DE102009013457B4 - Method and device for producing stone moldings for masonry blocks, in particular sand-lime bricks - Google Patents

Abstract

Method for producing stone moldings (50) for masonry blocks, in particular sand-lime bricks, in which a) a molding die (2) having at least two mold cavities (20, 21, 22, 23) which is in a cross-section or at least one dimension (d1, d2, d3, d4) perpendicular to a pressing direction (P), is used, and for each mold cavity of the forming die there is provided an associated pair of press dies movable relative to each other in a pressing direction, b) a filling device (7) by means of a filling drive to a first forming space (22) the forming die (2) is moved, c) by this filling device (7) at least once raw material (10) in the at least first mold space (22) is filled and by means of a first pair of press dies (32, 42) in the first Forming space is pressed to at least a first brick mold (50), d) a removal device (8) by means of a removal drive to the first mold space (22) of the forming die (2) bew egt), e) the first shaped article (50) is removed from this removal device (8), and subsequently f) the filling device (7) or another filling device by means of or another filling drive to a second mold space (23) of the forming die (2) is moved, g) from this filling device (7) at least once raw material (10) in the second mold cavity (23) is filled and by means of a second pair of press dies (33, 43) in the second mold space to at least a second brick mold (50) is pressed, h) the or another removal direction (8) by means of or another removal drive to the second mold space (22) of the forming die (2) is moved and i) the second stone molding (50) of this removal device (8 ) is taken.

Description

The invention relates to a method and an apparatus for producing stone moldings for masonry blocks, in particular sand-lime bricks.

Sand-lime bricks are made by pressing lime and sand in a press and then hardening under steam pressure.

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 press 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, a 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 wall elements of lime-sandstone in which a plurality of sand-lime bricks 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 layers of precursor are stacked on a curing trolley, 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 press plate moves perpendicular to the height of the rock in its position of use becomes.

DE 195 35 790 A1 discloses building blocks and a method for producing building blocks in a molding press, wherein the length of the individual building blocks is individually adapted by being 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.

DE 10 2005 031 236 A1 implements the production of masonry blocks of different sizes using a forming die with forming spaces with different cross sections. Each mold space is associated with lower and upper press punches. A filling position is specified. An adjusting drive moves the forming die, as well as the associated upper and lower pressing dies, into the filling position in order to press a stone molding.

From the GB 267 948 A For example, a method and an apparatus for pressing block moldings are known in which a forming die having a plurality, for example three, forming spaces each having the same cross section and an associated pair of mutually movable press dies is provided. For producing wedge-shaped stone moldings, wedge-shaped molds are arranged on the upper side of the lower molding dies and on the underside of the upper molding dies facing one another, so that the two-sided wedge shape of the stone moldings is produced during pressing. The Form spaces are filled at the same time by means of a filling device and the moldings are also pressed simultaneously and then ejected simultaneously by means of the lower mold punches again. The filling device or removal device is not displaced in the direction of individual mold spaces.

The GB 254 436 A also discloses a method and apparatus for pressing stone moldings. Here, four mold spaces arranged in a 2 × 2 matrix are provided, to each of which a mold pair is again assigned. The first pair of mold spaces is used for a first pressing operation (compressing) and the second pair of mold spaces for a second pressing process (repressing). The four upper mold punches for all four mold spaces are interconnected and moved with the same drive (crosshead). Of the lower four dies, only the forming dies intended for the first pressing operation are always moved by the lower drive, while the two lower forming dies provided for the second pressing operation are also carried by two support beams of the upper drive during another part of the pressing operation. The mold spaces each have the same cross section. Again, no displacement of the filling or removal device is provided in the direction of individual mold spaces.

The invention is based on the object of specifying a method and an apparatus for producing stone moldings for masonry blocks, in particular sand-lime bricks, in which stone moldings or stones of different dimensions can be produced quickly and reliably.

This object is achieved according to the invention in terms of the method with the features of claim 1 and with respect to the device with the features of claim 12. Further refinements and developments of the method and the device will become apparent from the claim 1 and claim 12 respectively dependent claims ,

The invention is based on the idea of implementing a quick changeover to another mold space on the basis of a fixed mold die and a movable filling and removal device. The position of the ram to the associated mold cavities is not affected here, so that the risk of malposition of this is not given.

