WO2023103691A1 - 用于pc构件生产的自动化立体流水线及其生产工艺 - Google Patents

用于pc构件生产的自动化立体流水线及其生产工艺 Download PDF

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Publication number
WO2023103691A1
WO2023103691A1 PCT/CN2022/130684 CN2022130684W WO2023103691A1 WO 2023103691 A1 WO2023103691 A1 WO 2023103691A1 CN 2022130684 W CN2022130684 W CN 2022130684W WO 2023103691 A1 WO2023103691 A1 WO 2023103691A1
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Prior art keywords
assembly line
mold
station
production
curing
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PCT/CN2022/130684
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English (en)
French (fr)
Inventor
余勤
潘寒
廖峰
胡中平
卢文达
赵胜涛
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中建科技武汉有限公司
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Publication of WO2023103691A1 publication Critical patent/WO2023103691A1/zh

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B15/00—General arrangement or layout of plant ; Industrial outlines or plant installations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/08—Producing shaped prefabricated articles from the material by vibrating or jolting
    • B28B1/087—Producing shaped prefabricated articles from the material by vibrating or jolting by means acting on the mould ; Fixation thereof to the mould
    • B28B1/0873—Producing shaped prefabricated articles from the material by vibrating or jolting by means acting on the mould ; Fixation thereof to the mould the mould being placed on vibrating or jolting supports, e.g. moulding tables
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
    • B28B11/245—Curing concrete articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
    • B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
    • B28B13/0215—Feeding the moulding material in measured quantities from a container or silo
    • B28B13/023—Feeding the moulding material in measured quantities from a container or silo by using a feed box transferring the moulding material from a hopper to the moulding cavities
    • B28B13/0235—Feeding the moulding material in measured quantities from a container or silo by using a feed box transferring the moulding material from a hopper to the moulding cavities the feed box being provided with agitating means, e.g. stirring vanes to avoid premature setting of the moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
    • B28B23/022—Means for inserting reinforcing members into the mould or for supporting them in the mould
    • B28B23/024—Supporting means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/38—Treating surfaces of moulds, cores, or mandrels to prevent sticking
    • B28B7/388—Treating surfaces of moulds, cores, or mandrels to prevent sticking with liquid material, e.g. lubricating

Definitions

  • the invention relates to the field of automatic production of precast concrete components, in particular to an automatic three-dimensional assembly line for the production of various PC (Precast Concrete, prefabricated concrete) components and a production process thereof.
  • PC Precast Concrete, prefabricated concrete
  • prefabricated buildings is a major change in the way of construction, which is conducive to saving resources and energy, reducing construction pollution, improving labor production efficiency and quality and safety levels, and is conducive to promoting the deep integration of the construction industry and industrialization informatization, cultivating new industries and new kinetic energy, and promoting the resolution of Overcapacity, after long-term development, my country's factory-fabricated buildings have made breakthroughs.
  • the main purpose of the present invention is to provide an automatic three-dimensional assembly line for the production of PC components and its production process, which aims to save the land use cost of the enterprise, and improve the production efficiency and quality at the same time, thereby reducing the production cost of the enterprise.
  • the automatic three-dimensional assembly line for the production of PC components further includes a second mold table lifter, the upper delivery point of the second mold table lifter is located at the head of the upper assembly line, and the lower delivery point of the second mold table lifter is located at the lower assembly line end of .
  • both the first mold platform elevator and the second mold platform elevator include a lifting frame body and a positioning device installed on the lifting frame body, a locking device, a lifting device, a safety protection device, a control sensor, a control cabinet and an operation tower.
  • one side of the lower assembly line is also provided with a torpedo can circular conveying track for transporting the torpedo can to each distribution point of the factory, and the torpedo can circular conveying track is equipped with an electrical control system, a torpedo can positioning device and a torpedo can flushing device .
  • the pre-curing kiln includes a curing bin and a first temperature control system installed on the curing bin, a first humidification system and a first steam curing system
  • the steam curing kiln includes a three-dimensional curing bin and a first temperature control system installed on the three-dimensional curing The second temperature control system, the second humidification system and the second steaming system on the warehouse.
  • steel bar processing equipment steel bar binding equipment, steel bar finished buffer racks, line-side mold warehouses and line-side shelves are also arranged on the upper floor of the workshop; mold table and mold cleaning equipment is also provided at the tail of the lower assembly line, and the mold table and mold cleaning equipment is used for After the mold table and the mold are demoulded, the concrete waste is cleaned.
