高度自动化的预制构件工厂规划原则

BAUMACHINA

2016Highlyautomatedprecast

plant:Principalsof

planning高度自动化的预制构件工厂：规划原则Vollert

profile:

沃勒特的形象（概况）TraditionalGermanfamilycompanywith90-yearsexperience拥有

90

年经验的传统德国家族企业Over 350 automatic precastlines

worldwide世界范围内打造

350

多条预制构件自动生产线Own

production

in

Germany

and270highlyqualified

specialists在德国拥有自主的生产及二百七十位高素质专家SuccessfulreferencejobsinChina在中国成功的项目实践STARTUP–lineswithupgrade

potentials具有升级潜力的新型生产线Vollert

todayVollert

todayHigh-End–integratedplantswiththeIndustry4.0-

philosophy高端的集成化工厂，并融合了工业

4.0

的理念Essential

questions:Whatbenefitsdoeshighautomation

bring?Whatshouldbeautomatedandwhat

not?Howmuchautomationis

justified?几个基本问题：高度自动化带来哪些效益？什么应该是自动化的而什么不应该？自动化程度达到多少才是合理的？Expectedbenefitsfromhigh

automation:

Moreperformanceinrepeatedoperations[similarorsameprecastelements,big

order]Lessmanualworkthrough

roboticsMorequalityandtransparencyin

processCost

reduction高度自动化的预期效益：重复操作带来更大产能（相同或相似的构件类型、大宗订单）通过机械设备减少人工工作生产过程中更高的质量及透明度成本节约Automationinprecastplant

means:Databased

operationsRobotized

shutteringAutomaticsteelmeshproductionand

supplyAutomatic

concretingAutomaticloading/unloading

operationsAutomaticcleaningand

oiling自动化在预制构件工厂中意味着：基于数据的操作机械手制模自动生产及供应钢筋网片自动浇筑混凝土自动装载/卸载操作自动清理及喷油Benefits

of

high

automation高度自动化的优势3DModelManagement管理Architecture建筑/体系结构Production产品/生产Construction施工Benefits

of

highautomation高度自动化的优势Production

产品Architecture

建筑Controlling

控制Benefitsofhigh

automation 高度自动化的优势What

can

be

automated?

哪些可以实现自动化？When

automation

makesless

sense:

何时不太需要自动化Stationaryproduction

whereindividualelementsand(small)orders

prevail以异形构件及小宗订单生产为主的固定台模生产方式When

automation

makesless

sense:

何时不需要自动化Howtoapproachthe

dilemma:如何处理生产中的困境：Capacity

生产能力Elements

预制件

Requirements

for

elements

预制件的要求Expected

changes

预期变化…How

to

approach

thedilemma:如何处理生产中的困境Circulationplantisaconveyor-typeproductionanditsoutputdependsonproductionalgorithmfrom“jobin”to“job

done”:循环（流水线？）工厂运用的是一种传送机形式的生产。其产能取决于从“作业输入”到“作业输出”的生产运算法则。制模/划线Shuttering/PlottingReinforcement

placing/binding

钢筋的摆放及绑扎Concreting/Compacting

混凝土浇筑/振捣密实Finishing

表面处理Curing/Storing

养护/存储Stripping/Unloading

脱模/卸载Shuttering/Plotting

制模/划线Tobedone

manually人工完成Tobedoneby

robot机器完成Shuttering/Plotting

–automatic制模/划线--自动Shuttering/Plotting

–manualwork

制模/划线--手动Reinforcement

–automatic 钢筋-自动Concreting/compacting

–

semi-automatic

浇筑/振捣-半自动Finishing–

manual

work

表面处理-手动Curing

andstoring–

automatic

养护及存储--自动Stripping/Unloading

–

semi-automatic

脱模/卸载-半自动ShanghaiBaoye-Gruppe2015increasesitscapacitiesbyupto800,000sqmofwallandslabelementsannuallywiththenewprecastconcrete

productionline借助新投入的混凝土构件生产线，上海宝业在2015

年将其墙板及楼板的合计年产能提升至了

80

万平方米。ASMARTSETshutteringrobotpositionstheshutteringprofilesonthe

preparedcirculationpalletfullyautomaticallyandCAD-/CAM-controlled在CAD/CAM

的控制下，制模机械手将模具全自动地摆放至钢模台上PreciseapplicationoftheconcretebyamodernSMART

CAST

automatic

concrete

distributor

通过一个现代化全自动混凝土布料机，实现对混凝土的精准应用TheMESproductionmanagement

systemdrawsupthebestmovementprogrammeforthenextconcreting

processMES

生产管理系统为下一步的混凝土振捣密实设定了最佳的运行程序Theinsulatedandheatedshelftowersofthecuringchamberarecontrolledvia

theVArioSTOREstorageretrieval

machine通过码垛机，实现对产品进出养护窑的控制。State-of-the-artVArioTURNpalletturningequipmentfordouble-wall

production翻板机用于生产双面叠合墙板ASMARTLOGISTICtruckconnectstheloadingareatothestoragesiteintheoutdoor

area

通过一个智能运输车将室内起吊装载区同室外的仓储区相连接Floorslabsareprovid