural load-bearing wall in one day.
  • the weight per square meter of wallboard is only 65 kilograms, and other physical properties fully meet and exceed national specifications.
  • the wall panel prepared by the above wall panel forming apparatus has spaced opposite outer walls interconnected by a plurality of spaced structural portions, so as to define a cavity between adjacent structural portions, which is required for modern building industrialization.
  • the surface is smooth and smooth, and can be painted without plastering, which saves labor, saves money and greatly improves building efficiency.
  • the above-mentioned wallboard forming equipment realizes the mold-releasing and separating technology of the vertical formwork and the wallboard by adding an eccentric wheel mechanism, and uses the eccentric core gear to classify the axial rotation to apply the template 6 having a large area of adsorption force to the outer upper direction of a certain angle. Move, statically offset the huge adsorption force formed during the pumping of the pressure pump, so that the newly formed and low strength wall panel can be successfully separated from the mold statically, thereby achieving the purpose of completely separating the template from the wall panel.
  • the invention significantly reduces the cost of the current hole-forming core drawing technology of the hollow wall panel and greatly improves the accuracy of the obtained cavity, thereby significantly improving the efficiency of the wall forming equipment.
  • the above-mentioned wallboard forming equipment utilizes the folding core-pulling member to realize the separation of the core-pulling member and the wall of the wall panel, and can ensure the smooth extraction of the core-pulling member, so as to solve the inserting member of the manufacturing equipment of the vertical prefabricated large-area building hollow wall panel.
  • the core problem is the following problem.
  • the above wallboard forming equipment utilizes a hose pump pressure pumping system to wet the composite slurry.