  • the steel bar processing equipment includes hoop bending machine, straightening and cutting machine, numerical control cutting line, wire drawing machine, numerical control truss bar automatic processing equipment and numerical control mesh bar automatic processing equipment.
  • both the upper assembly line and the lower assembly line are provided with quality inspection stations, the quality inspection station of the upper assembly line is located at the rear end of the embedded part installation station, and the quality inspection station of the lower assembly line is located at the vibrating station and the pre-installation station. Between the kilns.
  • all automation equipment on the upper and lower floors of the factory building are connected to the enterprise data acquisition and monitoring system through industrial Ethernet, and thus form a workshop ring network, so that all equipment can be interconnected.
  • the corresponding mold components are taken out from the mold library on the line side, and the mold is placed in the spraying station of the upper assembly line for spraying operation;
  • the mold table after spraying passes through the upper assembly line, and the mold installation, the reinforcement cage installation inside the mold table, and the embedded parts inside the mold table are installed in sequence. After the embedded parts inside the mold table are installed, the RFID electronic tags corresponding to the products to be produced are installed. In the designated place of the mold table;
  • the mold table is transported from the upper assembly line to the lower assembly line through the first mold table elevator.
  • the mixing station After receiving the product information to be produced, the mixing station starts to mix the concrete with the designated label of the station, and conveys it to the distributing station through the torpedo tank, and uses the distributing machine to start distributing , and use a vibrator to compact the concrete in the mold table;
  • the mold table is sequentially transported to the pre-curing kiln and the steam curing kiln for curing. After the curing is completed, the mold table is demoulded at the demoulding station.
  • the automatic three-dimensional assembly line for the production of PC components proposed by the present invention requires 36 workers for a single production line, which is 1/2 of the traditional PC production line, and the equipment cost is equal to that of the traditional PC production line.
  • the present invention adopts double-layer arrangement, and compared with the traditional PC production line, the site can be saved by 45%, which saves the land use cost of the enterprise, improves the production efficiency and quality, and reduces the production cost of the enterprise.
  • Fig. 1 is the three-dimensional layout schematic diagram of the automatic three-dimensional assembly line that the present invention is used for PC component production;
  • Fig. 2 is the plane layout schematic diagram of the automatic three-dimensional assembly line that the present invention is used for PC component production;
  • Fig. 3 is a workshop ring network topology diagram of the automatic three-dimensional assembly line used in the production of PC components according to the present invention.
  • the invention proposes an automatic three-dimensional assembly line for PC component production.
  • the platform is transferred to the lower assembly line, and the distributing station and the vibrating station are respectively provided with a distributing machine 13 and a concrete vibrator 14, and the pre-curing station and the steam-curing station are respectively provided with a pre-curing kiln 15 and a steam-curing kiln 16.
  • Spraying equipment is installed on the spraying station.
  • the automatic three-dimensional assembly line for the production of PC components also includes a second mold platform elevator 1, the upper delivery point of the second mold platform elevator 1 is located at the head of the upper assembly line, and the lower delivery point of the second mold platform elevator 1 is located at end of the lower pipeline.
  • one side of the lower assembly line is also provided with a torpedo can circular conveying track 12 for transporting the torpedo can to each distribution point of the factory, and the torpedo can circular conveying track 12 is equipped with an electrical control system and a torpedo can positioning device (for positioning the torpedo can) tank) and torpedo tank flushing device (for flushing torpedo tanks).
  • thermal insulation board processing system thermal insulation board on-line gripper, mesh processing equipment, and mesh on-line gripper, so as to perform secondary pouring of the shear wall with thermal insulation board after installing the thermal insulation board and mesh .
  • the pre-curing kiln 15 includes a curing bin and the first temperature control system installed on the curing bin, the first humidification system and the first steam curing system, and the steam curing kiln 16 includes a three-dimensional curing bin and a three-dimensional curing bin.
  • the second temperature control system, the second humidification system and the second steaming system includes a curing bin and the first temperature control system.
  • steel bar processing equipment 9, steel bar binding equipment, steel bar finished buffer rack 4, steel bar semi-finished product buffer rack 7, line-side material warehouse 6, line-side mold warehouse 2, and line-side shelves are also arranged on the upper floor of the workshop.
