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Precast Concrete Components Production
Nov 22, 2017

1. Pallet rotating equipment
The production of concrete preforms is usually done on formwork. Most preforms are machined in-plane, such as slabs (prefabricated hollow slabs and solid floors) and walls (solid walls, double-walled walls and sandwich preforms) as well as special pieces or other concrete preforms. Pallet rotating equipment can be rotated, producing unparalleled advantages in the production of such components. The device enables machines, tools and materials to be used in place to increase production, quality and productivity while reducing production costs. Compared with the fixed production process, although the investment is relatively high, but the production efficiency has also increased a lot, so investors can quickly get rewarded. The company supplies a wide range of pallet rotating equipment with varying degrees of automation, including simple, modular basic solutions for more sophisticated multi-function equipment. The equipment can be used to produce prefabricated hollow slabs, double-walled walls, prestressed slabs, non-prestressed hollow slabs, solid slabs / walls, sandwich walls and facade preforms.

 2. Battery pack template
Using a battery pack template can be used to produce concrete preforms with two smooth surfaces. Compared with the horizontal mode of production, the battery pack template vertical distribution, small footprint. A single horizontal floor adjusts the distance of the baffle to the size of the component, ie, modulo, thereby reducing the cost of purchasing the template and maximizing the use of the template floor. The template can be used to produce solid and exterior prefabricated parts.

 3. Pallet car rotating equipment
The equipment is used for the production of precast concrete pipe. Demolding robots can grab pipe machine turntable reinforced concrete pipe and placed it to accurately locate the measuring wheel controllable pallet truck. The robot opens the pipe mold and removes the mold from the pipe under the control of the auxiliary measuring device. The manipulator then returns the empty tube mold to the turntable of the tube. The process is repeated until the pallet truck is full. The pallet trolley controlled by the distance measuring wheel will be driven to the exact unloading position by the drive for the demolding robot to work. Depending on the size of the prefabricated concrete pipe, the number of prefabricated concrete pipes to be taken can be set accurately by pre-programmed procedures. The pallet truck is transported by the friction wheel drive to the loading / unloading rail on the mobile station. The mobile station then transfers the pallet truck to the drying equipment track. Steel cable winches are used to cushion pallet trucks loaded with goods.
Drying equipment at both ends with fast-moving sliding door, when a pallet truck into or out of the drying equipment, the sliding door opened for a short time. When leaving the drying chamber, the pallet truck with the drilled prefabricated concrete pipe will again be transported by the friction wheel drive to the transfer station. At this moment, the mobile station then transfers the pallet truck from the drying track to the loading / unloading track. In the unloading track, the pallet controlled by the distance measuring wheel is positioned by the friction wheel drive to a position suitable for unloading so that the demolding robot can work. The demolding robot then removes the dried concrete pipe from the pallet truck and delivers the concrete pipe to the prefabricated storage location with the aid of various post-processing stations and inspection stations. Repeat this process until the pallet truck is completely unloaded. After manual cleaning, the empty pallet truck will again be moved forward of the demolding robot via the friction wheel drive.

4. Mold rotating equipment
Concrete and prestressed concrete sleepers are mostly made on mold-turning equipment. The use of mold rotating equipment and fixed production compared to higher productivity, lower cost.

5. Folding board
For the production of double wall (to fill the prefabricated hollow floor vacancies). As a result, prefabricated concrete plants can produce a combination of prefabricated hollow slab and double wall on a fixture. Folding plates can also be fitted with heating coils and vibration-intensive devices for concrete.

6. tilt table
Concrete prefabricated pieces are produced on a fixed inclined table so that the wall prefabricated pieces can be removed vertically using hydraulically driven lifting devices. The maximum tilt angle of the tilt table is 80 °. The tilt table can be installed separately or in conjunction with other tilt tables. As with other fixed manufacturing processes, the tilt table can also be fitted with heating coils and vibratory compacting equipment. The production process can be used to produce solid wall panels, sandwich wall panels and exterior prefabricated parts.

7. Automatic crane system
Automatic crane system is widely used in the production of concrete pipes, the production process, can be used to transport molds and finished products. The equipment is mainly used to produce reinforced concrete pipe.

8. Concrete batching machine
Concrete batching machines can fill molds or mold frames in fixed-mode production or tray-mounted molds or mold frames in the production process using rotating equipment. According to the structure type can be divided into hydraulic skateboards, sprocket plate, worm and conveyor belt and simple gravity concrete batching machine.

9. Concrete delivery system
Due to the different layout of the production, it is not guaranteed that the concrete can be poured directly in the vicinity of the mixer. Therefore, the concrete delivery system is a link connecting the concrete mixer with the concrete batching machine. Concrete transportation system allows one mixer to supply multiple production lines. The use of a concrete batching machine to fill a tank track with a temporary storage bin installed serves as an additional buffer and at the same time greatly increases efficiency. Tank track system can be divided into many types according to the consistency of concrete, such as tipping bucket type and funnel type.

