English (UK) 
简体中文 What is the biggest headache of our precast component factory? Moulds can not be moved, concrete spilled all the way, maintenance kiln queue blocked into a dog - manual handling exhausting, the efficiency is not up! Today we will talk about how to useautomated conveying lineBring up capacity hard, save people and land and money! (table clapping)
🔧 I. Where is the traditional production line stuck? Three major pain points burn money and miss work
- Mould handling is labour intensiveA group of 5 tonne moulds is moved by forklift + 3 people, and it takes 2 hours a day just to move the moulds;
- Fabric accuracy is difficult to control: Manual trolley poured concrete, leakage rate exceeded 15%, rework and repair delayed the construction period;
- High idling rate of maintenance kilns: Moulds in and out by manual scheduling, the kiln space utilisation is less than 60%.
lesson learnt through blood and tearsAn underground tube sheet factory in Xi'an carried manual handling, the result of the monthly output of 3,000 pieces of top day - the introduction of roller conveyor line + intelligent scheduling, the production capacity directly soared to 4,500 pieces.Save $470,000 on equipment rental.
🚀 Second, the core of the conveyor line four-piece suite: the assembly line itself will "run errands"
As per the live configuration on page 1, these are the four key devices:
- Roller Conveyor: ∟50×6 angle steel skeleton, 600mm wide belt load-bearing 5 tonnes, the longest length of a single section of 15 metres (narrow plant can also be turned);
- Intelligent Lift TableHydraulic jacking + laser positioning, error ≤ 3mm, mould layer change like a lift;
- Corner Conveyor: Horizontal and vertical free switching, eliminating the need for manual reversing;
- Fabric Robot: Vacuum suction cup with load cell, concrete placing error is controlled within 1%.
💡Teacher's private trick: The height of the conveyor belt is pressed to 1.2 metres above the ground! Workers can overhaul by bending down, no need to climb the ladder for nothing.
🤖 Third, logistics scheduling triple linkage: let the moulds "identify their own way"
1. AGVs as movers
The AGV system at the Xicheng Railway prefabrication plant relies on magnetic stripe navigation to transport the hoop bars from the welding area to the tying table -One car for three strong labourers, 24 hours without shouting.
2. Laser alignment for anti-running
A roadside stone factory in Guangdong installed infrared sensors on both sides of the conveyor belt, the mould offset over 5mm automatic alarm ---Inferiority from 12% to 2%.
3. IoT platform governance
The Shenzhen-Shantou West Expressway project puts RFID chips on each mould, and a mobile phone scan will tell you:
- Which maintenance kiln should I enter;
- How long left to demould;
- Where to assemble next.
Kiln turnover pulled from 60% to 95%No longer afraid of moulds "blocking the door".
💰 IV. Costs to the boss: invest 2 million to make 5 million back!
| Cost items | Conventional production lines | automated production line | year |
|---|---|---|---|
| labour cost | 15 persons x 80,000 = 1.2 million | 3 persons x 100,000 = 300,000 | 900,000 |
| Concrete wastage | 15% x 2,000 square metres = $600,000 | 2% x 2,000 square metres = 80,000 | 520,000 |
| Loss of maintenance kiln vacancies | 40% x 500,000 = 200,000 | 5% x 500k = 25k | 175,000 |
| Equipment maintenance | Forklift maintenance 180,000 | Belt replacement 50,000 | 130,000 |
(Blackboard!)payback period: Based on data from the Xicheng Railway.Return on investment of $2 million in 9 months-- After all, it saves 15 workers and doubles capacity.
🛠️ V. Exclusive upgrade advice: don't copy! Learn these three tricks
1. Modular assembly is more flexible
Foshan PC board factory to the conveyor line into "blocks":
- Short distances are conveyed by rollers;
- Cross-shop relay with AGVs;
- Climbing section with additional chain traction.
Save $600,000 on factory remodellingThe old equipment will continue to be used as it is.
2. Kiln "layer feeding"
Refer to page 7 for maintenance kiln design:
- The lower level holds the short elements (cable channels/cover plates);
- Medium-sized boards in the centre stack;
- Top lifting T-beam.
Space utilisation from 60% to 85%The production has gone up and there is still no expansion of the land.
3. Putting "smart brains" into old threads
Qinghai Jianzha County Prefabrication Yard is the best - adding to the old production line:
- Infrared positioning sensors;
- Equipment operation monitoring probes;
- Central Dispatch Screen.
800,000 renovation costs in exchange for doubling production capacityThe cost of a new production line is $1.4 million less than a new production line.
📌Hardcore Data Town Hall: Average daily output of the automated high-speed line in Shenzhen-Shantou West16,000 componentsThe price is 5,15% over the manual 2,600 block surge - which is not an upgrade? It's simply a downgrade!
A final word of caution.: Conveyor lines are not as expensive as they are.Being able to disassemble and reorganise and understand data scheduling is more important than dropping money on high-end equipmentAfter all, our precast plant wants real concrete, not Cyber PPT! After all, let's precast, we want real concrete, not Cyber PPT!
