RU129538U1 - DEVICE FOR MANUFACTURING COMPOSITE REINFORCEMENT - Google Patents

Abstract

1. A device for the production of composite reinforcement, including sequentially installed creel with roving bobbins, leveling comb, drying unit, impregnating bath, molding unit, at least one polymerization chamber, water cooling bath, lingering rollers and cutting unit, characterized in that the forming unit includes a frame on which molding discs with through holes for passing rovings are installed perpendicular to the direction of movement of the rovings, coaxially with the forming discs on the frame forming tubes for passing individual roving bundles and pivotally mounted spiral winding disks, each of which has a hole in the center with a guide tube passed through it for passing a roving bundle inside, are helically mounted, while the spiral winding disks are kinematically connected using belt drives with a common motor shaft .2. The device according to claim 1, characterized in that the cutting unit is made in the form of a detachable carriage mounted in the rails with the possibility of moving along them and equipped with a clamping bar and a circular saw with a pneumatic drive installed with the ability to move relative to the carriage in a direction perpendicular to the direction of movement of the reinforcement, in addition, the carriage is provided with a returnable load in a flexible connection to return the carriage to its original position. 3. A device according to any one of claims 1 and 2, characterized in that the molding unit is equipped with an inclined trough-shaped tray for draining excess binder located under the molding disks. 4. A device according to any one of claims 1 and 2, characterized in that the molding unit is provided with

Description

The inventive utility model relates to devices intended for the manufacture of non-metallic reinforcing elements used in construction for reinforcing conventional and prestressed building structures.

A device for the manufacture of non-metallic reinforcement according to the patent of the Russian Federation No. 2075577, IPC E04C 5/07 (publ. March 20, 1997), including creel crest with roving bobbins mounted on its axes, annealing chamber, impregnation chambers with a tension device, molding unit with a die block , pre-polymerization chambers with wrapper, polymerization chambers, assemblies for winding and cutting reinforcement, pulling device, tension blocks mounted on the creel after each bobbin, leveling device installed in front of the annealing chamber and acting with a tensioning blocks, modular device disposed after the impregnation chamber, the axis of the creel are rotatable, and the impregnation chamber has a fluoroplastic coating on the inner walls and the bottom, taken with a bias to the center of the chamber. The leveling device is made in the form of a comb provided with porcelain inserts. The block of the dies of the molding unit is made of fluoroplastic, the annealing chamber is equipped with a high-frequency heater and is configured to operate in a pulsed mode.

The disadvantage of this technical solution is the complexity and low productivity of the line, as well as the inability to obtain composite reinforcement with high anchoring properties.

There is also known a device for the manufacture of non-metallic fittings (Frolov NL "Fiberglass reinforcement and glass concrete structures", Moscow, Stroyizdat, 1980, pp. 20-24), including creel with roving bobbins, leveling device, annealing chamber, impregnating bath with tensioning device, squeezing device, molding unit, spiral winding device, polymerization chambers, pulling device, cutting and reeling units. The disadvantage of this device is its complexity and not high enough performance.

A device for the manufacture of non-metallic reinforcement is known from the prior art, including a creel pulley with roving rods, a leveling device, an annealing chamber, an impregnating bath with a tension device, a squeezing device, a molding unit, a spiral winding device, polymerization chambers, a pulling device, a winding bundle winder , cutting and reeling unit (RF patent No. 2287646, IPC E04C 5/07, published November 20, 2006). The disadvantage of this device is its low productivity, as well as a limited range of manufactured non-metallic fittings.

Also known is a device for the manufacture of non-metallic reinforcement, including sequentially installed creel with roving rods, leveling device, annealing chamber, impregnating bath with a tension device, molding unit, spiral winding device, at least one polymerization chamber, water cooling unit, pulling device, a winder of a winding bundle, a cutting and reeling unit (see, for example, RU 90470 U1, publ. 10.01.2010, IPC E04C 5/07). The disadvantage of this device is the incomplete impregnation of roving threads with the resin composition; there is a need to reduce the speed of passage of threads through the impregnation bath, which, in turn, leads to a decrease in the performance of the device. Also, with the existing method of squeezing roving threads from excess resin, passing them through slots in a polyurethane tape, part of the fibers breaks, which affects the technical characteristics of the manufactured reinforcement.

Closest to the claimed is a device for the production of composite reinforcement, including sequentially installed creel with roving bobbins, a leveling comb, a drying unit, an impregnating bath, a molding unit, at least one polymerization chamber, a water cooling bath, lingering rollers and a cutting unit (see ., for example, RU 107803, published on August 27, 2011 Bull. No. 24).

A common disadvantage of the currently known devices is low performance and, as a result, high power consumption.

