DE102005031236B4 - Method and device for producing stone moldings for masonry blocks, in particular sand-lime bricks - Google Patents

Abstract

Process for producing stone moldings (50) for masonry blocks, in particular sand-lime bricks, in which
a) a forming die (2) having at least two mold cavities (20, 21, 22, 23), which differ in a cross-section or at least one dimension (d1, d2, d3, d4) perpendicular to a pressing direction (P) used becomes,
b) at least one first mold space (22) of the molding die is brought into at least one filling position (M) by adjusting the molding die in at least one adjustment direction (V) perpendicular to the pressing direction by means of an adjusting drive (16),
c) at least once raw material (10) in the at least one first mold space (22) in the at least one filling position is filled and by means of a first pair of mutually movable in a pressing direction press dies (32, 42) in the first mold space to at least a first brick mold (50) is pressed, and in which
d) then at least one second mold space (23) of the forming die by adjusting the forming die in the or at least one adjustment direction perpendicular to the ...

Description

The The invention relates to a method and an apparatus for manufacturing of stone moldings for masonry blocks, especially sand-lime bricks.

calcareous sandstone are submerged by pressing lime and sand in a press and then hardening Steam pressure produced.

DE 21 28 022 A1 discloses forming dies for producing Ganzstein- and half-brick blanks of artificial stone mass, in particular sand-lime brick in a molding box of a press, wherein the punch is divided into a punch body and a partial punch and the punch is releasably fixed to the punch body and the molding box. By separate, vertically mutually displaceable part punches the Formkasten- and stamp base can be either increased or decreased.

Out DE 22 64 247 A1 a method is known for the production of moldings for building blocks in a press, in which molding compound is used in a molding box, which is used in a horizontally movable table, filling material under a filling station and the filled molding compound pressed by the method of the table in a pressing station to form a molding becomes. A button continuously determines the height of the pressed and set moldings on a transport device and when exceeding tolerances is a stroke adjustment of the plunger in the pressing station and a pressure measuring device at under or exceeding the set pressure value in the pressing station, the filling of the molding box with molding compound in the filling station for the next molding in a corresponding manner increased or decreased.

DE 28 30 779 C2 discloses a hydraulic double pressure for sand-lime bricks with an upper, by means of a hydraulic drive cylinder vertically movable plunger, a stationary opposite this, stationary lower plunger and a vertically movably supported during a pressing operation by the friction of the molding compound on the mold wall downwardly entnehmbaren mold, the one through the press punches upper and lower side closable mold space for the molding compound with upper filling and lower bottom opening laterally limited and suspended at the lower ends of vertically filled piston rods of a group of hydraulic actuators, to actuate a hydraulic control circuit is provided. The hydraulic actuators are double-acting acted upon, located under the pressure piston cylinder chambers are connected to the control circuit and the control circuit includes a device that balances the weight of the mold during the pressing process and components supported by this and the mold alone from the friction with the Press mass specifies certain driving movement. The mold may also have a plurality of mold cavities for the simultaneous pressing of a plurality of moldings, wherein both the upper and the lower punch have a correspondingly adapted multiple formation.

DE 34 46 092 C2 discloses a method and apparatus for producing lime sandstone wall elements in which several lime sandstone moldings are made with a stone press and then joined together with mortar or adhesive to form a wall element and subsequently steam cured, wherein individual mold layers are stacked on a curing cart, thereby displacing Moldings with a smaller than whole stone length block assemblies are formed with all-round flat surfaces. To produce a molded article having a length smaller than the entire stone length, the molding space of the stone press is only partially filled and the molded article produced by the pressing process after removal from the mold and before insertion into a molding layer by 90 ° about an axis pointing in the direction of stone width turned.

Out DE 35 05 465 A1 is a method for producing a masonry block, in particular a sand-lime brick, using a stone press with a molding box for receiving the molding material and a movable into the molding box press plate for compressing the molding material known in which the pressure plate moves perpendicular to the height of the rock in its position of use becomes.

