高度自動(dòng)化的預(yù)制構(gòu)件工廠規(guī)劃原則

BAUMACHINA

2016Highlyautomatedprecast

plant:Principalsof

planning高度自動(dòng)化的預(yù)制構(gòu)件工廠：規(guī)劃原則Vollert

profile:

沃勒特的形象（概況）TraditionalGermanfamilycompanywith90-yearsexperience擁有

90

年經(jīng)驗(yàn)的傳統(tǒng)德國(guó)家族企業(yè)Over 350 automatic precastlines

worldwide世界范圍內(nèi)打造

350

多條預(yù)制構(gòu)件自動(dòng)生產(chǎn)線Own

production

in

Germany

and270highlyqualified

specialists在德國(guó)擁有自主的生產(chǎn)及二百七十位高素質(zhì)專家SuccessfulreferencejobsinChina在中國(guó)成功的項(xiàng)目實(shí)踐STARTUP–lineswithupgrade

potentials具有升級(jí)潛力的新型生產(chǎn)線Vollert

todayVollert

todayHigh-End–integratedplantswiththeIndustry4.0-

philosophy高端的集成化工廠，并融合了工業(yè)

4.0

的理念Essential

questions:Whatbenefitsdoeshighautomation

bring?Whatshouldbeautomatedandwhat

not?Howmuchautomationis

justified?幾個(gè)基本問(wèn)題：高度自動(dòng)化帶來(lái)哪些效益？什么應(yīng)該是自動(dòng)化的而什么不應(yīng)該？自動(dòng)化程度達(dá)到多少才是合理的？Expectedbenefitsfromhigh

automation:

Moreperformanceinrepeatedoperations[similarorsameprecastelements,big

order]Lessmanualworkthrough

roboticsMorequalityandtransparencyin

processCost

reduction高度自動(dòng)化的預(yù)期效益：重復(fù)操作帶來(lái)更大產(chǎn)能（相同或相似的構(gòu)件類型、大宗訂單）通過(guò)機(jī)械設(shè)備減少人工工作生產(chǎn)過(guò)程中更高的質(zhì)量及透明度成本節(jié)約Automationinprecastplant

means:Databased

operationsRobotized

shutteringAutomaticsteelmeshproductionand

supplyAutomatic

concretingAutomaticloading/unloading

operationsAutomaticcleaningand

oiling自動(dòng)化在預(yù)制構(gòu)件工廠中意味著：基于數(shù)據(jù)的操作機(jī)械手制模自動(dòng)生產(chǎn)及供應(yīng)鋼筋網(wǎng)片自動(dòng)澆筑混凝土自動(dòng)裝載/卸載操作自動(dòng)清理及噴油Benefits

of

high

automation高度自動(dòng)化的優(yōu)勢(shì)3DModelManagement管理Architecture建筑/體系結(jié)構(gòu)Production產(chǎn)品/生產(chǎn)Construction施工Benefits

of

highautomation高度自動(dòng)化的優(yōu)勢(shì)Production

產(chǎn)品Architecture

建筑Controlling

控制Benefitsofhigh

automation 高度自動(dòng)化的優(yōu)勢(shì)What

can

be

automated?

哪些可以實(shí)現(xiàn)自動(dòng)化？When

automation

makesless

sense:

何時(shí)不太需要自動(dòng)化Stationaryproduction

whereindividualelementsand(small)orders

prevail以異形構(gòu)件及小宗訂單生產(chǎn)為主的固定臺(tái)模生產(chǎn)方式When

automation

makesless

sense:

何時(shí)不需要自動(dòng)化Howtoapproachthe

dilemma:如何處理生產(chǎn)中的困境：Capacity

生產(chǎn)能力Elements

預(yù)制件

Requirements

for

elements

預(yù)制件的要求Expected

changes

預(yù)期變化…How

to

approach

thedilemma:如何處理生產(chǎn)中的困境Circulationplantisaconveyor-typeproductionanditsoutputdependsonproductionalgorithmfrom“jobin”to“job

done”:循環(huán)（流水線？）工廠運(yùn)用的是一種傳送機(jī)形式的生產(chǎn)。其產(chǎn)能取決于從“作業(yè)輸入”到“作業(yè)輸出”的生產(chǎn)運(yùn)算法則。制模/劃線Shuttering/PlottingReinforcement

placing/binding

鋼筋的擺放及綁扎Concreting/Compacting

混凝土澆筑/振搗密實(shí)Finishing

表面處理Curing/Storing

養(yǎng)護(hù)/存儲(chǔ)Stripping/Unloading

脫模/卸載Shuttering/Plotting

制模/劃線Tobedone

manually人工完成Tobedoneby

robot機(jī)器完成Shuttering/Plotting

–automatic制模/劃線--自動(dòng)Shuttering/Plotting

–manualwork

制模/劃線--手動(dòng)Reinforcement

–automatic 鋼筋-自動(dòng)Concreting/compacting

–

semi-automatic

澆筑/振搗-半自動(dòng)Finishing–

manual

work

表面處理-手動(dòng)Curing

andstoring–

automatic

養(yǎng)護(hù)及存儲(chǔ)--自動(dòng)Stripping/Unloading

–

semi-automatic

脫模/卸載-半自動(dòng)ShanghaiBaoye-Gruppe2015increasesitscapacitiesbyupto800,000sqmofwallandslabelementsannuallywiththenewprecastconcrete

productionline借助新投入的混凝土構(gòu)件生產(chǎn)線，上海寶業(yè)在2015

年將其墻板及樓板的合計(jì)年產(chǎn)能提升至了

80

萬(wàn)平方米。ASMARTSETshutteringrobotpositionstheshutteringprofilesonthe

preparedcirculationpalletfullyautomaticallyandCAD-/CAM-controlled在CAD/CAM

的控制下，制模機(jī)械手將模具全自動(dòng)地?cái)[放至鋼模臺(tái)上PreciseapplicationoftheconcretebyamodernSMART

CAST

automatic

concrete

distributor

通過(guò)一個(gè)現(xiàn)代化全自動(dòng)混凝土布料機(jī)，實(shí)現(xiàn)對(duì)混凝土的精準(zhǔn)應(yīng)用TheMESproductionmanagement

systemdrawsupthebestmovementprogrammeforthenextconcreting

processMES

生產(chǎn)管理系統(tǒng)為下一步的混凝土振搗密實(shí)設(shè)定了最佳的運(yùn)行程序Theinsulatedandheatedshelftowersofthecuringchamberarecontrolledvia

theVArioSTOREstorageretrieval

machine通過(guò)碼垛機(jī)，實(shí)現(xiàn)對(duì)產(chǎn)品進(jìn)出養(yǎng)護(hù)窯的控制。State-of-the-artVArioTURNpalletturningequipmentfordouble-wall

production翻板機(jī)用于生產(chǎn)雙面疊合墻板ASMARTLOGISTICtruckconnectstheloadingareatothestoragesiteintheoutdoor

area

通過(guò)一個(gè)智能運(yùn)輸車將室內(nèi)起吊裝載區(qū)同室外的倉(cāng)儲(chǔ)區(qū)相連接Floorslabsareprovid