The task to which the claimed technical solution is directed is to increase the productivity of manufacturing composite reinforcement.

The problem is solved due to the fact that in the device for the production of composite reinforcement, which includes serially installed creel with roving bobbins, a leveling comb, a drying unit, an impregnating bath, a molding unit, at least one polymerization chamber, a water cooling bath, lingering rollers and detachable unit, according to the technical solution, the molding unit includes a frame on which molding discs with through holes are installed perpendicular to the direction of movement of the rovings roving start-up, coaxially to the forming disks, molding tubes are installed on the frame for passing individual roving beams and pivotally mounted spiral winding disks, each of which has a hole in the center with a guide tube passed through it for passing the roving bundle inside, while the spiral winding disks are kinematically connected using belt drives with a common motor shaft.

The cutting unit can be made in the form of a detachable carriage mounted in rails with the possibility of moving along them and equipped with a clamping bar and a circular saw with a pneumatic drive installed with the ability to move relative to the carriage in the direction perpendicular to the direction of movement of the reinforcement, in addition, the carriage is equipped with a return load on a flexible communication to return the carriage to its original position.

The molding unit can be equipped with an inclined trough-shaped tray for swelling excess binder, located under the molding discs.

The molding unit can be equipped with additional inclined trough-shaped trays for swelling excess binder, installed in front of the spiral wound disks.

Each additional inclined trough-shaped tray can be equipped with a sleeve of material with a low coefficient of surface tension located in its side wall.

Molding tubes for passing the roving beam can be equipped with bushings made of material with a low coefficient of surface tension.

Each spiral winding disk may have a cantilever holder mounted on it, which is a rod made with the possibility of placing a bobbin with a winding harness on it and fixing it with a latch located on its free end, as well as a rod with a ring on its free end for storing the winding harness.

The impregnation bath can be made trapezoidal in its longitudinal section, a rotatably mounted drum is installed over the impregnation bath, a clamping bar for squeezing out excess binder, at least three metal transversely arranged strips for skipping rovings along the broken line for the purpose of additional squeezing leveling combs.

The through holes of the forming discs can be provided with inserts in the form of bushings made of a material with a low coefficient of surface tension, preferably ceramic or Teflon.

The device may be further provided with a device for squeezing out excess binder, installed after the molding unit.

The curing chamber may include a rectangular hinged lid with a pneumatic actuator.

Drawn rollers can be equipped with a sensor for measuring the length of the workpieces to determine the length of the finished product.

The device can be additionally equipped with a winding bundle winder installed in front of the cutting carriage.

The drying unit may be at least two tubular heaters installed parallel to each other.

The technical result provided by the given set of features is to increase the productivity of manufacturing composite reinforcement by providing the possibility of manufacturing several reinforcing bars in one cycle due to the device of the molding unit, which includes a frame on which molding discs with through holes for passing rovings are installed perpendicular to the direction of movement of rovings, coaxially to the forming discs, molding tubes are installed on the frame for passing individual beams s rovings and pivotally mounted wheels helical winding, each of which has a central aperture therethrough with a missed guide pipe for the passage of the beam inside the rovings, the spiral winding wheels kinematically linked via belt transmission with a common motor shaft.

The technical solution is illustrated by the following graphic materials and examples of implementation, not covering and, moreover, not limiting the entire scope of the claims of this technical solution:

figure 1 - shows the molding unit of the device, a General view;

figure 2 - shows the molding discs and molding tubes of the molding unit;

figure 3 - shows a disk of spiral winding of the molding unit.

A device for the production of composite reinforcement includes a creel-cord with roving rods in series, a leveling comb, a drying unit, an impregnating bath, a molding unit, at least one polymerization chamber, a water cooling bath, lingering rollers and a cutting unit.

The impregnation bath is made trapezoidal in its longitudinal section. Above the impregnation bath there is a rotatable drum, a pressure bar for squeezing out the excess binder, at least three metal transversely spaced bars for skipping rovings along the broken line for the purpose of additional spinning, as well as two leveling combs.