DE 195 35 790 A1 Finally, discloses blocks and a method for the production of blocks in a molding press, wherein the length of the individual blocks is thereby adapted individually that they are pressed in their length direction. The mold may be movable along the pressing direction thereby to follow the movement of the plunger or punches during the operation. The length of the compacts can be variably adjusted by adjusting the contents of the starting material in the mold.

Of the Invention is now the object of a method and a Apparatus for producing stone moldings for masonry blocks, in particular Sand-lime bricks, indicating where stone moldings or stones different dimensions can be produced.

This object is achieved according to the invention in terms of the method with the features of claims 1 and with respect to the device with the features of claim 9. Further refinements and developments of the method and the apparatus emerge from the dependent claim 1 or claim 9 dependent claims.

The Invention is based on the consideration, for Pressing of differently shaped stone moldings (or: stone compacts) a molding die or a molding tool (or: Press die or pressing tool) with differently designed mold cavities (or: press rooms) to use and by moving (or: translation, adjusting) the forming die by means of at least one adjusting a associated Shaping room for a desired one Stone molding to a filling position to bring there at least partially fill with raw material and then by means of two, generally in cross-section orthogonal to the pressing direction adapted to the mold space, press die in the mold space the ge wished To press stone molding. The shifting can be done by means of the adjusting drive automatic and very fast (quick tool adjustment), so no time consuming Tool change is required. Thus, for producing a given masonry needed Stones, in particular sand-lime bricks, of different sizes, in particular different wall thicknesses or dimensions such as heights, widths and / or lengths, with a mold and preferably by means of a predetermined Control system to be produced fully automated.

The The invention will be further explained below with reference to exemplary embodiments. there is also referred to the drawings, in whose

1 a device for pressing masonry blocks of different dimensions in a longitudinal section,

2 a part of the device according to 1 in a partially sectioned plan view of the mold,

3 the device according to 1 when filling a mold cavity of the mold in a longitudinal section,

4 the device according to 3 during pressing of the filling material in the associated mold space in a longitudinal section,

5 the device according to 3 and 4 when ejecting the pressed blank in a longitudinal section,

6 the device according to 1 with horizontally shifted form in a longitudinal section and

7 a part of the device according to 6 with shifted shape in a partially cutaway plan view,
are each shown schematically. Corresponding parts and sizes are in 1 to 7 provided with the same reference numerals.

The press or apparatus for pressing masonry blocks, in particular lime sandstones, according to 1 has an upper punch unit 3 and a lower punch unit 4 as well as a molding die 2 on.

An upper pestle 13 drives the upper punch unit 3 on and a lower pestle 14 the lower punch unit 4 , so that a linear movement of the punch units 3 and 4 relative to each other and away from each other in a vertical pressing direction P is possible.

The molding die 2 has four separate or spaced mold spaces 20 . 21 . 22 and 23 on, which have a rectangular cross-section with in a direction of displacement V different dimensions d1 of the mold space 20 , d2 of the shape space 21 , d3 of the mold space 22 and d4 of the mold space 23 , In the illustrated embodiment, d1 = 115 mm, d2 = 150 mm, d3 = 240 mm and d4 = 175 mm. Furthermore, the mold spaces 20 to 23 perpendicular to the displacement direction V, the same dimension a of, for example, a = 498 mm. In every form space 20 to 23 Thus, it is possible to press a preform with predetermined dimensions which differ from one another at least in the direction of displacement V.

The molding die 2 is over two arranged on opposite longitudinal sides linear guides, in particular guide rails, 11 and 12 in the direction of displacement V horizontally displaceable or movable. The displacement of the forming die 2 along the displacement direction V by means of an adjustment 16 that has a fastener 6 with the molding die 2 connected is.