  • the material is hit into the mold cavity to make the structure of the wallboard more uniform and higher density.
  • the injection molding principle is used to produce the wallboard, so that the physical properties of the wallboard are greatly improved, and the two faces of the wallboard are synchronized. It is made smooth and smooth without secondary processing.
  • the folding sleeve is provided by a bottom plate 58 placed at the bottom end of the main shaft 52, a folding flap 57 disposed around the bottom plate 58 and alternately disposed along the circumferential direction thereof, and a flexible connection.
  • the piece 56 is sealed and joined.
  • the folding flap 57 and the flexible connecting member 56 in the folding sleeve may be replaced by a soft sleeve 5a provided with a top opening, the soft sleeve 5a being made of a flexible non-elastic material. It is an integral part that is fitted to the bottom plate 58 and the main shaft 52 by the bottom end of the main shaft 52.
  • the folding sleeve is generally cylindrical in the open state, that is, the hollow structure of the wall panel defined by the folding sleeve has a circular cross section, but is not limited thereto.
  • the wall panel is The cross section of the hollow structure may be elliptical (including long elliptical), square, rectangular, hexagonal, octagonal, other polygons, etc., and the structure of the folded sleeve should be adaptively changed, and the connection relationship is the same as the above structure.

Abstract

一种墙板成型设备及其使用方法,该设备包括用以形成型腔的模具、模具驱动机构(9)、抽芯构件(5)、抽芯构件驱动机构(8)。模具驱动机构(9)包括与模板外侧连接的偏心轮机构,抽芯构件(5)固定在抽芯构件驱动机构(8)上,包括在墙板成型过程中插入型腔并处于打开状态、墙板成型后抽出型腔并处于闭合状态的多个折叠抽芯构件。该设备能够确保脱模时模板与墙板以及折叠抽芯构件的外表面与墙板孔壁之间彻底分离,同时避免损伤墙板。

Description

墙板成型设备及其使用方法 技术领域
本发明涉及一种墙板成型设备及其使用方法。
背景技术
现有的直立式预制建筑空心墙体或/和楼板制造设备主要以制造小型的的建筑条板为主。然而,这些小型的的建筑条板通常只作为非承重填充墙使用,其功能不能满足建筑工业化所需的大面积承重墙体或楼板要求,究其主要原因是现有的直立式预制建筑空心墙板的制造设备还存在以下关键技术问题。
第一.用于形成型腔的插入构件的抽芯问题
