JP3037556B2 - Method and apparatus for manufacturing PC panel with finishing material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for manufacturing a precast PC panel in which a finishing material such as a tile or a stone is previously attached to one surface of a precast concrete (PC) panel. The present invention relates to a manufacturing method and an apparatus for automatically and consistently performing processes from cleaning to inspection of a finishing material mounting portion.

[0002]

2. Description of the Related Art Conventionally, PC panels with pre-finished materials have been manufactured in the following steps. First, in the joint splitting process, a finishing material set sheet is laid on a formwork bed for PC panel production, and a large number of finishing materials are arranged on the sheet with the surface side facing down, and temporary between these finishing materials. Install joints and position the whole. Next, concrete is poured into the formwork which has completed the joint dividing step. When the poured concrete hardens, it is released from the mold, the PC panel is taken out, and the sheet is peeled off by hand to obtain a PC panel in which the finishing material is firmly joined to the lower surface of the concrete. Next, the surface side of this PC panel (the surface on which the finishing material is mounted) is manually washed with a spatula, and the dirt adhering to the surface of the finishing material and joints is manually removed. At this time, the temporary joint material serving as the temporary spacer and the packing is also manually removed. Then, the PC panel is dried, and a new joint material for finishing is attached to the joint portion.

[0003]

In the above-mentioned conventional method, the temporary joint material to be installed on the sheet in the joint dividing step is used not only as a spacer between the finishing materials but also from the joint portion when concrete is cast. It is also expected to function as a packing that prevents the cement paste from leaking to the surface of the finishing material. However, even if the material of the joint material is devised in various ways, it does not fulfill the role of the complete packing and cannot prevent the cement paste from leaking from the joint portion to some extent. For this reason, the above-mentioned convulsion washing operation as post-processing has been very troublesome. Conventionally, the surface of the PC panel is subjected to convulsion cleaning by a large amount of manpower and time, and labor saving and automation of this process have been strongly demanded.

The present invention has been made in view of the above-mentioned conventional problems, and has as its object to attach dirt due to cement paste leaking to the surface of a finished material and fine irregularities on the surface of the finished material from the beginning. It is an object of the present invention to provide a method and apparatus for manufacturing a reasonable finish material pre-installed PC panel suitable for performing a series of manufacturing steps including a dirt removal operation by an integrated automatic production system.

[0005]

A method of manufacturing a PC panel with a finishing material according to the present invention includes a PC panel forming station, a cleaning pre-processing station, a cleaning station, a drying station, and an inspection station along a moving direction of a conveying means. First, at the PC panel forming station, a finishing material is disposed on a sheet laid on the bottom surface of the PC panel forming form, and concrete is poured into the form to form a PC panel. Next, at the cleaning pretreatment station, the PC with the sheet transported from the PC panel molding station by the transporting means.
The panel is placed on a sheet peeling table, and the PC panel is pulled up while sucking the sheet with a suction device provided on the sheet peeling table, thereby peeling the sheet from the PC panel, and then, at the washing station, The PC panel transported from the cleaning pretreatment station by the transporting means is immersed in a first cleaning tank filled with a cleaning liquid and provided with an ultrasonic vibrator at the bottom, and is horizontally transported.
The PC panel is ultrasonically cleaned on the side of the finishing material mounting surface of the PC panel, and then the PC panel is further filled with super- degassed water.
And an ultrasonic vibrator and jet water flow
The raw device is immersed in a second washing tank arranged in this order;
Transfer horizontally, and finish the surface of the PC panel
Ultrasonic cleaning with degassed water and jet water flow
And then transported from the washing station by the transport means at the drying station.
Dry the panel and then at the inspection station,
The appearance of the finishing material mounting surface of the PC panel transported from the drying station by the transporting means is photographed by an imaging means, and the output is input to a computer to check for a defect.