The adjustment drive 16 and the connecting element 6 In particular, at least one, for example, telescopically extendable cylinder include. As a rule, a hydraulic drive or cylinder is provided. However, it is also possible to provide a pneumatic drive or even a drive with at least one electric drive motor and a mechanical transmission device such as a rack and pinion transmission. The adjustment drive 16 can drive stepwise or in discrete increments, or preferably continuously to any position.

The guides 11 and 12 are on a rack 5 attached to the device, on which also the plunger 13 and 14 are mounted vertically movable and guided with associated ram drives.

Each stamp unit 3 and 4 now has four press punches each 30 to 33 respectively. 40 to 43 on, the exact fit from above or from below in each one of the mold spaces 20 to 23 the molding die 2 can intervene in the pressing direction P. In the basic position according to 1 is the upper punch unit 3 still out of engagement of the molding die 2 and the lower punch unit 4 is arranged so that the lower press punches 40 to 43 each the form spaces 20 to 23 seal down, but not yet essential in the mold spaces 20 to 23 are moved in.

For additional guidance of the stamp unit 3 and 4 in the molding die 2 are additional upper guide elements 38 on the upper punch unit and lower guide elements 48 on the lower punch unit 4 provided, from the top and bottom in each case an associated guide space 28 in the molding die 2 intervention.

In contrast to known presses is the molding die 2 because of the linear horizontal guidance in the guides 11 and 12 not in the pressing direction P or vertically with the ram punch units 3 and 4 displaced.

At the of the hydraulic adjustment drive 16 and connecting element 6 opposite side is the forming die 2 from the guides 11 and 12 , generally after loosening of securing elements, removable to a tool change or a change of the forming die 2 to be able to make.

A press center or center plane or working plane of the apparatus is designated M and forms a filling position or working position for a respective molding space 20 to 23 the molding die 2 , In the area of the median plane M are on opposite sides of the forming die 2 on the one hand a Füllmaterialzuführeinrichtung (Füllschieber) 7 for feeding filler material or raw material, for lime sandstones in particular lime and sand, and on the opposite side a stone removal device 8th , For example, with a - not shown - gripping device and a transport device, in particular a conveyor belt provided to remove the finished pressed Steinformlinge and supply a hardening system or possibly previously a sawing or other separation plant.

In the basic position according to 1 and 2 is the shape space 22 the molding die 2 arranged in the median plane M. This form space 22 will now be in a filling step with filler 10 filled, with the punch 42 the lower punch unit 4 the shape space 22 seals down so that the filling material 10 can not fall down. Depending on the desired final dimension (c in 5 ) of the stone molding in the pressing direction P becomes the degree of filling or the filling height of the filling material 10 certainly. 3 shows the device after filling, here a complete filling with filler 10 of the form space 22 is provided.

Following the filling, a pressing process is now carried out in which the upper punch unit 3 and the lower punch unit 4 in the pressing direction P are moved towards each other, represented by the additional aligned arrows. Here are the punch 32 the upper punch unit 3 and the press stamp 42 the lower punch unit 4 , as in 4 shown in the form space 22 the molding die 2 moved in and compact or compress the filling material located there 10 , When the predetermined pressing pressure is reached, the stamps come 32 and 42 to a stop and the final final dimension of the raw material 10 now formed molding in the pressing direction P is reached. Parallel to the stamps 32 and 42 grab the stamps 30 . 31 and 33 respectively. 40 . 41 and 43 into the associated form spaces 20 . 21 and 23 , but they are empty, so there is no pressing of material. Furthermore, the upper guide elements engage 38 the upper punch unit 3 into the management rooms 28 while the lower guide elements 48 the lower punch unit still remain out of engagement.

5 now shows the ejection of the finished pressed stone molding 50 , The upper punch unit 3 has gone up again and the stamp 30 to 33 and guide elements 38 are disengaged from the forming die 2 Driven at a sufficient distance, leaving the compacted or compressed filling material 10 formed stone molding 50 with the help of the lower punch 42 the lower punch unit 4 up from the mold cavity 22 the molding die 2 is pushed out.