对于立模充胀式抽芯插入构件来说,墙板制备过程中,未注入浆料前,充胀式抽芯插入构件只需要进行横向膨胀使横截面达到设定空腔;在浆料凝固后需将抽芯插入构件放气使抽芯空腔缩小直至抽芯插入构件与墙板内孔脱离,以减小抽芯构件在往上抽走脱离墙内孔时其外径与墙板内孔之间的摩擦力。然而,由于现有立模充胀式插入构件通常采用天然橡胶或人造橡胶或其它材料所制成,当受到一定气压充气时,抽芯插入构件不能只横向或只纵向膨胀,而是横向和纵向同时膨胀,纵向膨胀对抽芯插入构件所施加的纵向拉力使插入构件在纵向上越拉越长,使抽芯插入构件变形并在抽芯插入构件下端凸起,导致插入构件往上脱模时因摩擦力巨大而抽出难度倍增,甚至插入构件在短时间内报废而需要更换,而更换抽芯插入构件将导致停产,进而降低生产效率,且生产维护成本大幅上升。
另外,抽芯插入构件是由很多气喉管组成的气囊,这些小气喉管受压力压迫时由于气管和接头的漏气使抽芯插入构件的实际膨胀系数大大减少,当抽芯插入构件放气时,导致外壁空间不够,抽芯插入 构件不能顺利抽出,其外气囊与墙板空腔的间隙不够,抽芯插入构件卡死在已成型的墙板内孔中。在这种情况下,只能将抽芯插入构件从其提升架上拆除,把墙板移出后将墙板锯开并取出抽芯插入构件,导致所生产的墙板报废。
第二.用于形成型腔的大型直立式模板的脱模问题
墙板制备过程中,大量轻质高强可固化湿复合浆料在泵送进入型腔时会产生流体静压作用,使在墙板外表面与直立式外模板的内表面之间形成巨大的吸附力。然而,一般地大型立式建筑预制模板设备如果采用液压系统硬性地将模板与墙板分离,其制造成本和维护成本高昂。因液压系统的应用容易发生故障,大大增加了损伤墙板和楼板的机会。
发明内容
有鉴于此,本发明的主要目的在于,提供一种能制备大面积承重墙板的墙板成型设备及其使用方法。
为达到上述目的,本发明提出了一种墙板成型设备,包括用以形成型腔的模具、驱动该模具进行开/合模的模具驱动机构、墙板成型过程中插入所述型腔中以限定出墙板的中空结构的抽芯构件、驱动该抽芯构件插入/抽出所述型腔并对其进行定位的抽芯构件驱动机构,以及起支撑作用的支撑装置。
优选的,所述模具包括相对置且直立式设置的一对模板,所述模具驱动机构对称设置在这一对模板的外侧。
采用上述结构,由于所述一对模板相对置且直立式设置,使模制出的墙板的两个壁面更精细和平坦,避免了平模设备模制出一面平一面粗糙的墙板。
优选的,所述模具驱动机构包括与所述模板外侧连接的偏心轮机构、驱动该偏心轮机构运转的驱动电机。
采用上述结构,墙板成型后需对模具进行脱模、开模时,所述驱动电机驱动所述偏心轮机构做朝向外上方方向的偏心转动,进而带动 与该偏心轮机构连接的模板相对于墙板做朝向外上方向的移动,由此实现模具的脱模、开模。墙板成型过程中需对模具进行合模时,驱动电机只需驱动偏心轮机构做反向运动即可,它主要运用偏芯齿轮分级轴向转动能将具有大面积吸附力的模板向一定角度的外上方方向移动,把在压力泵泵送浆料过程中所形成的巨大吸附力静态地抵销掉,从而达到模板与墙板彻底分离的目的,避免脱模时损伤墙板,有利于保证墙板外表面的光滑度,同时还低成本而有效地解决了大型立式建筑预制模板的脱模难题。
优选的,所述偏心轮机构包括偏心齿轮、一端与该偏心齿轮固定连接另一端与所述模板外侧连接的支撑臂,所述驱动电机与所述偏心齿轮的偏心轴传动连接。
采用上述结构,墙板成型后需对模具进行脱模、开模时,所述驱动电机运行带动与其传动连接的偏心轴转动,使偏心齿轮带动与其连接的支撑臂做朝向外上方方向的偏心转动,进而带动与该支撑臂连接的模板相对于墙板做朝向外上方向的移动并同时向左右方向打开,由此实现模具的脱模、开模,使刚成型且强度不高的墙板静态地成功脱离模具。墙板成型过程中需对模具进行合模时,驱动电机只需驱动偏心轮机构做反向运动即可。
优选的,位于同侧的所述偏心轮机构为多个且沿所述模板的上下方向间隔设置。
采用上述结构,由于位于同侧的多个偏心轮机构在上下方向上间隔设置,能够使大规格的直立式模板受力均衡,从而有利于保证脱模效果,避免因模板受理不均匀而导致已成型的墙板外表面脱落或破裂。
优选的,位于同侧的多个偏心轮机构的支撑臂及对应的偏心齿轮处于同一竖直平面内。
采用上述结构,使位于同侧的偏心轮机构对模板所施加的作用力在上下方向上处于同一直线上,保证对模板的施力效果。
优选的,位于同侧的所述偏心轮机构包括置于上部的上偏心轮机 构、置于中部的中偏心轮机构和置于下部的下偏心轮机构,所述驱动电机与中偏心轮机构的中偏心轴传动连接,该中偏心轴与所述上偏心轮机构的上偏心轴、下偏心轮机构的下偏心轴传动连接,且上偏心轴、中偏心轴和下偏心轴这三者的转动保持同步。
采用上述结构,墙板成型后需对模具进行脱模、开模时,所述驱动电机运行,带动中偏心轴转动,该中偏心轴通过传送链条带动上偏心轴和下偏心轴同步转动,这三个偏心轴所属的偏心齿轮带动与其对应的支撑臂做朝向外上方方向的偏心转动,进而带动与该支撑臂连接的模板相对于墙板做朝向外上方向的移动并同时向左右方向打开,由此实现模具的脱模、开模,使刚成型且强度不高的墙板静态地成功脱离模具。墙板成型过程中需对模具进行合模时,驱动电机只需驱动偏心轮机构做反向运动即可。
优选的,在所述支撑装置上于所述一对模板的外侧对称设置有立柱,所述模具驱动机构安装在该立柱上。
