| CLAIMS: 1. A concrete casting apparatus comprising: a base structure, a first end plate, a second end plate which is mobile relative to the base structure, a panel winch is arranged between the first end plate and the second end plate and is mobile relative to the base structure, the panel having a top edge, a bottom edge, two ends, a first face toward the first end plate for forming, in use, a surface of a first mould, and a second face toward the second end plate for forming, in use, a surface of a second mould; and a rail elevated relative to the base structure; the panel being supported at or near one end from the rail, and at or near us other end on the base structure. 2. A concrete casting apparatus as clauned in claim 1 wherein the rail is at a height above the top edge of the panel. 3. A concrete casting apparatus as claimed in either claim 1 or claim 2 including multiple panels between the first and second end plate. 4. A concrete casting apparatus as claimed any one of clauris 1 to 3 wherein the panel includes a fence hingingly connected to each edge, to pivot between a use condition wherein the fence is between a face of the panel and an end plate, and a non-use condition wherein the fence is outside the boundary of the face of the panel. 5. A concrete casting apparatus as claimed in any one of claims 1 to 4 wherein die tixst end plate is fixed relative to the base structure. 6. A concrete casting apparatus as clauned in any one of claims 1 to 5 wherein die base structure includes a rail and the panel is supported at the other end by a wheel able to roll on the rail. 7. A concrete casting apparatus as clauned in claim 6 wherein the rail is beyond the bottom edge of the panel. 8. A concrete casting apparatus as claimed in any one of claims 1 to 7 wherein die base structure includes a bed, and the first and second moulds are fully above die bed when assembled. 9. A concrete casting apparatus as claimed in any one of claims 1 to 8 including at least two actuators adjacent the base which in use urge the lower portion of the second end plate toward the lower portion of the first end plate. 10. A concrete casting apparatus as claimed in claim 9 wherein the actuators comprise rams acting between the base structure and the second end plate. 1 1 . A concrete casting apparatus as claimed in any one of claims 1 to 10 including at least two actuators adjacent the upper edge of the panel with the houlds assembled, which in use urge the lower portion of the second end plate toward the lower pordon of the first end plate. 12. A concrete casting apparatus as claimed in claim 1 1 wherein the actuators comprise rams acting between the first end plate and the second end plate. 13. A concrete casting apparatus as claimed in any one of claims 1 to 12 wherein the first end plate includes a face toward the panel which forms part of a mould surface in use. 14. A concrete casting apparatus as claimed in any one of claims 1 to 12 wherein the second end plate includes a face toward the panel which forms part of a mould surface in use. 15. A concrete casdng apparatus as claimed in any one of claims 1 to 14 wherein the base structure includes spaced apart rails extending transverse to the plane of the panel and the end plates, and the second end plate is movably supported on the rails. 16. A concrete casdng apparatus as claimed in claim 15 wherein the second end plate includes wheels rolling on the rails and at least one motor to move the end plate toward or away from the first end plate. 17. A concrete casting apparatus as claimed in claim 16 wherein the motor drives at least one of the wheels. 18. A concrete casting apparatus as claimed in any one of claims 15 to 17 wherein each rail includes a ridge, and each wheel includes an annular groove over the ridge, so that the wheel is aligned on the rail. 19. A concrete casting apparatus as claimed in any one of claims 1 to 18 wherein the rail at a height above the top edge of the panel is substantially above the top edge of die panel, for example at least 0.5m and preferably at least 1 m. 20. A concrete casting apparatus as claimed in any one of claims 1 to 19 including a gantry crane having a travelling beam extending transverse to the panel and end plates, and that is able to move above the panel and end plates in a direction aligned with the panel and end plates. 21 . A concrete casting apparatus as claimed in claim 20 wherein the travelling beam is less than twice the height above the base structure that the top edge of the panel is above the base structure. 22. A concrete casdng apparatus as claimed in any one of claims 1 to 21 including a thud end plate back to back with the first end, a fourth end plate mobile relative to the base structure, and another mobile panel located between the third end plate and the fourth end plate. 23. A concrete casting apparatus as claimed in either claim 6 or claim 7 wherein the panel includes only a single rolling axis on the rail of the base structure, so that the respective edge of the panel can pivot about the rolling axis while suspended. 24. A concrete casdng apparatus as claimed in either claim 9 or claim 10 wherein the base structure includes a plurality of rails on which the second end plate is mobile, and an actuator is provided adjacent at least one rail of the base structure to act between the base structure and the end plate. 25. A concrete casting apparatus as claimed in claim 24 wherein the base structure includes at least three and preferably tour or more rails. 26. A concrete casting apparatus as claimed in claim 25 including an actuator in respect of each rail. 27. A concrete casting apparatus as claimed in any one of claims 9, 10 and 24 to 26 wherein the actuator includes an abutment to act against the second end plate, and is pivotally connected to the base structure between an in use position aligned toward the second end plate and a non- use position. 28. A concrete casting apparatus as claimed in claim 27 wherein the second end plate is able to move onto an area of die base structure when the actuators are in the non-use posidon, that the actuators occupy when in the use position. 29. A concrete casting apparatus as claimed m either claim 1 1 or claim 12 wherein each actuator is pivotally connected to the tust or second end plate between an in use posidon aligned toward the other end plate and a non-use posidon, and the apparatus includes a releasable connection between the actuator and the other end plate. 30. A concrete casting apparatus as clauned in claim 29 wherein the actuator is pivotally connected to die first end plate and the releasable connection is with the second end plate. 