RU2526944C2 - Modular factory to produce mortar-concrete mixes - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: invention relates to the field of construction, namely, to production of construction materials, and may be used in equipment for production of mortar and concrete mixes, designed for external and internal works, production of compounds for arrangement of roads, paths, pavement tiles, floors, screeds, etc. The stated task is solved by the fact that in the proposed solution each hopper for a filler is equipped with a device for heating of its material in cold period of the year, a conveyor is made in the form of a batching conveyor and is placed under hoppers for fillers, the batching conveyor is installed on movable supports, weighed by means of strain gauges and is made as capable of smooth start, a cement batcher and a water batcher are installed above a concrete mixer, the water batcher is equipped with a device for heating, and the cement batcher determines the dose of fed cement by means of force-measuring strain gauges, which determine a rodless method for material mass measurement, transport is made in the form of an inclined conveyor or a skip hoist and is placed between the batching conveyor and the concrete mixer, the skip hoist is installed as capable of acceleration in the middle section of the path and smooth braking before discharge, and in the lower part of the cement storage silo there are nozzles installed to supply compressed air for aeration of cement, and on the roof of the cement storage silo there is a bag filter with a receiver and a safety valve, the bag filter is designed to prevent cement ingress into atmosphere, and the receiver is designed for filling of the necessary volume of compressed air and excessive pressure, by means of which bag filter bags are automatically shaken from cement, besides, the safety valve is designed to discharge excessive pressure in case of clogging of the bag filter.

EFFECT: development of a compact environmentally compatible plant, which could produce mortar and concrete mixes for construction needs of a specific region, city and another settlement, and which could be efficiently mounted from modular blocks produced depending on planned efficiency of production of mortar and concrete mixes.

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Description

The invention relates to the field of construction, namely to the production of building materials, and can be used in equipment for the preparation of mortar and concrete mixtures intended for external and internal works, the production of compositions for the device of roads, paths, paving slabs, floors, screeds and so on .

Known mortar-concrete installation according to the patent of the Russian Federation No. 2047489, class. B28C 9/00, 1995. It contains cement storage silos, consumables for fillers, a cement feeder and conveyors for conveying aggregates into a collection hopper. The dosing device is made in the form of a weighing platform on which a prefabricated hopper is installed, having a shutter and estrus. In this case, the collection hopper is made two-section in the form of a housing with a partition, the lower end of which is placed above the discharge opening with the formation of a gap. Bunker sections are made with volumes in the ratio of 1: 3 (cement: aggregates).

This installation is unsuitable for obtaining mortar mixtures, and dosing of components by means of a weighing platform reduces the productivity of the installation due to the alternate weighing of the components.

Known concrete mixing plant according to the patent of the Russian Federation No. 2054999, class. B28C 9/00, 1996 with volumetric dosing of the components of the mixture, with the ability to control the values of the dosed portions of the mixture. It contains consumable containers of concrete components, made in the form of a warehouse with separate sections, a dosing device, a mixer, a hopper of the finished mixture, a device for feeding components to the mixer, including a bucket, guides and a drive. The dosing device is made in a single unit with a bucket containing movable partitions forming sectors of variable bucket volumes corresponding to each discharge window of one consumable container. The windows are equipped with movable shutters regulating the flow of components.

The disadvantage of this installation is the manual rearrangement of the partitions forming the sectors of the variable volumes of the bucket, which leads to the need to clean the guide cells. In the place where the dosing bucket and consumables are connected, spilling of components is inevitable, which also leads to the need for constant cleaning. The above auxiliary operations of stripping lead to interruptions in the operation of the installation, reduce its productivity, increase the complexity of the process. In addition, the use of components in an un-dried form leads to the sticking of inert materials to the walls of the bucket, which causes metering errors.

It should be noted that the rash of components in the open form leads to high dustiness, i.e. a known installation can only work on an open production site.