优选的,所述抽芯构件包括固定在所述抽芯构件驱动机构上、墙板成型过程中插入所述型腔中并处于打开状态以限定出墙板的中空结构、墙板成型后处于闭合状态以从所述型腔中抽出的多个折叠抽芯构件。
采用上述结构,墙板成型过程中,所述多个折叠抽芯构件插入所述型腔中并处于打开状态以限定出墙板的中空结构,墙板成型后所述多个折叠抽芯构件处于闭合状态,在折叠抽芯构件与模板的孔壁之间形成间隙,使多个折叠抽芯构件的外表面与墙板孔壁更容易地分离,以确保多个折叠抽芯构件顺利地从所述型腔中抽出,以解决直立式预制大面积建筑空心墙板的制造设备的插入构件的抽芯问题。
优选的,每个所述折叠抽芯构件包括安装在所述抽芯构件驱动机构上的一主轴、顶部敞口设置并由所述主轴的底端套装在所述主轴上的折叠套、套装在所述主轴上的驱动装置、围绕所述主轴设置且连接所述驱动装置与所述折叠套的多组折叠支撑杆。
采用上述结构,墙板成型过程中,所述驱动装置推动所述折叠支 撑杆沿着主轴向下滑动,使折叠支撑杆处于打开状态,该折叠支撑杆推动折叠套打开以限定出墙板的中空结构,则折叠抽芯构件处于打开状态;相反地,墙板成型后需要抽芯时,所述驱动装置牵拉所述折叠支撑杆沿着主轴向上滑动,使折叠支撑杆处于折叠状态,由该折叠支撑杆带动折叠套朝向主轴靠拢,则折叠抽芯构件处于闭合状态,在折叠抽芯构件与模板的孔壁之间形成间隙,从而实现抽芯。
优选的,所述折叠套包括多个由刚性材料制成的折叠挡板,并这多个折叠挡板通过柔性连接件连接。
采用上述结构,由于折叠挡板由刚性材料制成,能够更好地抵挡浆料所形成的巨大流体静压力,以更好地限定出墙板的中空结构;由于相邻折叠挡板通过柔性连接件连接,这样更加有利于多个折叠挡板进行变形即打开或折叠
优选的,在所述主轴的底端设置一底板,所述折叠挡板和柔性连接件沿该底板的周向交替设置,且所述底板、折叠挡板和柔性连接件这三者密封连接。
采用上述结构,由所述底板、折叠挡板和柔性连接件这三者共同限定出墙板的中空结构,墙板成型过程中,浆料填充在模具的型腔壁与前述中空结构的孔壁之间,由于前述三者密封连接,能够避免制成墙板的浆料进入折叠套内。
可选的,所述折叠套为由柔性非弹性材料制成的软套。
优选的,所述驱动装置为油压机,多个所述折叠抽芯构件由同一个油压机统一驱动。
采用上述结构,能使多个折叠抽芯构件的运动方向、速度等保持一致,以保证多个折叠抽芯构件保持同步运行。
优选的,每个所述折叠抽芯构件还包括置于所述折叠套底部外侧的定位插头,所述模具还包括置于底部的墙板成型平台,在该墙板成型平台上设有与所述定位插头相匹配的定位孔。
采用上述结构,所述定位插头与定位孔相匹配,定位插头插入对应的定位孔中,对每个折叠抽芯构件进行定位。
优选的,所述抽芯构件驱动机构包括用以调整多个折叠抽芯构件的位置使所述定位插头与所述定位孔相配合的调整装置,所述主轴的顶端安装在该调整装置上。
采用上述结构,由于设有所述调整装置,能够对所述多个折叠抽芯构件进行准确定位。
优选的,还包括一墙板移出装置,所述墙板成型平台设置在该墙板移出装置上。
优选的,在所述支撑装置上设有延伸至所述模具上方的龙门架,所述抽芯构件驱动机构安装在该龙门架上。
优选的,还包括用以向所述型腔内送料的软管泵送机。
采用上述结构,所述软管泵送机能在所设定时间内均匀地持续不断地在控制频率和压力下,将浆料输送到模具的型腔中,使形成的墙板具有像注塑产品一样的混合整体性能和高密度优质性能。
优选的,在所述模具的底部设有连通所述软管泵送机与所述型腔的进料通道。
采用上述结构,由于进料通道设置在所述模具的底部使可固化的混合料是从模具的下部注入,可以充分利用浆料自身的重力和地心吸引力使模制出的墙板更密实、均匀,有效减少气泡的产生。
优选的,所述进料通道为一对且对称设置在所述模具的底部。
采用上述结构,能够使浆料从模具底部对称均匀地进入模具型腔内,以保证进料均匀性,有利于使模制出的墙板更均匀坚固。
优选的,在所述模具的底部还设有与所述进料通道连通的排料通道,且在所述进料通道内设有进料阀门。
采用上述结构,当模制的墙板已达到设定的高度时,或者是在紧急状态时,所述软管泵送机也可以根据PLC的指示把剩余或要废弃的浆料泵通过排料通道送到废料池,回收循环利用。
本发明同时提出了一种墙板成型设备的使用方法,所述墙板成型设备具有前述中任一所述的结构,至少包括以下步骤:
步骤A.利用所述抽芯构件驱动机构将所述抽芯构件下降至模具 内并定位,然后将多个所述折叠抽芯构件处于打开状态;
步骤B.所述驱动电机带动所述偏心轮机构做朝向内下方方向的偏心移动,使所述模板闭合,完成模具的合模;
步骤C.利用所述软管泵送机向所述模具的型腔内泵送已混合好的浆料;
步骤D.当所注入的浆料达到凝固状态后,将多个所述折叠抽芯构件处于闭合状态,使所述折叠式抽芯构件与已凝固的墙板的孔壁分离;
步骤E.利用所述抽芯构件驱动机构将所述抽芯构件往上提升从所述模具的型腔内抽出,所有折叠式抽芯构件与墙板脱离;