31. A concrete casting apparatus comprising: a base structure, a first end plate, a second end plate which is mobile relative to the base structure, a panel which is arranged between the first end plate and the second end plate and is mobile relative to the base structure, the panel having a first face toward the first .end plate for forming, in use, a surface of a first mould, and a second face toward the second end plate for forming, in use, a surface of a second mould; and at least two actuators adjacent the base which in use urge the lower pordon of the second end plate toward the lower portion of the fust end plate. 32. A concrete casting apparatus as claimed in claim 31 wherein the actuators comprise rams acting between the base structure and the second end plate. 33. A concrete casting apparatus as clauned in either claim 31 or claim 32 including at least two upper actuators adjacent the upper edge of the panel with the houlds assembled, which in use urge the lower pordon of die second end plate toward the lower pordon of the first end plate. 34. A concrete casdng apparatus as claimed in claim 33 wherein the upper actuators comprise rams acting between the first end plate and die second end plate. 35. A concrete casting apparatus as claimed in any one of claims 31 to 34 wherein the base structure includes a plurality of rails on which the second end plate is mobile, and an actuator is provided adjacent at least one rail of the base structure to act between the base structure and the end plate. 36. A concrete casting apparatus as claimed in claim 35 wherein the base structure includes at least three and preferably four or more rails. 37. A concrete casdng apparatus as claimed in claim 36 including an actuator in respect of each rail. 38. A concrete casdng apparatus as claimed in any one of claims 31 to 37 wherein the actuator includes an abutment to act against the second end plate, and is pivotaUy connected to the base structure between an in use posidon aligned toward the second end plate and a non-use position. 39. A concrete casting apparatus as claimed in claim 38 wherein the second end plate is able to move onto an area of die base structure when die actuators are in the non-use posidon, that the actuators occupy when in the use posidon. 40. A concrete casting apparatus as claimed in either claim 33 or claim 34 wherein each upper actuator is pivotaUv connected to the first or second end plate between an in use position aligned toward the other end plate and a non-use posidon, and the apparatus includes a releasable connecdon between the actuator and the other end plate. 41 . A concrete casdng apparatus as claimed rn claim 40 wherein the actuator is pivotaUy connected to the fust end plate and the releasable connection is with the second end plate. 42. A concrete casdng apparatus as claimed in any one of claims 31 to 41 including multiple panels between the fust and second end plate. 43. A concrete casting apparatus as claimed in any one of claims 31 to 42 wherein the panel includes a fence hingingly connected to each edge, to pivot between a use condition wherein the fence is between a face of the panel and an end plate, and a non-use condition wherein the fence is outside the boundary of the face of the panel. 44. A concrete casting apparatus as claimed in any one ot claims 3 1 to 43 wherein the first end plate is fixed relative to the base structure. 45. A concrete casting apparatus as claimed in any one of claims 31 to 44 wherein the base structure includes a bed, and the first and second moulds are fully above the bed when assembled. 46. A concrete casting apparatus as claimed in any one of claims 31 to 45 wherein the first end plate includes a face toward the panel which forms part of a mould surface in use. 47. A concrete casting apparatus as claimed in any one of claims 31 to 46 wherein die second end plate includes a face toward the panel which forms part of a mould surface in use. 48. A concrete casting apparatus as claimed in any one of claims 31 to 47 wherein the base structure includes spaced apart rails extending transverse to the plane of the panel and the end plates, and the second end plate is movably supported on the rails. 49. A concrete casting apparatus as claimed in any one of claims 31 to 48 wherein the second end plate includes wheels rolling on the rails and at least one motor to move the end plate toward or away from the first end plate. 50. A concrete casting apparatus as claimed in claim 49 wherein the motor drives at least one of the wheels. 51. A concrete casting apparatus as claimed in any one of claims 48 to 50 wherein each rail includes a ridge, and each wheel includes an annular groove over the ridge, so that the wheel is aligned on the rail. 52. A concrete casting apparatus as claimed in any one of claims 31 to 51 including a gantry crane having a travelling beam extending transverse to the panel and end plates, and that is able to move above the panel and end plates in a direction aligned with the panel and end plates. 53. A concrete casting apparatus as claimed in claim 52 wherein the travelling beam is less than twice the height above the base structure that the top edge of the panel is above the base structure. 54. A concrete casting apparatus as claimed in any one of claims 31 to 53 including a third end plate back to back with the hrst end, a fourth end plate mobile relative to die base structure, and another mobile panel located between the third end plate and the fourth end plate. 55. A concrete casting apparatus substantially as herein described with reference to and as illustrated by the accompanying drawings. 56. A method of casting concrete panels comprising: assembling a set of mould cavities in an apparaais as claimed in claim 1 , filling the assembled mould cavities with concrete, allowing the concrete to achieve an initial cure, supporting each concrete panel from an overhead crane, and opening the respective mould cavity, removing the concrete panel from the mould cavity through the side of the apparatus without substantially lifting the panel. 57. A method of casting concrete panels comprising: assembling a set of vertical mould cavities including a fixed end plate, a set of mobile panels and a mobile end plate, applying pressure against the base of the mobile end plate toward the fixed end pla te, and independent to an upper portion of the mobile end plate toward the fixed end plate, filling the moulds with concrete, allowing the concrete to reach an initial cure, releasing the pressure from the top and bottom of the mobile end plate, opening the moulds and removing the concrete panels. |
Filed of the Invention
The present invention relates to apparatus for manufacturing concrete panels.