For pressing differently sized rock moldings (or stone compacts), a molding die or a molding tool (or: press die or pressing tool) with differently shaped mold spaces (or: press cavities) is used and by moving (or: translation, adjustment) of the filling means At least one adjusting drive, the filling device is brought to an associated mold space for a desired stone molding, then the mold cavity is at least partially filled with raw material and then pressed by means of two, generally in cross-section orthogonal to the pressing direction adapted to the mold space, press die in the mold space of the desired stone molding , Subsequently, the stone molding is removed by means of a removal device which has been moved by displacement by means of at least one adjusting drive to the desired mold space. The displacement can be done automatically and very quickly by means of the adjustment drive. There is no time-consuming tool change required for different stone sizes. Thus, for the production of a predetermined masonry required stones, in particular sand-lime bricks, different format, in particular different wall thicknesses or dimensions such as heights, widths and / or lengths can be made fully automated with a mold and preferably by means of a predetermined control system for filling and removal device.

The filling device can be mounted in front of or behind the stone press. Thus, it is located on one side of the forming die, from which, viewed from the mold spaces are arranged side by side. The filling device moves along this side in the direction of adjustment to the desired shape space. To fill this, the filling device moves over the forming die and this forming space. It is also possible to move the filling device by means of a non-linear movement over the desired forming space.

Furthermore, it is possible to attach the filling device next to the stone press. This is on the side of the forming die, from which, viewed from the mold spaces are arranged one behind the other. In this case, the filling device is moved with a rectilinear horizontal movement in the adjustment direction over the desired mold space.

Preferably, a filling device can fill a plurality of different mold spaces by each being driven over the desired mold space. This allows a flexible control of the filling device. However, it is also possible to install a filling device for particular mold spaces and to install further filling devices for further mold spaces or even to provide a separate filling device for each mold space. This is especially advantageous if different raw material for certain sizes to be used.

Furthermore, the removal device, as well as the filling device in front of or behind the stone press, can also be installed and operated as described above. But it is also possible as in the filling device to install the removal device next to the stone press.

Preferably, the sampling device may be assigned to a plurality of different shape spaces, i. H. she can remove stone moldings of different sizes from different locations of the molding die. Again, this facilitates the control, since only one device must be operated. However, it is also possible to provide individual removal devices for a particular mold space or even for each mold space an associated removal device.

Preferably, the filling device and the removal device are moved before the pressing process to the mold space to be filled in the direction of displacement. For example, the removal device is located in front of the stone press and the filling device behind the stone press. In this arrangement, the filling of the mold space, pressing and subsequent removal of the stone molding can be done quickly and accurately. This sequence and structure is advantageous, above all, when a change of shape space is relatively rare.

Furthermore, it is also possible that the removal device is moved after the pressing process from its initial position to the mold space in the direction of displacement to remove the stone molding.

The adjusting drive may in particular comprise at least one, for example telescopically extendable, cylinder. 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 can drive stepwise or in discrete increments, or preferably continuously to any position.

Preferably, at least one removal device has a gripper to allow a flexible and secure removal by gripping the stone moldings.

The invention will be explained below with reference to exemplary embodiments. Reference is also made 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 a part of the device according to 1 in a partially sectioned plan view of the mold, in an alternative embodiment too 2
are each shown schematically. Corresponding parts and sizes are in 1 to 6 provided with the same reference numerals.

The press or apparatus for pressing masonry blocks, in particular lime sandstones, according to 1 and 2 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 filling device 7 and the withdrawal facility 8th are horizontally displaceable or movable along the direction of displacement V. The displacement of the filling device 7 and the removal device 8th along the displacement direction V by means of an adjusting drive, not shown.

On a rack 5 the device are the plungers 13 and 14 with associated plunger drives mounted vertically movable and guided.

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 not in the pressing direction P or vertically with the ram punch units 3 and 4 displaced.

The molding die 2 is 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.

