RU2597341C2 - Process line for production of composite rebars - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: present invention relates to devices for production of reinforcing bars. Process line for production of composite reinforcing bars contains a frame with roving reels that is supplied to the straightening device for separating the roving reel into separate strings that are moved into a drying chamber to remove excess moisture, to an impregnation bath filled with a polymer binder for soaking the strips that rare submerged into it the strips are then passed through a squeezing device for squeezing excess binder, which is returned into the bath; a polymer rebar blank shaper that includes a device of combining strips into a rod and a rewinder that feeds lacing thread rotating it around the rod and forms a spiral winding of this thread on the rod; a polymerization chamber with furnace sections for heating; a cooling device which includes a series-arranged fan air cooling unit; a water cooling unit that uses rain nozzles and a water bath for complete immersion of the fragments of polymerised bulk blank that is drawn by a pulling mechanism located in front of a cutting assembly that cut the cooled polymerised bulk blank into separate fragments coming in a coiler.

EFFECT: production of reinforcing bars.

1 cl, 3 dwg

Description

The invention relates to devices for the manufacture of reinforcement, for example for concrete, from non-metallic materials.

Composite polymer reinforcement is an innovative development in the field of modern building materials. For the manufacture of reinforcement, metal has traditionally been used. Modern technologies have allowed to create a material that surpasses steel in strength and resistance to external influences, while at the same time eliminating all the shortcomings that are characteristic of metal reinforcing products. Polymer reinforcement is much stronger than steel reinforcement, it is able to withstand a greater impact on the gap at which steel is destroyed. Moreover, the thermal conductivity of the composite is lower than that of the metal by about 100 times, and the absolute chemical inertness makes the reinforcement of the composite extremely reliable and durable. Another important quality of reinforcement made of a polymer composite is its low weight, which is very important not only for the general lightening of concrete structures, but also saves money on the use of special equipment for its laying and installation.

A known installation for the manufacture of composite reinforcement, including sequentially installed frames with roving bobbins, a leveling device, a drying chamber, an impregnating bath with a tensioning device, a squeezing device, a molding unit with a winder, a polymerization chamber, a cooling device, a pulling mechanism and a cutting unit. The forming unit consists of an outer rotating pipe on which the winder is mounted. A spacer sleeve is connected to the end of the rotating pipe with a slot for the passage of the winding bundle from the winder to the valve stem. A matrix with a through hole is connected to the other end of the spacer sleeve. A fixed tube is installed inside the outer rotating pipe. All components of the molding unit are installed coaxially, i.e. their geometric axes are on the same straight line, providing a rectilinear trajectory of the bundles forming the rod and the reinforcement (RU 87444, Е04С 5/07, publ. 10.10.2009).

The disadvantages of the installation is insufficient performance.

Also known is a technological line for the production of composite reinforcement, which includes the following equipment installed in series: frame with roving bobbins, leveling device, drying chamber, impregnating bath with a tension device, squeezing device, bundle former with winder, polymerization chamber, cooling device, pulling mechanism and assembly cutting, bundle shaper is made in the form of two external rotating pipes mounted on bearing bearings parallel to each other with n by winders, each winder containing a reel seat and a stacker of winding ropes installed on one end and a counterweight on the other, fixed tubes are installed coaxially with clamps and center bearings inside each outer rotating tube, to the ends of which are interchangeable molding units with holes corresponding to the size of the reinforcement, in this case, after molding units, the reinforcing rods in front of the polymerization chamber are in contact with one pair of guide rollers from their outer side, and from goy - a pair of guide rollers - with their inner side in the direction of movement of the reinforcement bars. In this case, the drying chamber is equipped with an electronic temperature controller, the polymerization chamber consists of four sections and is equipped with an electronic temperature controller, the pulling mechanism is equipped with an electronic length meter and, in addition, the line is equipped with a coil winder installed after the cutting unit (RU 129129, Е04С 5/07, publ. . 06/20/2013). This decision was made as a prototype.

The disadvantage of this line is that there are no means of monitoring the conduct of this operation at the posts or sections of individual operations. As a result, for example, at the site of impregnation of tows, the quality of impregnation directly depends on the level of compound in the bath. When the level decreases, the tows do not have full impregnation over the entire surface. In addition, the lack of control does not allow checking the oversaturation of the bundles with an excess of compound. In addition, there is no way to control the total consumption of the compound per shift, that is, the length of the harnesses used in relation to the output of the finished product. And in the area of the winding of the rod with a thread there is no control over the remainder of the winding thread on the spool. In addition, the polymerization process of the product requires a more efficient and dispersed cooling time to prevent the appearance of the so-called water hammer after the furnace leaves the product to prevent cracking in the product.

