EP0812252A1

EP0812252A1 - Process and device for producing longitudinal mouldings of a pourable material, especially foundation mats

Info

Publication number: EP0812252A1
Application number: EP96931719A
Authority: EP
Inventors: Willi Messerli; Armin Etter
Original assignee: FMG Verfahrenstechnik AG
Current assignee: FMG Verfahrenstechnik AG
Priority date: 1995-11-14
Filing date: 1996-10-07
Publication date: 1997-12-17
Also published as: WO1997018070A1

Abstract

The longitudinal mouldings are cast at a casting station (1) in parallel adjacent trough-like moulds. The mould support or the mould itself is an endless conveyor (3). The material is poured from a movable filler (4). After the moulding compound has hardened, the conveyor (3) is driven and the mouldings, possibly several dozen metres long, are taken directly to a cutting station (2) where they are divided into shorter sections. The use of an endless conveyor as the mould support or mould considerably simplifies the working process and obviates the need for expensive transport and demoulding processes.

Description

Method and device for producing elongated molded articles from a castable material, in particular lintel boards

The invention relates to a method for producing elongated molded articles from a castable material, in particular lintel boards, according to the preamble of claim 1. Such methods are already known as construction aids for the production of elongated load-bearing components.

A disadvantage of the known methods and devices is that, despite the low productivity, complicated systems and thus high investments are required. Accordingly, the production costs are also high. Changing production to different lengths or even to different cross-sectional shapes requires lengthy changeover work, which also does not meet today's requirements for flexible production and low storage.

It is therefore an object of the invention to provide a method of the type mentioned at the outset, with the aid of which moldings of different quality can be produced in a rational manner without complex systems. The process should also be able to be carried out without technically trained personnel, and finally the operational safety should also be improved. This object is achieved according to the invention with a method which has the features in claim 1.

The filling of the formwork and the hardening of the casting compound on an endless traction means make it possible to transport the molded body out of the casting station immediately after the hardening. Additional lifting and conveying means are thus unnecessary. The longer the traction device is formed, the longer the molded body can be produced in a single operation and then for Further processing can be carried out continuously or step by step from the casting station. It is particularly advantageous if the molded body is divided into shorter sections at a cutting station after the casting compound has hardened and if the molded body is transported to the cutting station with the traction means.

As with the methods known per se, reinforcement and / or prestressing elements can be positioned in the formwork before the formwork is filled. For example, at least one tension wire can be held under prestress in the formwork, the prestress being maintained until the pulling means is actuated.

The formwork is advantageously filled from a filling device which travels in the feed direction via the feed strand of the traction means. This ensures that the casting compound is evenly distributed over long distances. Productivity can be increased if several formworks arranged in parallel next to each other are filled and their content hardens at the same time.

As formwork, separate formwork sections can be placed on the feed strand of the traction means, which are connected by the hardened casting compound and which become part of the molded body. These formwork sections can, for example, be clay elements with a U-shaped or E-shaped cross-section, the opening always pointing upwards. The formwork sections are held laterally at least when pouring the casting compound, so that all formwork sections are aligned with one another. The bracket can be carried out, for example, via a laterally sprung rail which is pressed against the formwork sections from both sides.

The feed strand of the towing but can also be used as formwork itself, the molded body being released from the surface of the feed strand after the casting compound has hardened. The traction device practically takes on the function of an endless and pushable mold. The demolding takes place at the curvature between the feed strand and the return strand, whereby larger impurities are also thrown off at this point. Incidentally, this also applies when separate formwork sections are placed on the traction means. However, the traction means can also be cleaned and / or oiled on its return run so that it is prepared for the next casting process on the conveyor run. Formwork lengths of at least thirty meters are advantageously filled with casting compound on the traction means. For example, thirty lintel boards with a length of one meter can be produced in a single operation, this number being multiplied by the number of formworks lying next to one another in parallel. The formwork length and thus the length of the traction device can easily be several dozen meters.

The invention also relates to a device for producing elongated shaped articles from a castable material, in particular lintel boards, beams or the like, which has the features in the preamble and in the characterizing part of claim 13. The traction means is preferably a conveyor belt, in particular made of a flexible material such as e.g. Rubber, spring steel or the like. In certain cases, the traction means could also be a chain.