The stone molding 50 now has the transverse dimension d3 and the further transverse dimension a of the forming space 22 taken over and has the dimension c in the third coordinate direction or dimension in the pressing direction P. In the illustrated embodiment, the dimension c corresponds to the length of the masonry brick in the bricked state and may be, for example, c = 650 mm. Here, therefore, the pressing direction P is directed in the longitudinal direction of the stone. Likewise, however, the pressing direction P can also be in one of the other dimensions or dimensions, for example in the direction of d3 or b, of the shaped article 50 be directed, according to the stone height or stone width.

The guide elements 48 the lower punch unit 4 take action now 5 in the leadership rooms 28 the molding die 2 one. The finished stone molding 50 is now from the stone removal facility 8th (in 2 shown) from the molding die 2 removed and transported away for hardening and possibly for subsequent or previous sawing in special forms such as miter or bevels.

Now, in a next process step for the production of another stone molding with other dimensions, the molding die 2 and the stamp units 3 and 4 in the direction of displacement V shifted so far until a desired other shape space, in the example of 6 and 7 the shape space 23 , the molding die 2 comes to lie in the median plane M of the device. To the stamp units 3 and 4 by the same adjustment with the forming die 2 To be able to move or adjust in the displacement direction V are in the associated plungers 13 and 14 linear guides, in particular guide rails, 53 and 54 provided, which is a displacement of the stamp unit 3 or 4 relative to the plunger 13 respectively. 14 allow in the direction of displacement V.

In a preferred embodiment, first the upper punch unit 3 with their guiding elements 38 and the lower punch unit 4 with their guiding elements 48 each in the associated management rooms 28 the molding die 2 introduced or retracted and thus a positive connection between the forming die 2 and the two stamp units 3 and 4 generated in the direction of displacement V (not shown). Subsequently - not shown - securing or fixing such as hydraulic clamping devices for fixing or fixing the stamp units 3 and 4 at the respective leadership 53 respectively. 54 solved, allowing a displacement of the punch units 3 and 4 in their guides 53 and 54 is made.

Now the adjustment drive 16 with the connecting element 6 pressed and the molding die 2 in linear guides 11 and 12 - according to 6 and 7 each to the left - moves until the mold space 23 with the dimension d4 in the median plane M between the filler supply means 7 and the stone removal facility 8th is arranged. These move in the form of die 2 engaging stamp units 3 and 4 in their guides 53 and 54 synchronously or with the same adjustment path with the forming die 2 as a closed tool unit in the direction of displacement V with.

In general, the stamps used for pressing each 32 and 42 in 4 and 33 and 43 in 6 in the middle plane M and at the same time in the middle of the ram 13 and 14 arranged to achieve optimum power transmission and to generate no torque.

While in 3 to 5 a stone mold with the dimensions a = 498 mm, d3 = 240 mm and c = 650 mm is produced, can be used with the shifted forming die 2 according to 6 and 7 Now a stone molding with also a = 498 mm and c = 650 mm, but manufactured with the other dimension d4 = 175 mm in the third coordinate direction. The process with filling, pressing and ejecting happens analogous to the 3 to 6 , just in the form space 23 instead of the shape space 22 ,

For the production of stone moldings with the dimensions d1 and d2, the molding die 2 in contrast, in an analogous manner in the direction of displacement V according to 6 and 7 Move to the right until the respective shape space 20 or 21 to lie in the middle plane M.

For moving the stamp units 3 and 4 relative to their pestles 13 and 14 in the direction of displacement V can - not shown - separate drives, in particular hydraulic, electric or pneumatic drives, may be provided so that an engagement of the stamp units 3 and 4 into the molding die 2 when adjusting is not required.

