EP3334577B1 - Device for producing solid and hollow gypsum wallboard elements in quick succession - Google Patents

Description

Device for the production of solid and hollow plaster components in quick alternation.

The invention relates to a device for the production of solid and hollow plaster components.

Gypsum blocks are construction elements made of solid plaster of paris for the production of non-load-bearing inner partitions, shaft walls, facing shells or support cladding in the interior.

The walls are erected with plaster glue without a substructure. Because of this fundamental difference, gypsum blocks should not be confused with the thinner gypsum plasterboards that are used as planking for stud walls.

The prior art on the subject of gypsum blocks is from the patent literature, among other things, the document DE-A-1162252 known. It relates to a chrome-plated chamber wall for casting molds in plaster molding machines for the production of plasterboard.

More recently, the prior art is on the printed matter DE-T2-697 11 644 referenced. This document relates to a method for producing thin plates from a castable material, in particular gypsum, a device for carrying out the method and a product made therewith.

In this case, the starting point is a method for producing thin plates from a castable material, in particular plaster of paris, which sets with expansion during the molding process and solidifies in the mold spaces of a molding chamber.

1. 1. Aufnehmen des gegossenen Werkstoffs in einem der Formung entsprechenden Volumen der Formräume in der Formkammer,
2. 2. Rütteln des in der Formkammer gegossenen Werkstoffs in der Weise, dass die darin enthaltene Luft daraus entweicht und dabei die Einfüllhöhe vollständig gut verteilt wird,
3. 3. Formen der Formräume im Inneren der Formkammer,
4. 4. Erfassen der Formkammer, damit diese der Abbindung und Verfestigung der Formplatten während der Dauer des Formvorgangs ohne Verformung widerstehen kann, beispielsweise mit Hilfe eines starren Außenrahmens, der um die Formkammer verschoben wird,
5. 5. Lösen der Einfassung der Formkammer nach dem Formen in der Weise, dass der Druck auf die Formräume, der beim Formen des Werkstoffs herrscht, gelöst wird, und
6. 6. Herausnehmen der Formräume und des geformten Werkstoffs zur weiteren Bearbeitung.

In order to prevent material from accumulating at the opening of the mold or, when using material with glass fibers, the air contained in the mixture in question can only be removed with difficulty, claim 1 claims a method which includes the following steps :

1. 1. Receiving the cast material in a volume of the mold spaces in the mold chamber that corresponds to the molding,
2. 2. Vibrating the material cast in the molding chamber in such a way that the air contained in it escapes and the filling level is completely well distributed,
3. 3. Shaping the mold spaces inside the mold chamber,
4. 4. Grasping the mold chamber so that it can withstand the setting and solidification of the mold plates during the molding process without deformation, for example with the aid of a rigid outer frame that is moved around the mold chamber,
5. 5. Releasing the enclosure of the molding chamber after molding in such a way that the pressure on the molding spaces that prevails during molding of the material is released, and
6. 6. Removal of the mold spaces and the shaped material for further processing.

From the pamphlet WO-A1-01 / 08859 a device for producing solid and hollow blocks is known, "replacing" a closed wear plate by an open wear plate enables the production of solid blocks and hollow blocks with a system.

From the pamphlet US-A-3178791 a conventional device for producing bricks from ceramic materials is known, the ceramic material being fed from a silo onto a scale and from there being fed to a mixer and mixed with water.

From the pamphlet US-A-1481159 Another conventional device for the production of plastic building blocks is known, wherein a plurality of different molding boxes are arranged on a turntable. The molding boxes can be filled as well as the surface smoothed and tongue and groove structures can be generated by means of planing traverses.

Furthermore, from the publication DE-U1-29520788 a device for the production of concrete blocks and in particular hollow blocks is known, with recesses can also be made on the outer sides of the block.

Furthermore, from the publication EP-A1-0294508 a device for the production of exactly dimensionally stable gypsum components is known, with tongue and groove structures being formed on the end faces of the gypsum boards and all walls delimiting the molding chambers being hard chrome-plated and highly polished on their respective facing sides.

From the pamphlet US-A-3995068 a method for producing cast components is known, wherein the casting mold consists of a synthetic polymer or is coated with a synthetic polymer.

Finally it is from the pamphlet DE-A1-19955347 a device for exchanging a molding box for a concrete block casting machine is known, a molding box feed line and a feed path area arranged orthogonally thereto facilitate the replacement of molding boxes and the feeding of the molding boxes under the casting machine.

The object of the present invention is to create a device with which the production of plaster of paris construction elements can be carried out faster and more safely while maintaining consistently high quality, with a quick change between the production of solid and hollow construction elements being possible.