步骤F.所述驱动电机带动偏心轮机构做朝向外上方方向的偏心移动,所述模板与墙板外表面静态地分离,完成模具的开模、脱模。
附图说明
图1为墙板成型设备的整体示意图;
图2为模具驱动机构与模板的装配示意图;
图3为模具驱动机构的示意图;
图4为抽芯构件的示意图,为第一实施例;
图5为抽芯构件的俯视图;
图6为抽芯构件的示意图,为第二实施例。
具体实施方式
下面参照图1~图6对本发明所述的墙板成型设备及其使用方法的具体实施方式进行详细的说明。
如图1所示,墙板成型设备主要包括用以形成型腔的模具、驱动该模具进行开/合模的模具驱动机构9、墙板成型过程中插入型腔中以限定出墙板的中空结构的抽芯构件5、驱动该抽芯构件5插入型腔/从型腔抽出并对该抽芯构件进行定位的抽芯构件驱动机构8,以及起支撑作用的支撑装置11和用以移送成型后的墙板的墙板移出装置 10。墙板成型设备还包括依次连通的全自动配料系统1、全自动上料搅拌机2、软管泵送机3,以及连通软管泵送机3与型腔的进料通道4、与进料通道4连通的排料通道41、与该排料通道41连通的污水收集和处理装置13。另外,墙板成型设备还包括一PLC全自动控制系统12。
如图1所示,模具包括相对置且直立式设置的一对模板6,置于这一对模板6之间且位于底部的墙板成型平台101、置于前述一对模板6两端并在墙板成型过程中实现这一对模板两端密封连接的连接部件,由前述一对模板6、墙板成型平台以及连接部件共同围成与预制墙板的外形尺寸相对应的型腔。本实施例中,墙板成型平台101安装在墙板移出装置10上,在该墙板成型平台101上设有多对与下述抽芯构件5上的定位插头59相匹配的定位孔102。
进料通道4为一对且对称设置在前述一模板6的底部,相应地,排料通道41亦为一对且对称设置在前述一模板6的底部,且位于同侧的进料通道4与排料通道41相连通,形成一整条通道。其中,在进料通道4上设有双向进料阀门42,采用这种结构,当模制的墙板已达到设定的高度时,或者是在紧急状态时,软管泵送机3也可以根据PLC全自动控制系统12的指示把剩余或要废弃的浆料通过废料管泵送到废料池,回收循环利用。另外,由于进料通道4设置在一模板6的底部,墙板成型过程中可固化的浆料从模具的下部注入,可以充分利用浆料自身的重力和地心吸引力有效减少气泡的产生,使模制出的墙体和楼板更密实、均匀。
如图1和图2所示,支撑装置11对称设置在前述一对模板6的外侧,该支撑装置11上对称设有立柱111,模具驱动机构9对称安装在该立柱111上。如图2和图3所示,模具驱动机构9对称设置在一对模板6的外侧,以置于其中一个模板6外侧的模具驱动机构9为例,该模具驱动机构9包括与模板外侧连接的偏心轮机构、驱动该偏心轮机构运转的驱动电机99。其中,偏心轮机构为多个且位于同侧的多个偏心轮机构沿模板6的上下方向间隔设置,以保证模板6受力均衡。 单个偏心轮机构包括一偏心齿轮、一端与该偏心齿轮固定连接另一端与模板外侧连接的支撑臂,本实施例中,如图3所示,在立柱111上固定一个安装座113,该安装座113具有相对置并间隔设置的一对安装板,在这一对安装板上开设相对准的一对安装孔,在支撑臂的相反于模板6的一端设有偏心齿轮的母接头,利用与该母接头相匹配的一偏心轴(构成偏心齿轮的公接头)贯穿前述安装孔和偏心齿轮的母接头使支撑臂转动连接在安装座113上,由形成在支撑臂的相反于模板6的一端的母接头和与其匹配的偏心轴共同构成本发明所述的偏心齿轮结构,不难理解,还可通过其他替换结构实现偏心连接。驱动电机99与偏心齿轮的偏心轴传动连接,并位于同侧的多个偏心轮机构的支撑臂及对应的偏心齿轮处于同一竖直平面内,使位于同侧的偏心轮机构对模板6所施加的作用力在上下方向上处于同一直线上,保证对模板6的施力效果。
本实施例中,位于同侧的偏心轮机构分别为上偏心轮机构、中偏心轮机构、下偏心轮机构,上偏心轮机构包括具有上偏心轴96的上偏心齿轮、上支撑臂92,中偏心轮机构包括具有中偏心轴97的中偏心齿轮、中支撑臂93,下偏心轮机构包括具有下偏心轴98的上偏心齿轮、下支撑臂94,其中,驱动电机99与中偏心轴97通过传送带传动连接,该中偏心轴97与上偏心轴96、下偏心轴98通过传动链条910传动连接,且上偏心轴96、中偏心轴97和下偏心轴98这三者的转动保持同步。值得注意的是,如图3所示,上偏心轴96、中偏心轴97和下偏心轴98在平行于模板6的方向上具有一定的长度,除了每个偏心轴的中部与模板6形成偏心转动连接外,每个偏心轴的两端亦与模板6形成偏心转动连接,这样,能够增加偏心轮机构与模板6的连接部位,有利于增加模板6的受力面积,使其受力更加均衡,保证对模板6的施力效果。
墙板成型后需对模具进行脱模、开模时,驱动电机99运行,带动中偏心轴97转动,该中偏心轴97通过传送链条910带动上偏心轴96和下偏心轴98同步转动,这三个偏心轴所属的偏心齿轮带动与其 对应的支撑臂做朝向外上方方向的偏心转动,进而带动与该支撑臂连接的模板6相对于墙板做朝向外上方向的移动并同时向左右方向打开,由此实现模具的脱模、开模,使刚成型且强度不高的墙板静态地成功脱离模具。墙板成型过程中需对模具进行合模时,驱动电机99只需驱动偏心轮机构做反向运动即可。