10. Palletizer
Palletizers are used to store pallets containing freshly poured concrete onto shelves. During operation, the palletizer moves to the top of the pallet and grabs the pallet with the spreader beam. Depending on the size of the shelf system, the stack is adjusted to accommodate the storage capacity. To ensure first-in first-out principle, palletizing needs to be re-stacked during hardening. Cargo out of the library can be completed by palletizing machine, but also through a separate unstacking device to achieve. Here, each step can be fully automated.

11. Central host
The complex equipment configuration in prefabricated concrete product lines is controlled by the modern CAD-CAM central host system, which means that the CAD data used to produce concrete preforms can be used in different production steps. The central host is the factory's central interface for the generation of technical in-room data and for managing the enterprise's existing ERP system. The use of a central main unit enables optimum distribution of pallets, machine control, automatic pallet transport, management of the order of discharges and hardening times, as well as large amounts of statistical data for concrete prefabrication plants. Printout of labels, prefabricated production plans or distribution plans simplifies production flow and subsequent storage location management.

12. Maintenance room
The conservatory consists of an optimized shelving system. The shelf system side by side, up and down and arranged in front of a number of pallet. Tray through the pulley into the hardened room storage. During the curing of the new casting preform, the curing chamber is used to store the load tray or the empty tray. Control the movement of the pallet through the pallet control equipment. Shelf systems can be fitted with isolation panels and equipped with sectional door units. According to customer needs can also install heating equipment. Dedicated brake system ensures that stored trays do not slip when vibrated.

13. Heating equipment
After the concrete pouring process is finished, the preform will be sent to the isolation chamber in order to post-treat the concrete preform. With the help of heating equipment to maintain the indoor temperature around 40 ° C, accelerating the hydration and hardening of the concrete, so as to achieve the strength required for transport and delivery of concrete in the next shift. The introduction of heating equipment to achieve a multi-shift operation. The actual temperature in the cabin can be measured by the temperature sensor and controlled by the thermostat. The thermostat controls the heat supply by comparing the actual temperature with the nominal temperature. During the production cycle, the compartment temperature needs to be strictly maintained at the required temperature after every day at zero. The heat loss caused by the chamber walls, chamber lid or chamber door will be balanced by heating equipment.

14. Pallet commutator
When producing double-walled walls, it is necessary to rotate the hardened top surface 180 °. Rotation can be achieved by the tray commutator. When the tray is reversed, lock the mold tray with the help of a special beam and rotate it. The patented telescopic arm system ensures easy operation. Depending on the equipment requirements, fixed-tray commutators or ceiling-mounted commutators may be used.

15. Vacuum commutator
The production of double walls need to use commutator flip wall panels, the use of vacuum commutator can achieve the goal. The vacuum diverter allows the gap between the two wallboards to be reduced to almost zero, thus forming a double-sided smooth wallboard. Here, the "first wall plate" of the double-walled wall can be moved from the mold tray to the vacuum face of the commutator by a crane after hardening. Under pressure, the "first wall" can be fixed on the reversing frame. The hardened panels are then turned 180 ° to the newly cast "second panel", the "first wall" on the commutator is released by closing the vacuum, the welded structure is strictly sealed to ensure vacuum tightness and automatic Vacuum monitoring facilitates the widespread use of this modern technology.

16. Low-frequency compact shaking table
The use of a low-frequency compact vibrator when vibrating fresh concrete on rotating pallets can greatly reduce the noise present in conventional compaction processes. Due to the company's patent, a low frequency compact vibrating table, also called a vibrating table, delivers more energy to concrete components that need to be vibrated and can also save on expensive costs associated with modifying concrete formulations. The savings in production operations can be used for investment related to the building structure. In addition, the software can adjust the mode of dense movement (circular motion, along the tray vertical and horizontal movement), but also choose the combination of low-frequency density and high-density method. Dense processes can be distinguished by the direction of movement, compacting time, excitation frequency and amplitude, all of which can be programmed on the company's equipment and can be called at any time. Therefore, the control parameters required for the control system can be set for different products.

17. High-frequency compact vibrating table
When high-frequency concrete is freshly mixed, the pallet can vibrate through a device equipped with an external vibrator. By using a frequency converter, you can determine the best density for user-defined concrete mix ratios. During the production of concrete members wider than 3 m, the external vibrator is adjusted by means of an additional device which contains an additional crane station and descent station so that the vibrator can act in the center of the pallet.

18. trowel
The trowel consists of adjustable rotor blades and different clamp-on discs for the smoothing of concrete components. During the production process, the concrete preform is taken out of the curing chamber or bumper and placed on a trowel workstation after a certain residence time. Trowel run to the bottom of the tray polished concrete surface.

19. Control technology
Control technology is not a strange word at Walter. From electrical structures to PLCs and visual programming, the company's automation division offers its customers a broad, holistic and efficient solution. The company can perform simulation and visualization of the equipment for the customer before installing the control system. Their control system can be installed, driven and staffed by their technical specialists. If required, remote maintenance of the machine's operation can also be provided.