Background to the Invention
Concrete building panels are used in a range of applications. They can be used for building free-standing walls, retaining walls or as the walls, floors and ceilings of buildings. The panels are manufactured independendy of their final location before being moved to and positioned in their final location and secured in place. The pre-casting can occur at the building site or at a remotely located factory site.
The most common method of forming pre-cast concrete panels involves arranging form work on a horizontal casting bed, pouring concrete and floating the exposed surface of the concrete. The floated surface forms one face of the panel, while the other face of die panel is formed against the casting bed. The edges of the panel are formed against the formwork. Once the concrete has reached an initial cure, the formwork is removed, the panel is lifted from the casting bed and stored for further curing before being transported to the building site.
In a manufacturing facility producing a high volume of panels, the horizontal casting bed can take up a large floor area.
For large volume applications such as fence panels or retaining wall panels, vertical casting machines have been developed. These include a pair of ends, at least one of which is mobile. Each end includes a casting surface. A set of intermediate panels is arranged between the ends. Each of the intermediate panels includes a casting surface on each side. The intermediate panels are also mobile. For use, formwork is assembled to the ends, the intermediate panels or both and the mobile end and mobile panels are brought together with the fixed end to create a series of open-topped moulding cavities defined by the faces of the ends, the faces of the intermediate panels and the formwork. These tall, wide and comparatively thin moulding cavities are dien filled from above. For example, they may be filled by concrete from a hopper suspended from an overhead gantry crane. After initial curing, the mobile end is released and one by one, die mould cavities are opened and concrete panels are lifted free. Known vertical casting systems have limitations relating to die manner that the moulds are secured in the casting condition, the arrangement of die formwork, the stability of the mobile panels and the handling of die finished concrete panel products.
Summary of the Invention An object of the present invention is to provide a vertical casting apparatus which goes some way toward overcoming the disadvantages of existing systems or which will at least provide the industry with a useful choice.
In one aspect, the present invention consists in a concrete casting apparatus comprising a base structure, a first end plate, a second end plate which is mobile relative to the base structure, a panel which is arranged between the first end plate and the second end plate and is mobile relative to die base structure, the panel having a top edge, a bottom edge, two ends, a first face toward the first end plate for forming, in use, a surface of a first mould, and a second face toward the second end plate for forming, in use, a surface of a second mould; and a rail at a height above the top edge of the panel; the panel being supported at or near one end from the rail, and at or near its other end on the base structure.
According to a further aspect, the concrete casting apparatus includes multiple panels between the first and second end plate.
According to a further aspect, the panel includes a fence hingingly connected to each edge, to pivot between a use condition wherein the fence is between a face of the panel and an end plate, and a non-use condition wherein the fence is outside the boundary of die face of the panel.
According to a further aspect, the first end plate is fixed relative to the base structure.
According to a further aspect, the base structure includes a rail and the panel is supported at the other end by a wheel able to roll on the rail.
According to a further aspect, the rail is beyond the bottom edge of the panel.
According to a further aspect, the base structure includes a bed, and the first and second moulds are fully above the bed when assembled.
According to a further aspect, the concrete casting apparatus includes at least two actuators adjacent die base which in use urge the lower portion of the second end plate toward the lower portion of the first end plate.
According to a further aspect, the actuators comprise rams acung between the base structure and the second end plate.
According to a further aspect, the concrete casting apparatus includes at least two actuators adjacent the upper edge of die panel with die houlds assembled, which in use urge the lower portion of die second end plate toward the lower portion of the first end plate.
According to a further aspect, die actuators comprise rams acting between the first end plate and the second end plate.
According to a further aspect, the first end plate includes a face toward die panel which forms part of a mould surface in use. According to a further aspect, the second end plate includes a face toward the panel which forms part of a mould surface in use.
According to a further aspect, the base structure includes spaced apart rails extending transverse to the plane of the panel and die end plates, and the second end plate is movably supported on the rails.
According to a further aspect, the second end plate includes wheels rolling on the rails and at least one motor to move the end plate toward or away from the first end plate.
