目前我國管樁生產線待改造的生產設備
本文所指管(guan)樁(zhuang)(zhuang)為(wei)PHC管(guan)樁(zhuang)(zhuang),全(quan)稱為(wei)預應力(li)高強(qiang)度(du)(du)混(hun)凝(ning)土(tu)管(guan)樁(zhuang)(zhuang),是采(cai)用(yong)先張法預應力(li)工藝(yi)和(he)離心成型法制(zhi)成的長圓筒形混(hun)凝(ning)土(tu)預制(zhi)構件,主要由混(hun)凝(ning)土(tu)、籠筋、端頭板(ban)和(he)鋼套箍等組(zu)成。作(zuo)為(wei)樁(zhuang)(zhuang)基(ji)材料,可以應用(yong)于(yu)高層建筑、民(min)用(yong)住宅、公用(yong)工程及橋梁、公路、港口碼頭、大型設備等工程基(ji)礎中,與其(qi)他樁(zhuang)(zhuang)基(ji)礎相(xiang)比(bi),具(ju)有制(zhi)作(zuo)工藝(yi)簡單、質量容易保證、植樁(zhuang)(zhuang)方便、耐(nai)打性好、造價便宜、檢(jian)測方便、施工速(su)度(du)(du)快、樁(zhuang)(zhuang)基(ji)抗(kang)震性好等優點,所以從上世紀九十年代開(kai)始(shi),其(qi)生產(chan)和(he)應用(yong)得到了迅(xun)猛的發展(zhan)。如今(jin),我國已成為(wei)世界最大的管(guan)樁(zhuang)(zhuang)生產(chan)和(he)應用(yong)基(ji)地。
一、管樁生產企業用工形勢嚴峻,加快自動化改造刻不容緩
我(wo)國(guo)自1987年(nian)從(cong)日本(ben)(ben)(ben)引進(jin)(jin)(jin)首條管(guan)樁(zhuang)生(sheng)產線至(zhi)今(jin)20多年(nian)的(de)(de)(de)時間(jian)里,經過我(wo)國(guo)設備(bei)廠(chang)家的(de)(de)(de)消化吸收,管(guan)樁(zhuang)生(sheng)產的(de)(de)(de)主要設備(bei)如鋼(gang)筋定長切斷機(ji)、鐓頭機(ji)、籠筋 滾(gun)焊(han)機(ji)、混凝(ning)土攪拌(ban)機(ji)、預應力(li)張拉機(ji)、離(li)心機(ji)、起重機(ji)等(deng)單(dan)機(ji)設備(bei)都(dou)實現(xian)了國(guo)產化。但(dan)由(you)于(yu)我(wo)國(guo)的(de)(de)(de)勞動(dong)力(li)資源豐富,成本(ben)(ben)(ben)低(di)廉,導(dao)(dao)致企(qi)業規模(mo)不(bu)斷擴大卻沒有進(jin)(jin)(jin)行(xing)生(sheng)產裝備(bei)的(de)(de)(de)大幅改進(jin)(jin)(jin),管(guan)樁(zhuang)作(zuo)為鋼(gang)筋混凝(ning)土制(zhi)品(pin)再(zai)加(jia)上生(sheng)產設備(bei)自動(dong)化程度較(jiao)低(di),有許(xu)多工(gong)(gong)序仍為手工(gong)(gong)操(cao)作(zuo),導(dao)(dao)致管(guan)樁(zhuang)生(sheng)產勞動(dong)強度高,工(gong)(gong)作(zuo)條件差。管(guan)樁(zhuang)行(xing)業現(xian)行(xing)的(de)(de)(de)生(sheng)產裝備(bei)自動(dong)化水平不(bu)但(dan)遠遠落后于(yu)日本(ben)(ben)(ben)、韓國(guo)同行(xing),而且也已經遠遠落后于(yu)我(wo)國(guo)其他先進(jin)(jin)(jin)行(xing)業的(de)(de)(de)發展(zhan)。
近(jin)年來隨著(zhu)我國教育水平(ping)的(de)(de)提高和(he)生(sheng)(sheng)活水平(ping)的(de)(de)改(gai)善,“新生(sheng)(sheng)代(dai)農民工(gong)(gong)(gong)(gong)(gong)”的(de)(de)工(gong)(gong)(gong)(gong)(gong)作(zuo)(zuo)(zuo)價值觀(guan)已(yi)發(fa)生(sheng)(sheng)變化,不(bu)再只單(dan)純追求工(gong)(gong)(gong)(gong)(gong)資和(he)溫飽(bao)問題,更(geng)注重(zhong)工(gong)(gong)(gong)(gong)(gong)作(zuo)(zuo)(zuo)種類和(he)工(gong)(gong)(gong)(gong)(gong)作(zuo)(zuo)(zuo)環(huan)境等。