JP6877054B2 - Concrete on-site kneading manufacturing unit - Google Patents

Description

According to the present invention, when a casting operation (a work of pouring concrete into a formwork) is performed at a construction site, concrete can be produced by kneading concrete materials such as cement, aggregate, and water at the construction site. Regarding the on-site kneading unit, in particular, the on-site kneading manufacturing unit suitable for repair work and repair work of existing structures.

Currently, ready-mixed concrete (so-called ready-mixed concrete: ready-mixed concrete) is used in many works. Since ready-mixed concrete is manufactured in large quantities in a well-maintained factory based on certain standards, stable quality concrete can be obtained, and the quality is guaranteed at the time of shipment.

Since the quality of ready-mixed foods changes with the passage of time, the standard limits the transportation time of ready-made foods within a certain period of time. Therefore, in order to stably obtain high-quality concrete using ready-mixed concrete, there is a disadvantage that the process from manufacturing to transportation and placing must be performed in a limited time.

In that respect, on-site kneading, in which concrete material and water are kneaded at the construction site, has the advantage of not being restricted by transportation time.

For example, in Patent Document 1, concrete materials such as cement, sand, gravel, and water packed in a predetermined amount are transported to a construction site by a truck separately from a mixer truck, and each concrete material transported at the construction site is described. A method of producing concrete by kneading with a mixer truck is disclosed.

A truck-integrated weighing device capable of weighing each concrete material and mixing them in a predetermined composition has also been proposed (Patent Document 2).

The weighing device there is composed of a measuring hopper for cement, a measuring hopper using sand, a measuring hopper for sand, a belt conveyor, and the like, and is integrally assembled with the loading platform of the truck. After each concrete material is weighed by a weighing hopper, it is sequentially transferred by a belt conveyor and stored in a container bag.

Then, the container bag is transported to a construction site, and the concrete is manufactured by putting each concrete material stored in the container bag into a mixer and kneading it together with the measured water.

Japanese Unexamined Patent Publication No. 2006-123285 Japanese Unexamined Patent Publication No. 2014-151577

In the repair work and renovation work of existing structures in the city such as office buildings, the work time is often limited to nighttime, etc., and there are also sites where the mixer truck itself cannot be used. Moreover, since there are many sites where it is difficult to use ready-mixed concrete, such as indoors and rooftops, and the amount of concrete required is smaller than that of new construction, on-site kneading is often performed.

At such sites, workers often manually weigh each concrete material and water and knead them using a small mixer. Therefore, the work load on the worker is heavy, and the quality of concrete tends to vary.

Moreover, in the case of repair work, unlike new construction work, it is necessary to adjust the type of concrete material used and the amount of water added according to the existing structure, so management of manufacturing conditions is complicated and weighing errors occur. There is also the drawback that the risk of occurrence is high.

Therefore, an object of the present invention is to provide a concrete on-site kneading manufacturing unit suitable for small-scale casting work such as repair work.

In the concrete on-site kneading manufacturing unit according to the present invention, a plurality of related devices are integrally incorporated on a unit stand that can be loaded on a truck bed for transportation and loading / unloading.

The related devices include a main hopper and a sub hopper, each of which receives a concrete material, a belt conveyor that conveys the concrete material received by the main hopper and puts it into the mixer, and the concrete material received by the sub hopper. It includes a screw feeder that is conveyed and charged into the mixer, a water supply device that supplies water to the mixer, a control device that controls the mixer, the belt conveyor, the screw feeder, and the water supply device.

The unit base has a shape with a long side when viewed from above, and is configured to be able to be loaded and transported on a truck bed. The mixer, the main hopper, the sub hopper, the belt conveyor, the screw feeder, the water supply device, and the control device are integrally incorporated in the unit stand.

The mixer is arranged at the center of one short side of the unit stand, and each of the main hopper and the sub hopper is arranged side by side over substantially the entire other short side of the unit stand. There is. The belt conveyor and the screw feeder are installed so as to extend substantially in parallel from below each of the main hopper and the sub hopper toward the upper part of the mixer.

Therefore, according to this on-site kneading manufacturing unit, related equipment for manufacturing concrete such as a mixer is integrated on the unit stand, so that the on-site kneading manufacturing unit can be simply transported to the construction site and installed. , Easy on-site kneading.