The forming unit includes a frame 1 on which molding discs 2 are mounted perpendicular to the direction of movement of the rovings. In the forming discs 2, through holes 3 are made for passing rovings. Coaxially to the forming disks 2, on the frame 1, molding tubes 4 are installed for passing individual roving bundles and pivotally mounted spiral winding disks 5. Each spiral winding disk 5 has a hole in the center with a guide pipe 6 passed through it to let the roving beam pass through it, a cantilever-fixed rod with a latch on the free end for placement of a bobbin with a winding harness on it, and a cantilever-mounted rod with a ring on the free end for storage winding harness. The spiral winding disks 5 are kinematically connected using belt drives 7 to a common motor shaft mounted on the frame of the molding unit (not shown conventionally in the drawings). The forming unit is equipped with an inclined trough-shaped tray 8 for swelling excess binder located under the molding discs 2. There are also additional inclined trough-shaped trays 9 for sweeping excess binder, installed in front of the spiral-wound disks 5. Each additional inclined trough-shaped tray 9 is equipped with a sleeve 10 of material with a low coefficient of surface tension located in its side wall. Molding tubes 4 for the passage of the beam of rovings are equipped with bushings of material with a low coefficient of surface tension. Each spiral winding disk 5 has a cantilever holder 11 mounted on it to accommodate bobbins with a winding bundle on it. The holder 11 is a rod with a latch made at its free end. In addition, on each disk 5 of the spiral winding, a rod with a ring at its free end is cantilevered for storing the winding cord (not shown conventionally in the illustrations). The through holes 3 of the molding discs 2 are provided with inserts in the form of bushings made of a material with a low coefficient of surface tension, preferably ceramic or Teflon.

The described implementation of the molding unit allows you to simultaneously form several reinforcing bars in the number equal to the number of installed molding disks 2 and disks 5 of spiral winding, which significantly increases the performance of this device, and also reduces energy consumption.

The polymerization chamber includes a rectangular hinged lid with a hydraulic actuator and is equipped with at least one heat reflector and at least one thermoelectric heater. The walls of the polymerization chamber are multilayer.

Broaching rollers are equipped with a sensor for measuring the length of the workpieces.

The cutting unit is made in the form of a detachable carriage mounted in rails with the possibility of moving along them and equipped with a clamping bar and a circular saw with a pneumatic drive. The circular saw is installed with the ability to move relative to the carriage in a direction perpendicular to the direction of movement of the reinforcement, in addition, the carriage is equipped with a return load on a flexible connection to return the carriage to its original position.

The drying unit is at least two tubular heaters installed parallel to each other.

The device can additionally be equipped with a winding bundle winder installed in front of the cutting carriage and a device for squeezing excess binder, installed after the molding unit.

A device for the manufacture of composite reinforcement works as follows. Rings from mineral (glass, basalt, carbon, etc.), polymer (nylon, polyester, etc.), as well as vegetable fibers from bobbins mounted on creel, pass through a leveling comb and enter the drying unit for preliminary drying of rovings. In the drying unit, moisture is removed at a processing temperature of 180-280 ° C. In addition, the node has an additional separation function, which is necessary so that the roving threads do not get mixed up with each other. Then the rovings enter the impregnation bath filled with a polymer binder with a temperature of 40-80 ° C. The design of the impregnation bath is such that the lower part of the drum is in a polymer binder, for example, resin. When the drum rotates, the resin remaining on its surface impregnates the roving threads. The clamping bar for squeezing out excess binder removes excess resin, flattening the roving threads to almost the minimum thickness, which in turn allows the roving to be impregnated with resin throughout the volume. The pressed polymer binder (resin) constantly flows down the surface of the drum into the impregnation bath. Due to the constant rotation of the drum, roving threads are constantly in squeezed resin, which further improves their impregnation. The rotation of the drum occurs due to the friction forces of the threads on its surface. This spinning method prevents even partial rupture of roving threads, which significantly improves the technical characteristics of the manufactured fittings.

Further, the roving filaments enter the molding unit, passing through the through holes 3 of the molding disks 2 mounted on the frame 1 perpendicular to the direction of movement of the rovings, the roving filaments are formed in separate bundles by means of the forming tubes 4, which are mounted on the frame 1 coaxially to the forming disks 2. To maintain integrity roving threads and beams as a whole, as well as for squeezing excess polymer binder, the through holes 3 of the forming discs 2 and the forming tubes 4 are equipped with bushings of material with a small coefficient Ohm surface tension, preferably ceramic or teflon. The excess binder flows into the inclined trough-shaped tray 8 located under them, common to all molding discs 2. Next, each formed bundle enters an individual guide tube 6, passed through the central hole of the articulated disk 5 of the spiral winding. A rod 11 is cantileverly fixed to the disk 5 to accommodate a bobbin with a winding cord, which, by means of an additional rod cantileverly mounted on the disk 5, has a ring at the free end (not shown conditionally in the illustrations) for storing the winding cord. When rotating the disk 5 spiral winding around its axis wraps a bunch of rovings with a winding bundle, forming a reinforcing bar. All disks 5 spiral winding synchronously rotate, due to their kinematic connection using belt drives 7 with a common motor shaft, which allows you to maintain the same winding pitch on all reinforcing bars. At this stage, excess polymer binder flows into additional inclined trough-shaped trays 9 installed in front of the spiral winding disks 5. A sleeve 10 of a material with a low surface tension coefficient located in the side wall of the additional inclined trough-shaped tray 9 helps to remove excess binder from the roving beam. After the beam passes through the guide tube 6 of the spiral winding disk 5, the reinforcement body takes a cylindrical shape and a rod with a periodic reinforcement profile is formed . For the formation of a clearly defined periodic profile of the reinforcement, the winding rope must be round in cross section and of sufficient diameter to form a relief.