According to the invention, this object is achieved by the features of claim 1.

Further advantageous embodiments of the invention are characterized in the subclaims.

Fig.1:

eine erfindungsgemäße Anlage in der Draufsicht,

Fig.2:

eine perspektivische Ansicht einer hohlen Gipswandbauplatte,

Fig.3:

eine perspektivische Teilansicht eines Formkastens 3 mit Hohlplatteneinsätzen,

Fig.4:

eine Draufsicht auf einen Formkasten mit Hohlräumen,

Fig.5:

eine Schnittdarstellung eines Formkastens mit Antriebszylindern,

Fig.6:

eine Serie von Schnittansichten der Herstellung massiver Platten,

Fig.7:

eine Serie von Schnittansichten der Herstellung hohler Platten,

Fig.8:

eine Draufsicht einer Dreheinrichtung 26 eines Doppel-Formkastens,

Fig.9:

eine Draufsicht auf einen Verschiebe-Bahnhof für Formkästen,

The device according to the invention is described in more detail below. They show in detail:

Fig. 1:

a system according to the invention in plan view,

Fig. 2:

a perspective view of a hollow plasterboard,

Fig. 3:

a perspective partial view of a molding box 3 with hollow sheet inserts,

Fig. 4:

a top view of a molding box with cavities,

Fig. 5:

a sectional view of a molding box with drive cylinders,

Fig. 6:

a series of sectional views of the manufacture of solid panels,

Fig. 7:

a series of sectional views of the manufacture of hollow panels,

Fig. 8:

a plan view of a rotating device 26 of a double molding box,

Fig. 9:

a top view of a shifting station for molding boxes,

Fig. 1 : shows a system according to the invention in plan view.

The central element in the plan view of the plant shown is the molding box 3 in the middle on the right-hand side of the Fig. 1 . Here, a molding box 3, which essentially serves to produce the plaster components, is shown from above.

In the Fig. 3 this molding box 3 can be seen in a perspective partial view. Left
and on the right on the sides of the molding box 3, two elongated crane tracks 1 can be seen which are used to move panel grippers that transport the transportable gypsum components from the area of the molding box 3 to the area of the transport carriage 2, with which they are transported to the dryer, for example. A screw conveyor 5 is used to supply the molding box 3 with the base material gypsum, which transports gypsum from a silo 6 indirectly via a gypsum scale 32 with another screw conveyor to a gypsum mixer 4, where this gypsum is mixed with water from a water tank 7 to form gypsum slurry. The molding box 3 is supplied with energy by means of the energy supply and process control unit 8 and receives its production impulses here. The hydraulic unit 9 supplies the operating pressure required for the process. In the area of the dryer 10, the panels, which are still moist after the production process, are dried down to the desired moisture content.

Fig. 2 : shows an example of a perspective view of a hollow gypsum wall panel as a wall component 13. Such a panel equipped with profile elements can be used as an independent wall component, since several panels can be non-positively connected to one another. The side surfaces of such a wall component 13 are usually treated further as visible surfaces 12. These wall elements can be designed as solid material or, as in the Fig. 2 shown, be provided with cavities 11. In addition to the round shape shown, the hollow cores can have a rectangular or oval cross-section.

Fig. 3 : shows a perspective partial view of a molding box 3 with hollow sheet inserts. The base supports 14, of which the left and the middle are designated, serve as the foundation of such a molding box 3. As also from the Fig. 4 As can be seen, the molding box 3 consists of numerous molding chambers 19 lying next to one another, each of which replicates the external dimensions of a plaster of paris construction element. The gypsum paste, which after drying will form the later gypsum building elements, is poured into these molding chambers 19 from above. The cavity pins 17 necessary for the production of cavity plates are designated on a molding chamber 19 arranged on the left-hand side of the molding box shown. Since the top of the gypsum building elements produced to achieve a A defined structured surface has to be processed and excess gypsum paste has to be cleaned, a planing crossbeam 20 is provided which sweeps over the mold chambers 19 arranged in parallel.

As from the Fig. 2 To see, the planing cross member 20 can have a certain defined profile shape for this purpose, which the negative leaves behind after the planing of the respective finished plaster construction element , Guide units 18. Since the plaster of paris construction elements have to be conveyed vertically upwards from the molding chambers for further processing after a certain setting time, an ejector 16 is provided for each molding chamber 19, with a total of two, parallel arranged crossbars 15 are operated. The entire drive of the device for ejecting the gypsum components takes place by means of drive cylinders 22 which apply the lifting energy required for this via the cross member 15. When producing cavity plates and the cavities required for this purpose, the drive cylinders 21 come into action before the molding chambers 19 are filled with gypsum paste by pushing the cavity pins 17 vertically upwards into the molding chambers.