Famous mini-factory for the production of dry building mixtures according to the certificate for a utility model of the Russian Federation No. 12069, class. B28C 9/00, 1999, adopted by the applicant for the prototype. It contains consumable containers of the mixture components, means for dispensing and supplying these components to the mixer, mixing device, container for the finished mixture, is made in the form of a beam structure, including an inert-dosing unit of inert material, a dosing unit of binders, a mixing unit and a finished dispensing unit mixtures, while in the flow-metering unit of inert material, a feed hopper, a conveyor-type conveying device, a drying drum are installed in the technological sequence n, a vibrating screen, a hopper of dry inert material, equipped with a shutter providing the delivery of a certain portion of material in a certain time, a means of transporting dry inert material to the mixer, made in the form of a skip hoist, at least two hoppers are installed in the batching unit of binders dispensers mounted above the mixer and connected with it by nozzles and a pipeline with a warehouse of binders, moreover, these metering hoppers are equipped with screw pi In order to dispense a certain portion of binders into the mixer for a certain time, a vibrating screen mounted under the mixer is installed in the mixing unit, the finished mixture dispensing unit is installed under the mixing unit during the process and contains a finished product bin and a device for packaging the finished mixture.

However, this mini-factory is mainly intended for the preparation of dry building mixes, its technological process and equipment used only after refinement, including the supply and connection of water, will be able to use “wet” processes, namely to produce mortar or concrete mixtures .

The technical task of the invention is the creation of a compact, environmentally friendly plant, which could produce mortar and concrete mixes for the construction needs of a specific region, city and other settlement, and which could be quickly mounted from modular blocks, performed depending on the planned production rate of mortar concrete mixtures.

The problem is solved in that in the proposed solution, each aggregate hopper is equipped with a device for heating the material contained in it in the cold season, the conveyor is designed as a metering conveyor and placed under the aggregate hoppers, the metering conveyor is mounted on movable supports, hung out by load cells and made with the possibility of smooth inclusion, the cement dispenser and the water dispenser are installed above the concrete mixer, the water dispenser is equipped with a heating device, and the cement dispenser determines the dose supplied cement by means of load-measuring strain gauge sensors that determine the leverless method of measuring the mass of material, the transport is made in the form of an inclined conveyor or skip elevator and placed between the metering conveyor and the concrete mixer, the skip elevator is mounted with the possibility of acceleration in the middle part of the path and smooth braking before the rash, in the lower silo parts for cement storage fittings for supplying compressed air to cement aeration are installed, and on the roof of the silo for cement storage a bag filter with a receiver and a safety valve are installed, a bag filter is designed to prevent cement from entering the atmosphere, and a receiver is designed to fill the required volume of compressed air and excess pressure, whereby the bag filter bags are automatically shaken from the cement, and the safety valve is designed to discharge excess pressure with clogged bag filter.

The technical result obtained from the use of the present invention consists in the optimal technological and structural layout, and due to the exact dosage of aggregates, cement and water, and their accurate, lossless transportation to the concrete mixer, the optimum material consumption and high quality of the produced mixtures are obtained, and due to the exact implementation of the planned recipe while maintaining the inherent performance.

Figure 1 shows a General view of a modular plant for the production of mortar-concrete mixtures, side view;

Figure 2 - modular plant for the production of mortar concrete mixtures, top view;

In Fig.3 - view A in Fig.1, a silo for storing cement is not shown.

The modular plant for the production of mortar-concrete mixtures, depending on the planned performance of the production of mixtures, is performed in the form of modules that are designed and manufactured for this capacity. Therefore, the plant can be divided into three modular blocks: aggregate module, mixing module and warehouse module for cement storage.

The aggregate module is a frame metal structure 1, on which silos 2 with closures 3 are placed on top in the number of aggregates intended for the production of mortar-concrete mixtures. Each hopper 2 is equipped with a device 4 for heating the material contained in it during the cold season, which allows to maintain the accuracy of the dosage and formulation of the mortar-concrete mixture produced without disruption or malfunction of the process and the estimated performance.

