Robots cut and saw concrete system floors at DycorePrint this page
Dycore Systeemvloeren has taken in use a completely automated and mechanised production plant at Lelystad, where ribs of floor elements are being produced in a very innovative way. With the integration of a number of robots, Valk Welding participated in this new production facility. The production procedure, the application of self-compacting concrete and the use of industrial robots in the production process is unique in Europe. Especially the robot that is cutting the floor elements to size at the end of the process is a striking thing.
The ribs of floor elements at Dycore are made in moulds of 20 meter length with pure foam elements (eps) as a base. Here, a robot with a filament cuts a conic form for the notches. This cutting robot is placed at the beginning of the production line and receives information about the position and form of the notches from a central computer system. Not one element is identical and each element receives a unique identification number, to ensure that during production the corresponding production information is carried out in the exact position. The cellular elements are stored in a gigantic automated warehouse, functioning as an intermediate buffer and brought to the production moulds on demand. In the moulds, the cellular elements are then provided with pre-stressed reinforcement and filled with shingle concrete; this completely computer controlled process ensures the correct dosage of concrete.
After the hardening process, each of the elements needs to be cut in the correct length. The robot integrated by Valk Welding, handles a hydraulic sawing unit (supplied by Lunze from Barneveld), with which the elements can be cut at right angles or with the mitre saw. The robot has a capacity of 200 kg. In order to protect the robot in the non-air-conditioned space against moisture, cold and dirt, it is provided with a protective cover, giving the robot its pet name 'Big Bird'.
After hardening, it is difficult to exactly position the heavy elements under the sawing unit. That is why the robot is provided directly with a camera under the sawing head, to register the start and end position and to ensure that the element is being cut in the correct position. The camera recognises the identification number with information about the correct cutting length from the central PC. Valk Welding has written custom-made software on a C++ level both for the integration of the cutting robot and the sawing robot in order to link the various partial controls to the company system of Dycore.
(Source: various professional magazines, March 2002)