According to a further aspect, the motor drives at least one of the wheels.
According to a further aspect, each rail includes a ridge, and each wheel includes an annular groove over the ridge, so that the wheel is aligned on the rail.
According to a further aspect, the rail at a height above die top edge of the panel is substantially above the top edge of the panel, for example at least 0,5m and preferably at least 1 m.
According to a further aspect, the concrete casting apparatus includes a gantry crane having a travelling beam extending transverse to the panel and end plates, and that is able to move above the panel and end plates in a direction aligned with the panel and end plates.
According to a further aspect, the travelling beam is less than twice the height above the base structure that the top edge of die panel is above die base structure.
According to a further aspect, the concrete casting apparatus includes a thud end plate back to back with the first end, a fourth end plate mobile relative to the base structure, and another mobile panel located between the third end plate and the fourth end plate.
According to a furdier aspect, the panel includes only a single rolling axis on the rail of the base structure, so that the respective edge of the panel can pivot about the rolling axis while suspended.
According to a further aspect, the base structure includes a plurality of rails on which the second end plate is mobile, and an actuator is provided ad|acent at least one rail of the base structure to act between die base structure and the end plate.
According to a further aspect, the base structure includes at least three and preferably four or more rails.
According to a further aspect, the concrete casting apparatus includes an actuator in respect of each rail.
According to a further aspect, die actuator includes an abutment to act against the second end plate, and is pivotally connected to die base structure between an in use position aligned toward die second end plate and a non-use position. According to a further aspect, the second end plate is able to move onto an area of the base structure when the actuators are in the non-use position, that the actuators occupy when in the use posidon.
According to a further aspect, each actuator is pivotally connected to the first or second end plate between an in use posidon aligned toward the other end plate and a non-use position, and the apparatus includes a releasable connecdon between the actuator and the other end plate.
According to a further aspect, the actuator is pivotally connected to the first end plate and the releasable connecdon is with the second end plate.
In another aspec the present invention consists in a concrete casdng apparatus comprising a base structure, a fust end plate, a second end plate which is mobile reladve to the base structure, a panel which is arranged between die fust end plate and the second end plate and is mobile reladve to the base structure, the panel having a fust face toward the first end plate for forming, in use, a surface of a fust mould, and a second face toward the second end plate for forming, in use, a surface of a second mould; and at least two actuators ad]acent the base which in use urge the lower portion of the second end plate toward the lower pordon of the first end plate.
According to a further aspect, the acaiators compnse rams acting between the base structure and the second end plate.
According to a further aspect, the concrete casdng apparatus includes at least two upper actuators adjacent the upper edge of the panel with the houlds assembled, which in use urge the lower pordon of the second end plate toward the lower pordon of the fust end plate.
According to a further aspect, the upper acaiators comprise rams acting between the fust end plate and the second end plate.
According to a further aspect, the base structure includes a plurality of rails on which the second end plate is mobile, and an actuator is provided adjacent at least one rail of the base structure to act between die base structure and the end plate.
According to a further aspect, the base structure includes at least three and preferably four or more rails.
Accorduig to a further aspect, the concrete casdng apparatus includes an actuator in respect of each rail.
According to a further aspect, the actuator includes an abutment to act against the second end plate, and is pivotally connected to the base structure between an in use posidon aligned toward the second end plate and a non-use posidon. According to a further aspect, the second end plate is able to move onto an area of the base structure when the actuators are in the non-use position, diat die actuators occupy when in the use posidon.
According to a further aspect, each upper actuator is pivotally connected to die first or second end plate between an in use position aligned toward the other end plate and a non-use posidon, and the apparatus includes a releasable connecuon between the actuator and the other- end plate.
According to a further aspect, the actuator is pivotally connected to the first end plate and the releasable connection is with the second end plate.
According to a further aspect, the concrete casdng apparatus includes multiple panels between the first and second end plate
According to a further aspect, the panel includes a fence hingingly connected to each edge, to pivot between a use condition wherein the fence is between a tace of the panel and an end plate, and a non-use condition wherein die fence is outside the boundary of the face of the panel.
According to a further aspect, the fust end plate is fixed relative to the base structure.
According to a further aspect, the base structure includes a bed, and die first and second moulds are fully above the bed when assembled.
According to a further aspect, the first end plate includes a face toward the panel which forms part of a mould surface in use.
According to a further aspect, the second end plate includes a face toward the panel which forms part of a mould surface in use.
According to a further aspect, the base structure includes spaced apart rails extending transverse to the plane of the panel and the end plates, and the second end plate is movably supported on the rails.
According to a further aspect, the second end plate includes wheels rolling on the rails and at least one motor to move the end plate toward or away from the first end plate.
According to a further aspect, the motor drives at least one of the wheels.
According to a further aspect, each rail includes a ridge, and each wheel includes an annular groove over the ridge, so that the wheel is aligned on the rail
According to a further aspect, the concrete casting apparatus includes a gantry crane having a travelling beam extending transverse to the panel and end plates, and that is able to move above the panel and end plates in a direcdon aligned with die panel and end plates.