In the apparatus for manufacturing a PC panel with pre-finished material according to the present invention, a PC panel forming station, a cleaning pre-processing station, a cleaning station, a drying station, and an inspection station are arranged along the moving direction of the conveying means. The PC panel forming station includes a PC panel manufacturing form in which a finishing material is disposed on a sheet laid on the bottom surface, and a concrete being cast in the form to form a PC panel.
A setting device for forming a panel, wherein the cleaning pretreatment station includes a sheet peeling table on which the PC panel with the sheet conveyed from the PC panel forming station by the conveying means is placed; A suction device provided on a sheet peeling stand for sucking the sheet from the PC panel so as to peel the sheet from the PC panel; the washing station is filled with a washing liquid and an ultrasonic vibrator is arranged at a bottom portion thereof; The PC panel transported from the pre-cleaning station is immersed
And a first cleaning tank that is transported horizontally and ultrasonically cleans the surface of the PC panel on which the finishing material is attached , and is filled with super- degassed water.
And an ultrasonic vibrator and jet water flow
The raw devices are arranged in this order and are cleaned in the first cleaning tank.
The PC panel is further immersed and transported horizontally.
Then, the surface of the PC panel to which the finishing material is attached is super-degassed water.
Cleaning with ultrasonic cleaning and jet water flow
A drying tank , wherein the drying station is the PC transferred from the washing station by the transfer means.
A drying device for drying the panel, the inspection station is an imaging unit that captures the appearance of the finishing material mounting surface of the PC panel transported from the drying station by the transport unit and outputs a video signal thereof, And a computer for receiving a video signal from the imaging means and inspecting for the presence or absence of a defect.

[0007]

The operation of the present invention will be described. First, in a PC panel forming station, concrete is poured into a PC panel manufacturing form prepared by arranging a finishing material on a sheet by a driving device. Wait for curing to obtain PC panel. At the next pre-cleaning treatment station, the PC panel with the sheet is placed on the sheet peeling stand by the transport means,
While sucking the sheet with the suction device, P
The sheet is automatically peeled off from the PC panel by pulling up the C panel. In the next cleaning station, the PC panel is suspended by the transporting means, and the PC panel is first immersed in the first cleaning tank and transported horizontally, and the surface of the PC panel on which the finishing material is attached is automatically subjected to ultrasonic cleaning. With the high detergency of the ultrasonic waves, the dirt adhering to the surface of the finishing material and joints is removed in a short time. Then, the PC is further placed in the second cleaning tank.
Dip the panel and transport it horizontally to finish PC panel
When the installation surface side is automatically ultrasonically cleaned using super degassed water
Both are washed with a jet stream. Ultrasonic using super-degasified water
By performing the cleaning, the cleaning power is further enhanced. Also jet
Washing with a stream of water weakens the adhesion in ultrasonic cleaning.
Completely removes any dirt that has
The separated dirt can be prevented from reattaching
You. In the next drying station, the PC panel is automatically dried by the drying device. In the next inspection station, the appearance of the finishing material mounting surface of the PC panel is photographed by the imaging means, and the video signal is processed by a computer to automatically inspect for the presence or absence of the defect. These series of manufacturing steps can be performed almost automatically.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Finishing material P according to one embodiment of the present invention
FIGS. 1 to 6 show an outline of a method and an apparatus for manufacturing a C panel. A hoist 2 travels along a rail 1 installed at the top of the building. A PC panel forming station shown in FIG.
The cleaning pretreatment station of FIG. 2, the cleaning station of FIGS. 3 and 4, the drying station of FIG. 5, and the inspection station of FIG. 6 are provided.

In the PC panel forming station shown in FIG. 1, a form bed 3 is placed on a work table 52, and a frame 4 is combined therewith to form a PC panel forming form 50.
Is configured. A sheet 5 is laid on the form bed 3, and a finishing material 6 such as a tile or a stone and a temporary joint material 7 are positioned and laid on the sheet 5 (joint dividing step). Next, the concrete 8 is cast into the formwork 50 by the casting device 51. Although not shown, an eyebolt or the like serving as a fulcrum for lifting the PC panel 11 with the hoist 2 is embedded in the concrete 8. When the concrete 8 has hardened, the PC panel 11 is lifted by the hoist 2. This is transported to the next washing preparation station.

In the pre-cleaning processing station shown in FIG. 2, the PC panel with the conveyed sheet 5 is detached from a sheet peeling table 9.
Put on top. A table 53 having a number of small holes (suction holes) formed on the upper surface side of the sheet peeling table 9, and a hollow portion 9 a is provided below the table 53, and the hollow portion 9 a communicates with the vacuum pump 10. . When the pump 10 is operated, the negative pressure of the hollow portion 9 a acts on the sheet 5 from below through the suction hole formed in the table 53, and the sheet 5 is strongly attracted to the table 53. When the PC panel 11 is pulled up by the hoist 2 in this state, the sheet 5 and the temporary joint material 7 are peeled from the PC panel 11 and
Remain on the third side. In this way, the PC panel 11 from which the sheet 5 has been automatically peeled is conveyed to the next washing station.