他們寧愿(yuan)(yuan)到收(shou)入(ru)低(di)但工(gong)(gong)(gong)(gong)(gong)作(zuo)(zuo)(zuo)環(huan)境好的(de)(de)行業(ye)(ye),也(ye)不(bu)愿(yuan)(yuan)干收(shou)入(ru)高但臟、重(zhong)、累(lei)的(de)(de)活。所以,一(yi)(yi)(yi)方面大(da)量學校畢業(ye)(ye)生(sheng)(sheng)找不(bu)到工(gong)(gong)(gong)(gong)(gong)作(zuo)(zuo)(zuo),另一(yi)(yi)(yi)方面勞動(dong)密集型企(qi)(qi)業(ye)(ye)卻(que)招工(gong)(gong)(gong)(gong)(gong)困(kun)難,在(zai)我國目前勞動(dong)力充(chong)足(zu)的(de)(de)情況下(xia)出現(xian)了(le)(le)“用工(gong)(gong)(gong)(gong)(gong)荒”現(xian)象。在(zai)此形(xing)勢下(xia),“招工(gong)(gong)(gong)(gong)(gong)難、留(liu)住員(yuan)工(gong)(gong)(gong)(gong)(gong)更(geng)難” 已(yi)成為困(kun)擾管(guan)樁(zhuang)(zhuang)生(sheng)(sheng)產(chan)(chan)企(qi)(qi)業(ye)(ye)的(de)(de)大(da)問題。盡管(guan)很多管(guan)樁(zhuang)(zhuang)生(sheng)(sheng)產(chan)(chan)企(qi)(qi)業(ye)(ye)在(zai)不(bu)斷提高工(gong)(gong)(gong)(gong)(gong)資收(shou)入(ru)和(he)福利待遇(yu),工(gong)(gong)(gong)(gong)(gong)作(zuo)(zuo)(zuo)環(huan)境也(ye)在(zai)不(bu)斷改(gai)善,卻(que)仍因一(yi)(yi)(yi)線員(yuan)工(gong)(gong)(gong)(gong)(gong)流失(shi)大(da)導致開工(gong)(gong)(gong)(gong)(gong)不(bu)足(zu)、設備(bei)閑置,影響(xiang)了(le)(le)企(qi)(qi)業(ye)(ye)的(de)(de)生(sheng)(sheng)產(chan)(chan)經(jing)營和(he)發(fa)展(zhan)。現(xian)在(zai),先進的(de)(de)管(guan)樁(zhuang)(zhuang)生(sheng)(sheng)產(chan)(chan)企(qi)(qi)業(ye)(ye)已(yi)逐漸(jian)認識(shi)到,通過(guo)改(gai)造生(sheng)(sheng)產(chan)(chan)線,提高自動(dong)化水平(ping),降低(di)勞動(dong)強度和(he)改(gai)善工(gong)(gong)(gong)(gong)(gong)作(zuo)(zuo)(zuo)條件不(bu)但可(ke)以解決人員(yuan)不(bu)足(zu)的(de)(de)問題,而(er)且可(ke)以提高生(sheng)(sheng)產(chan)(chan)效率,減少人工(gong)(gong)(gong)(gong)(gong)作(zuo)(zuo)(zuo)業(ye)(ye)影響(xiang)而(er)大(da)大(da)提高產(chan)(chan)品質量,從而(er)大(da)幅(fu)降低(di)企(qi)(qi)業(ye)(ye)的(de)(de)生(sheng)(sheng)產(chan)(chan)成本。
二、目前管樁生產設備的自動化改造措施
那到(dao)底如何升級我們的(de)(de)產(chan)業設(she)備(bei)(bei)(bei)呢?除(chu)了引(yin)進設(she)備(bei)(bei)(bei)進行消化吸(xi)收(shou)外,管(guan)樁(zhuang)(zhuang)設(she)備(bei)(bei)(bei)企業和管(guan)樁(zhuang)(zhuang)生(sheng)產(chan)企業還(huan)必須共同努力,投入資金、組織人(ren)員進行自(zi)主創新,把自(zi)動(dong)化程度較高的(de)(de)單機設(she)備(bei)(bei)(bei)整合成(cheng)自(zi)動(dong)流水線、重體力的(de)(de)手(shou)工操作改為(wei)機械(xie)化、自(zi)動(dong)化設(she)備(bei)(bei)(bei)。下(xia)面就目前(qian)我國管(guan)樁(zhuang)(zhuang)生(sheng)產(chan)中(zhong)的(de)(de)管(guan)樁(zhuang)(zhuang)鋼構件(抱箍、端頭板(ban)、籠筋)及成(cheng)品管(guan)樁(zhuang)(zhuang)的(de)(de)常用生(sheng)產(chan)設(she)備(bei)(bei)(bei)自(zi)動(dong)化改造(zao)談一下(xia)個(ge)人(ren)的(de)(de)想法。