In the lower part of the frame metal structure 1 there is a conveyor for transporting aggregates, which is made in the form of a conveyor-dispenser 5. The conveyor-dispenser 5 is mounted on movable supports 6, hung out using strain gauges 7 and made with the possibility of smooth switching on. Due to the use of strain gauge conveyor 5, due to the use of load cells 7, a weight measuring device and the possibility of smooth switching on, not only exact dosing of aggregates is carried out, but also their transportation is accurate, without losses, because it conveys at the optimum speed at which the aggregates do not crumble. And this ensures the minimum required consumption of materials, and hence maintaining the recipe and obtaining high quality prepared mixtures.

The mixing module is also a frame metal structure 8, the lower part of which is made with a height for the passage of the mixer 9 for loading. An operator room 10 is made on top of the frame metal structure 8. A concrete mixer 11 is placed in the module, and a cement dispenser 12 and a water dispenser 13 are installed above the concrete mixer 11. An unloading hopper 14 is mounted under the concrete mixer 11, from which the ready-mixed concrete mixture is discharged into the mixer 9.

The camera room 10 is located in a separate room in which the control panel, the launcher shield and the power assembly are mounted. The control panel is provided with communication with the control room and other concrete facilities during the operation of the plant. From the control panel, the operator can control the technological process of the plant in manual or automatic mode.

The water dispenser 13 is equipped with a device for heating 15, which ensures uninterrupted operation of the mechanisms of the mixing module, without compromising the quality of the prepared mixtures.

The cement dispenser 12 determines the exact dose of the supplied cement by means of force-measuring strain gauge sensors 16, which determine the leverless method of measuring the mass of the material, ensuring optimal material consumption while maintaining the recipe and high quality of the produced mixtures.

To transport the dry aggregate material to the concrete mixer 11, the mixing module is equipped with transport, which can be either an inclined belt conveyor or a skip elevator 17. A skip elevator 17 is placed between the metering conveyor 5 and the concrete mixer 11 and mounted with acceleration in the middle of the path and smooth braking before the rash, which eliminates losses during transportation and rash, eliminates dust.

The warehouse module for cement storage is a silo 18 and a screw 19 for transporting, feeding and dosing cement to a concrete mixer 11. Silo 18 serves to provide the necessary cement supply. The supply of cement to the silo 18 is made from a cement truck through a cement pipeline mounted on a silo 18 or from a cement warehouse. At the bottom of the silo 18 for cement storage, fittings 20 are installed for supplying compressed air to aeration of cement, and a bag filter 21 with a receiver 22 is installed on the roof of the silo 18. Bag filter 21 is designed to prevent cement from entering the atmosphere, and the receiver 22 is designed to fill the necessary the volume of compressed air and excess pressure, whereby the automatic shaking of the sleeve filter bag 21 from the cement is carried out. Moreover, a safety valve 23 is installed on the roof of the silo 18, which is designed to relieve excess pressure when the bag filter 21 is clogged. This design of the warehouse module eliminates the emission of cement into the atmosphere, its losses during transportation, thereby confirming the high environmental friendliness of the process and the plant as a whole.

The claimed mortar-concrete mix production plant has a modularity system both in design and manufacturing, which allows laying a number of unified plant modules with different capacities at the lowest cost during design, which greatly simplifies the manufacturing process and reduces the time for their installation. In addition, the claimed plant reflects the optimal technological and structural layout.

The modular plant for the production of mortar-concrete mixtures works as follows.

Before starting work, the mechanisms of the plant are in the initial position, namely, all the bins 2 for aggregates are filled, the gates 3 of the bins 2 are closed; the bucket of the skip hoist 17 is located in the lower position, the tank for powering the water dispenser 13 is filled with water, the silo 18 for storing cement is filled, its shutter is closed.