Moreover, a mixer is installed in the on-site kneading manufacturing unit, and a belt conveyor and a screw feeder are installed side by side as a means for weighing and inputting concrete material into the mixer.

Therefore, a belt conveyor can be used for crushed stones having a large particle size, and a screw feeder can be used for materials having a fine particle size.

The mixer is preferably a pan-type mixer. That is, it has a bottomed cylindrical kneading container, a driving unit connected to the kneading container, and a stirring blade attached to a rotating shaft of the driving unit protruding from the center of the kneading container and rotating. It may be.

Further, for example, the unit stand has a rectangular floor surface composed of a short side of 1.5 m or less and a long side of 3 m or less, and the related device is installed so as to fit on the floor surface. Therefore, it is advisable to set the total weight to 2000 kg or less.

By doing so, it can be easily transported by loading it on the loading platform of a small truck and can be easily loaded and unloaded, which is suitable for small-scale casting work such as repair work.

According to the on-site kneading manufacturing unit of the present invention, even on a small-scale construction site such as repair work, on-site kneading can be easily performed, high-quality concrete can be manufactured, and quality assurance can be performed.

It is a flowchart which shows the main process of the manufacturing method of on-site concrete. It is a flowchart which shows each process in the material manufacturing process. (A) and (b) are schematic views which show the bagging form of a concrete material. It is a schematic side view which shows the on-site kneading manufacturing unit. It is a schematic plan view which shows the on-site kneading manufacturing unit. It is a schematic side view which shows one form of the on-site kneading manufacturing unit. It is a block diagram which shows the main structure of a control device.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. However, the following description is essentially merely an example and does not limit the present invention, its application or its use.

<Manufacturing method of on-site concrete>
The manufacturing method shown in this embodiment is mainly established for construction sites where work time and work space are limited, such as repair work, repair work, and reinforcement work of existing structures, and is a concrete material. This is a so-called on-site kneaded concrete manufacturing method in which water is kneaded and manufactured at a construction site. This manufacturing method is devised so that on-site kneaded concrete (also simply called concrete) can be stably manufactured while ensuring high quality, and the quality can be guaranteed.

FIG. 1 shows a flowchart showing the main process. This manufacturing method includes a material manufacturing process S1, a manufacturing unit installation process S2, a material transporting process S3, an on-site kneading process S4, a manufacturing condition storage process S5, and the like.

(Material manufacturing process)
The material manufacturing step S1 is a preparatory step. In the material production step S1, the concrete material used for producing concrete is packed in a dry state.

FIG. 2 shows the details of the material manufacturing step S1. The concrete material referred to here refers to a solid material other than water used in the production of concrete, and specifically, cement, admixture, sand (fine aggregate), crushed stone (coarse aggregate) and the like. The admixture is, for example, fly ash, silica fume, blast furnace slag powder, or the like. The material itself of the concrete material is common in this industry and can be appropriately selected according to the situation of the construction site.

In this manufacturing method, in order to stably secure the high quality of concrete and to guarantee the quality, the moisture of the concrete material used is thoroughly eliminated.

Since the water content of commonly used cements and admixtures is at an error level with respect to the amount of water supplied, cements and admixtures can usually be used as they are.

However, aggregates such as sand and crushed stone generally contain water inside even if the surface is dry (surface dry state), and the amount thereof is not small. Therefore, if it is used as it is, the quality of concrete may become unstable due to the variation in the amount of water. In particular, it is easily affected when a small amount of concrete is manufactured in batch.

Therefore, the aggregate used in this manufacturing method is dried by using a rotary kiln or the like until it is in an absolutely dry state (a state in which it is dried until there is no water that evaporates at a temperature of 100 ° C. or higher) (aggregate). Drying step S6).

Each aggregate dried in an absolutely dry state is classified into a predetermined particle size, weighed to a certain amount, and then wrapped in a packaging material having excellent moisture resistance to prevent water absorption.

The packaging form can be appropriately selected according to the specifications. For example, each concrete material may be packed in a bag, or a plurality of concrete materials may be mixed and packed in a bag. All of the concrete materials may be mixed and packaged.