2.1 鋼構件加工
管樁中的鋼(gang)結構件主(zhu)要(yao)由(you)抱箍、端頭板、籠筋三部分組成(cheng)。目(mu)前各部分的加工(gong)呈分散的狀態,既(ji)增加了人員的操作,半成(cheng)品又占用場(chang)地。改造時只要(yao)把(ba)各部分設備(bei)整合在一起,就可(ke)以形成(cheng)一條自動流水(shui)線。
2.1.1 抱箍加工
目前有自動(dong)切(qie)斷、人(ren)工卷(juan)圓(yuan)焊接(jie)、自動(dong)壓(ya)型(xing)(xing)等工序。近年(nian)來(lai)自動(dong)壓(ya)型(xing)(xing)機(ji)(ji)的(de)(de)研制成(cheng)功使人(ren)工卷(juan)圓(yuan)焊接(jie)和自動(dong)壓(ya)型(xing)(xing)工序連在一起,由焊工焊好(hao)后(hou)直接(jie)為壓(ya)型(xing)(xing)機(ji)(ji) 上料(liao),節(jie)省了(le)壓(ya)型(xing)(xing)機(ji)(ji)的(de)(de)人(ren)工操作。人(ren)工卷(juan)圓(yuan)焊接(jie)可改為自動(dong),只需在切(qie)斷機(ji)(ji)推出切(qie)斷的(de)(de)抱(bao)箍板時用機(ji)(ji)械手接(jie)住然(ran)后(hou)卷(juan)成(cheng)圓(yuan)環形,使兩端對齊壓(ya)緊(jin),并(bing)采用自動(dong)焊接(jie)設備進行(xing)焊接(jie),焊好(hao)后(hou)再自動(dong)推入壓(ya)型(xing)(xing)機(ji)(ji)的(de)(de)上料(liao)架上,這樣從(cong)鐵皮下料(liao)到(dao)壓(ya)型(xing)(xing)結束即成(cheng)為自動(dong)流水線。
2.1.2 端頭板加工
目前端(duan)頭板毛坯加(jia)(jia)工由(you)(you)專業端(duan)頭板生產廠家完成,管樁生產企(qi)業一般(ban)完成車外圓、止口(kou)、凹槽,加(jia)(jia)工螺紋(wen)孔(kong)(kong)、沉頭孔(kong)(kong)、連接槽等(deng)(deng)后道加(jia)(jia)工。雖然近(jin)期已有專業的(de)數(shu)控(kong)(kong)立式車床、數(shu)控(kong)(kong)沖(chong)孔(kong)(kong)沖(chong)床、數(shu)控(kong)(kong)鉆攻機等(deng)(deng)問世(shi),生產效率已得(de)到(dao)很大(da)提高。但每臺設備(bei)的(de)上(shang)(shang)下料仍(reng)由(you)(you)工人(ren)手(shou)工搬運,工序物料轉運仍(reng)用吊機吊運,進一步(bu)提高效率很困難(nan)。若把單機上(shang)(shang)下料通(tong)過自(zi)(zi)動(dong)(dong)控(kong)(kong)制氣缸驅動(dong)(dong)推桿(gan)和托盤動(dong)(dong)作來完成,上(shang)(shang)下工序之間設備(bei)采用滾筒輸(shu)送線進行連接,加(jia)(jia)上(shang)(shang)自(zi)(zi)動(dong)(dong)控(kong)(kong)制系(xi)統,可(ke)形成全(quan)自(zi)(zi)動(dong)(dong)的(de)流(liu)水線。
2.1.3 樁(zhuang)抱(bao)(bao)箍(gu)加工(gong)(抱(bao)(bao)箍(gu)、端(duan)頭(tou)板(ban)裝(zhuang)配(pei))
早期抱箍圈與端頭(tou)(tou)板(ban)的(de)(de)裝(zhuang)配(pei)在人工(gong)套(tao)裝(zhuang)后(hou),用(yong)焊接的(de)(de)方式聯接。后(hou)來改(gai)為把抱箍圈的(de)(de)一(yi)邊壓入(ru)端頭(tou)(tou)板(ban)凹(ao)槽(cao)的(de)(de)方式進(jin)行(xing)聯接,并使用(yong)專(zhuan)用(yong)設(she)備加(jia)工(gong),但(dan)抱箍圈與端頭(tou)(tou)板(ban)的(de)(de)套(tao)合還是采(cai)用(yong)人工(gong)操作。自動(dong)套(tao)合裝(zhuang)置可(ke)(ke)采(cai)用(yong)卡盤把抱箍圈撐(cheng)圓再對(dui)中端頭(tou)(tou)板(ban)套(tao)入(ru),安裝(zhuang)在現(xian)有的(de)(de)自動(dong)壓合機上組(zu)成(cheng)一(yi)臺整機,即可(ke)(ke)實(shi)現(xian)抱箍端頭(tou)(tou)板(ban)裝(zhuang)配(pei)的(de)(de)自動(dong)化。