Then the rods enter the polymerization chamber, where they are exposed to temperatures up to 400 ° C. From the polymerization chamber, the rods are pulled through the water cooling unit by pulling rollers, fed to the carriage of the cutting unit and, by the signal of the sensors for measuring the length of the workpieces that determine the length of the finished product installed on the broaching rollers, are pressed to it by a clamping bar. The carriage is set in motion by reinforcement rods fixed on it, which in turn advance the pulling rollers. The carriage moves along the guides. Also, according to the signal of the sensors for measuring the length of the workpieces installed on the broaching rollers, a circular saw is switched on. Armature blanks are cut with a circular saw with a pneumatic drive mounted with the possibility of movement relative to the carriage in a direction perpendicular to the direction of movement of the armature. After cutting the reinforcement, the clamping plate mounted on the carriage releases the reinforcement and the carriage returns to its original position due to the return load suspended from it on the flexible connection thrown across the crossbeam.

The presented device is characterized by low power consumption, ease of maintenance and allows you to produce high-quality products with high technical characteristics and high performance.

Claims (14)

1. A device for the production of composite reinforcement, including sequentially installed creel with roving bobbins, leveling comb, drying unit, impregnating bath, molding unit, at least one polymerization chamber, water cooling bath, lingering rollers and cutting unit, characterized in that the forming unit includes a frame on which molding discs with through holes for passing rovings are installed perpendicular to the direction of movement of the rovings, coaxially with the forming discs on the frame forming tubes for passing individual roving bundles and pivotally mounted spiral-wound discs, each of which has a hole in the center with a guide tube passed through it for passing a roving bundle inside, are spiral-wound, while the spiral-wound discs are kinematically connected using belt drives with a common motor shaft . 2. The device according to claim 1, characterized in that the cutting unit is made in the form of a detachable carriage mounted in rails with the possibility of movement along them and equipped with a clamping bar and a circular saw with a pneumatic drive installed with the possibility of movement relative to the carriage in a direction perpendicular to the direction of movement valves, in addition, the carriage is equipped with a returnable load on a flexible connection to return the carriage to its original position. 3. The device according to any one of claims 1 and 2, characterized in that the molding unit is equipped with an inclined trough-shaped tray for draining excess binder located under the molding discs. 4. The device according to any one of claims 1 and 2, characterized in that the molding unit is equipped with additional inclined trough-shaped trays for draining excess binder, installed in front of the spiral winding disks. 5. The device according to claim 4, characterized in that each additional inclined trough-shaped tray is equipped with a sleeve of material with a low surface tension coefficient located in its side wall. 6. The device according to any one of claims 1 and 2, characterized in that the molding tubes for passing the roving beam are provided with bushings made of material with a low surface tension coefficient. 7. The device according to any one of claims 1 and 2, characterized in that each spiral winding disk has a cantilever holder mounted on it, which is a rod made with the possibility of placing a bobbin with a winding bundle on it and fixing it with a latch placed on it the free end, as well as a cantilever-fixed rod with a ring on its free end for storing the winding cord. 8. The device according to any one of claims 1 and 2, characterized in that the impregnation bath is made trapezoidal in its longitudinal section, the drum is rotatable over the impregnation bath, the pressure bar for pressing the excess binder, at least three metal transversely spaced bars for skipping rovings along the broken line for the purpose of additional spinning, as well as two leveling combs. 9. A device according to any one of claims 1 and 2, characterized in that the through holes of the forming discs are provided with inserts in the form of bushings made of a material with a low coefficient of surface tension, preferably ceramic or Teflon. 10. The device according to any one of claims 1 and 2, characterized in that it is additionally equipped with a device for squeezing excess binder, installed after the molding unit. 11. The device according to any one of claims 1 and 2, characterized in that the polymerization chamber includes a rectangular hinged lid with a pneumatic actuator. 12. The device according to any one of claims 1 and 2, characterized in that the broaching rollers are equipped with a sensor for measuring the length of the workpieces to determine the length of the finished product. 13. The device according to any one of claims 1 and 2, characterized in that it is additionally equipped with a winding bundle winder installed in front of the cutting carriage. 14. The device according to any one of claims 1 and 2, characterized in that the drying unit is at least two tubular heaters installed parallel to each other.

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