In particular, a mortar pack is made by weighing a fixed amount of a mixture of cement, admixture, and sand in a predetermined mixing ratio and packing them in a bag, and at the same time, crushed stone is weighed independently and put into a bag. It is preferable to prepare a coarse aggregate pack by packing.

If a plurality of materials with fine particles are mixed in advance, the burden of mixing at the construction site can be reduced and the quality can be improved. As will be described later, the compact manufacturing unit 1 is used and a simple operation is performed. Highly accurate compounding can be realized.

As shown in FIG. 3A, the bagging form is preferably a general bagging of several tens of kg, but a 1000 kg level container bag as shown in FIG. 3B may be used. .. In this embodiment, the mortar pack MP and the coarse aggregate pack KP as shown in FIG. 3A will be described as an example.

In the manufacturing method of the present embodiment, identification data SD such as symbols and barcodes are added to each of the mortar pack MP and the coarse aggregate pack KP (identification data addition step S7).

In the material preparation step S1, each of the mortar pack MP and the coarse aggregate pack KP has data (material data) related to the quality of concrete, such as the date data produced, the lot of the concrete material used, and the measurement data. To be acquired.

A manufacturing condition database is implemented in a predetermined computer system 100 (an example of an external terminal, see FIG. 4), and the acquired material data is stored in the manufacturing condition database in a state associated with the identification data SD. It has become so.

In the present embodiment, the identification data SD is attached to the outer surfaces of the mortar pack MP and the coarse aggregate pack KP by printing or sealing. The mortar pack MP and the coarse aggregate pack KP thus produced are stored in a warehouse or the like until they are used.

(Manufacturing unit installation process)
The manufacturing unit installation step S2 is a preparatory step. In the manufacturing unit installation step S2, a dedicated on-site kneading manufacturing unit is used.

The on-site kneading manufacturing unit is easy to transport and can be installed even in a narrow construction site, and is devised so that high-quality concrete can be stably manufactured with simple operations. Next, the details of the on-site kneading manufacturing unit 1 will be described.

<On-site kneading manufacturing unit>
4 and 5 show an example of the on-site kneading manufacturing unit (also simply referred to as manufacturing unit 1). This manufacturing unit 1 is a small-quantity batch-type manufacturing device in which the amount of concrete manufactured at one time is about 50 to 200 L, and a plurality of related devices required for on-site kneading are integrated on one compact unit stand 10. It is configured by incorporating it in.

Specifically, the unit base 10 is composed of a rectangular floor surface 11, a support frame 12, and the like. The length W of the short side of the floor surface 11 is set to 1.5 m or less, and the length of the long side L is set to 3 m or less. The support frame 12 includes a lower frame installed along the edge of the floor surface 11, a rectangular upper frame arranged so as to face above the lower frame, and a plurality of erected between the lower frame and the upper frame. It is composed of a support frame and the like.

Related devices include a mixer 20, a main hopper 30, a sub hopper 31, a belt conveyor 40, a screw feeder 50, a water supply device 60, a control device 70, and the like.

These related devices are collectively installed on the unit base 10 so as to fit on the floor surface 11 and not protrude to the outside of the floor surface 11, and the height H from the floor surface 11 does not exceed 2 m. It is installed like this. The total weight of the manufacturing unit 1 is set to be 2000 kg or less.

As a result, the manufacturing unit 1 can be easily transported by loading it on the loading platform of a light truck, and can be easily loaded and unloaded.

The mixer 20 is a so-called pan-type mixer, and is composed of a kneading unit 21 and a drive unit 22 connected to the lower portion thereof. The kneading portion 21 can be opened and closed by a bottomed cylindrical kneading container 23 having a shallow bottom, an upper lid 24 covering the upper part of the kneading container 23, and a stirring blade 25 installed inside the kneading container 23. It has a payout port 26. A motor 27 is installed inside the drive unit 22, and a stirring blade 25 is attached to a rotating shaft of the motor 27 protruding inside the kneading container 23.

A dust collector 28 is attached to the mixer 20. The dust collector 28 captures the dust generated inside the kneading container 23 during kneading and suppresses the dust from diffusing to the outside.