2.1.4 籠筋加工
籠(long)(long)筋(jin)生產設備包(bao)括(kuo)鋼(gang)棒(bang)(bang)下(xia)料(liao)(liao)(liao)切斷(duan)機(ji)(ji)(ji)、鐓(dui)(dui)頭機(ji)(ji)(ji)、籠(long)(long)筋(jin)滾(gun)(gun)(gun)(gun)(gun)焊(han)機(ji)(ji)(ji)等,目前部分(fen)管樁企(qi)業進(jin)行(xing)了鐓(dui)(dui)頭機(ji)(ji)(ji)的(de)(de)自(zi)(zi)(zi)(zi)動(dong)送(song)料(liao)(liao)(liao)改(gai)造(zao),使(shi)鋼(gang)棒(bang)(bang)切斷(duan)后可(ke)(ke)自(zi)(zi)(zi)(zi)動(dong)送(song)入(ru)鐓(dui)(dui)頭機(ji)(ji)(ji)進(jin)行(xing)鐓(dui)(dui)頭,兩頭依次鐓(dui)(dui)好后,自(zi)(zi)(zi)(zi)動(dong)滾(gun)(gun)(gun)(gun)(gun)入(ru)料(liao)(liao)(liao)堆堆放(fang)。鐓(dui)(dui)頭機(ji)(ji)(ji)廠家(jia)若能把(ba)設備改(gai)成上面進(jin)料(liao)(liao)(liao),下(xia)面出(chu)料(liao)(liao)(liao)的(de)(de)結(jie)構,可(ke)(ke)大(da)(da)大(da)(da)簡化送(song)料(liao)(liao)(liao)機(ji)(ji)(ji)構。另外,再設計(ji)制作一臺(tai)測長機(ji)(ji)(ji)進(jin)行(xing)自(zi)(zi)(zi)(zi)動(dong)檢驗(yan),篩除(chu)不(bu)合格(ge)的(de)(de)鐓(dui)(dui)頭鋼(gang)棒(bang)(bang),達(da)到(dao)籠(long)(long)筋(jin)滾(gun)(gun)(gun)(gun)(gun)焊(han)所需(xu)的(de)(de)鋼(gang)棒(bang)(bang)條數后即用小(xiao)(xiao)車自(zi)(zi)(zi)(zi)動(dong)送(song)到(dao)滾(gun)(gun)(gun)(gun)(gun)焊(han)機(ji)(ji)(ji)前。現有的(de)(de)滾(gun)(gun)(gun)(gun)(gun)焊(han)機(ji)(ji)(ji)穿筋(jin)盤和小(xiao)(xiao)車盤改(gai)成可(ke)(ke)自(zi)(zi)(zi)(zi)動(dong)分(fen)度間歇(xie)轉動(dong),方便(bian)鋼(gang)棒(bang)(bang)的(de)(de)自(zi)(zi)(zi)(zi)動(dong)依次穿入(ru)。改(gai)為一體化后可(ke)(ke)以(yi)(yi)減(jian)少目前鐓(dui)(dui)頭機(ji)(ji)(ji)到(dao)滾(gun)(gun)(gun)(gun)(gun)焊(han)機(ji)(ji)(ji)的(de)(de)吊(diao)運、人工比鐵(長度檢驗(yan))和滾(gun)(gun)(gun)(gun)(gun)焊(han)機(ji)(ji)(ji)上料(liao)(liao)(liao)等人工操作,從鋼(gang)棒(bang)(bang)盤條吊(diao)入(ru)下(xia)料(liao)(liao)(liao)切斷(duan)機(ji)(ji)(ji)放(fang)料(liao)(liao)(liao)架到(dao)籠(long)(long)筋(jin)滾(gun)(gun)(gun)(gun)(gun)焊(han)結(jie)束可(ke)(ke)以(yi)(yi)全(quan)部實(shi)現自(zi)(zi)(zi)(zi)動(dong)化。
2.1.5 樁抱箍、籠筋裝(zhuang)配