如图1所示,在支撑装置11上设有延伸至模具上方的龙门架112,抽芯构件驱动机构8安装在该龙门架112上,它主要由定位和提升系统构成,该抽芯构件驱动机构8还包括用以调整抽芯构件5的下述多个折叠抽芯构件的位置的调整装置51。抽芯构件5包括固定在抽芯构件驱动机构8上、墙板成型过程中插入型腔中并处于打开状态以限定出墙板的中空结构、墙板成型后处于闭合状态以从型腔中抽出的多个折叠抽芯构件。
如图4和图5所示,每个折叠抽芯构件包括顶端安装在调整装置51上的一主轴52、顶部敞口设置并由主轴52的底端套装在主轴52上的折叠套、套装在主轴52上的驱动装置7、围绕主轴52设置且连接驱动装置7与折叠套的折叠支撑杆55。在主轴52的底端设有一底板58,折叠套包括配置在该底板58四周并沿其周向交替设置的折叠挡板57和柔性连接件56,且底板58、折叠挡板57和柔性连接件56这三者密封连接。其中,折叠挡板57由刚性材料制成,它主要起支撑作用,用于抵挡浆料所形成的巨大流体静压力,以更好地限定出墙板的中空结构,柔性连接件56主要用于连接相邻的折叠挡板57,它由帆布和橡胶复合而成的柔性材料制成,本实施例中,折叠挡板57的整体形状与圆柱体的纵剖面类似,柔性连接件56呈细长条形,在折叠套处于打开状态下,折叠挡板57与柔性连接件56共同围成一圆柱形,用于限定出墙板的中空结构。本实施例中,驱动装置7为油压机,多个折叠抽芯构件由同一个油压机统一驱动,该驱动装置7通过一连接板54与折叠支撑杆55连接。采用这种结构,能使多个折叠抽芯构件的运动方向、速度等保持一致,以保证多个折叠抽芯构件保持同步运行。
每组折叠支撑杆55由多个杆件转动连接,以其中一组折叠支撑杆55为例,它包括一端与连接板54连接另一端抵接在底板58上的第一杆件551、一端与底板58的靠近主轴52侧连接另一端与第一杆件551的下部连接的第二杆件552、连接该第二杆件552的中部与第一杆件551底端的第三杆件553、与第一杆件551呈“V”形设置且底端与第一杆件551和第三杆件553底端连接的第六杆件556、连接第一杆件551上部与第六杆件556上部的第四杆件554、置于该第四杆件554下方并连接第一杆件551与第六杆件556的第五杆件555,前述这多个杆件之间、第一杆件551与连接板54之间、第二杆件552与底板58之间均通过可转动的连接头557连接在一起。
另外,每个折叠抽芯构件还包括置于折叠套底部的定位插头59,该定位插头59插入前述成型平台101上的定位孔102中,通过这两者相配合对每个折叠抽芯构件进行定位。
墙板成型过程中,抽芯构件在抽芯构件驱动机构8的驱动下相对于模具向下移动直至多个折叠抽芯构件插入模具的型腔中,而后通过调整装置51调整各个折叠抽芯构件的具体位置并使每个折叠抽芯构件上的定位插头59插入成型平台101上的定位孔102中。然后,驱动装置7推动折叠支撑杆55沿着主轴52向下滑动,使折叠支撑杆55处于打开状态,由该折叠支撑杆55带动折叠套打开,通过该折叠套限定出墙板的中空结构,则折叠抽芯构件处于如图4所示的打开状态。
相反地,墙板成型后需要抽芯时,驱动装置7牵拉折叠支撑杆44沿着主轴52向上滑动,使折叠支撑杆55处于折叠状态,由该折叠支撑杆55带动折叠套朝向主轴52靠拢,则折叠抽芯构件处于闭合状态,在折叠套的外表面与模板的孔壁之间形成间隙。然后,抽芯构件在抽芯构件驱动机构8的驱动下相对于模具向上移动使定位插头59从成型平台101上的定位孔102中拔出,并直至多个折叠抽芯构件从模具的型腔中抽出。
下面参照图1~图4结合上述结构描述,对利用墙板成型设备制备墙板的使用方法进行简单的说明,整个墙板的生产过程是由PLC全 自动控制系统12按预先设定的程序进行。
步骤1.利用抽芯构件驱动机构8将抽芯构件5下降至模具内,并使每个折叠抽芯构件底部的定位插头59插入成型平台101上的定位孔102内以定位,然后利用驱动装置7使多个折叠抽芯构件处于打开状态;
步骤2.驱动电机99带动偏心轮机构做朝向内下方方向的偏心移动,使前述一对相对置且直立式设置的模板6闭合,完成模具的合模;
步骤3.全自动配料系统1根据所需要生产的墙板将各物料按比例混合好,并按照上料程序和速度将各物料输入到全自动上料搅拌机2内进行搅拌,形成纳米级纤维轻质高强可固化复合浆料,这里原材料为可固化的混合料,由石膏基复合材料或水泥基混合物和和纳米级晶须纤维所组成;
步骤4.当搅拌到预期混合效果后,软管泵送机3接收了开始泵送信号后,把双向进料阀门42打开而排废料阀门关闭;
步骤5.利用软管泵送机3按设定的频率和速度往模具型腔内泵送已混合好的纳米级纤维轻质高强可固化复合浆料;
步骤6.当所注入的纳米级纤维轻质高强可固化复合浆料达到凝固状态后,利用驱动装置7使多个折叠抽芯构件处于闭合状态,使折叠式抽芯构件的折叠套的外表面与已凝固的墙板的孔壁分离;