According to a further aspect, the travelling beam is less than twice the height above the base structure that the top edge of die panel is above die base structure. According to a further aspect, the concrete casting apparatus includes a third end plate back to back widi die first end, a fourth end plate mobile relative to the base structure, and another mobile panel located between the thud end plate and the fourth end plate.
In another aspect, the present invention consists in a concrete casting apparatus substantially as herein described with reference to and as illustrated by die accompanying drawings.
In another aspect, the present invention consists in a method of casting concrete panels comprising assembling a set of mould cavities in an apparatus as claimed in claim 1 , filling the assembled mould cavides with concrete, allowing the concrete to achieve an initial cure, supporting each concrete panel from an overhead crane, and opening the respective mould cavity, removing die concrete panel from the mould cavity through the side ot the apparatus without substantially lifting the panel.
In another aspect, the present invention consists in a method of casdng concrete panels comprising assembling a set of vertical mould cavides including a fixed end plate, a set of mobile panels and a mobile end plate, applying pressure against the base of the mobile end plate toward the fixed end plate, and independent to an upper portion of the mobile end plate toward the fixed end plate, filling the moulds with concrete, allowing the concrete to reach an initial cure, releasing the pressure from the top and bottom of the mobile end plate, opening the moulds and removing die concrete panels.
The term "comprising" is used in the specification and claims, means "consisting at least in part of. When interpreting a statement in this specification and claims that includes "comprising", features other than that or those prefaced by the term may also be present. Related terms such as "comprise" and "comprises" are to be interpreted in the same manner.
To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and applications of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting.
In this specification where reference has been made to patent specifications, other external documents, or otiier sources of information, this is generally for the purpose of providing a context for discussing die features of the invention. Unless specifically stated otherwise, reference to such external documents is not to be construed as an admission that such documents, or such sources of information, in any jurisdiction, are prior art, or form part of the common general knowledge in the art.
Brief Description of the Drawings
A preferred embodiment of the present will be described with reference to the accompanying drawings.
Figure 1 is a side view of a vertical casting apparatus incorporating aspects of the present invention.
Figure 2 is an end view of the vertical casting apparatus of Figure 1.
Figure 3 is a cross-sectional end view through line AA of Figure 1 of the casting apparatus of Figure 1 .
Figure 4A and 4B illustrate some steps in preparing the casting apparatus tor use.
Figure 4A is a side elevation of the apparatus with the mobile end plate moved up agamst the set ot mobile intermediate panels.
Figure 4B shows hydraulic actuators in position to urge upper and lower portions ot the mobile end plate toward the fixed end plate.
Figures 5A to 5C are a sequence illustrating removal of a complete concrete product from the casdng apparatus.
Figure 5A is a cross-sectional end elevation showing a completed concrete panel in one ot the mould cavities.
Figure 5B shows a gantry crane connected to Lifting lugs of the panel.
Figure 5C shows the gantry crane lifting the panel out dirough the side of the casdng apparatus.
Detailed Description
The overall structure of the casting machine, according to a preferred embodiment, is best illustrated in Figure 1 . This provides an overview of the apparatus, but some details are not illustrated in Figure 1 . The omitted details include an overhead gantry crane for lifting a concrete supply above the casdng cavities or removing the completed concrete panels, and casting formwork which fits between the mobile panels and between the mobile panels and the end plates to define the edges of the moulding cavities.
The casdng apparatus includes a base structure 102. In pracdce, the base structure 102 is secured to the floor of a factory. The base structure 102 mcludes a series of rails. The base structure 102 may also include a floor panel, or floor panels, between the tracks. The rails and floor sUTJCture may be formed from any suitable material, steel being typical. A first end plate 104 is mobile relative to the base structure 102. The end plate 104 includes a surface 106 which forms part of a mould cavity in use. The end plate is supported on a carriage 108 which can roll on the tracks of the base structure 102. The carriage includes a substantial bracing structure 1 10 behind the face 106, supporting the face 106 across the width and height of the end plate 104. A weight 1 12 may rest on or be fitted to the carriage 108 to increase the mass of the carriage and stabilise the carriage against forces that may tend to tip the carriage backwards. The preferred carriage includes at least one abutment face 1 14, facing backward.
TypicaUy, the carriage and the bracing structure 1 10 may be formed from a framework of steel beams. The framework may be open or infilled with enclosing panels. The surface 106 may ¬ be a sheet of steel supported on a framework of beams connected to the carriage 108.
A second end 1 16 is preferably fixed to the base structure 102. The second end could be fixed to the floor of the factory and thereby fixed relative to the base structure 102. Alternatively, the second end could also be mobile, rolling on the tracks of base structure 102. The second end 1 16 preferably includes a moulding surface 1 18 and a bracing structure 120. The construction of bracing structure 120 and moulding surface 1 18 may be similar to the bracing structure 1 10 and mould surface 106 of the first end plate 104.