The mixer 20 is arranged on one short side side of the unit base 10, and is supported by the unit base 10 via a load cell 80. The load cell 80 is a sensor that converts a load into an electric signal, and the load cell 80 can measure a change in the weight of the mixer 20.

Each of the main hopper 30 and the sub hopper 31 is a box-shaped container having a large input port 33 for receiving concrete material at the upper part and a small discharge port 34 at the lower part, and is arranged on the other short side side of the unit base 10. It is installed in. In the present embodiment, the main hopper 30 and the sub hopper 31 are formed to have the same shape and the same dimensions, and both are configured to be separable at an intermediate portion in the height direction.

Specifically, each of the main hopper 30 and the sub hopper 31 is composed of a fixed lower portion 35 fixed to the unit base 10 and a detachable upper portion 36 detachably attached to the upper side of the fixed lower portion 35. By attaching and detaching the detachable upper part 36, it is possible to change between a container back specification that secures a large storage capacity and a pouch specification that can be easily put in by hand as shown in FIG.

The belt conveyor 40 is installed between the main hopper 30 and the mixer 20 so as to convey the concrete material received by the main hopper 30 and put it into the mixer 20.

Specifically, an end portion on the introduction side of the belt conveyor 40 is installed below the discharge port 34 of the main hopper 30, and an end portion on the lead-out side of the belt conveyor 40 is installed above the mixer 20. The intermediate portion of the belt conveyor 40 is inclined upward from the end on the introduction side toward the end on the lead-out side. The end portion on the lead-out side is inserted into the inside of the introduction duct 43 communicating with the inside of the kneading container 23.

The screw feeder 50 is installed between the sub hopper 31 and the mixer 20 so as to convey the concrete material received by the sub hopper 31 and put it into the mixer 20.

Specifically, the end on the introduction side of the screw feeder 50 is installed below the discharge port 34 of the sub hopper 31, and the end on the outlet side of the screw feeder 50 is installed on the upper part of the mixer 20. The screw feeder 50 is inclined upward from the end on the introduction side toward the end on the lead-out side. The end on the lead-out side is connected to an introduction duct 53 communicating with the inside of the kneading container 23.

The water supply device 60 includes a water supply pipe 61, an electromagnetic on-off valve 62, a flow meter 63, a buffer tank 64, and the like. The downstream end of the water supply pipe 61 enters the inside of the kneading container 23. Although not shown, the upstream end of the water supply pipe 61 is connected to a water supply device 60 composed of a water storage tank, a pump, or the like, or a water supply source such as a pipe for industrial water or the like.

A temperature sensor 90 is arranged in the vicinity of the mixer 20 to measure the ambient temperature.

The control device 70 is composed of a computer, various software mounted on the computer, and the like, and executes control for mechanically manufacturing concrete. Further, the control device 70 is also provided with a function of storing manufacturing conditions for each batch and a function of performing data communication with the computer system 100 in order to guarantee the quality of the concrete to be manufactured.

Further, the control device 70 is also provided with a monitor capable of displaying manufacturing conditions and the like, an input device capable of inputting instruction data and identification data SD, an output device capable of printing manufacturing conditions and the like.

FIG. 7 shows the main configuration of the control device 70. The control device 70 includes a manufacturing control unit 71, a manufacturing condition storage unit 72, a measurement control unit 73, a data communication unit 74, and the like. The measurement control unit 73 of the manufacturing unit 1 is provided with a water supply amount correction unit 75.

The manufacturing control unit 71 controls the belt conveyor 40, the screw feeder 50, the mixer 20, and the electromagnetic on-off valve 62, and executes manufacturing-related controls such as operation timing, water supply timing, and operation time of the mixer 20.

The manufacturing condition storage unit 72 stores each of the measured value of the load cell 80 that changes with the operation of the belt conveyor 40, the measured value of the load cell 80 that changes with the operation of the screw feeder 50, and the amount of water supply for each manufacturing process. Remember. In the manufacturing condition storage unit 72 of the manufacturing unit 1, the measured value and the water supply amount of the load cell 80 can be stored in association with the identification data SD.