這道工(gong)(gong)序(xu)原來(lai)在管樁成品(pin)加工(gong)(gong)的(de)(de)裝(zhuang)(zhuang)(zhuang)(zhuang)模(mo)工(gong)(gong)序(xu)由人工(gong)(gong)操作,可改為在籠筋(jin)(jin)車(che)間由自動裝(zhuang)(zhuang)(zhuang)(zhuang)配機(ji)完成,既可提高生(sheng)產效率,又減少了(le)裝(zhuang)(zhuang)(zhuang)(zhuang)模(mo)工(gong)(gong)序(xu)的(de)(de)工(gong)(gong)作量。加工(gong)(gong)好的(de)(de)籠筋(jin)(jin)從滾(gun)焊機(ji)輸送(song)到(dao)固定的(de)(de)V形(xing)臺(tai)(tai)(tai)上(shang)(shang),樁抱箍(gu)則由輸送(song)機(ji)分別送(song)到(dao)V形(xing)臺(tai)(tai)(tai)的(de)(de)兩端(duan)。V形(xing)臺(tai)(tai)(tai)的(de)(de)兩端(duan)分別有一臺(tai)(tai)(tai)裝(zhuang)(zhuang)(zhuang)(zhuang)配機(ji),裝(zhuang)(zhuang)(zhuang)(zhuang)配機(ji)轉(zhuan)軸上(shang)(shang)裝(zhuang)(zhuang)(zhuang)(zhuang)一個卡(ka)盤,裝(zhuang)(zhuang)(zhuang)(zhuang)配時(shi)用卡(ka)盤夾住(zhu)端(duan)頭(tou)(tou)板的(de)(de)內(nei)孔(kong)或外圓,機(ji)體(ti)上(shang)(shang)下升(sheng)降,待(dai)端(duan)頭(tou)(tou)板與(yu)籠筋(jin)(jin)中心對(dui)中(端(duan)頭(tou)(tou)板螺紋(wen)孔(kong)位與(yu)籠筋(jin)(jin)的(de)(de)鋼(gang)筋(jin)(jin)對(dui)中)時(shi),轉(zhuan)軸頭(tou)(tou)帶著樁抱箍(gu)前移以一定的(de)(de)壓力(li)頂住(zhu)籠筋(jin)(jin)的(de)(de)鋼(gang)筋(jin)(jin)鐓(dui)頭(tou)(tou),然后(hou)慢慢順時(shi)針(zhen)旋轉(zhuan),待(dai)端(duan)頭(tou)(tou)板螺紋(wen)孔(kong)與(yu)鋼(gang)筋(jin)(jin)鐓(dui)頭(tou)(tou)對(dui)中套入(ru)(ru)后(hou),轉(zhuan)到(dao)沉頭(tou)(tou)孔(kong)位置時(shi)再往回退,把所(suo)有鋼(gang)筋(jin)(jin)的(de)(de)鐓(dui)頭(tou)(tou)拉入(ru)(ru)到(dao)相應的(de)(de)沉頭(tou)(tou)孔(kong)里,裝(zhuang)(zhuang)(zhuang)(zhuang)配工(gong)(gong)作就(jiu)完成了(le)。
2.2 管樁成品加工
管(guan)(guan)樁成品加工即是(shi)把裝配好的籠筋樁抱箍(gu)放入管(guan)(guan)模內,加入攪拌好的混凝土,經過張拉后進行離(li)心成型,再經過蒸養(yang)(yang)、脫模后進行壓蒸養(yang)(yang)護(hu)。其中(zhong)吊運、 布料、合模螺絲拆(chai)(chai)裝、清模、噴灑脫模劑、拆(chai)(chai)裝張拉擋(dang)板(ban)和頭(tou)尾板(ban)等工序用工人(ren)數多、勞動(dong)強度大(da)、工作環境差,很(hen)有必要改為(wei)自動(dong)操作。
2.2.1 吊運
成品加工(gong)車間至少使(shi)用(yong)(yong)4臺普(pu)通(tong)吊(diao)機進行工(gong)序間管(guan)(guan)(guan)模(mo)(mo)、管(guan)(guan)(guan)樁的(de)(de)(de)吊(diao)運,由(you)于管(guan)(guan)(guan)模(mo)(mo)、管(guan)(guan)(guan)樁長而重的(de)(de)(de)特點,自動(dong)(dong)(dong)(dong)(dong)專(zhuan)用(yong)(yong)吊(diao)具的(de)(de)(de)使(shi)用(yong)(yong)不但可(ke)以降低工(gong)人(ren)勞動(dong)(dong)(dong)(dong)(dong)強度,而且減少安(an)全(quan)隱患(huan)。目前,吊(diao)管(guan)(guan)(guan)模(mo)(mo)跑輪和吊(diao)底(di)(di)模(mo)(mo)的(de)(de)(de)氣動(dong)(dong)(dong)(dong)(dong)吊(diao)具都已開(kai)發(fa)出(chu)(chu)來,國內較(jiao)先進的(de)(de)(de)回形(xing)布局車間已全(quan)面采用(yong)(yong)。而對(dui)于較(jiao)早前的(de)(de)(de)直(zhi)線形(xing)布局,由(you)于吊(diao)底(di)(di)模(mo)(mo)吊(diao)具操作空(kong)間要求較(jiao)大(da),無法適(shi)應(ying)現有(you)工(gong)作條件,使(shi)用(yong)(yong)受到限制(zhi)。