Deviating from the standard EN 12859, the molding boxes can have dimensions that enable the production of gypsum building elements in special geometric dimensions (thickness, length, width) and shapes, with and without profiles.

the Fig. 4 Figure 11 shows a plan view of a molding box with a plurality of cavities. Here, the guide units 18 for the planing traverse 20 can be seen on the left and right sides of the molding box shown transversely. The individual molding chambers 19 are clearly shown, the profile webs 23 being specifically designated on the two end faces in the molding chamber on the left-hand side of the molding box. Some gypsum building elements 13 are also designated as well as individual cavities 11.

The materials of the molding chamber parts that come into contact with the gypsum paste, such as, for example, floor strips and side profiles, can preferably be made of plastic and / or have other coatings.

The system according to the disclosure can also have molding boxes which are suitable for the production of gypsum building elements as composite panels with other materials. For example, Styrofoam cores can be used in the cavities 11. The components can also consist of other building materials such as cement, wood fiber composites, foam concrete or similar building materials. A molding box can furthermore have molding chambers, the dimensions of which are suitable for the production of products of different thickness and shape, with exchangeable hollow cores also being able to be used for the hollow spaces 11. the Fig. 5 shows a sectional view of a molding box with drive cylinders. Here is essentially the partial perspective view from FIG Fig. 3 shown in section. In addition to the base supports 14, the lower illustration shows the drive cylinders 21 for the cavity pins 17 and the drive cylinders 22 for the ejection device, these acting directly on a cross member 15 shown. In addition, a horizontally displaceable bottom strip 24 can be seen in this illustration, which is partially provided with holes. This bottom strip 24, which enables the bottom area of the molding chambers to be closed, has an area without round holes and an area with round holes for cavity pins 17 to pass through.

In the event that the gypsum building elements produced are to have cavities over the entire length or in partial areas of the molding box, it enables the cavity pins 17 to pass through this base strip 24 from below. In addition, such a baseboard 24, according to the Fig. 2 , have a raised profile web in the middle in order to create a longitudinal profile in the finished gypsum building element. In the section, individual gypsum components 13 are also designated here. The planing traverse 20 can be seen in its two guide units 18 in cross section. At least one temperature sensor 31 is provided in each case for measuring the temperature of each individual gypsum component 13. By means of the metrological tracking of the temperature profile over time, the course of the hardening of each plaster of paris construction element 13 and thus of the entire molding box 3 can be tracked.

the Fig. 6 shows a series of sectional views of the manufacture of solid panels. Here is under the Fig.6a ) to see in section a molding chamber 19, wherein a closed area of the bottom strip 24 closes the bottom of the molding chamber at the bottom and the plaster mixer 4 is not active. In the representation of the Figure 6b ) the plaster mixer 4 pours its liquid plaster mixture 25 into the molding chamber. In the representation of the Figure 6c ) the plaster mixer is inactive again and the plasterboard in the form of a wall element 13 is ejected by means of the ejection device.

the Fig. 7 Figure 10 shows a series of cross-sectional views of the manufacture of hollow panels.

Here is in the Figure 7a ) again to see a section of a molding chamber 19, with a closed area of the bottom strip 24 closing the bottom of the molding chamber downwards again and the plaster mixer 4 not being active. In the representation of the Figure 7b ) the gypsum mixer 4 pours its liquid gypsum mixture 25 into the molding chamber 19, although the perforated area of the base bar 24 with openings was pushed under the molding chamber 19 and the cavity pins 17 were able to pass through these openings. In the representation of the Figure 7c ) the plaster mixer 4 is inactive and the plaster component in the form of a wall element 13 with cavities is ejected from the mold chamber after the curing phase.

the Fig. 8 shows a plan view of a rotating device 26 of a double molding box.

In order to increase the system performance for the production of gypsum building elements, a double molding box is provided according to the invention. Such a double molding box is attached to a rotating device 26 and can alternately be passed under a plaster mixer 4. The foundation with the basic supports 14 and the drive cylinders 21 and 22 is of course available in duplicate in this case. Should there be a need for a further increase in the plant output for the production of plaster of paris, further molding boxes and also corresponding rotating devices 26 can of course be installed.

Fig. 9 : shows a plan view of an arrangement of transverse rails and longitudinal rails with intersection points, which to a certain extent represents a shifting station as a magazine for molding boxes.

The magazine shown and described here creates the possibility of reacting flexibly and quickly to changed order situations.

To produce plaster of paris construction elements with different dimensions and different uses, differently designed molding boxes 3 with different molding chambers 19 are required.

The one in the Fig. 9 The system shown as an example thus offers an expandable concept for a process optimization that can be changed quickly.