On opposite sides of the molding die 2 on the one hand a filling device (filling slide) 7 for feeding filler material or raw material, for lime sandstones in particular lime and sand, and on the opposite side of a 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. By one or in each case an adjusting drive, not shown, the filling device 7 and the withdrawal facility 8th moved to the respective desired shape space.

In the basic position according to 1 and 2 is the shape space 22 the molding die 2 selected. The filling device 7 is by means of an adjustment to the mold space 22 emotional. 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 in the leadership 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 stone removal device 8th (in 2 shown) is, if not already done, by an adjustment to the mold space 22 of the stone molding to be removed 50 emotional. The finished stone molding 50 is now from the stone removal facility 8th 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.

In a further method step for the production of a further block molding with other dimensions, the filling device 7 along 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 can be filled.

In a preferred embodiment, the filling device 7 and the withdrawal facility 8th brought before the pressing process by means of an adjustment along the direction of displacement V in a position to the selected mold space.

While in 3 to 5 a stone molding with the dimensions a = 498 mm, d3 = 240 mm and c = 650 mm is produced, can with the displaced filling unit 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 5 , just in the form space 23 instead of the shape space 22 ,

An alternative embodiment of the removal device 8th is in 6 shown. The removal device 8th is next to the molding die 2 arranged. The filling of the mold space 22 and the pressing takes place as already described. The removal device 8th meanwhile stays in their original position. After the pressing process, the removal device 8th via an adjusting drive in the direction V to the pressed stone molding 50 emotional. This is taken by moving back along the direction of displacement V.

LIST OF REFERENCE NUMBERS

2

forming die

3

upper punch unit

4

lower punch unit

5

frame

7

filling device

8th

removal device

10

filling material

13

upper plunger

14

lower plunger

20, 21

cavity

22, 23

cavity

28

guide space

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

a, c

dimension

d1, d2

dimension

d3, d4

dimension

V

displacement direction

P

pressing direction

Claims (23)