  • the line-side shelf is used to cache embedded parts, wire pipes, tool boxes, etc. required for production;
  • the line-side mold library 2 is used to store mold storage racks, power-assisted grippers, and tool boxes, and is used for mold switching during component production.
  • the tail of the lower assembly line is also provided with mold table mold cleaning equipment 18, and the mold table mold cleaning equipment 18 is used to clean the concrete waste slag after the mold table and the mold are demoulded.
  • the steel bar processing equipment 9 includes hoop bending machine, straightening and cutting machine, CNC cutting line, wire drawing machine, CNC truss bar automatic processing equipment and CNC mesh bar automatic processing equipment.
  • Rebar binding equipment includes binding tooling, semi-finished product assembly racks, toolboxes, and electronic kanban boards for task planning. After the semi-finished steel bar is bound and formed, it is cached in the designated place, and the finished steel bar is installed to the steel bar mold entry station by crane.
  • quality inspection stations are all provided, and the quality inspection station on the upper assembly line is located at the rear end of the embedded part installation station, and the quality inspection station on the lower assembly line is located at the vibrating station and Between 15 pre-culture kilns.
  • the production process execution management system accepts the order plan of the enterprise's ERP system, issues production instructions to each production unit, sends production information to the equipment control cabinet and electronic kanban through industrial Ethernet and industrial network switches, and guides the automation of equipment through the equipment control cabinet Operation, the on-site workers are guided to operate according to the standard through the electronic kanban; each component produced has a built-in RFID electronic tag, and the RFID electronic tag can conveniently and accurately record the process information and process operation information on the production line. Time, operation, and quality inspection results, the component production information is fed back to the production process management system through the RFID terminal; equipment operation information and product production information are input into the production process execution management system through the data collection and monitoring network, and finally connected to the enterprise ERP system .
  • Each production station of the upper and lower assembly lines is in the state of production preparation
  • the production process execution management system accepts the order plan of the enterprise ERP system and issues production instructions to each production unit;
  • the mold installation process includes the installation of the four-sided mold and the installation of the inner mold
  • the steel bar processing equipment 9 After receiving the production instructions from the production management system, the steel bar processing equipment 9 will automatically produce semi-finished steel bar products according to the order. After the workers pack the semi-finished steel bar products, they will be delivered to the steel bar binding station in a centralized manner. At the same time, the process information of steel bar binding will be displayed on the On the electronic kanban board in the binding area, workers complete the binding task of the steel skeleton according to the instructions, and store it in the finished steel bar buffer rack. When the mold table moves to the steel skeleton mold entry station, the steel skeleton is hoisted into the mold table mold by the workshop crane;
  • the material warehouse After receiving the production instructions from the production management system, the material warehouse prepares embedded parts and RFID electronic tags according to the order product information, packs them and distributes them to the line side warehouse. After the mold table arrives at the embedded parts installation station, the workers will install the embedded parts and RFID electronic tags in designated places according to the production information displayed on the electronic kanban;
  • the mold table is transported from the second-floor factory building to the first-floor factory building through the first mold table elevator 8;
  • the demoulding station uses the driving to carry out the demoulding operation.
  • the demoulded components are transported to the component yard by the flat trolley, and the mold table is cleaned at the same time. After demoulding, the mold table is transferred to the initial station. Proceed to the next round of production.
  • the automatic three-dimensional assembly line for the production of PC components proposed by the present invention requires 36 workers for a single production line, which is 1/2 of the traditional PC production line, and the equipment cost is equal to that of the traditional PC production line.
  • the present invention adopts double-layer arrangement, and compared with the traditional PC production line, the site can be saved by 45%, which saves the land use cost of the enterprise, improves the production efficiency and quality, and reduces the production cost of the enterprise.
  • the invention proposes a production process of an automatic three-dimensional assembly line for PC component production.
  • a production process based on the above-mentioned automated three-dimensional assembly line for PC component production includes the following steps:
  • the corresponding mold components are taken out from the lineside mold library 2, and the mold is placed in the spraying station of the upper assembly line for spraying operation;
  • the mold table after spraying passes through the upper assembly line, and the mold installation, the reinforcement cage installation inside the mold table, and the embedded parts inside the mold table are installed in sequence. After the embedded parts inside the mold table are installed, the RFID electronic tags corresponding to the products to be produced are installed. In the designated place of the mold table;
  • the mold table is transported from the upper assembly line to the lower assembly line through the first mold table elevator 8.