Before starting work, the concrete mixer 11 is put into operation. During the subsequent cycles of the plant, the electric drive of the concrete mixer 11 does not turn off.

The mass adjusters set the values of the dosed fractions of the aggregates. The shutter 3 of the first hopper 2 of the aggregate hoppers opens. The fillers, under the influence of their own weight, fall onto the conveyor-dispenser belt 5. The impact of the mass of material on the conveyors dispensed on the conveyor-dispenser belt 5 is fixed by the load cells 7 of the dispenser conveyor 5 and transferred to the pointer of the weighing device of the conveyor-dispenser 5.

Upon reaching the set value of the mass of the portion of the fillers, a cut-off occurs, the shutter 3 closes. Closing the shutter 3 of the first hopper 2 serves as a signal to open the shutter 3 of the second hopper 2. Further, dosing from the second hopper 2 is similar to dosing from the first hopper 2, and closing the shutter 3 of the second hopper 2 serves as a signal to enable movement of the conveyor-dispenser 5. The given portion of fillers the moving conveyor-dispenser 5 pours into the bucket of the skip hoist 17, which moves along the rails up, where the aggregates are automatically unloaded, after which the bucket returns to its original, lower position. The inclusion of the drive of the conveyor-dispenser 5 occurs only with the lower position of the bucket.

Simultaneously with the dosing of aggregates, cement is dosed. From the nearby silo 18, on the command from the control panel, the screw engine 19 is turned on and cement is supplied by the screw 19 to the cement batcher 12. After reaching a certain value of the cement mass, a command is sent to turn off the screw 19.

Simultaneously with the dispensing of aggregates and cement, the water is dispensed in the water dispenser 13. From the control panel, the pump engine receives a signal to turn on, after reaching the specified mass of water in the water dispenser 13, the pump turns off.

After the unloading of aggregates is completed, a signal is sent to open the gates at the outlet of the cement batchers 12 and water 13, and supply them to the concrete mixer 11.

After emptying the dispensers of cement 12 and water 13, a timer for mixing materials is turned on.

When the time relay is set, configured for a specific duration of mixing, a signal is sent to open the unloading hopper 14 and unload the finished mixture in the mixer 9. One cycle of preparation of mortar-concrete mixture is completed.

In subsequent cycles of operation of the plant in automatic mode, the moment of switching on the timer for mixing materials in the concrete mixer 11 is a signal for the beginning of the next cycle, thereby winning the time to prepare the mixture and thereby increase productivity.

Using the proposed technical solution, it was possible to create a compact and environmentally friendly plant, with the ability to control the technological process for the preparation of mortar concrete mixtures both in manual and automatic mode, which produces mortar and concrete mixes for the construction needs of a particular region, city, quickly mounted from modular blocks made depending on the planned production rate of mortar-concrete mixtures.

Claims (1)

A modular mortar-concrete mixture production plant containing hoppers by the number of aggregates placed under the hopper conveyor-dispenser, transport for feeding a dosed batch of aggregates into the concrete mixer, concrete mixer, cement dispenser and water dispenser, silo for storing cement with a bag filter, characterized in that the conveyor - the dispenser is mounted on movable supports, hung out by means of strain gauges and made with the possibility of smooth switching on, the cement dispenser and the water dispenser are installed above the concrete mixer, doses the water ator is equipped with a heating device, and the vehicle for feeding a metered batch of aggregates to the concrete mixer is made in the form of an inclined conveyor or skip elevator and is placed between the metering conveyor and concrete mixer, and the skip elevator or inclined conveyor is mounted with the possibility of acceleration in the middle of the path and smooth braking before emptying, the silo for cement storage is equipped with a receiver and a safety valve; in the lower part of the silo, fittings for supplying compressed air to radio cement, wherein the receiver is configured to fill the required amount of compressed air and overpressure, whereby the carry automatic shaking bag filter sleeves of the cement, and a safety valve for dumping excess pressure when clogged filter bag.

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