The measurement control unit 73 executes control regarding measurement of concrete material and water. Specifically, the input amount and the water supply amount of the concrete material to the mixer 20 are controlled based on the instruction data. The instruction data is data for instructing the control device 70 to manufacture concrete, including manufacturing conditions such as a blending ratio.

In particular, the manufacturing unit 1 can control the input amount and the water supply amount of the concrete material to the mixer 20 based on the identification data SD input for each manufacturing process.

The data communication unit 74 has a function of transmitting and receiving data to and from the computer system 100. The water supply amount correction unit 75 executes control for correcting the water supply amount based on the measured value of the temperature sensor 90. Details of each of these controls will be described later.

In the manufacturing unit installation process S2, the manufacturing unit 1 having such a structure is installed at the construction site.

(Material transportation process)
The material transportation step S3 is a step of transporting the packaged concrete material to the construction site. The material transportation step S3 is not limited to after the manufacturing unit installation step S2, but may be before or at the same time. The point is that the amount of concrete material required for construction should be transported to the construction site during the construction period.

(On-site kneading process)
The on-site kneading step S4 is a step of mechanically producing concrete by operating the manufacturing unit 1. Specifically, the worker operates the manufacturing unit 1 to introduce a certain amount of concrete material and water into the mixer 20 and knead them for a certain period of time to manufacture concrete. Since there are multiple manufacturing patterns, an example is shown below.

The operator takes out crushed stone from the coarse aggregate pack KP and puts it in an appropriate amount into the main hopper 30, and takes out the mixed material from the mortar pack MP and puts it in an appropriate amount into the sub hopper 31. By operating the control device 70, the instruction data is manually input to operate the manufacturing unit 1.

Then, the manufacturing control unit 71 drives the belt conveyor 40, and the crushed stone is put into the mixer 20. Based on the measured value of the load cell 80, the weighing control unit 73 weighs the crushed stones to be charged, and when one batch of crushed stones is charged, the manufacturing control unit 71 stops the belt conveyor 40.

Subsequently, the manufacturing control unit 71 drives the screw feeder 50, and the mixed material is charged into the mixer 20. Based on the measured value of the load cell 80, the measurement control unit 73 weighs the mixed material to be charged, and when one batch of the mixed material is charged, the manufacturing control unit 71 stops the screw feeder 50. The order of adding the crushed stone and the mixed material may be reversed.

Subsequently, the manufacturing control unit 71 opens the electromagnetic on-off valve 62 to supply water to the mixer 20. The measurement control unit 73 measures the amount of water supplied based on the flow meter 63, and closes the electromagnetic on-off valve 62 when the amount of water corresponding to the concrete material charged into the mixer 20 is supplied.

After that, the production control unit 71 operates the mixer 20 to produce concrete. The produced concrete is discharged from the payout port 26. By repeating such on-site kneading step S4, a required amount of concrete is produced.

Since the concrete material used contains almost no water, water management can be easily performed, and concrete having a constant water ratio can be stably produced. In addition to crushed stone with a large particle size, materials with a fine particle size are collectively weighed with a screw feeder 50 with high weighing accuracy, so the mixing ratio is stable and higher quality concrete can be produced.

Moreover, since it is mechanically manufactured while being weighed by the manufacturing unit 1, human error is eliminated and stable manufacturing can be performed even with a small amount of on-site kneading.

(Manufacturing condition storage process)
In the manufacturing condition storage step S5, the manufacturing conditions are stored in batch units. Specifically, every time the on-site kneading process S4 is performed, measurement data of mixed materials, crushed stones, and water, date data of batch processing, manufacturing data such as operating time of the mixer 20 and ambient temperature, etc. The manufacturing condition data is stored in the manufacturing condition storage unit 72.

Therefore, since the data affecting the quality of concrete is stored for each batch, the quality of concrete can be guaranteed.

At the construction site, the identification data SD of the mortar pack MP and the coarse aggregate pack KP to be input is input to the control device 70 by reading it with a reader or the like, and the data of the manufacturing conditions is stored in association with the identification data SD. May be good. By doing so, the corresponding material data can be identified, and a higher level of quality assurance can be performed.

Further, the stored manufacturing condition data may be transmitted from the manufacturing unit 1 to the computer system 100 (data communication process). Specifically, the manufacturing condition data is transmitted to the computer system 100 through the data communication unit 74, and the transmitted manufacturing condition data is stored in association with the identification data SD together with the corresponding material data.