Either or both end plates could be constructed without an attached moulding surface 106. In that case they would act instead against a mobile moulding panel of a type described below. For the purpose of the present application, an end plate without a moulding surface and separate mould surface abutting the end plate is considered an end plate including a moulding surface.
Between the mobile end plate 104 and the fixed end plate 1 16 are one or more mobile moulding panels 122. Any number of mobile moulding panels may be provided. Preferably between four and ten mobile panels are provided.
Each mobile panel is able to move toward and away from the fixed end plate 1 16 and thereby away from or towards the mobile end plate 104.
Preferably, each panel includes a casting surface 124 on one side facing the mobile end plate 104 and a casting surface 126 on the other side facing fixed end plate 1 16.
Alternatively, but less preferably, some of the panels could include only one mould surface with this mould surfacing either the mobile end plate 104 or fixed end plate 1 16. In that case, two such panels would typically be arranged back to back and for the purpose of the present application, that pair of panels are considered to be a single panel. The basic structure of each panel 122 may include a steel sheet forming each face and a structure of beams between the steel sheets, maintaining each sheet as a flat plane against die pressure of concrete in the moulding cavity in use.
The mobile panels and the moulding surfaces of the mobile panels may be formed from other materials or in other ways, but the steel structure has an advantage of allowing magnetic connection of formwork components to the moulding surfaces.
The mobile panels and/or the end plate may incorporate internal vibrators for consolidating the paired concrete in use.
Referring to Figure 3, according to a particular aspect of the invention herein, each of the mobile panels 1 22 is supported adjacent one lower corner and an opposite upper corner.
Preferably at least one upper corner of each panel is not supported. Most preferably, the opposite lower corner is also not supported.
Each panel includes a top edge 303, a bottom edge 305 and a pair of end edges 307 and 309. One lower corner 31 1 of the panel is supported on a rail 308 of the base structure 102. The opposite upper corner 313 of the panel is supported on an elevated rail 3 1 5 which is above the level of the upper edge 303 of the panel.
The rail 31 5 may be supported on a suitable beam, which in turn may be supported by any suitable structure such as posts 140. At the lower corner 31 1 , a wheel 317 is rotatably connected to an end portion 319 of the panel. The end portion 319 may protrude beyond the side of the moulding face 124.
The wheel 317 may be either a plain wheel or gear and may be of any suitable material. Preferably, the wheel and the rail that it runs on include features to retain the wheel centrally on the rail as it rolls. For example, the illustrated wheel includes an annular or circumferential groove and the rail includes a protruding ridge that fits within the groove. In the case of a gear wheel, the rail would include a toothed truck, but can still include a locating ridge.
The other edge 309 of the panel includes a member that protrudes beyond the casting surface 124 and extends above the upper edge 303. The member could extend from a position within the area of casting surface 124 rather than from a position beyond edge 309. The member 321 extends as a cantilever from the panel, up to the height of die track 31 5 and is supported from a wheel 323 running on the track.
The wheel 323 may be a plain wheel or gear. The wheel, the track or both may include features so that the wheel stays engaged on the track. The illustrated wheel includes a circumferential groove and the illustrated track includes a ridge that fits inside die groove of die wheel. According to this aspect of the invention, which is further illustrated in Figures 5A to 5C, each mobile panel 122 is supported so that it is easily moved and is stable, yet one side of the machine is free from structures wliich inhibit removal of the concrete panel products.
Stability is enhanced by increasing the height of support of the upper corner 313. In particular, the rail 315 is preferably displaced a substantial distance above the upper edge 303 of the panel casting surface 124. The rail 315 is preferably more than 0.5metres above the upper edge 303 and most preferably more than 1 metre above the upper edge 303. This means that, even with the cast panel in place, the centre of mass of the mobile panel, and any cast concrete panel that is formed on the mobile panel remains below a line joining the wheels 317 and 323. This relationship is illustrated in Figure 5A with the typical centre of mass 502 being below the pivot line 504 of die mobile panel.
As can be seen in Figure 5B, after a panel has been cast and the moulds have been opened, the gantry crane 506 is positioned above the lifting points of the panel and connected to the lifting points by lifting cables 508.
The rails 510 of the gantry crane run substantially parallel to the plane of the panels and end plates of the machine. The mobile rail 512 of the gantry crane runs substantially
perpendicular to the plane of the mobile panels and end plates.
The gantry crane 506 takes up the weight of the panel 514. Either the gantry crane 506 is moved along the mobile rail 51 2, or the mobile casting panel is moved along the base structure, so that the concrete panel 514 separates from the mobile casting panel.
Referring to Figure 5C, the gantry crane then extracts the cast product 514 from the moulding area, dirough the side of the machine, unobstructed by any structure and without having to be sigruficandy lifted. The panel need only be lifted sufficiently that its weight is fully taken up by the gantry crane 506 before being separated from the mobile casting panel.
Another aspect ot the present invention is best illustrated with respect to Figures 4A and 4B wliich help to illustrate how the moulds of the present invention are brought together and secured for use.