Considering that the lines belong to the automatic category for the continuous production of linear products, the conditions for the operation in each section require coordination with the modes of operations in neighboring sections. Compliance with these consistencies will eliminate the appearance of deformation processes in the polymer material of the reinforcement.

In the prototype line, with the exception of heating temperatures, the control is visual in nature and requires constant operator involvement, which is not always justified due to the possibility of the appearance of the so-called human factor. The exclusion of this factor and the introduction of control automation at the level of signal information will allow not only to maintain a constant technology for manufacturing polymer reinforcement per shift, but also to improve the quality of the finished product.

Non-metallic reinforcement is a heterogeneous system consisting of oriented fibers (glass fibers, basalt fibers and carbon-containing fibers) and a binder. Its properties depend on the properties and structural features of the constituents, as well as on their physicochemical interaction, behavior during the perception of external loads, exposure to aggressive reagents, changes in temperature and humidity conditions and other factors. Fibers, almost completely perceiving the effects of tensile or compressive forces, determine the deformability of the reinforcement. A binder glues fibers into a monolithic core, ensures their joint work and protects against mechanical damage and direct exposure to moisture and aggressive reagents.

For example, for the manufacture of polymer composite reinforcement, the following raw materials are used: roving (basalt and / or glass roving), resins, bobbin thread (roving, which will be used for winding, along the entire length there are peculiar coils, the so-called stiffeners, they are needed to the reinforcement firmly “sat” in concrete so that it would not be torn out of it), acetone, ethyl alcohol, dicyandiamide. Raw materials may vary.

Fiberglass (SPA) and basalt-plastic (BPA) fittings are the most popular today in Russia, but there is also a combined view - a fiberglass rod, and the relief (ribs) of "basalt".

Most often, thermosetting synthetic resins act as binders, among which are organosilicon and phenolaldehyde resins (they harden during the polycondensation reaction); epoxy and unsaturated (do not emit by-products during the curing process). Among other polymers that have occupied a solid niche, polyimide, polybenzimidazole, and polybenzothiazole should be mentioned. These resins are often used with the addition of other polymers.

In order to obtain fiberglass reinforcement with a high level of resistance to various kinds of corrosion, an epoxyphenolic binder should be used. The polyester binder will give reinforcement increased electrical properties.

The basis for the production of non-metallic reinforcement has already become the traditional method of fiberglass production - drying and unwinding of fiber, impregnating it with a binder, polymerization.

The listed aspects of the formation of polymer reinforcement show the need for precise control at each section of the production line of the parameters of the influence of temperature conditions, humidity, amount of binder, polymerization conditions, etc. to obtain the final product with a uniformly formed structure of the bundle and winding materials. This is only possible with automation as a means of control.

The present invention aims to achieve a technical result, which consists in increasing the manufacturability of the line for the production of composite fittings by applying temperature control and the constancy of the level of liquid components in the bathtubs and a three-stage cooling process to eliminate surface cracks in the fittings.

The specified technical result is achieved by the fact that in the production line for the production of composite reinforcement containing a frame with roving rods, fed to a leveling device for separating the roving blade into separate bundles entering the drying chamber to remove excess moisture, an impregnation bath filled with a polymer binder for impregnation recessed harnesses drawn into it, drawn through a squeezing device to separate excess binder, which returns to the bath, former of the polymer reinforcement comprising a means for combining the bundles into a rod and a winder feeding a winding thread in rotation around the rod and forming a spiral winding of this thread on it, a polymerization chamber with furnace heating sections, a cooling device, a pulling mechanism and a cutting unit for cooling the polymerized linear billet into separate fragments entering the coils installed after the cutting unit, under the impregnation bath there are scales to control the weight of the compound in the bath and the total weight of the spent compound for changing p On the winder, which wraps the core with a winding thread, a pulse sensor is installed to monitor the remainder of the winding thread on the bobbin, each furnace section for heating the polymerization chamber is equipped with a temperature control sensor in the section, and the cooling device includes sequentially located fans for air cooling, water cooling with a rain of nozzles and a bath with water for complete immersion of fragments of a polymerized linear billet pulled by a pulling mechanism located in front of the cutting unit, with temperature sensors located in each unit of the cooling device, the pulling mechanism equipped with a pedometer for reading the meter of the stretched polymerized linear billet and issuing a signal to the cutting unit control unit, under the bath of the cooling device there are scales to control the water level by its weight in bath, while these sensors and a pedometer are connected with a computerized means for taking into account current parameters and making corrective control signals to actuators triads and knots of the line.

These features are significant and are interconnected with the formation of a stable set of essential features sufficient to obtain the desired technical result.