  • the mixing station 11 starts to mix the concrete with the designated label of the station 11, and conveys it to the distribution station through the torpedo tank.
  • the machine 13 starts to distribute the material, and the concrete in the mold table is compacted by the vibrator;
  • the mold table is sequentially transported to the pre-curing kiln 15 and the steam curing kiln 16 for curing. After the curing is completed, the mold table is demoulded at the demoulding station.
  • the production process of the automatic three-dimensional assembly line for the production of PC components proposed in this embodiment can realize the automatic operation of PC production, and its production automation degree is high and the production efficiency is high.

Abstract

本发明公开了一种用于PC构件生产的自动化立体流水线及其生产工艺。本用于PC构件生产的自动化立体流水线包括第一模台升降机、上流水线和下流水线，上流水线上依次设置喷涂工位、模具安装工位、钢筋笼安装工位、模具固定工位和预埋件安装工位，下流水线上依次设置布料工位、振捣工位、预养窑、蒸养窑和脱模工位，第一模台升降机的上运送点位于上流水线的尾部，第一模台升降机的下运送点位于下流水线的头端，布料工位和振捣工位上分别设置有布料机和混凝土振捣机。本用于PC构件生产的自动化立体流水线，采用双层布置，场地对比传统PC生产线可节约45％，节约了企业土地使用成本，同时提高生产效率和质量。

Description

用于PC构件生产的自动化立体流水线及其生产工艺 技术领域
本发明涉及预制混凝土构件自动化生产领域，尤其涉及一种用于多种PC(Precast Concrete，预制混凝土)构件生产的自动化立体流水线及其生产工艺。
背景技术
发展装配式建筑是建造方式的重大变革，有利于节约资源能源、减少施工污染、提升劳动生产效率和质量安全水平，有利于促进建筑业与工业化信息化深度融合、培育新产业新动能、推动化解过剩产能，经过长期发展，我国工厂化装配式建筑取得了突破性进展。
但由于建筑业的纯建筑的思维保守性，对引进制造业先进的技术和理念意愿不强。在工厂化装配式建筑这一块，可借鉴对象少，工人技术水平和素质普遍不高，一直坚守传统的建筑施工方式，导致国内PC工厂流水线技术一直停滞不前，占地面积大，设备老旧，工艺落后等问题突出。同时我国作为装配式建筑重点推进区域，基本上均为一线城市，土地成本直接影响到PC厂的建厂成本和投资回报期，另外传统PC构件厂经过多年的发展，整体水平仍处于自动化初级阶段，生产线布置落后，未充分利用立体空间，信息化方面基本没有，整体生产状态充满随意性。
发明内容
本发明的主要目的在于提供一种用于PC构件生产的自动化立体流水线及其生产工艺，旨在节约了企业土地使用成本，同时提高生产效率和质量，从而降低了企业生产成本。