The conveyor belt is provided, at least over part of its total length, with at least two webs running in the conveying direction, which form the lateral formwork walls. This forms an elongated trough or trough of possibly several dozen meters, which can be filled with the casting compound. The webs can be at right angles or at an angle be arranged to the level of the conveyor belt, so that rectangular or trapezoidal shaped bodies are formed in cross section. Other cross-sectional shapes are of course also possible, and in extreme cases even undercuts are conceivable. However, a prerequisite is always sufficient elasticity of the webs to enable demolding in the area of curvature between the feed strand and the return strand.

The webs can also only extend approximately over the length of the conveyor belt, so that an approximately equally long section of the conveyor belt is designed as a flat belt. This arrangement has the advantage that different basic types of shaped bodies can be produced on the same band, namely those in which the formwork is formed by placed formwork sections and those in which the band itself forms the formwork. On the conveyor belt, however, a plurality of webs can also be easily arranged side by side in parallel, which form adjacent formwork of the same and / or different width. However, it is also conceivable for a plurality of endless traction means to be arranged parallel to one another, which can be driven separately. In this way, different cross-sectional shapes can be produced on the same system, only slight additional investments being required. The cutting station advantageously has a cutting table which adjoins the conveying run of the traction means and is arranged approximately on the same level and above which at least one adjustable and pushable milling head is arranged. The milling head can be arranged on a crane element which can be displaced transversely to the conveying direction of the traction means and which is simultaneously designed as a lifting and conveying means for the cut-to-length shaped bodies. The cutting table itself can also be displaceable in the same direction of movement, so that it can be attached to different traction means sections. The cut moldings can be removed from the cutting station without changing the relative position. The pre-tensioning of the shaped elements takes place particularly advantageously if holding devices for tensioning at least one tensioning wire are arranged in the formwork at the beginning and at the end of the feed strand, a permanent tension being transferable to the tensioning wire by means of a tensioning device. The holding devices are not connected to the traction means, so that the traction means can be set in motion after the tensioning wire has been separated from the holding devices.

The filling process can be carried out and automated particularly well if a filling device with a storage container and with a discharge device for the casting compound is arranged above the feed strand and can be displaced in the feed direction. However, it would also be conceivable to pump the casting compound out of a fixed tank into the formwork via flexible lines or the like.

Embodiments of the invention are shown in the drawings and are described in more detail below. Show it:

FIG. 1 shows a perspective illustration of an overall system for producing lintel boards,

FIG. 2 shows a plan view of a cutting station of an alternative exemplary embodiment,

FIG. 3 shows a side view of the cutting station according to FIG. 2,

FIG. 4 shows a top view of a filling device,

FIG. 5 shows a side view of the filling device according to FIG. 4, FIG. 6 is a view of the filling device according to FIG. 4 seen in the conveying direction,

FIG. 7 shows a top view of the wire feed at a casting station,

FIG. 8 shows a side view of the arrangement according to FIG. 7,

FIG. 9 shows a section of a sound crash board in a perspective view,

FIG. 10 shows a detail from a concrete lintel board in a perspective view,

FIG. 11 shows a side view of a traction means, and

FIG. 12 shows a cross section through the traction device according to FIG. 11.

In FIG. 1, a production plant is shown in a highly simplified manner, which essentially consists of a casting station 1 and a cutting station 2 which is connected to the casting station at the end. Lintel boards of various designs can be produced on the system, the formwork being cast on an endless traction means 3 from a filling device 4. On the casting station, overlong lintel boards are cast next to each other in several parallel rows, which are then cut to the desired length at the cutting station and discharged for removal.

To pre-stress the lintel, tensioning wires are inserted into the formwork before pouring with concrete and held there under tension. For this purpose, individual wire roll holders 5 are arranged in front of the traction means, from which wires 30 can be pulled off. After the front When the wires are inserted into the formwork, they are pulled off with the aid of a drive-over device 11 over the entire length of the traction means 3, anchored, and held under tension with the aid of a prestressing device 7 until the concrete mass has hardened.