目前普(pu)遍采用(yong)(yong)的(de)(de)(de)自動(dong)(dong)(dong)(dong)(dong)脫鉤,管(guan)(guan)(guan)模(mo)(mo)出(chu)(chu)蒸(zheng)養(yang)(yang)池(chi)時(shi)還需工(gong)人(ren)進入蒸(zheng)養(yang)(yang)池(chi)掛(gua)鉤,勞動(dong)(dong)(dong)(dong)(dong)強度高且存在安(an)全(quan)隱患(huan)。必須盡快研(yan)制(zhi)出(chu)(chu)既能吊(diao)跑輪又能吊(diao)底(di)(di)模(mo)(mo)且能在蒸(zheng)養(yang)(yang)池(chi)使(shi)用(yong)(yong)的(de)(de)(de)吊(diao)具,吊(diao)底(di)(di)模(mo)(mo)夾具必須采用(yong)(yong)張開(kai)不能太大(da)、收攏(long)時(shi)不占用(yong)(yong)空(kong)間的(de)(de)(de)機構才(cai)適(shi)合使(shi)用(yong)(yong)。吊(diao)管(guan)(guan)(guan)樁專(zhuan)用(yong)(yong)的(de)(de)(de)真(zhen)空(kong)吸盤吊(diao)具可(ke)以在模(mo)(mo)蓋移走后(hou)將管(guan)(guan)(guan)樁從(cong)底(di)(di)模(mo)(mo)中直(zhi)接吊(diao)出(chu)(chu),國外(wai)已成熟使(shi)用(yong)(yong);近年來國內雖有(you)仿制(zhi),但性能不夠(gou)理(li)想(xiang),專(zhuan)業生(sheng)產廠家需加大(da)研(yan)發(fa)力度,提升穩定性和可(ke)靠性,才(cai)能得到普(pu)及使(shi)用(yong)(yong)。
2.2.2 布料
國外有一種先進的(de)(de)(de)布(bu)(bu)料(liao)(liao)(liao)方式(shi),就是在合(he)模后采(cai)用混(hun)凝(ning)土泵(beng)把料(liao)(liao)(liao)從尾孔(kong)打入管模內,具有自動(dong)(dong)化(hua)程度高(gao)(gao),布(bu)(bu)料(liao)(liao)(liao)時(shi)間短,減少合(he)縫漏漿質量缺(que)陷等優點;但混(hun)凝(ning)土泵(beng)的(de)(de)(de)投資較(jiao)大而且(qie)要求混(hun)凝(ning)土的(de)(de)(de)流動(dong)(dong)性(xing)較(jiao)高(gao)(gao),國內還(huan)未普(pu)及(ji)采(cai)用。我國目(mu)前普(pu)遍采(cai)用的(de)(de)(de)是合(he)模前布(bu)(bu)料(liao)(liao)(liao),不(bu)管是移(yi)動(dong)(dong)的(de)(de)(de)喂料(liao)(liao)(liao)機還(huan)是固定(ding)的(de)(de)(de)喂料(liao)(liao)(liao)機,都(dou)還(huan)沒(mei)有一種可以(yi)消除砼(tong)料(liao)(liao)(liao)散(san)落(luo)的(de)(de)(de)擋(dang)料(liao)(liao)(liao)裝(zhuang)(zhuang)置(zhi)。設計時(shi)除了要采(cai)用與管模內徑吻(wen)合(he)的(de)(de)(de)布(bu)(bu)料(liao)(liao)(liao)模,保證布(bu)(bu)出的(de)(de)(de)料(liao)(liao)(liao)形好(hao);還(huan)必(bi)須有擠(ji)壓裝(zhuang)(zhuang)置(zhi),防止布(bu)(bu)好(hao)的(de)(de)(de)料(liao)(liao)(liao)坍落(luo)下滑(hua)。布(bu)(bu)料(liao)(liao)(liao)裝(zhuang)(zhuang)置(zhi)還(huan)必(bi)須可以(yi)配合(he)喂料(liao)(liao)(liao)車或(huo)平(ping)車的(de)(de)(de)移(yi)動(dong)(dong)控制(zhi)喂料(liao)(liao)(liao)的(de)(de)(de)量,當砼(tong)料(liao)(liao)(liao)高(gao)(gao)于底模時(shi)減少喂料(liao)(liao)(liao)速度。若能研制(zhi)成功,也可以(yi)減少鏟料(liao)(liao)(liao)、抹(mo)漿和掃平(ping)車的(de)(de)(de)操作人員、減少廢料(liao)(liao)(liao)損失,降低勞動(dong)(dong)強度,提高(gao)(gao)生產效(xiao)率(lv),改善(shan)工(gong)作環境。