为实现上述目的，本发明提供一种用于PC构件生产的自动化立体流水线，包括第一模台升降机、以及分别位于厂房上下层的上流水线和下流水线，其中，上流水线上依次设置喷涂工位、模具安装工位、钢筋笼安装工位、模具固定工位和预埋件安装工位，下流水线上依次设置布料工位、振捣工位、预养工位、蒸养工位和脱模工位，第一模台升降机的上运送点位于上流水线的尾部，第一模台升降机的下运送点位于下流水线的头端以将上流水线运输过来的模台转送至下流水线，布料工位和振捣工位上分别设置有布料机和混凝土振捣机，预养工位和蒸养工位分别设置有预养窑和蒸养窑，喷涂工位上安装有喷涂设备。[0006]
优选地，所述用于PC构件生产的自动化立体流水线还包括第二模台升降机，第二模台升降机的上运送点位于上流水线的头部，第二模台升降机的下运送点位于下流水线的尾端。
优选地，所述第一模台升降机和第二模台升降机均包括提升框架本体以及安装于提升框架本体上的定位装置、锁紧装置、提升装置、安全防护装置、控制传感器、控制柜以及操作台。
优选地，所述下流水线一侧还设置有用于将鱼雷罐运输到工厂各个布料点的鱼雷罐环形输送轨道，鱼雷罐环形输送轨道配套设置有电气控制系统、鱼雷罐定位装置以及鱼雷罐冲洗装置。
优选地，所述预养窑包括养护仓以及安装于养护仓上的第一温控系统、第一加湿系统和第一蒸养系统，所述蒸养窑包括立体养护仓、以及安装于立体养护仓上的第二温控系统、第二加湿系统和第二蒸养系统。
优选地，厂房上层还布置有钢筋加工设备、钢筋绑扎设备、钢筋成品缓存架、线边模具库以及线边货架；下流水线的尾部还设置有模台模具清理设备，模台模具清理设备用于模台和模具在构件脱模后进行混凝土废渣清理。
优选地，所述钢筋加工设备包括有弯箍机、调直切断机、数控剪切线、拔丝机、数控桁架筋自动加工设备和数控网片筋自动加工设备。
优选地，所述上流水线和下流水线上均设置有质检工位，上流水线的质检工位位于预埋件安装工位后端，下流水线的质检工位位于振捣工位和预养窑之间。
优选地，厂房上下层的所有自动化设备均通过工业以太网接入企业数据采集与监控系统，并以此形成车间环网，使所有设备实现互联互通。
本发明进一步提出一种基于上述用于PC构件生产的自动化立体流水线的生产工艺，包括以下步骤：
根据待生产产品信息和对应的模具信息，从线边模具库中取出对应模具组件，并将模具放置到上流水线的喷涂工位进行喷涂操作；
喷涂后的模台通过上流水线，依次进行模具安装、模台内部钢筋笼安装以及模台内部预埋件安装，在模台内部预埋件安装完成后，将待生产产品对应的RFID电子标签安装在模台指定地方；
模台通过第一模台升降机从上流水线输送到下流水线，在接收到待生产产品信息后，搅拌站开始搅拌站指定标号的混凝土，并通过鱼雷罐输送到布料工位，利用布料机开始布料，并通过振捣机将模台内的混凝土捣密实；
混凝土浇筑完成后，模台依次运输至预养窑和蒸养窑中进行养护，养护完成后，模台在脱模工位进行脱模操作。
本发明提出的用于PC构件生产的自动化立体流水线，单生产线所需工人数量为36人，为传统PC生产线1/2，设备成本与传统PC生产线持平。本发明采用双层布置，场地对比传统PC生产线可节约45％，节约了企业土地使用成本，同时提高生产效率和质量、降低了企业生产成本。
附图说明
图1为本发明用于PC构件生产的自动化立体流水线的立体布置示意图；
图2为本发明用于PC构件生产的自动化立体流水线的平面布置示意图；
图3为本发明用于PC构件生产的自动化立体流水线的车间环网拓扑图。
图中，1-第二模台升降机，2-线边模具库，3-模台机运线，4-钢筋成品缓存架，5-钢筋绑扎设备，6-线边物料库，7-钢筋半成品缓存架，8-第一模台升降机，9-钢筋加工设备，10-钢筋原材料，11-搅拌站，12-鱼雷罐环形输送轨道，13-布料机，14-混凝土振捣机，15-预养窑，16-蒸养窑，17-码垛机，18-模台模具清理设备。
本发明目的的实现、功能特点及优点将结合实施例，参照附图做进一步说明。
具体实施方式
应当理解，此处所描述的具体实施例仅仅用以解释本发明，并不用于限定本发明。