In not shown embodiments may also in at least two adjustment directions, such as matrix-shaped, arranged mold cavities in the mold and a corresponding adjustability in the Adjustment directions and / or in several mold spaces or at several filling positions at the same time a filling and pressing are made. The guides for the stamp units and / or the molding die must In particular, then not be linear, but also other trajectories exhibit.

2

forming die

3

upper stamp unit

4

lower stamp unit

5

frame

6

connecting element

7

filling material supply

8th

removal device

10

filling material

11 12

guide

13

upper tappet

14

lower tappet

16

adjustment

20 21

cavity

22 23

cavity

30 31

upper stamp

32 33

upper stamp

38

upper guide element

40 41

lower stamp

42 43

lower stamp

48

lower guide element

50

Stone molding

53 54

guide

a, c

dimension

d1 d2

dimension

d3, d4

dimension

V

displacement direction

M

midplane

P

pressing direction

Claims (21)

Method for producing stone moldings ( 50 ) for masonry blocks, in particular sand-lime bricks, in which a) a forming die ( 2 ) with at least two mold spaces ( 20 . 21 . 22 . 23 ) which differ in a cross-section or in at least one dimension (d1, d2, d3, d4) perpendicular to a pressing direction (P), b) at least one first forming space ( 22 ) of the forming die by adjusting the forming die in at least one adjustment direction (V) perpendicular to the pressing direction by means of an adjusting drive ( 16 ) is brought into at least one filling position (M), c) at least once raw material ( 10 ) into the at least one first mold space ( 22 ) is filled in the at least one filling position and by means of a first pair of mutually movable in a pressing direction pressing punches ( 32 . 42 ) in the first mold space to at least a first stone molding ( 50 ) is pressed, and in the d) then at least a second mold space ( 23 ) of the forming die is brought into the at least one filling position by adjusting the forming die in the or at least one adjustment direction perpendicular to the pressing direction by means of the or a further adjusting drive and e) at least once raw material is filled in the at least one second forming space in the at least one filling position and by means of a second pair of press dies movable relative to one another in a pressing direction ( 33 . 43 ) is pressed in the second mold space to at least a second stone molding. The method of claim 1, wherein the one or in the at least one filling position moving mold cavity of the forming die associated pair of press dies also to the filling position is moved. Method according to Claim 1 or Claim 2, in which a) two stamp units which are movable relative to one another in the pressing direction ( 3 . 4 ) each having at least one, preferably a plurality, pressing die (s) are used, wherein each of a mold cavity of the forming die associated pair of press dies for pressing a block with a punch of the first punch unit and an associated punch of the second punch unit is formed, and b ) the punch units when adjusting the forming die are also adjusted in the same adjustment direction, to move the one or the moving in the at least one filling position mold space of the forming die associated pair of press dies also in the filling position. Method according to claim 3, wherein each punch unit is supported by an associated pusher ( 13 . 14 ) is driven in the pressing direction and on the associated plunger in an associated guide ( 53 . 54 ) Is mounted displaceably in the at least one adjustment. The method of claim 4, wherein each stamp unit in all or different positions in the or each adjustment direction at the guides by means of at least one releasable Fixing element is fixable and for adjusting each punch unit solved each fixing is and the stamp unit in the associated guide to the same adjustment how the forming die or its cavity is moved and then the Stamp unit in the new position reached again by means of at least one fixing element is fixed. Method according to one of claims 3 to 5, wherein at least one or both stamp unit (s) prior to adjustment with the forming die at least regarding the at least one adjustment direction are positively connected and together adjusted with the forming die in the at least one adjustment become. The method of claim 6, wherein the molding die and the form-fitting connected punch unit (s) together by means of the same adjusting drive be adjusted. Method according to one of claims 3 to 7, wherein at least one or both stamp unit (s) with an associated own or independent Adjusting drive is adjusted or become. Apparatus for producing stone moldings ( 50 ) for masonry blocks, in particular sand-lime bricks, with a) a forming die ( 2 ) with at least two mold spaces ( 20 . 