The cleaning station is a first cleaning tank 1 shown in FIG.
2 and a second cleaning tank 13 in FIG. The first cleaning tank 12 contains a weak alkaline cleaning liquid, and a plurality of ultrasonic transducers 14 are arranged at the bottom.
The ultrasonic cleaning tank 54 is constituted. The PC panel 11 hung on the hoist 2 is lowered to a predetermined position on the first cleaning tank 12, the finishing material mounting surface side of the PC panel 11 is immersed in a cleaning liquid, and the PC panel 11 is slowly and horizontally conveyed. The ultrasonic wave from the vibrator 14 is applied to the finishing material 6. The frequency of the ultrasonic wave is preferably about 25 to 100 KHz, and the ultrasonic output is appropriately set in accordance with other cleaning conditions such as cleaning time, type and concentration of the cleaning liquid. Since the PC panel 11 is slowly moved, the entire surface can be uniformly irradiated with ultrasonic waves. If the PC panel 11 is slowly moved up and down in addition to the horizontal movement, the action of the ultrasonic wave can be further uniformed.
Conversely, when ultrasonic waves having a high directivity are radiated obliquely to the PC panel 11, the back of the joint portion becomes shaded with respect to this irradiation direction, and unnecessary ultrasonic energy strongly reaches the concrete surface behind the joint. Can be avoided.

As is well known, the cleaning effect using the ultrasonic energy is extremely large, and the dirt adhering to the surface and joints of the finishing material 6 can be efficiently removed. By the way, the removed dirt (sludge) accumulates in the ultrasonic cleaning tank 12.
The sludge is continuously separated and discharged to the outside of the tank by a cleaning and cleaning system added to the washing tank, and a new washing liquid is additionally supplied into the washing tank 12 as needed.

After moving to the end point of the first washing tank 12, the PC
The panel 11 is pulled up once and transported to the second cleaning tank 13. As shown in FIG. 4, ultra-degassed water is contained in the second cleaning tank 13 as a cleaning liquid for finish cleaning and rinsing, and an ultrasonic vibrator 15 is provided at the bottom of the first half thereof to form an ultrasonic cleaning tank. 55, and a jet water jet generator 16 is installed at the bottom of the latter half to form a jet washing tank 56. Similarly, in the second cleaning tank 13, the hoist 2 is horizontally moved at a low speed in a state in which the finishing material mounting surface side of the PC panel 11 is immersed in the cleaning liquid, and the ultrasonic cleaning tank 55 and the jet cleaning tank 56 are similarly operated. Are sequentially passed. Thus, the dirt attached to the PC panel 11 is automatically and almost completely removed. The circulation of the cleaning liquid and the additional system are the same as described above.

The cleaning liquid in the first cleaning tank 12 is applied to the second cleaning tank 13.
Rinsing, so that it is possible to eliminate stains generated when drying with the washing liquid. When ultrasonic cleaning is performed using super-deaerated water, the cleaning power is further enhanced. In addition, by washing with a jet water stream, it is possible to completely remove stains that have weakened adhesion in ultrasonic cleaning but have adhered thereto, and to prevent the stains once separated from re-adhering.

After passing through the washing station, the PC panel 11 passes through the drying station of FIG. 5 at a low speed. The drying station is provided with a hot air generator 17 from which hot air coming upward is blown onto the PC panel 11 to be automatically dried. In addition, the temperature of the warm air gradually decreases in the transport direction of the PC panel 11. In this station, other means such as natural drying and vacuum closed drying may be employed.

The PC panel 11 having passed through the drying station is advanced to the inspection station shown in FIG. 6, where it is turned upside down and placed on the inspection table 18. A laser measuring device 19 is installed above the inspection table 18, and the surface of the PC panel 11 on the side of the finishing material 6 is imaged by the measuring device 19.
The imaging output is input to a computer (not shown), and an automatic inspection is performed by a pattern matching method or the like to determine whether or not the bonding state of the finishing material 6 has a defect.

[0017]

[0018]

According to the method and the apparatus for manufacturing a PC panel with a finishing material according to the present invention, dirt due to cement paste leaking to the surface of the finishing material and fine irregularities on the surface of the finishing material are adhered from the beginning. A series of manufacturing processes including a dirt removal operation can be performed by an integrated automatic production system, which is highly effective in saving labor and efficiency in manufacturing a finishing material pre-installed PC panel.

[Brief description of the drawings]

FIG. 1 is a finishing material pre-installed PC according to an embodiment of the present invention.
It is the schematic of the PC panel forming station of a panel manufacturing apparatus.

FIG. 2 is a schematic diagram of a pre-cleaning processing station in the same apparatus.

FIG. 3 is a schematic view of a first cleaning tank of a cleaning station in the same apparatus.

FIG. 4 is a schematic view of a second cleaning tank of a cleaning station in the same apparatus.