需要说明的是，在本发明的描述中，术语“横向”、“纵向”、“上”、“下”、“前”、“后”、“左”、“右”、“竖直”、“水平”、“顶”、“底”、“内”、“外”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述本发明和简化描述，并不是指示或暗示所指的装置或元件必须具有特定的方位、以特定的方位构造和操作，因此不能理解为对本发明的限制。此外，术语“第一”、“第二”等仅用于描述目的，而不能理解为指示或暗示相对重要性。
本发明提出一种用于PC构件生产的自动化立体流水线。
参照图1和图2，本优选实施例中，一种用于PC构件生产的自动化立体流水线，包括第一模台升降机8、以及分别位于厂房上下两层的上流水线和下流水线，其中，上流水线上依次设置喷涂工位、模具安装工位、钢筋笼安装工位、模具固定工位、预埋件安装工位，下流水线上依次设置布料工位、振捣工位、预养工位、蒸养工位和脱模工位，第一模台升降机8的上运送点位于上流水线的尾部，第一模台升降机8的下运送点位于下流水线的头端以将上流水线运输过来的模台转送至下流水线，布料工位和振捣工位上分别设置有布料机13和混凝土振捣机14，预养工位和蒸养工位分别设置有预养窑15和蒸养窑16，喷涂工位上安装有喷涂设备。
进一步地，本用于PC构件生产的自动化立体流水线还包括第二模台升降机1，第二模台升降机1的上运送点位于上流水线的头部，第二模台升降机1的下运送点位于下流水线的尾端。
具体地，本实施例中，第一模台升降机8和第二模台升降机1均包括提升框架本体以及安装于提升框架本体(运送板相对于提升框架可上下升降，运送板上平台可放置模台)上的定位装置(定位装置用于实现运送板的精确定位)、锁紧装置(锁紧装置用于在运送板在定位后，将其锁紧)、提升装置(提升装置用于上下提升运送板)、安全防护装置(安全防护装置用于防护，防止人员误操作而造成的损失)、控制传感器(传感器用于控制定位)、控制柜(控制柜上安装有各种电路板)以及操作台(操作台用于人工操作)。
进一步地，下流水线一侧还设置有用于将鱼雷罐运输到工厂各个布料点的鱼雷罐环形输送轨道12，鱼雷罐环形输送轨道12配套设置有电气控制系统、鱼雷罐定位装置(用于定位鱼雷罐)以及鱼雷罐冲洗装置(用于冲洗鱼雷罐)。
进一步地，布料机13前还配置有保温板加工系统、保温板上线抓手、网片加工设备、网片上线抓手，以安装保温板和网片后进行带保温板剪力墙二次浇筑。
具体地，保温板加工系统用于切割与成型装配式板材的保温板，保温板上线抓手用于将加工好的保温板运输到生产线上的相关工位；网片加工设备用于加工装配式板材中的钢筋网片；网片上线抓手用于将加工好的钢筋网片运输到生产线上的相关工位。
具体地，预养窑15包括养护仓以及安装于养护仓上的第一温控系统、第一加湿系统和第一蒸养系统，蒸养窑16包括立体养护仓、以及安装于立体养护仓上的第二温控系统、第二加湿系统和第二蒸养系统。
进一步地，厂房上层还布置有钢筋加工设备9、钢筋绑扎设备、钢筋成品缓存架4、钢筋半成品缓存架7、线边物料库6、线边模具库2以及线边货架。线边货架用于缓存生产时所需的预埋件、线管、工具箱等；线边模具库2用于放置模具存放架、助力抓手、工具箱，用于 构件生产过程中模具切换。
进一步地，下流水线的尾部还设置有模台模具清理设备18，模台模具清理设备18用于模台和模具在构件脱模后进行混凝土废渣清理。
钢筋加工设备9包括有弯箍机、调直切断机、数控剪切线、拔丝机、数控桁架筋自动加工设备和数控网片筋自动加工设备。
钢筋绑扎设备包括绑扎工装、半成品集配架、工具箱、任务计划电子看板，当钢筋半成品绑扎成型后，缓存于指定地点，通过行吊将钢筋成品安装到钢筋入模工位。
生产过程执行管理系统下达生产订单后，产品数据经处理下载到钢筋数控设备上，钢筋加工设备9自动开始生产加工钢筋半成品，转运工人根据电子看板将钢筋半成品通过集配车配送到钢筋加工设备9后端的钢筋绑扎工位；钢筋绑扎完成后，缓存于后端线边钢筋成品缓存架4，总成线上工人根据电子看板，通过行吊将钢筋成品安装到钢筋入模工位。[0040]进一步地，上流水线和下流水线上均设置有质检工位，上流水线的质检工位位于预埋件安装工位后端，下流水线的质检工位位于振捣工位和预养窑15之间。