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) is used, and for each molding space of the forming die, an associated pair of pressing punches movable toward each other in a pressing direction is provided , b) a filling device ( 7 ) by means of a filling drive to a first mold space ( 22 ) of the molding die ( 2 ), c) from this filling device ( 7 ) at least once raw material ( 10 ) into the at least first shape space ( 22 ) and by means of a first pair of press dies ( 32 . 42 ) in the first mold space to at least a first stone molding ( 50 ) is pressed, d) a removal device ( 8th ) by means of a removal drive to the first mold space ( 22 ) of the molding die ( 2 ), e) the first block ( 50 ) from this sampling facility ( 8th ) and in which subsequently f) the filling device ( 7 ) or a further filling device by means of or a further filling drive to a second mold space ( 23 ) of the molding die ( 2 ), g) from this filling device ( 7 ) at least once raw material ( 10 ) into the second cavity ( 23 ) and by means of a second pair of press dies ( 33 . 43 ) in the second mold space to at least one second stone molding ( 50 ) is pressed, h) the or another removal direction ( 8th ) by means of or another removal drive to the second mold space ( 22 ) of the molding die ( 2 ) is moved and i) the second stone molding ( 50 ) from this sampling facility ( 8th ) is taken. Method according to Claim 1, in which at least one filling device ( 7 ) on one side of the molding die ( 2 ), from which the mold spaces ( 20 . 21 . 22 . 23 ) are arranged side by side, is arranged and in a horizontal displacement along the mold spaces ( 20 . 21 . 22 . 23 ), which is assigned to the mold cavity to be filled and in a 90 ° rotated horizontal movement over the forming die ( 2 ) is brought into a filling position. Method according to Claim 1, in which at least one filling device ( 7 ) on one side of the molding die ( 2 ), from which the mold spaces ( 20 . 21 . 22 . 23 ) are arranged one behind the other, is arranged and in a horizontal displacement over the forming die ( 2 ), is placed over the filling space to be filled and in filling position. Method according to one of claims 1 to 3, wherein a filling device ( 7 ) can be assigned to at least two different mold spaces to be filled. Method according to one of claims 1 to 3, wherein each filling space on the basis of a filling device associated with this filling ( 7 ) can be filled. Method according to one of the preceding claims, in which at least one removal device ( 8th ) on one side of the molding die ( 2 ), from which the mold spaces ( 20 . 21 . 22 . 23 ) are arranged side by side, is arranged and in a horizontal displacement along the mold spaces ( 20 . 21 . 22 . 23 ), the mold cavity with the stone molding ( 50 ) and in a 90 ° horizontal movement across the forming die ( 2 ) to the stone molding ( 50 ) is moved and removes this. Method according to one of the preceding claims, in which at least one removal device ( 8th ) on one side of the molding die ( 2 ), from which the mold spaces ( 20 . 21 . 22 . 23 ) are arranged one behind the other, is arranged and in a vertical displacement over the forming die ( 2 ) to the mold cavity with the stone molding ( 50 ) and the stone molding ( 50 ) removes. Method according to one of the preceding claims, in which a removal device ( 8th ) can be assigned to at least two different shape spaces. Method according to one of the preceding claims, in which the stone moldings ( 50 ) of a mold space by means of a removal device ( 8th ) can be removed. Method according to Claims 2 and 6, in which the filling device ( 7 ) and the withdrawal facility ( 8th ) are assigned to the mold space to be filled before the pressing process. Method according to one of the preceding claims, in which the removal device ( 7 ) after the pressing process the mold cavity with the stone molding ( 50 ). Apparatus for producing stone moldings ( 50 ) for masonry blocks, in particular sand-lime bricks, in particular for carrying out a method according to one of the preceding claims, 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) at least one filling device ( 7 ) for filling in each case at least one mold space ( 20 . 21 . 22 . 23 ) of the molding die ( 2 ) with raw material ( 10 ), c) for each shape space ( 20 . 21 . 22 . 23 ) of the molding die ( 2 ) in each case an associated pair of pressing dies movable relative to one another in a pressing direction (P), of which at least one pressing die is adapted in cross-section perpendicular to the pressing direction to the cross-section of the forming space and for pressing a shaped article ( 50 ) on the raw material filled in the mold space ( 10 ) can be moved into the molding space in the pressing direction, d) at least one removal device ( 8th ) for removing at least each of the in a mold space ( 20 . 21 . 22 . 23 ) pressed stone molding ( 50 ), and e) at least one adjusting drive for adjusting the filling device ( 7 ) and / or the removal device ( 8th ) such that the filling device ( 7 ) moved to the filling space to be filled or that the removal device ( 8th ) moved to the filling space with the stone molding to be removed and then moved away with the stone molding. Apparatus according to claim 12, with at least one filling device ( 7 ) on one side of the molding die ( 2 ), from which the considered Form spaces ( 20 . 21 . 22 . 23 ) are arranged side by side. Apparatus according to claim 12, with at least one filling device ( 7 ) on one side of the molding die ( 2 ), from which the mold spaces ( 20 . 21 . 22 . 23 ) are arranged one behind the other. Device according to one of claims 12 to 14, with a filling device ( 7 ) for at least two different mold spaces to be filled. Device according to one of claims 12 to 14, with for each mold space ( 20 . 21 . 22 . 23 ) each one filling device ( 7 ). Device according to one of claims 12 to 16, with at least one removal device ( 8th ) on one side of the molding die ( 2 ), from which the mold spaces ( 20 . 21 . 22 . 23 ) are arranged side by side. Device according to one of claims 12 to 16, with at least one removal device ( 8th ) on one side of the molding die ( 2 ), from which the mold spaces ( 20 . 21 . 22 . 23 ) are arranged one behind the other. Device according to one of claims 12 to 18, with a removal device ( 8th ) for stone moldings ( 50 ), from at least two different form spaces. Device according to one of claims 12 to 18, each with a removal device ( 8th ) for stone moldings ( 50 ) of a mold space. Device according to one of claims 12 to 20, with an adjustment, which takes place pneumatically, hydraulically or mechanically. Device according to one of claims 12 to 21, with at least one adjusting drive comprising at least one telescopically extendable and retractable adjusting cylinder. Device according to one of claims 12 to 22, with at least one removal device having a gripper.

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