21 . 22 . 23 ), wherein the at least two mold spaces differ in cross-section perpendicular to a pressing direction in at least one dimension (d1, d2, d3, d4), b) a filling device ( 7 ) with at least one predetermined filling position (M) for filling ever c) for each molding space of the molding die, in each case one associated pair of pressing dies movable relative to each other in a pressing direction (P) (c) at least one molding space of the molding die (c) 30 . 31 . 32 . 33 . 40 . 41 . 42 . 43 ), of which at least one ram is adapted in cross section perpendicular to the pressing direction to the cross section of the mold space perpendicular to the pressing direction and for pressing a stone molding ( 50 ) from the mold space located in the at least one filling position ( 22 ) filled raw material ( 10 ) can be moved into the molding space in the pressing direction, and with d) at least one adjusting drive ( 16 ) for adjusting the forming die in at least one adjustment direction perpendicular to the pressing direction such that each forming space of the forming die is movable into at least one predetermined filling position of the filling device. Apparatus according to claim 9 with two punch units which are movable relative to one another in the pressing direction ( 3 . 4 ) each having at least one, preferably a plurality of, pressing dies (s) ( 30 . 31 . 32 . 33 . 34 . 40 . 41 . 42 . 43 ), wherein each of a mold space of the forming die associated pair of press dies for pressing a molded block with a punch of a first punch unit and an associated punch of the second punch unit is formed. Apparatus according to claim 10, wherein the stamp units when adjusting the forming die also in the same adjustment and / or adjustable by the same adjustment, to the one or the placed in the at least one filling position molding space associated with the molding die Pair of press dies also in the same filling position bring to. Apparatus according to claim 10 or claim 11, wherein each stamp unit is mounted on an associated plunger ( 13 . 14 ) for driving the stamp unit axially to the pressing direction in an associated guide ( 53 . 54 ) Is mounted displaceably in the at least one adjustment. Apparatus according to claim 12, wherein each stamp unit in all or in different positions in the or each adjustment direction at the guides by means of at least one releasable Fixing element is fixable or fixed. Device according to one of claims 10 to 13, wherein at least one or both punch unit (s) are positively connected before adjustment with the forming die at least with respect to the at least one adjustment direction, in particular via the or in the associated mold cavity engaging press punches or at least one positively in at least one guide space ( 28 ) in the forming die engaging guide element ( 38 . 48 ) of the stamp unit (s), so that the stamp unit (s) are adjustable together with the forming die in the at least one adjustment direction. Device according to one of claims 9 to 14, wherein at least one adjusting drive via at least one connecting element ( 6 ) is coupled to the forming die. Device according to one of claims 9 to 15, wherein at least one or both stamp unit (s) with at least one associated one Adjustment drive over at least one connecting element is or are coupled. Device according to one of claims 9 to 16, wherein at least an adjusting drive comprises a hydraulic drive. Device according to one of claims 9 to 17, wherein at least an adjustment a telescopically extendable and retractable adjusting cylinder includes. Device according to one of claims 9 to 18 with in the at least one adjustment direction extending guides ( 11 ), in which the forming die is displaceably mounted and by means of the adjusting drive and / or by means of fixing elements at all or at different positions can be fixed. Device according to one of Claims 9 to 19, in which the molding die has at least one guide space ( 28 ) and each stamp unit each have a guide element ( 38 . 48 ) for each guide space of the forming die, wherein the cross sections of guide spaces and associated guide elements are adapted to each other perpendicular to the pressing direction. Device according to one of claims 9 to 20, wherein at the at least one filling position on one side of the molding die, the filling device ( 7 ) for filling the molding space of the molding die at the filling position and on the other side of the molding die a molding removal device ( 8th ) are arranged for removal of the finished pressed stone moldings or can be arranged.