2.2.3 合模螺(luo)絲拆裝
目(mu)前采(cai)用(yong)平(ping)衡吊懸(xuan)掛風扳(ban)手(shou)(shou)的方式(shi),大大減(jian)輕了工人拆裝螺(luo)(luo)絲(si)(si)的勞(lao)動(dong)強度,但操作人數基本不變。自(zi)動(dong)合模螺(luo)(luo)絲(si)(si)拆裝機可(ke)(ke)(ke)設計成門式(shi),沿管模兩(liang)(liang)側(ce)旁軸向軌(gui)道移(yi)動(dong),具備(bei)自(zi)動(dong)探測合模螺(luo)(luo)絲(si)(si)位置的功能,兩(liang)(liang)邊各裝一(yi)臺(tai)可(ke)(ke)(ke)上下移(yi)動(dong)的風扳(ban)手(shou)(shou)或電動(dong)螺(luo)(luo)絲(si)(si)機,拆裝一(yi)條管模時,可(ke)(ke)(ke)用(yong)兩(liang)(liang)臺(tai)設備(bei),同(tong)時從兩(liang)(liang)端往中間或從中間往兩(liang)(liang)端移(yi)動(dong),相(xiang)當于4個風炮手(shou)(shou)同(tong)時操作,可(ke)(ke)(ke)極大提(ti)高工作效率,操作人員的數量(liang)也可(ke)(ke)(ke)大大減(jian)少。
2.2.4 清模和噴脫模劑(ji)
目前模(mo)具的(de)清理(li)(li)(li)和(he)(he)(he)往(wang)模(mo)腔表面噴(pen)(pen)(pen)灑(sa)脫模(mo)劑均由人(ren)工(gong)進(jin)行(xing)。特別是人(ren)工(gong)噴(pen)(pen)(pen)灑(sa)脫模(mo)劑,環境(jing)較(jiao)臟,采(cai)用(yong)自(zi)(zi)動(dong)(dong)(dong)設(she)(she)備有(you)利于減輕工(gong)人(ren)勞(lao)動(dong)(dong)(dong)強度(du)和(he)(he)(he)環境(jing)污染。設(she)(she)計時(shi)可(ke)采(cai)用(yong)管模(mo)軸向(xiang)移(yi)動(dong)(dong)(dong),脫模(mo)劑噴(pen)(pen)(pen)頭縱向(xiang)移(yi)動(dong)(dong)(dong)定位的(de)方式,噴(pen)(pen)(pen)頭兩側和(he)(he)(he)底部可(ke)安裝(zhuang)海(hai)綿隔離,避免噴(pen)(pen)(pen)霧(wu)泄露。清模(mo)主要是指(zhi)模(mo)內(nei)兩端和(he)(he)(he)模(mo)邊的(de)水泥(ni)塊(kuai)和(he)(he)(he)密封草(cao)繩(sheng)的(de)清理(li)(li)(li),自(zi)(zi)動(dong)(dong)(dong)清理(li)(li)(li)頭可(ke)用(yong)刮鏟和(he)(he)(he)轉(zhuan)動(dong)(dong)(dong)的(de)鋼絲(si)盤刷,再裝(zhuang)上海(hai)綿刷頭可(ke)對清理(li)(li)(li)過的(de)地(di)方自(zi)(zi)動(dong)(dong)(dong)打油(you);清理(li)(li)(li)出的(de)廢料(liao)采(cai)用(yong)料(liao)斗收(shou)集處理(li)(li)(li)。
2.2.5 拆裝(zhuang)張(zhang)拉擋板和頭尾板
由于頭(tou)(tou)(tou)尾(wei)板(ban)(ban)(ban)(ban)和張(zhang)(zhang)(zhang)拉(la)(la)擋(dang)(dang)(dang)板(ban)(ban)(ban)(ban)很(hen)重(每件(jian)至少30千克),拆(chai)(chai)裝(zhuang)時(shi)需(xu)工人彎腰拆(chai)(chai)裝(zhuang)和移(yi)動(dong),是目(mu)前管樁生產企業中(zhong)最重的(de)(de)體力工作(zuo)。首(shou)先(xian)必(bi)須(xu)設計(ji)一臺自動(dong)旋(xuan)松(song) 裝(zhuang)置代替目(mu)前人工錘(chui)擊(ji)拆(chai)(chai)卸(xie)(xie)(xie)張(zhang)(zhang)(zhang)拉(la)(la)螺(luo)(luo)母(mu)。拆(chai)(chai)頭(tou)(tou)(tou)尾(wei)板(ban)(ban)(ban)(ban)螺(luo)(luo)絲裝(zhuang)置可(ke)使用(yong)兩(liang)個拆(chai)(chai)卸(xie)(xie)(xie)頭(tou)(tou)(tou),具備自動(dong)分(fen)(fen)度(du)機(ji)構,針(zhen)對(dui)不(bu)同(tong)規格(ge)的(de)(de)管樁方(fang)便調整拆(chai)(chai)卸(xie)(xie)(xie)頭(tou)(tou)(tou)之間的(de)(de)夾角和徑向位置。