进一步地，参照图3，厂房上下层的所有自动化设备均通过工业以太网接入企业数据采集与监控系统，并以此形成车间环网，使所有设备实现互联互通。生产过程执行管理系统接受企业ERP系统的订单计划，对各生产单元下达生产指示，通过工业以太网和工业网络交换机将生产信息下发到设备控制柜和电子看板，通过设备控制柜指导设备的自动化运行，通过电子看板指导现场工人按标准操作；所生产每个构件中均内置RFID电子标签，RFID电子标签在生产流水线上可以方便准确地记录工序信息和工艺操作信息，同时可记录工人工号、时间、操作、质检结果，通过RFID终端将构件生产信息反馈到生产过程管理系统；设备运行信息、产品生产信息均通过数据采集与监控网络输入到生产过程执行管理系统，最后接入企业ERP系统。
本用于PC构件生产的自动化立体流水线具体工艺流程如下。
a.上下流水线各生产工位处于生产准备状态；
b.生产过程执行管理系统接受企业ERP系统的订单计划对各生产单元下达生产指示；
c.一层下流水线的空模台通过第二模台升降机1输送到二层厂房。同时，工人根据电子看板显示的产品信息和相应的模具信息从模具库中取出对应模具组件，通过机械助力抓手将模具放置到模台上，并采用电动扳手固定；
d.模具安装完成后到达喷涂工位，通过自动喷涂机均匀喷涂脱模剂和缓凝剂，随后，将模具进行安装(模具的安装过程包括四边模安装和内胆模具安装)；
e.钢筋加工设备9接收到生产管理系统的生产指示后，按照订单产品开始自动生产钢筋半成品，工人将钢筋半成品打包好后，集中配送到钢筋绑扎工位，同时钢筋绑扎的工艺信息同步显示在绑扎区域电子看板上，工人根据指示完成钢筋骨架的绑扎任务，存储到钢筋成品缓存架。当模台运行到钢筋骨架入模工位时，通过车间行吊将钢筋骨架吊运至模台模具中；
f.物料仓库接收到生产管理系统的生产指示后，按照订单产品信息准备预埋件和RFID电子标签等，打包好后集中配送到线边库。模台到达预埋件安装工位后，工人根据电子看板显示的生产信息将预埋件和RFID电子标签等安装指定地方；
g.钢筋骨架和预埋件等安装完毕后，进入到质检工位，工人通过手持RFID终端反馈确认质检信息，并上传到数据库服务器；
h.模台通过第一模台升降机8从二层厂房输送到一层厂房；
i.接收到生产管理执行系统的产品信息后，搅拌站11开始搅拌站11指定标号的混凝土，并通过鱼雷罐输送到布料工位，然后利用布料机13开始布料，振捣机将混凝土捣密实；
j.混凝土浇筑完成后，到达质检修补工位，然后再通过模台横移机分配到预养窑15的预养仓；
k.预养完成后，输送到蒸养窑16的码垛机17处，码垛机17根据蒸养窑16控制系统的指令将构件自动分配到蒸养仓；
l.构件经过养护完成后，再脱模工位利用行车进行脱模操作，脱模后的构件通过平板小车运输到构件堆场，同时开始清理模台，脱模后模台转运到初始工位进行下一轮生产。
本发明提出的用于PC构件生产的自动化立体流水线，单生产线所需工人数量为36人，为传统PC生产线1/2，设备成本与传统PC生产线持平。本发明采用双层布置，场地对比传统PC生产线可节约45％，节约了企业土地使用成本，同时提高生产效率和质量、降低了企业生产成本。
本发明提出一种用于PC构件生产的自动化立体流水线的生产工艺。
本优选实施例中，一种基于上述的用于PC构件生产的自动化立体流水线的生产工艺，包括以下步骤：
根据待生产产品信息和对应的模具信息，从线边模具库2中取出对应模具组件，并将模具放置到上流水线的喷涂工位进行喷涂操作；
喷涂后的模台通过上流水线，依次进行模具安装、模台内部钢筋笼安装以及模台内部预埋件安装，在模台内部预埋件安装完成后，将待生产产品对应的RFID电子标签安装在模台指定地方；
模台通过第一模台升降机8从上流水线输送到下流水线，在接收到待生产产品信息后，搅拌站11开始搅拌站11指定标号的混凝土，并通过鱼雷罐输送到布料工位，利用布料机13开始布料，并通过振捣机将模台内的混凝土捣密实；
混凝土浇筑完成后，模台依次运输至预养窑15和蒸养窑16中进行养护，养护完成后，模台在脱模工位进行脱模操作。