The filling of the concrete mass into the formwork is carried out with the aid of the filling device 4. This is arranged on the drive-over device 11 so as to be displaceable, which in turn can be pushed forward on the crane tracks 8, 8 'in the direction of arrow a. The crane tracks laterally delimit a table frame 22 which at the same time carries the guide elements for the endless traction means 3.

The cutting station 2 adjoins the table frame 22 in the feed direction a. It has a transversely displaceable cutting table 9 which can be moved to individual sections of the traction means 3 and which takes over the individual shaped bodies after the casting and curing. Crane tracks 10, 10 'are arranged above the cutting table, on which a crane bridge 12 can be moved. A lifting device 14 is arranged on the crane bridge, with which the shaped bodies which have been cut can be transported from the cutting table 9 in the direction of arrow b to a roller conveyor 15. However, a plurality of milling heads 13 are also arranged on the lifting device 14, and their distance from one another can be adjusted. With these milling heads, the lintel boards lying on the cutting table 9 are divided into shorter sections by lowering and advancing the lifting device.

The cut-to-length lintel boards can be advanced in the direction of arrow c to a strapping machine 16 on the roller conveyor 15. There they are bound into packages and can then be transported by forklift. The individual functions of the entire system can be programmed or controlled on a control unit 17. To operate the whole The system requires little personnel, although no special technical knowledge is required.

Depending on the local conditions, the material flow could also continue in the conveying direction a of the traction device after being cut to length. Further transport in a vertical direction to another floor would also be conceivable.

Further details of the device result from an alternative exemplary embodiment, which is shown in FIGS. 2 to 8 and which differs from the exemplary embodiment according to FIG. 1 mainly by the construction of the cutting station 2.

According to FIGS. 2 and 3, the cutting station 2 only has a single crane running rail 21 which is attached to the booms 18, 18 '. Such a construction is sufficient if the length of the cutting table 9 does not exceed a certain dimension. The overall width of the endless traction means 3 is also smaller than in the exemplary embodiment according to FIG. 1. The cutting table 9 has approximately half the width of the traction means 3 and can therefore remove the lintel boards from the traction means 3 in two positions.

On the crane rail 21, a trolley 19 is attached, which carries the lifting device 14. Instead of a roller conveyor, a simple storage table 20 is used to accommodate the cut-down lintel boards. The construction of the cutting station 2 can also partially be seen in FIG. 6. Here, too, two milling heads 13 are arranged on the rear of the lifting device.

FIG. 3 also shows the course of the upper feed run 23 and the lower return run 24 of the endless traction means 3. In order to avoid sagging, in particular of the feed run 23, the table frame 22 is not here . " _Λ ""PCT / CH96 / 00351 O 97/18070

- 9 -

Support plates and support rollers shown in more detail. The traction means are driven by drive motors, not shown here.

A filling device 4 is shown in FIGS. 4 to 6. It can be displaced in the direction of arrow d on the drive-over device 11. The drive-over device is supported on both sides on the drives 25 and 25 ', the drive being effected via a drive motor with drive shafts on the wheels of the drives 25, 25'. In certain cases, the drive-over device 11 could also be pulled over side chains.

The filling device 4 is provided with a storage container 26 which can hold a certain amount of concrete. A filling funnel 27 is arranged on the side, wherein filling funnels with different outlet openings can be flanged as required. The concrete is discharged via one or more discharge screws 28. An operator can observe and control the filling process from a platform 29. The filling device is also provided with a vibrator, not shown here, which serves to compact the filled concrete mass in the formwork.

A total of four wire roll holders 5 are shown in FIGS. 7 and 8, from which a tensioning wire 30 can be pulled off. The pretensioning device 7 essentially consists of a hydraulic pressure medium cylinder with a continuously adjustable tensile load. The clamping force is transferred to the tensioning wire using collets not shown here. The relatively rigid tension wire 30 is introduced into the formwork using the drive-over device 11.