FIG. 5 is a schematic view of a drying station in the same apparatus.

FIG. 6 is a schematic diagram of an inspection station in the same device.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Rail 2 Hoist 3 Form bed 4 Frame 5 Sheet 6 Finishing material 7 Temporary joint material 8 Concrete 9 Sheet peeling stand 10 Vacuum pump 11 PC panel 12 First cleaning tank 13 Second cleaning tank 14 Ultrasonic oscillator 15 Ultrasonic wave Vibrator 16 Jet water flow generator 17 Hot air generator 18 Inspection table 19 Laser measuring device 50 Formwork for PC panel production 51 Casting device 54 Ultrasonic cleaning layer 55 Ultrasonic cleaning layer 56 Jet cleaning layer

──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Tatsuya Wakisaka 4-640 Shimoseito, Kiyose-shi, Tokyo, Japan Inside the Obayashi Corporation Technical Research Institute (72) Yoshimasa Hayashi 4-640 Shimoseito, Kiyose-shi, Tokyo, Ltd. Inside Obayashi Technical Research Institute (72) Inventor Miki Aoyama 4-640 Shimoseito, Kiyose-shi, Tokyo Inside Obayashi Technical Research Institute Co., Ltd. (56) References JP-A-3-128206 (JP, A) JP-A-5-261718 ( JP, A) JP-A-4-216904 (JP, A) JP-A-6-15620 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B28B 1/16 B28B 11/22

Claims (2)

(57) [Claims] 1. A PC panel forming station, a pre-cleaning station, a cleaning station, a drying station, and an inspection station are arranged along the moving direction of the conveying means. A finishing material is arranged on a sheet laid on the bottom of the frame, concrete is poured into the mold to form a PC panel, and then, at the cleaning pretreatment station, the PC panel is formed by the transport means. The PC panel with the sheet conveyed from the station is placed on a sheet peeling stand, and the PC panel is pulled up while sucking the sheet with a suction device provided on the sheet peeling stand, thereby removing the sheet from the PC panel. Then, at the washing station, the washing pretreatment station is transported by the transport means. PC from above
The panel is immersed in a first cleaning tank, which is filled with a cleaning liquid and the bottom of which is provided with an ultrasonic oscillator, and is horizontally conveyed.
Then, the surface of the PC panel on which the finishing material is mounted is ultrasonically cleaned,
Thereafter, the PC panel is further filled with ultra-degassed water,
And an ultrasonic vibrator and jet water flow generator at the bottom
The apparatus is immersed in a second washing tank arranged in this order and
To the surface of the PC panel where the finishing material is attached.
Ultrasonic cleaning with water and cleaning with jet water flow
And, then, above the drying station, dried the PC panels that have been conveyed from the cleaning station by the conveying means, then, at the inspection station, the finish of the PC panels that have been transported from the drying station by the conveying means A method of manufacturing a PC panel with pre-finished material, characterized in that the appearance of a material mounting surface is photographed by an imaging means, and the output is input to a computer to check for the presence or absence of a defect. 2. A PC panel forming station, a cleaning pretreatment station, a cleaning station, a drying station, and an inspection station are arranged along the moving direction of the conveying means, and the PC panel forming station is provided on a sheet laid on a bottom surface. A PC panel manufacturing form in which a finishing material is disposed, and a setting apparatus for forming a PC panel by setting concrete in the form, and the cleaning pretreatment station is provided by the transfer means. A sheet peeling stand on which the PC panel with the sheet conveyed from the PC panel forming station is placed, and a suction device provided on the sheet peeling stand for sucking the sheet to separate it from the PC panel. The cleaning station is filled with a cleaning liquid and an ultrasonic vibrator is arranged at a bottom thereof; The P transported from the pre-cleaning station by transport means
A first cleaning tank in which the C panel is immersed and conveyed horizontally to ultrasonically clean the finishing material mounting surface side of the PC panel ;
The super-deaerated water is filled and the ultrasonic vibrator and
And the jet stream generator are arranged in this order,
1 Is the PC panel washed in the washing tank further immersed?
Is transported horizontally and the PC panel finish material mounting surface side
Is ultrasonically cleaned using super-degassed water and jet water flow
In a second cleaning tank for cleaning, the drying station comprises a drying device for drying the PC panel which has been conveyed from the cleaning station by the conveying means, the inspection station, the drying station by the conveying means Imaging means for photographing the appearance of the finishing material mounting surface of the PC panel conveyed from the apparatus and outputting a video signal thereof, and a computer for receiving a video signal from the imaging means and inspecting for a defect. An apparatus for manufacturing a PC panel with pre-finished materials.