本实施例提出的用于PC构件生产的自动化立体流水线的生产工艺，可实现PC生产的自动化操作，其生产自动化程度高且生产效率高。
以上仅为本发明的优选实施例，并非因此限制本发明的专利范围，凡是利用本发明说明书及附图内容所作的等效结构变换，或直接或间接运用在其他相关的技术领域，均同理包括在本发明的专利保护范围内。

Claims (10)

  1. 一种用于PC构件生产的自动化立体流水线，其特征在于，包括第一模台升降机、以及分别位于厂房上下层的上流水线和下流水线，其中，上流水线上依次设置喷涂工位、模具安装工位、钢筋笼安装工位、模具固定工位和预埋件安装工位，下流水线上依次设置布料工位、振捣工位、预养工位、蒸养工位和脱模工位，第一模台升降机的上运送点位于上流水线的尾部，第一模台升降机的下运送点位于下流水线的头端以将上流水线运输过来的模台转送至下流水线，布料工位和振捣工位上分别设置有布料机和混凝土振捣机，预养工位和蒸养工位分别设置有预养窑和蒸养窑，喷涂工位上安装有喷涂设备。
  2. 如权利要求1所述的用于PC构件生产的自动化立体流水线，其特征在于，还包括第二模台升降机，第二模台升降机的上运送点位于上流水线的头部，第二模台升降机的下运送点位于下流水线的尾端。
  3. 如权利要求2所述的用于PC构件生产的自动化立体流水线，其特征在于，所述第一模台升降机和第二模台升降机均包括提升框架本体以及安装于提升框架本体上的定位装置、锁紧装置、提升装置、安全防护装置、控制传感器、控制柜以及操作台。
  4. 如权利要求1所述的用于PC构件生产的自动化立体流水线，其特征在于，所述下流水线一侧还设置有用于将鱼雷罐运输到工厂各个布料点的鱼雷罐环形输送轨道，鱼雷罐环形输送轨道配套设置有电气控制系统、鱼雷罐定位装置以及鱼雷罐冲洗装置。
  5. 如权利要求1所述的用于PC构件生产的自动化立体流水线，其特征在于，所述预养窑包括养护仓以及安装于养护仓上的第一温控系统、第一加湿系统和第一蒸养系统，所述蒸养窑包括立体养护仓、以及安装于立体养护仓上的第二温控系统、第二加湿系统和第二蒸养系统。
  6. 如权利要求1所述的用于PC构件生产的自动化立体流水线，其特征在于，厂房上层还布置有钢筋加工设备、钢筋绑扎设备、钢筋成品缓存架、线边模具库以及线边货架；下流水线的尾部还设置有模台模具清理设备，模台模具清理设备用于模台和模具在构件脱模后进行混凝土废渣清理。
  7. 如权利要求6所述的用于PC构件生产的自动化立体流水线，其特征在于，所述钢筋加工设备包括有弯箍机、调直切断机、数控剪切线、拔丝机、数控桁架筋自动加工设备和数控网片筋自动加工设备。
  8. 如权利要求1所述的用于PC构件生产的自动化立体流水线，其特征在于，所述上流水线和下流水线上均设置有质检工位，上流水线的质检工位位于预埋件安装工位后端，下流水线的质检工位位于振捣工位和预养窑之间。
  9. 如权利要求1至8中任意一项所述的用于PC构件生产的自动化立体流水线，其特征在于，厂房上下层的所有自动化设备均通过工业以太网接入企业数据采集与监控系统，并以此形成车间环网，使所有设备实现互联互通。
  10. 一种基于权利要求2至9中任意一项所述的用于PC构件生产的自动化立体流水线的生产工艺，其特征在于，包括以下步骤：
    根据待生产产品信息和对应的模具信息，从线边模具库中取出对应模具组件，并将模具放置到上流水线的喷涂工位进行喷涂操作；
    喷涂后的模台通过上流水线，依次进行模具安装、模台内部钢筋笼安装以及模台内部预埋件安装，在模台内部预埋件安装完成后，将待生产产品对应的RFID电子标签安装在模 台指定地方；
    模台通过第一模台升降机从上流水线输送到下流水线，在接收到待生产产品信息后，搅拌站开始搅拌站指定标号的混凝土，并通过鱼雷罐输送到布料工位，利用布料机开始布料，并通过振捣机将模台内的混凝土捣密实；
    混凝土浇筑完成后，模台依次运输至预养窑和蒸养窑中进行养护，养护完成后，模台在脱模工位进行脱模操作。
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