FIGS. 9 and 10 show two fundamentally different types of lintel boards. FIG. 9 shows a sound drop 31, which is composed of E-shaped sound elements 34 on the outside. stands. These clay elements are placed on a flat belt 35 and form the formwork for receiving the concrete mass 33, which connects the individual clay elements to one another after curing. The whole construction is prestressed with two tension wires 30. The tone elements 34 could also have a different cross-sectional shape if required.

FIG. 10 shows a concrete lintel 32 which consists exclusively of a prestressed concrete sleeper. The formwork is formed by the profile belt 36, which is provided with lateral webs 37. The concrete mass 33 is poured into the trough formed in this way and is also prestressed by two tensioning wires 30.

Details of such a profile belt are shown in Figures 11 and 12. The profile belt is stretched around the front roller 40 and the rear roller 41. A total of seven vertical webs 37 form six trough-like formworks which lie directly next to one another. In order to give the outermost webs 37 sufficient vertical stability, a band section 42 and 42 'remains in each case up to the outermost edge. The vertical webs 37 do not extend over the entire traction means 3, but only approximately over the length of the feed strand 23. A section of the traction means of approximately the same length is thus designed as a simple flat belt. As a result, lintel lintels 31 according to FIG. 9 and concrete lintels 32 according to FIG. 10 can be produced on the flat side with the same traction means.

Alternatively, the profile belt could also have an upper and a lower run with a different number and / or shape of the webs.

The illustration according to FIG. 11 shows the traction means just when turning for the preparation of a new production of Concrete lintels. When the hardened lintel boards are extended, they come out of the formwork in the area of curvature of the front roller 40. The band curvature also blows away concrete residues. Contaminants still adhering to the belt are removed via cleaning brushes 38. The surface of the belt is then oiled via spray nozzles 39 so that the falls can be detached from the belt more easily.

The device works as follows in the production of sound drops: the individual sound elements are lined up one behind the other and on the flat side of the traction means 3, the tape being able to be slowly advanced. To facilitate this process, a displaceable insertion platform can be arranged at the beginning of the belt in the area of the rear roller, from which the clay elements can be removed at the correct height. The maximum possible length that can be fitted with clay elements corresponds to the length of the feed strand 23. After the clay elements have been arranged, aligned and possibly laterally tensioned, the tensioning wires are drawn into each individual row of clay elements. The tensioning wires are then brought to the desired tension using the pretensioning device. Now the formwork formed by the clay elements is poured out with the aid of the filling device 4, several formworks being able to be filled simultaneously, depending on the type of filling funnel used. The filling device simultaneously scrapes and compactes the concrete mass on the surface.

After the formwork has been filled, the concrete mass hardens, usually overnight. If necessary, the hardening process can be accelerated by suitable means. The tension wires remain under tension during the entire curing time. After curing, the traction means 3 is set in motion, and depending on the construction of the device, only individual sections can be driven. The drive takes place until a partial length of the lintel boards lies on the cutting table 9. This is followed by cutting to length with the milling heads and removing the cut lintel boards. Then the traction device is set in motion again and the process is repeated until the entire cast length of the lintel boards has been discharged and cut to length.

When producing concrete lintels according to FIG. 10, there is no need to apply clay elements. The tensioning wires are drawn in and pre-tensioned directly into the profiled side of the traction means according to FIG. Then the procedure is exactly the same as for the production of the sound drops. The webs 37 of the profile belt are so elastic that they can follow the curvature on the deflecting rollers without suffering any damage.

Of course, the described method and the described device are not limited to the manufacture of lintel boards. According to the same principle, other elongated shaped bodies can also be produced from castable material, e.g. Concrete sleepers for railroad tracks, concrete piles for agriculture, insulation elements for building insulation, floor slabs and much more. In addition to the various types of concrete, wood cement, etc., plastics or pourable metals can also be used as pourable material. In certain cases, it would also be conceivable that the individual formworks already have transverse subdivisions, so that subsequent cutting to length at a cutting station is not necessary and the individual molded bodies are cast in the correct dimension.

Claims

claims

1. A method for producing elongated molded articles from a castable material, in particular lintel boards, in which at least one trough-like formwork at a casting station (1) is filled with a casting compound from above, characterized in that the filling of the formwork and the curing of the casting compound takes place on an endless traction means (3) and that the molded body is transported away from the casting station after the hardening with the traction means.