步骤7.利用抽芯构件驱动机构8将抽芯构件5往上提升,使每个折叠抽芯构件底部的定位插头59脱离成型平台101上的定位孔102内,然后继续上移直至从型腔内抽出,使所有折叠抽芯构件与墙板脱离;
步骤8.驱动电机99带动偏心轮机构做朝向外上方方向的偏心移动,使前述一对相对置且直立式设置的模板6与墙板外表面静态地分离,完成模具的开模、脱模,而已成型的墙板直立在墙板移出装置10上;
步骤9.利用墙板移出装置10把墙板移出整套设备,完成墙板的一个生产周期。每个生产周期需时约四十分钟。
在步骤5后,还包括一与剩余步骤同步的步骤,即为,在浆料定量泵送完成后,双向进料阀门42关闭而废料阀口打开,同时全自动上料搅拌机2启动水清洗程序以清洗软管泵送机3内的浆料,软管泵送机3内的废水经排料通道41排放到污水收集和处理装置13内进行过滤后重用,形成一个完善的生产循环周期。
另外,在步骤3之前,还包括一步骤,即为,将脱模剂施加于模具上,该脱模剂用于使墙板容易地从模具中移走。
上述墙板成型设备适合制造大面积空心建筑承重墙板,能够在一天时间生产30件12米长*3米高*130至200mm厚的轻质高强耐水内墙和外墙的结构承重墙,其每平方米墙板的重量只有65公斤,其它物理性能完全达到和超过国家规范要求。利用上述墙板成型设备所制备的墙板具有通过多个间隔的结构部而互连的间隔对置外壁,以至在相邻结构部之间分别限定出空腔,它是现代建筑工业化所需求的质轻、高强耐水、防火、防虫、节能环保绿色承重墙体和楼板,其表面平整光滑,不需抹灰便能上油漆,真正做到省工,省钱和建筑效率大幅提高。
上述墙板成型设备通过增设偏心轮机构来实现直立式模板与墙板的脱模分离技术,运用了偏芯齿轮分级轴向转动能将具有大面积吸附力的模板6向一定角度的外上方方向移动,把在压力泵泵送浆料过程中所形成的巨大吸附力静态地抵销掉,使刚成型且强度不高的墙板静态地成功脱离模具,从而达到模板与墙板彻底分离的目的,避免脱模时损伤墙板,有利于保证墙板外表面的光滑度,同时还低成本而有效地解决了大型立式建筑预制模板的脱模难题。本发明将建筑空心墙板目前成孔抽芯技术成本显著地降低和取得的型腔精确度大幅提高,从而使墙板成型设备效率显著提升。
同时,上述墙板成型设备利用折叠式抽芯构件实现抽芯构件与墙板孔壁的分离,能够保证抽芯构件顺利抽出,以解决直立式预制大面积建筑空心墙板的制造设备的插入构件的抽芯问题。
同时,上述墙板成型设备利用软管泵压力泵送系统把湿的复合浆 料打到模具型腔中,使墙板的结构更均匀和密度更高,换句话说即使用注塑原理来生产墙板,使墙板的物理性能大大提高,而且墙板的两个面因同步制成故光滑平整不需要二次加工。
以上所述仅为本发明的较佳实施例而已,并不用以限制本发明,凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
例如,在上述实施例中,如图4和图5所示,折叠套由置于主轴52底端的底板58、配置在该底板58四周并沿其周向交替设置的折叠挡板57和柔性连接件56密封连接而成。然而并非局限于此,如图6所示,折叠套中的折叠挡板57和柔性连接件56还可由一顶部敞口设置的软套5a替代,该软套5a由柔性非弹性材料制成,它是一整体部件,由主轴52的底端套装在底板58和主轴52上。
另外,在上述实施例中,折叠套在打开状态下整体呈圆柱形,即折叠套所限定出的墙板的中空结构的截面为圆形,然而并非局限于此,实际应用中,墙板的中空结构的截面可以为椭圆形(包括长椭圆形)、方形、矩形、六边形、八边形、其他多边形等,则折叠套的结构应该做适应性变化,其连接关系与上述结构相同。

Claims (23)

  1. 一种墙板成型设备,其特征在于,包括用以形成型腔的模具、驱动该模具进行开/合模的模具驱动机构(9)、墙板成型过程中插入所述型腔中以限定出墙板的中空结构的抽芯构件(5)、驱动该抽芯构件(5)插入/抽出所述型腔并对其进行定位的抽芯构件驱动机构(8),以及起支撑作用的支撑装置(11)。
  2. 根据权利要求1所述的墙板成型设备,其特征在于,所述模具包括相对置且直立式设置的一对模板(6),所述模具驱动机构(9)对称设置在这一对模板(6)的外侧。
  3. 根据权利要求2所述的墙板成型设备,其特征在于,所述模具驱动机构(9)包括与所述模板外侧连接的偏心轮机构、驱动该偏心轮机构运转的驱动电机(99)。
  4. 根据权利要求3所述的墙板成型设备,其特征在于,所述偏心轮机构包括偏心齿轮、一端与该偏心齿轮固定连接另一端与所述模板外侧连接的支撑臂,所述驱动电机(99)与所述偏心齿轮的偏心轴传动连接。
  5. 根据权利要求4所述的墙板成型设备,其特征在于,位于同侧的所述偏心轮机构为多个且沿所述模板(6)的上下方向间隔设置。
  6. 根据权利要求5所述的墙板成型设备,其特征在于,位于同侧的多个偏心轮机构的支撑臂及对应的偏心齿轮处于同一竖直平面内。