The present invention is illustrated by a specific example of execution, which, however, is not the only possible, but clearly demonstrates the possibility of achieving the desired technical result.

In FIG. 1 - production line for the production of composite reinforcement;

FIG. 2 - continuation of the line of FIG. one;

FIG. 3 is a continuation of the line of FIG. 2.

According to the present invention, an improved design of a processing line for the production of composite reinforcement is described, configured to monitor operations in each technological section, e and the processing parameters of the polymer material.

The production line for the production of composite reinforcement (Fig. 1-3) includes the following posts or technological sections located in series:

- a frame with bobbins 1 (coils) of roving 2, on which there are scales 3 connected with a computerized means that displays the consumption of roving by changing its weight on the bobbin and the need to replace empty bobbins (coils) with new ones;

- from bobbins 1 roving is fed to the leveling device 4 for dividing the roving canvas into separate bundles 5;

- these tows 5 enter the drying chamber 6 to remove excess moisture. The drying chamber 6 is equipped with an electronic temperature controller (not shown) and current temperature sensors (Fig. 1). The drying chamber is a sequentially located heating elements 7 (for example, heating elements), passing through which the bundles lose moisture to the set value. An electronic temperature controller allows you to set the overall heating level, and the current temperature sensors show the actual heating temperature on each heating element, which allows you to control the overall heating level and enter a heating correction for each heater to prevent overheating of the bundles on a separate specific heater.

The dried tows enter the impregnation bath 8, filled with a polymer binder 9 (a compound, for example, a thermosetting synthetic resin) to impregnate recessed harnesses drawn through a squeezing device (not shown) to separate the excess binder, which returns to the bath (Fig. 1) . Impregnation is carried out by simply dipping the tows in the bath under their own weight. Special scales 10 are installed under the impregnation bath, which allow you to control the weight of the remaining compound in the bath during operation and also electronically control the total weight for a whole change of the spent compound. These scales are connected with a computerized means for displaying at the end of the shift in the form of a graph and a table the consumption and weight indicators of the binder.

The bundles impregnated with a binder enter the former 11 of the polymer reinforcement blank. At this post, there are means for combining 12 bundles into a rod and a winder 13, which feeds the winding thread 14 in rotation around the rod and forms a spiral winding of this thread on it. A pulse sensor 15 is mounted on the thread winder, which winds the rod itself with thread, in order to monitor the remainder of the winding thread on the spool (Fig. 2).

The design of the shaper 11 for the preparation of polymer reinforcement is described in detail in RU 87444 or 129129. The shaper 11 consists of an external rotating pipe on which a rewinder 13 is mounted. A spacer with a slot is connected to the end of the external rotating pipe for the winding thread to pass from the winder to the future reinforcement bar. A matrix with a through hole is connected to the other end of the spacer sleeve. A fixed tube is installed inside the outer rotating pipe. All components of the shaper 11, namely the outer rotating tube, the fixed tube, the sleeve and the matrix, are installed coaxially, i.e. their geometrical axes are on one straight line, providing a rectilinear trajectory of motion in the former of 11 bundles forming a rod.

Or the bundle former is made in the form of two external rotating pipes mounted on bearing bearings parallel to each other with winders placed on them. Each winder contains a reel seat and a stacker of winding filament installed at one end, and a counterweight for synchronous movement of the winders at the other. Fixed tubes are installed coaxially with the inside of each external rotating pipe, to the ends of which are interchangeable molding units with openings corresponding to the standard size of the reinforcement.

The rod 16 in the form of combined bundles with spiral winding on the outer surface is drawn through the polymerization chamber 17 with the furnace heating sections 18. The polymerization chamber 17 consists of four sections 18 and is equipped with an electronic temperature controller (not shown). Each furnace section for heating the polymerization chamber is equipped with a temperature control sensor 19 in the section. From the polymerization chamber 17, the reinforcement blank enters the cooling device 20 (Fig. 3).

The cooling device 20 includes sequentially located unit 21 for air cooling of the drawn fittings by fans 22, a unit 23 for water cooling with rain from nozzles 24 and a bathroom 25 with water 26 for completely immersing fragments of the polymerized linear billet pulled by a pulling mechanism 27 located in front of the cooled cutting unit 28 polymerized linear billet into individual fragments 29 entering the coil winder installed after the cutting unit.

At the same time, temperature sensors are placed in each node of the cooling device. The pulling mechanism 27 consists of four shafts with a chain mechanism for driving their rotation and is equipped with a pedometer 30 for reading the meter of the extended polymerized linear billet and issuing a signal to the control unit of the cutting unit. The pedometer reads the meter and sends a signal to both auto-cut and the electronics unit to account for the meter.