為方(fang)便拆(chai)(chai)裝(zhuang),可(ke)以(yi)在張(zhang)(zhang)(zhang)拉(la)(la)擋(dang)(dang)(dang)板(ban)(ban)(ban)(ban)上(shang)(shang)對(dui)應頭(tou)(tou)(tou)板(ban)(ban)(ban)(ban)孔(kong)(kong)位開兩(liang)個圓孔(kong)(kong),在松(song)開張(zhang)(zhang)(zhang)拉(la)(la)螺(luo)(luo)母(mu)后(hou)(hou),可(ke)把拆(chai)(chai)卸(xie)(xie)(xie)頭(tou)(tou)(tou)從孔(kong)(kong)內伸入拆(chai)(chai)裝(zhuang)頭(tou)(tou)(tou)板(ban)(ban)(ban)(ban)螺(luo)(luo)絲,轉(zhuan)動(dong)角度(du)時(shi)擋(dang)(dang)(dang)板(ban)(ban)(ban)(ban)跟著轉(zhuan)動(dong),不(bu)需(xu)要把擋(dang)(dang)(dang)板(ban)(ban)(ban)(ban)和張(zhang)(zhang)(zhang)拉(la)(la)螺(luo)(luo)母(mu)拆(chai)(chai)下(xia)來再裝(zhuang)上(shang)(shang)去,可(ke)大(da)大(da)節(jie)省工時(shi)。張(zhang)(zhang)(zhang)拉(la)(la)擋(dang)(dang)(dang)板(ban)(ban)(ban)(ban)和頭(tou)(tou)(tou)板(ban)(ban)(ban)(ban)拆(chai)(chai)卸(xie)(xie)(xie)時(shi)可(ke)以(yi)套住張(zhang)(zhang)(zhang)拉(la)(la)螺(luo)(luo)桿進行固定(ding)(ding);拆(chai)(chai)尾(wei)板(ban)(ban)(ban)(ban)螺(luo)(luo)絲時(shi),可(ke)用(yong)卡盤卡住尾(wei)板(ban)(ban)(ban)(ban)內孔(kong)(kong)進行固定(ding)(ding)。頭(tou)(tou)(tou)尾(wei)板(ban)(ban)(ban)(ban)與(yu)端頭(tou)(tou)(tou)板(ban)(ban)(ban)(ban)拆(chai)(chai)開后(hou)(hou),只要分(fen)(fen)別朝后(hou)(hou)稍移(yi)動(dong),待管樁吊走后(hou)(hou),馬上(shang)(shang)放(fang)入裝(zhuang)配(pei)(pei)好的(de)(de)籠筋樁抱箍,再把頭(tou)(tou)(tou)尾(wei)板(ban)(ban)(ban)(ban)分(fen)(fen)別往回移(yi)動(dong),與(yu)端頭(tou)(tou)(tou)板(ban)(ban)(ban)(ban)進行裝(zhuang)配(pei)(pei)。若不(bu)馬上(shang)(shang)裝(zhuang)配(pei)(pei),可(ke)把把配(pei)(pei)板(ban)(ban)(ban)(ban)拆(chai)(chai)下(xia)來的(de)(de)張(zhang)(zhang)(zhang)拉(la)(la)擋(dang)(dang)(dang)板(ban)(ban)(ban)(ban)、頭(tou)(tou)(tou)板(ban)(ban)(ban)(ban)、尾(wei)板(ban)(ban)(ban)(ban)帶(dai)著螺(luo)(luo)絲放(fang)到專用(yong)架上(shang)(shang),待需(xu)要時(shi)再送到管模兩(liang)端與(yu)模內端頭(tou)(tou)(tou)板(ban)(ban)(ban)(ban)裝(zhuang)配(pei)(pei)。
除(chu)以上所述(shu)外,設(she)備改造過(guo)程中還需注(zhu)意提高(gao)原有設(she)備的精(jing)度(du),否則定位(wei)不準,自動化就難以實現。
三、結論
本(ben)文簡單地列舉(ju)了管樁專用生產設(she)備的一些自動(dong)化改造(zao)設(she)想,權(quan)作(zuo)拋(pao)磚引(yin)玉(yu),希望有(you)更多的同行(xing)真正(zheng)重視管樁生產設(she)備的技術(shu)改造(zao),加強技術(shu)交流與合 作(zuo),不斷進行(xing)技術(shu)創新,使我國的管樁制造(zao)技術(shu)達(da)到甚至超過國外的先進水平。