  7. 根据权利要求5所述的墙板成型设备,其特征在于,位于同侧的所述偏心轮机构包括置于上部的上偏心轮机构、置于中部的中偏心轮机构和置于下部的下偏心轮机构,所述驱动电机(99)与中偏心轮机构的中偏心轴(97)传动连接,该中偏心轴(97)与所述上偏心轮机构的上偏心轴(96)、下偏心轮机构的下偏心轴(98)传动连接,且上偏心轴(96)、中偏心轴(97)和下偏心轴(98)这三者的转动保持同步。
  8. 根据权利要求3所述的墙板成型设备,其特征在于,在所述 支撑装置(11)上于所述一对模板(6)的外侧对称设置有立柱(111),所述模具驱动机构(9)安装在该立柱(111)上。
  9. 根据权利要求1所述的墙板成型设备,其特征在于,所述抽芯构件(5)包括固定在所述抽芯构件驱动机构(8)上、墙板成型过程中插入所述型腔中并处于打开状态以限定出墙板的中空结构、墙板成型后处于闭合状态以从所述型腔中抽出的多个折叠抽芯构件。
  10. 根据权利要求9所述的墙板成型设备,其特征在于,每个所述折叠抽芯构件包括安装在所述抽芯构件驱动机构(8)上的一主轴(52)、顶部敞口设置并由所述主轴(52)的底端套装在所述主轴(52)上的折叠套、套装在所述主轴(52)上的驱动装置(7)、围绕所述主轴(52)设置且连接所述驱动装置(7)与所述折叠套的多组折叠支撑杆(55)。
  11. 根据权利要求10所述的墙板成型设备,其特征在于,所述折叠套包括多个由刚性材料制成的折叠挡板(57),并这多个折叠挡板(57)通过柔性连接件(56)连接。
  12. 根据权利要求11所述的墙板成型设备,其特征在于,在所述主轴(52)的底端设置一底板(58),所述折叠挡板(57)和柔性连接件(56)沿该底板(58)的周向交替设置,且所述底板(58)、折叠挡板(57)和柔性连接件(56)这三者密封连接。
  13. 根据权利要求10所述的墙板成型设备,其特征在于,所述折叠套为由柔性非弹性材料制成的软套(5a)。
  14. 根据权利要求10所述的墙板成型设备,其特征在于,所述驱动装置(7)为油压机,多个所述折叠抽芯构件由同一个油压机统一驱动。
  15. 根据权利要求10所述的墙板成型设备,其特征在于,每个所述折叠抽芯构件还包括置于所述折叠套底部外侧的定位插头(59),
    所述模具还包括置于底部的墙板成型平台(101),在该墙板成型平台(101)上设有与所述定位插头(59)相匹配的定位孔(102)。
  16. 根据权利要求15所述的墙板成型设备,其特征在于,所述 抽芯构件驱动机构(8)包括用以调整多个折叠抽芯构件的位置使所述定位插头(59)与所述定位孔(102)相配合的调整装置(51),所述主轴(52)的顶端安装在该调整装置(51)上。
  17. 根据权利要求15所述的墙板成型设备,其特征在于,还包括一墙板移出装置(10),所述墙板成型平台(101)设置在该墙板移出装置(10)上。
  18. 根据权利要求1所述的墙板成型设备,其特征在于,在所述支撑装置(10)上设有延伸至所述模具上方的龙门架(112),所述抽芯构件驱动机构(8)安装在该龙门架(112)上。
  19. 根据权利要求1或2所述的墙板成型设备,其特征在于,还包括用以向所述型腔内送料的软管泵送机(3)。
  20. 根据权利要求18所述的墙板成型设备,其特征在于,在所述模具的底部设有连通所述软管泵送机(3)与所述型腔的进料通道(4)。
  21. 根据权利要求20所述的墙板成型设备,其特征在于,所述进料通道(4)为一对且对称设置在所述模具的底部。
  22. 根据权利要求20或21所述的墙板成型设备,其特征在于,在所述模具的底部还设有与所述进料通道(4)连通的排料通道(41),且在所述进料通道(4)内设有进料阀门(42)。
  23. 一种墙板成型设备的使用方法,所述墙板成型设备具有权利要求1~22中任一所述的结构,其特征在于,至少包括以下步骤:
    步骤A.利用所述抽芯构件驱动机构(8)将所述抽芯构件(5)下降至模具内并定位,然后将多个所述折叠抽芯构件处于打开状态;
    步骤B.所述驱动电机(99)带动所述偏心轮机构做朝向内下方方向的偏心移动,使所述模板(6)闭合,完成模具的合模;
    步骤C.利用所述软管泵送机(3)向所述模具的型腔内泵送已混合好的浆料;
    步骤D.当所注入的浆料达到凝固状态后,将多个所述折叠抽芯构件处于闭合状态,使所述折叠式抽芯构件与已凝固的墙板的孔壁分 离;
    步骤E.利用所述抽芯构件驱动机构(8)将所述抽芯构件(5)往上提升从所述模具的型腔内抽出,所有折叠式抽芯构件与墙板脱离;
    步骤F.所述驱动电机(99)带动偏心轮机构做朝向外上方方向的偏心移动,所述模板(6)与墙板外表面静态地分离,完成模具的开模、脱模。
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