20. Uninstall the machine
The unloader consists of a steering mechanism and an easy-to-operate wireless remote control system for unloading concrete preforms from the mold tray. Generally speaking, it is mainly used for unloading the first surface of prefabricated hollow slab and double wall. Unloader Structure Many lifting points on the girder can be used to lift concrete preforms. Dedicated spring unit can load evenly distributed to all the lifting point. The unloader can also be mounted on a crane bridge.

21. Outbound system platform
Exhaust system can be concrete prefabricated parts from the rotating equipment work area to the warehouse cargo space. Depending on the product, the geographical relationship and the handling of the transport unit, it can be divided into a number of different delivery systems. Simple transport vehicles, warehouse lifting trolley, the integration of two or three horizontal lifting trolley system. In the transport of concrete prefabricated, the use of auxiliary frame is necessary. Can be used in the tray center.

22. Unloading spar and transport frame
The unloaded beam is used to remove concrete prefabricated parts (mainly walls) from the tilt table. The lifting beam has a running rail bracket that can be moved by two landing gear attached to the overhead crane. The unloaded beam also includes multiple cable winches, each connected to the undercarriage. When working manually, it can be controlled by wireless remote control. Cable winch can advance and retreat, can take off and land, and can be connected with other cable winches as needed, after the cable winch articulated by wireless remote control.
Due to their variability, concrete performs of different sizes and different lifting points can be removed from the tilting table and placed in a carrier or A-tube for further transport. Most plants also use additional auxiliary shelves.

23. Pulley transport orbiter
Pallet turning equipment can transport the mold tray vertically to the pulley transport track. When designing a pulley transport track, the company considered that there was no risk of crushing between each pulley support and the mold tray.

24. Workstation system
the station system is a shelf mounted along the pallet, with a pallet height and with walkways. It can be used to store mold materials, magnets and components. The station system can be considered as a movable tool holder for simpler handling. It can move along the pallet and pick up materials, tools and fasteners or hot glue gun.

25. Overweight handling machine
Overweight handlers are used to manually place the mold onto the mold tray, and also remove the mold from the mold tray and place it in the mold transport system during release. Overweight handling machine along the tray can be vertical or horizontal movement to the demolding position above.

26. Horizontal lifting car
When rotating, the lateral hoisting trolley is used to transfer the die tray by die. Therefore, a pair of horizontal lifting trolley transported to the bottom of the mold tray to be transported and precise positioning. Raise the pallet hydraulically and move to the next pallet position. In this position the pallet can be lowered onto the pulley support or the unloading support. The cross hoisting trolley then prepares for the transfer of the next die tray.

27. Central shift station
The central truck can be used as a trip tray dispenser. Ideal Figure 3 - In the case of production where the product will take a long time to complete, use the central truck.
The center shift truck distributes the pallets to different stations, moving them to the next working step if needed. Therefore, logistics bottlenecks can be avoided, and the pallets can surpass each other. The truck can be distinguished on the basis of performance, either by lifting the pallet parallel to the direction of movement or by picking up the pallet perpendicular to the direction of travel. The tray can be assigned either manually or automatically.

28. Painting robot
it is necessary to use a retarder-containing release agent on the forming surfaces of the exterior perform and the dewed concrete perform. Spray-paint robots can dispense retarder-containing release agent onto the formwork through automatic programming controls.

29. Mold robot
fully automatic mold robots place the mold on the mold tray with high precision in accordance with CAD data already provided. Mold types and mold lengths for special rotating equipment are found in the mold library. If the required mold assembly is not listed in the existing product, it needs to be manually installed in the other stroke position. The robot can also access the mold by scanning the tray. Precise and flexible die robots are the ideal choice for automation in the production of different concrete performs.

30. Large plotter / MRP large plotter
Draw mold arrangement and components on the mold tray. Here, the use of water-soluble, easily removed pigment. Therefore, in most cases a large plotter can be connected to a central host computer equipped with a CAD system in a visualization host or a concrete prefabrication plant.

31. Mold cleaning / oiling equipment
Additional devices such as mold cleaners / lubricators, tray cleaners / lubricators optimize production flow and reduce manual intervention in production operations. Pallet cleaners remove excess concrete adhering to the pallet surface and can be cleaned using a knife, bar brush, roller brush or pan brush. Tray filler will automatically spray the mold oil in the mold tray surface. The use of mold cleaners and lubricators to clean and lubricate molds allows them to be set manually or automatically in a new round of production runs.

32. Mold tray
The mold tray is a metal frame with a blank finish. Surface quality can be adjusted according to customer needs. The size and type of concrete prefabrication and the equipment design philosophy are used to determine the size of the pallet and the maximum surface load. From start-up to the unloading of concrete preforms, the mold trays run from one stroke position to the next in the rotating equipment and serve as a conveyance for molds, reinforcing bars, components and concrete. In order to optimize the travel position, the mold tray may be attached to a fixed frame mold.