Then, a high level of quality assurance can be easily performed. It is also advantageous in that an increase in the storage amount of the manufacturing condition storage unit 72 can be suppressed.

In the case of this manufacturing unit 1, concrete can be manufactured more easily by using the identification data SD.

That is, the identification data SD and the instruction data corresponding to the concrete material are associated with each other, and the identification data SD is read and input to the control device 70 before inputting. Then, since the instruction data can be input mechanically, it is not necessary to manually input the instruction data, and the control device 70 can be operated easily and surely.

Further, this manufacturing method is devised so that the influence of temperature on the quality can be suppressed.

That is, it is known that the appropriate amount of water supply changes depending on the ambient temperature at the time of kneading. Therefore, water supply correction data capable of obtaining the optimum water supply amount according to the temperature is created by an experiment or the like, and the water supply correction data is stored in the control device 70 in advance. The water supply amount correction unit 75 automatically corrects the water supply amount based on the water supply correction data and the measured value of the temperature sensor 90.

Therefore, even if the ambient temperature during kneading changes, appropriate water supply can be performed, so that high-quality concrete can be stably produced. Since the corrected measurement data is stored in the manufacturing condition storage unit 72, its quality can be guaranteed.

The on-site kneading manufacturing method according to the present invention is not limited to the above-described embodiment, and includes various other configurations.

In the embodiment, mortar pack MP and coarse aggregate pack KP have been described as examples of the concrete material, but the concrete material is a mixture of cement, admixture, and sand individually packed in a bag or all of them. It may be packed in a bag.

1 On-site kneading manufacturing unit 10 Unit stand 20 Mixer 30 Main hopper 31 Sub hopper 40 Belt conveyor 50 Screw feeder 60 Water supply device 70 Control device 71 Manufacturing control unit 72 Manufacturing condition storage unit 73 Measurement control unit 74 Data communication unit 75 Water supply amount correction unit 80 Load cell 100 Computer system S1 Material manufacturing process S2 Manufacturing unit installation process S3 Material transportation process S4 On-site kneading process S5 Manufacturing condition storage process S6 Aggregate drying process S7 Identification data addition process MP Mortal pack KP Coarse aggregate pack SD Identification data

Claims (3)

It is a concrete on-site kneading manufacturing unit in which multiple related devices are integrally incorporated on a unit stand that can be loaded on a truck bed for transportation and unloading.
The related device is
With a mixer
A main hopper and a sub hopper that accept all solid materials used in the production of concrete,
A belt conveyor that conveys a material having a relatively large particle size, including crushed stone, received by the main hopper and puts it into the mixer.
A screw feeder that conveys a relatively fine-grained material, including cement and sand, received by the sub-hopper and feeds it into the mixer.
A water supply device that supplies water to the mixer,
A control device that controls the mixer, the belt conveyor, the screw feeder, and the water supply device.
Including
The unit base has a shape with a long side when viewed from above, and is configured to be able to be loaded and transported on the truck bed.
The mixer, the main hopper, the sub hopper, the belt conveyor, the screw feeder, the water supply device, and the control device are integrally incorporated in the unit stand.
The mixer is arranged at the center of one short side of the unit stand, and each of the main hopper and the sub hopper is arranged side by side over substantially the entire other short side of the unit stand. Ori,
The on-site kneading manufacturing unit in which the belt conveyor and the screw feeder are installed so as to extend substantially in parallel from below each of the main hopper and the sub hopper toward the upper part of the mixer. In the on-site kneading manufacturing unit according to claim 1,
The mixer is a pan-type mixer.
A bottomed cylindrical kneading container and
The drive unit connected to the kneading container and
A stirring blade that is attached to the rotating shaft of the driving unit and rotates, which protrudes from the center of the kneading container.
Has an on-site kneading manufacturing unit. In the on-site kneading manufacturing unit according to claim 1 or 2.
The unit base has a rectangular floor surface composed of a short side of 1.5 m or less and a long side of 3 m or less, and the related device is installed so as to fit on the floor surface.
An on-site kneading unit with a total weight of 2000 kg or less.

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