With the last plate of prefabricated parts landing, there was a burst of cheers from the production workshop, and a "competition" of output in a race against time came to an end. "Through automated production, we completed the production of about 6.08 million prefabricated parts in three months, shortening the production cycle by eight months. Pan Xunxue, deputy chief engineer of the Guangdong Shenzhen-Shanxi Reconstruction and Expansion Project of the Second Harbor Bureau, looked at the winding highway and said happily.
The Shenzhen-Shanxi Reconstruction and Expansion Project is a high-speed expansion project with 4 lanes to 8 lanes, with a total length of 1196 kilometers, the whole process requires a total of more than 600 prefabricated parts. The project period is tight, and the demand for prefabricated components is large and demanding, and the traditional manual prefabricated parts process takes at least 11 months to produce the required prefabricated parts.
Pan Xunxue led the project technical team to discuss and research, and decided to design an automated production line by simulating manual mold installation and vibrating mold, and install and vibrate the mold according to the center of gravity and force direction of the mold on the basis of mechanization. The project team innovated in the vibrating mold, using high-strength plastic molds to replace the previous steel molds, avoiding the deviation of the finished product caused by the collision of the fixed steel molds, reducing the weight of each prefabricated part from 20 kg to 10 kg, which can reduce equipment and personnel input during transportation, and greatly improve the transportation efficiency.
As a result, compared with the shaped steel mold and plug-in vibrator used in traditional production, the production time of veneer prefabricated parts under the automatic production line has been shortened by 5 minutes, the production efficiency has been increased by 30%, and the production time of prefabricated parts has been shortened from 11 months to 8 months. The project team also added sensors in the discharging process, changing the previous manual control of discharging, and improving the work efficiency from 1 cubic meter of concrete per person per shift to 5 cubic meters. In this way, it can not only achieve accurate discharging, avoid problems such as concrete overflow and spillage, but also solve the problem of insufficient production manpower.
The successful experience of simulating manual installation and vibrating the mold made the technical team more confident, and in order to further improve the production efficiency, they started the "idea" of the mold steaming and curing link. By comparing the speed and quality of mold curing in natural steaming and greenhouse steaming environments, the technical team found that the hardness of molds in the greenhouse steaming environment is much stronger than that of natural steaming and curing due to the relatively stable temperature and humidity. After the approval of the owner, the automated production workshop has an additional 168 square meters of steaming room. Under the steaming curing of 85 degrees Celsius, the steaming and curing time of the veneer mold is shortened from 7 days to 3 days of natural steaming, the overall hardness is increased by 20%, and the overall production time is shortened to 6 months.
Pan Xunxue said at the regular meeting of the project production: "While improving the production efficiency of prefabricated parts, it is necessary to ensure the construction quality, so as to achieve quality and efficiency 'with both hands'." Considering that the current 6-month output can only meet the use of each prefabricated part once, it is necessary to keep a part of the backup prefabricated parts to ensure the qualified rate of the prefabricated parts. He Zhongze, director of the project engineering department, said: "Leaving a part of the spare prefabricated parts means that the production of prefabricated parts will continue to 'accelerate', but the production time has been shortened to 6 months, what other aspects can we start?" Pan Xunxue led the technical team to carry out research on mechanized equipment, and placed automatic demoulding equipment next to the conveyor belt of the steaming and curing room, through simulated manual demoulding and flipping, 12 molds can be demolded in 30 seconds, and the demoulding speed of veneer molds is increased by 150% compared with manual demoulding, and the overall production time of prefabricated parts is shortened to 3 months.
Since the application of the automated assembly line, the production efficiency of the prefabricated parts has increased by 5 times. Pan Xunxue said proudly.
Today, the Shenzhen-Shanxi reconstruction and expansion project has entered the final stage, and the prefabricated parts on both sides of the high-speed bridge demonstrate the innovative spirit of CCCC builders to help the prosperity and development of the Guangdong-Hong Kong-Macao Greater Bay Area. (CCCG).