The water cooling unit and the water bath of the cooling device are made with a closed loop water system hydraulic system. Such a system is described in detail in RU 135677 "Technological line for the manufacture of composite reinforcement"). Also on this bath are water level sensors. The automatic supply and circulation of the closed water cycle is controlled from a computerized means, and temperature sensors display the current values on the display, which made it possible to get away from the so-called water hammer after furnaces and cracks in the product, and the product itself has become better quality.

Under the bath 25 of the cooling device, weights 31 are placed to control the water level by its weight in this bath, while these sensors in the cooling device and the pedometer 30 are connected with computerized means for taking into account current parameters and making corrective control signals to the actuators of the devices and nodes of the line.

Separate fragments of polymer reinforcement after the cutting unit enter the coil winder, on which the scales are placed in order to control not only the meter of reinforcement due to the pedometer, but also the weight of each coil, these indicators are also transferred to a computerized tool.

After the pedometer, a marking device 32 of the armature is installed before auto-cutting.

Rings made of mineral, such as fiberglass or basalt, fibers from the bobbins of the frame pass through a leveling device 4, which has the additional function of dividing the roving cloth into separate bundles. The roving installed in the bays during unwinding and pulling by a pulling device is initially passed through individual devices for each bundle that create almost the same tension in the bundles. After the leveling device, the bundles enter the drying chamber, where moisture is removed from them. Then roving harnesses enter the impregnation bath filled with a polymer binder, are impregnated with it and pass through a tension device made of elastic material, where excess binder is separated, which returns to the bath. After exiting the bath, a glass fiber is wound (with a certain step) onto a sealed fiberglass rod, creating a spiral dent at the point of contact with the rod, forming a periodic profile on its surface. Next, roving bundles enter the fixed tubes of the bundle former 11 and there, due to the binder, combine into rods, which then move through the pipes and pass through interchangeable molding units - dies, the diameter of the holes of which corresponds to the size of the reinforcement. The diameter of the die corresponds to the diameter of the manufactured reinforcement. The die is designed to seal and form a glass fiber impregnated with a binder and to remove excess binder and air between the fibers. Using the drive 33, a spiral winding of the bundle from the winders of parallel moving rods is carried out through the stacker of the winding thread. Further, the wound rods in the direction of movement enter the polymerization chamber, where they are subjected to heat treatment.

Then the reinforcement rods pass through the cooling device 20 with the help of a pulling mechanism 27 to form the finished reinforcement in the coils on the coil winder. To fill the bays using the cutting unit 28, the reinforcement is cut and sent to the finished goods warehouse.

As the installation experience showed, the manufacture of polymer fittings using continuous technology does not require expensive equipment and qualified maintenance personnel. The technological process of manufacturing valves, excluding recharging coils with a winding thread, can be fully automated. Serving the pilot plant and controlling its operation is carried out by two people whose functions include also delivering batches of source material and binder components to the workshop, as well as packaging manufactured batches of polymer reinforcement.

Claims (1)

A processing line for the production of composite reinforcement, containing a frame with roving rods fed to a leveling device for separating the roving blade into separate bundles entering the drying chamber to remove excess moisture, an impregnation bath filled with a polymer binder to impregnate recessed harnesses drawn into it a device for separating excess binder, which is returned to the bath, a shaper of the procurement of polymer reinforcement, including a means for combining the bundles into a rod n and the winder feeding the winding thread in rotation around the rod and forming a spiral winding of this thread on it, a polymerization chamber with furnace heating sections, a cooling device, a pulling mechanism and a cutting unit for cooling the polymerized linear billet into individual fragments entering the coil winder installed after cutting unit, characterized in that under the impregnation bath there are scales for controlling the weight of the compound in the bath and the total weight of the spent compound for changing work, on the rewinder the core is wrapped with a winding thread, a pulse sensor is installed to monitor the remainder of the winding thread on the coil, each furnace section of the polymerization chamber is equipped with a temperature control sensor in the section, and the cooling device includes sequentially located air cooling unit with fans, a unit for water cooling with a rain from nozzles and a bathroom with water to completely immerse fragments of the polymerized linear billet pulled by a pulling mechanism placed in front of the cutting unit, while in each node of the cooling device has temperature sensors, the pulling mechanism is equipped with a pedometer for reading the meter of the extended polymerized linear billet and issuing a signal to the control unit of the cutting unit, under the bath of the cooling device there are scales to control the water level by its weight in the bath, while these sensors and the pedometer associated with a computerized tool for taking into account current parameters and making corrective control signals to the actuators of devices and nodes of the line.

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