In typical use, fences or formwork are assembled against the casting surface of second end plate 1 18 or against the surface 402 of the first mobile casting panel 404. The mobile panel 404 is dien brought towards the first end plate 1 16 so that the formwork or casting elements (not shown) are sandwiched between. The same procedure is applied sequentially in relation to the mould between the first mobile panel 404 and the second mobile panel 406, between die second mobile panel 406 and the diird mobile panel 408, between the durd mobile panel 408 and die fourth mobile panel 410 and between the fourth mobile panel 410 and the casting surface 106 of the first end plate. At each stage, the respective mobile casting panel or the mobile end plate are brought toward the fixed end plate 1 16 after assembling the relevant formwork. In the case of die mobile panels 404, 406, 408 and 410, these can be manhandled along their supporting rails. In the case of die mobile end plate 104, the carriage 108 is preferably equipped with one or more drive motors to rotate at least one wheel 420 and drive a carriage toward or away from die fixed end plate 1 16.
After assembling each of the vertical moulds, the initial drive of carriage 108 toward the second end plate 1 16 provides a first closing pressure to keep all of the mobile panels and their respective formwork pressed together. However, on its own, this pressure would not be sufficient once concrete is poured in the open tops of the mould cavities unless the drive motors were extremely strong and the carnage 108 extremely heavy. A more realistic structure is made sufficient by providing external pressure to the end plate 104.
In particular, according to an aspect of the present invention, pressure is brought to bear against the lower portion of the mobile end plate 104, toward the fixed end plate 1 16. Separately, pressure is brought to bear against the upper portion of mobile end plate 104 toward the tixed end plate 1 16. In each or both cases, the pressure may be provided by one or more linear actuators acting between the fixed structure and the mobile end plate 104. The linear actuators may be hydraulic or electric drive (for example). Typically the actuators are hydraulic rams.
In the case of the lower actuators, the actuator acts between the base structure 102 and the carriage 108 of the end plate 104. The preferred arrangement includes an actuator 430 associated with each rail 202 of die base structure 102. Each actuator 430 is pivotable between a first position in which it does not impede the positioning of the carriage 108 and a second position in which it lays adjacent the rail and projects toward the carriage 108 and the fixed end plate 1 16. Extension of the ram 430 in this position pushes an abutment plate 432 against the end surface 1 14 of the carriage 108. Tins presses the carriage toward the fixed end plate 1 16. By providing a ram 430 in relation to each rail 202, a plurality of rams apply pressure evenly across the width of the carriage 108.
At the upper end, pressure is also preferably provided by a plurality of Linear actuators These actuators preferably act between the upper edge of the end plate 104. In each case, the actuators preferably act between the bracing structures of the respective end plates.
In the case of the bracing structure 1 10 of the mobile end plate 1 14, a plurality ot brackets 436 are provided at spaced positions across the width of the structure. In the case of the bracing structure 120 of fixed end plate 1 16, brackets 438 are provided at spaced locations across the widdi of the structure 120.
Upper actuators 440 are preferably pivotally connected to one of these brackets, and most preferably to the brackets of fixed end plate 1 16. The Linear actuators can thus be positioned substantially vertically, outside the casting area, or horizontally to lie across the top of the casting area. The linear actuators 440 could be electric or hydraulic drive, but preferably the actuators are hydraulic rams.
In the case of either the upper or lower actuators, substantial actuator travel is not required as they are only required to take up any play in the assembled moulds after the carnage 108 initially pushes the moulds together, and thereafter to exert pressure to keep the moulds together. On the other hand, the closing system should allow for variation in the number of mould cavities in use and in the thickness of the panels being cast. Preferably some form of spacer or variable connection of the actuator to the fixed portion of the apparatus is provided.
For example, in the illustrated embodiment, the upper rams 440 are connected to a tension bar 442. In turn, the tension bar 442 is connected, in use, to the upper brackets 436 of the end plate 104. The tension bar 442 may be connected by a pin joint to the brackets 436, with the pin being removable to disconnect the bar 442 from the mobile end plate 104. The tension bar 442 may have a series of holes spaced along it to provide a macro adjustment, allowing the hydrauhc ram travel to be kept short.
At the lower end, the ram 430 may be secured to a carriage that itself moves along and is, for example, pinned to the rail. Alternatively spacer blocks may be provided between die pressure plate 432 and the back surface 1 14 of the carriage 108. It is preferred that the pressure plate 432 have a notch to fit over the peak of the preferred rail formation to keep the ram 430 aligned with the rail. The spacer blocks may have a similar groove to sit on the rail.
In the preferred apparatus, the casting surfaces of the end plates and mobile panels are sufficient to cast concrete panels up to three metres high and nine metres wide. As illustrated in Figure 2 and Figure 3, the base structure 102 includes a plurality of supporting rails 202. The carriage 108 of the mobile end plate preferably includes a pan- of wheels running on each of these rails. With a nine metre width, preferably up to four or more rails 202 are provided, spaced across die width of the machine. In the preferred embodiment, four lower rams 430 are provided and four rams 440 at the top. In total, eight rams are provided spaced around die perimeter of the end plate at approximately even intervals.