On the left in the middle of the Fig. 9 For this purpose, a double molding box with a rotating device 26 is shown in the area of a plaster mixer 4 to which cross rails 27 lead from two sides. The cross rails 27 have a crossover connection to longitudinal rails 28 on two longitudinal sides. On the rails shown, molding boxes 3 can be moved in any direction by means of drive and running wheels 29. The intersection connections between the transverse rails 27 and the longitudinal rails 28 are shown here only formally with regard to their mobility options. A person skilled in the art is familiar with the design of the drive and running wheels 29 as well as the crossing points and the switches and switch positions in this regard.

In addition to the usual electronic detection elements, several sensors, in particular light field sensors 30, are used to monitor the position and the charge status of the individual molding boxes 3.

With regard to the light field sensors 30 used, reference is made to the development of so-called mini lenses, which collect optical information in the form of hundreds of mini lenses according to the light field principle, which are then later compiled for images with a desired resolution and / or a desired viewing angle can. Such mini lenses are 3 - D capable, inexpensive to manufacture and follow the principle of an insect 's eye. With the aid of these light field sensors 30, in addition to the normal pivotability, the desired viewing angle and / or the desired enlargement of an image section can be achieved in a purely electronic way.

After the plate elements have completely dried out in the dryer 10, they must be conveyed to a station (not shown) and then packaged ready for dispatch.

It should be noted that in principle, instead of plaster of paris, other materials such as cement or plastic can be processed with known composite materials to form corresponding construction elements. For example, composites made of wood and plastic or of cement and cement fiber can be produced here.

The complex control of the motion sequences described requires a special control program

List of reference symbols

1

Crane runway for slab grabs

2

Carriage for gypsum building elements

3

Molding box

4th

Plaster mixer

5

Conveyor screw for plaster of paris

6th

Plaster silo

7th

Water tank for process water

8th

Power supply and process control unit

9

Hydraulic power unit

10

dryer

11

Cavities

12th

Visible surface of a plate

13th

Gypsum building element

14th

Basic supports

15th

Traverse for ejector

16

Ejector

17th

Cavity-pin

18th

Guide unit for the planing traverse 20

19th

Mold chamber

20th

Planer crossbeam

21

Drive cylinder for cavity pins

22nd

Drive cylinder for the ejection device

23

Profile webs in the molding chambers

24

Bottom rail in the molding box

25th

liquid plaster mix

26th

Rotary device of a double molding box

27

Cross rails for turning device 26

28

Longitudinal rails of the shifting station

29

Drive and running wheels of a molding box

30th

Monitoring sensors (light field sensors)

31

Temperature sensors

32

Plaster scale with transport screw

Claims (5)

1. Apparatus for the production of solid and hollow gypsum building elements (13) in rapid alternation, comprising a gypsum silo (6), a gypsum scale (32), a gypsum mixer (4), the apparatus further comprising:

   a) a transport screw (5) which is designed in such a way that it conveys gypsum from the gypsum silo (6) via the gypsum scale (32) with a further transport screw to the gypsum mixer (4),

   b) a water tank (7) from which process water may additionally be supplied to the gypsum mixer (4),

   c) a moulding box (3) for moulding gypsum building elements (13) with a plurality of parallel moulding chambers (19) which are open on the upper side and have profile webs (23) on the two end faces, each moulding chamber (19) being provided with a displaceable base strip (24) which optionally has a closed region and a region provided with openings for receiving cavity pins (17), the base strip (24) additionally having web-like elevations for generating profile structures,

   d) a number of drive cylinders (21) for vertical displacement of the cavity pins (17) into the moulding chambers (19),

   e) a planing crossbeam (20) guided in guide units (18) above the moulding box (3) for smoothing the surface of the gypsum building elements (13), the planing crossbeam (20) having moulding grooves for generating tongue and groove structures,

   f) a number of drive cylinders (22) for vertically oriented lifting of the gypsum building elements (13), and

   g) a rotating device (26) which enables two moulding boxes (3) to be filled at short intervals.
2. Apparatus according to claim 1, characterized in that parts of the moulding chambers (19) which come into contact with gypsum mush are made of plastic or other coatings.
3. Apparatus according to claim 1 or 2, characterized in that the moulding box (3) is moved into or removed from a magazine by means of transverse rails (27) or longitudinal rails (28).
4. Apparatus according to any of the preceding claims, characterized in that the moulding box (3) has differently dimensioned moulding chambers (19) for the production of differently dimensioned gypsum building elements (13).
5. Apparatus according to any of the preceding claims, characterized in that the cavity pins (17) for producing hollow gypsum building elements have different and replaceable hollow cores for the cavities (11).

Images