2. The method according to claim 1, characterized in that the shaped body after the hardening of the casting compound at a cutting station (2) is divided into shorter sections and that the molded body is transported to the cutting station with the traction means (3).

3. The method according to claim 1 or 2, characterized gekennzeich¬ net that reinforcing and / or prestressing elements are positioned in the formwork before filling the formwork.

4. The method according to claim 3, characterized in that at least one tension wire (30) is held under prestress in the formwork and that the prestress is maintained until the pulling means is actuated.

5. The method according to any one of claims 1 to 4, characterized in that the formwork is filled from a filling device (4) traveling in the feed direction via the feed strand (23) of the traction means (3).

6. The method according to any one of claims 1 to 5, characterized in that several formworks arranged in parallel next to each other are filled.

7. The method according to any one of claims 1 to 6, characterized in that separate formwork sections (34) are placed as formwork on the feed strand of the traction means, which are connected by the hardened casting compound (33) and which are part of the shaped body (31 ) become.

8. The method according to claim 7, characterized in that the formwork sections (34) are held laterally at least when filling the casting compound (33).

9. The method according to any one of claims 1 to 6, characterized in that the feed strand (23) of the Zugmit¬ means itself is used as formwork and that the molded body (32) after the curing of the casting compound (33) from the surface of the feed strand becomes.

10. The method according to any one of claims 1 to 9, characterized in that the traction means (3) on its Rück¬ return run (24) is cleaned and / or oiled.

11. The method according to any one of claims 1 to 10, characterized in that formwork lengths of at least thirty meters are filled with casting compound on the traction means (3).

12. Use of the surface of an endless and correspondingly profiled band (36) made of an elastic material as formwork for receiving a curable casting compound (33) for producing elongated shaped bodies.

13. Device for producing elongated molded articles from a castable material (33), in particular lintel boards, with at least one trough-like formwork, which can be filled with the casting compound at a casting station (1), characterized in that an endless traction means (3) is arranged at the casting station (1) as a supporting element for the formwork and can be driven to transport the molded bodies away.

14. The apparatus according to claim 13, characterized in that in addition to the casting station (1) a cutting station (2) for dividing the moldings after curing of the casting compound is arranged in shorter sections and that the cutting station connects to the Zugmit¬ tel in the conveying direction.

15. The apparatus of claim 13 or 14, characterized gekenn¬ characterized in that the traction means is a conveyor belt (35, 36).

16. The apparatus according to claim 15, characterized in that the conveyor belt is provided at least over part of its total length with at least two webs (37) running in the conveying direction, which form the lateral formwork walls.

17. The apparatus according to claim 16, characterized in that the webs only extend approximately over the length of the Förder¬ strand (23).

18. The apparatus according to claim 15 or 16, characterized gekenn¬ characterized in that a plurality of webs are arranged in parallel next to each other on the conveyor belt, which form adjacent formwork of the same and / or different width.

19. Device according to one of claims 15 to 18, characterized in that a plurality of endless traction means are arranged in parallel next to one another, which can be driven separately.

20. Device according to one of claims 13 to 19, characterized in that each traction means in the region of its return run (24) is provided with a cleaning device (38).

21. The device according to claim 14 and according to one of claims 15 to 20, characterized in that the cutting station (2) adjoins the conveyor run (23) of the traction means (3) and is approximately at the same level arranged cutting table (9), above which at least one adjustable and feedable milling head (13) is arranged.

22. The apparatus according to claim 21, characterized in that the milling head is arranged on a crane element which is displaceable transversely to the conveying direction of the traction means and which is simultaneously designed as a lifting and conveying means for the cut-to-length shaped bodies.

23. Device according to one of claims 13 to 22, characterized in that holding devices for tensioning at least one tensioning wire (30) are arranged in the formwork at the beginning and at the end of the conveyor section (23) and that by means of a tensioning device (7) permanent voltage is transferable to the tension wire.

24. Device according to one of claims 13 to 23, characterized in that above the conveyor strand (23) a displaceable in the feed direction filling device (4) with a storage container (26) and with a discharge device (27, 28) for the casting compound is.