Accordingly to a further aspect of the invention, which is illustrated in Figure 5A, each of the mobile panels, and eidier or both of the end plates, are provided with a pivoting fence assembly to improve the ease of mould assembly. In particular, at each vertical edge of the mobile panel or end plate, a fence is attached to die edge at spaced apart hinges located along the edge outside the perimeter of the moulding surface. Dogleg bars that are secured to the fence extend to each hinge. The fence pivots about the hinges from a first location adjacent the moulding surface of the mobile panel or end plate, to a position outside the mould area. In the first position, the dogleg extends parallel to the mould before turning to meet the hinge. Tins pivoting fence assembly provides improved productivity by easing or preparing the moulding surfaces.
In practice, detailed formwork may be attached to the pivoting fences, or to the surfaces of the mould, or supported in the mould cavity from the floor of the base structure. The floor of the base structure and the mould surfaces are typically formed from steel so these formwork components can be secured magnetically in place. Once the mould closes, this securement will be enhanced by the closing pressure from the actuators. Preferably at least the perimeter formwork is provided with seals to reduce the leakage of concrete trom the mould cavities in use.
Retelling again to Figure 1 , according to a further aspect of the invention, the apparatus may include a second arrangement of mobile moulding panels and a second mobile end plate. In this arrangement, the fixed end plate 1 16 includes a second moulding surface effectively back to back with the first moulding surface 1 18. This essentially builds two independent vertical moulding complexes in the same overall apparatus. Each complex can be operated
independendy of the other.
The sequence of use for producing cast concrete products using the apparatus the present invention comprises three main sections, being: mould preparation and assembly; casting of the concrete product; and mould disassembly and removal of the concrete product.
The Inst sequence includes cleaning and preparing the mould surfaces of the mobile panels and end plates. The formwork is then assembled to the mould surfaces of the mould cavities, including pivoting in the pivoting fences if included, assembling edge profiles to the fences, assembling other formwork components to the mould surface. These ate preferably completed in sequence starting from the mould cavity adjacent the fixed end plate.
Formwork in the cavities can provide for forming surface textures or inlays, window and door openings, other apertures or channels. The formwork can also support reinforcing, and support services conduits in the mould cavity, such diat they will be encapsulated by and included in the concrete. This could include pre-tensioned reinforcing. For example, rein forcing spanning the widdi of the panel and passing through apertures in the formwork could be tensioned before casting by applying forces outside the mould cavities.
Once all of the mould cavities have been completed, the last mould cavity is completed by advancing the mobile end plate along the rails of the base structure to push the completed mould assemblies together and hold them in place.
The lower hydraulic rams are then pivoted into position against the rails and extended to abut the carriage of the mobile end plate. The upper rams are pivoted into position, and the tension bars are pinned to the upper end of the mobile end plate. The upper rams are then retracted to pull the upper end of die mobile end plate toward the fixed end plate. Once the initial assembly is complete the rams are extended or retracted to apply full pressure, on the mobile end plate toward the fixed end plate. The moulds are then ready for filling.
The mould cavities are filled with concrete through the open top edges. The concrete can be supplied from a hopper carried by the overhead gantry crane, or alternatively using a concrete pump through an articulated or flexible pipeline extending above the mould assemblies. The moulds or concrete may be vibrated to help consolidation, as required. Lifting eyes may be inserted after or during tilling of the mould cavities with the concrete, or the lifting eyes may be integrated with the reinforcing for the panels and extend clear of the top edge of the moulds. The top edge of the concrete is scieeded to remove any excess concrete and floated. With all the cavities filled, the concrete is allowed to remain in the assembled mould system to reach an initial cure. The amount of time for the initial cure depends on the concrete composition and strength requu'ed before the panel can be lifted and handled.
After the initial cure, the panels are removed from the mould by opening the mould assemblies in the reverse of the assembly process.
The upper rams are extended and the lower rams retracted. Upper ram tie rods are released from the upper edge of the mobile carriage. The lower rams are pivoted up away from die rails and out of the way of the mobile carriage. The concrete panel in the mould cavity adjacent the mobile end plate is secured to the gantry crane by its lifting eyes. Once the concrete panel is supported by the gantry, the mobile end plate is fully withdrawn and the gantry carries the panel out through the side of the mould. No more lifting is required then to fully support the weight of the panel. The gantry then returns and is secured to the lifting eyes of the next panel. That mould cavity is opened by separating the first mobile panel from the others. The panel is freed from the cavity and withdrawn through the side of the machine. The process is repeated until all of the panels have been extracted.
Any formwork attached to the panels, which can include formwork for creating edge profiles, windows and surface details, for example, is removed from the panels after they leave the mould. The panels are then stored for further curing.
Once the remaining formwork has been removed, or in die case of the pivoting fences, pivoted out of the way, die mould surfaces are ready for cleaning and next use.
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