RU2655860C1 - Technological line for manufacture of concrete products using technical sulfur as a binder and the method of manufacture of such equipment - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: group of inventions refers to the field of building material production, namely, the production of sulfur concrete goods. Concrete goods production line contains a closed conveying contour, formed by conveyors, equipped with a loading post of forms with concrete, a post of vibration shaping, a fasting of products. In this case, the closed transporting contour is made of four successively installed and technologically connected conveyors, on which the molds are mounted, which may be moved on conveyors. First conveyor is made in a heat-insulated chamber equipped with heaters. Second conveyor is equipped with a loading post and a measurement of the mass of the mold and a post of vibroforming. Third conveyor is made in a cooling chamber. Fourth conveyor is equipped with a fastening post of products and a post-installation of molds. Method for concrete products manufacturing is also described.

EFFECT: increase in the concrete products quality level, efficiency and safety of production, expanded range of molded products.

19 cl, 2 dwg, 1 tbl

Description

FIELD OF THE INVENTION

This technical solution relates to the production of building materials, namely the production of products from sulfur concrete.

State of the art

Known devices for producing concrete products based on cement, in which concrete is fed into molds before filling their volume, followed by smoothing the surface and removing excess concrete. After filling out the forms, the products are heat treated. In the process of filling out forms, they produce a vibration effect to improve the distribution of concrete in the mold volume (Patent Review. Concrete Forming Machines and Equipment. Moscow. 2006).

The disadvantage of these devices is the absence in the mechanisms of the system for maintaining the required temperature of the concrete mixture, the inability to obtain high-quality products from the mixture using technical sulfur as an astringent, since when dumping excess sulfur concrete on such devices it cools below the melting temperature of sulfur and cannot already reused in these devices, low production efficiency of products.

Closest to the present is the device cited on page 10 in the book "Technological fundamentals of manufacturing reinforced concrete structures for housing and civil engineering" Bratsk. 2010. Author T.F. Shlyakhtina. In this device, the molds are placed on a closed conveying circuit formed by two conveyors and two transfer bridges, while on one conveyor the molds are filled with concrete and the mixture is smoothed out with a vibrorail, and on the other - heat treatment and stripping of the products.

The disadvantage of this solution is that the molds supplied to the molding do not have a system for heating them to the required temperature, and concrete dropped from the surface when smoothing the products with a vibrorail will cool below the hardening temperature of the mixture and cannot be reused in the manufacture of products from sulfur concrete . This will lead to increased losses of the mixture, an increase in the cost of products, a decrease in the quality and efficiency of the production of concrete products.

The claimed invention eliminates these disadvantages and allows to achieve the claimed technical result.

Disclosure of invention

The objective of this technical solution is to develop a device that allows to manufacture products from concrete, obtained using technical sulfur as an astringent.

The technical result is the production of concrete products using technical sulfur as an astringent, improving the quality of products, increasing the efficiency and safety of manufacturing products, expanding the range of molded products.

To solve the problem with the achievement of the claimed technical result, the technological line for the production of concrete products contains a closed conveying circuit formed by conveyors, equipped with a concrete mold loading station, vibroforming station, product stripping station, and the closed conveying circuit is made of four sequentially installed and technologically connected conveyors on which forms are mounted, made with the possibility of movement on conveyors, while the first onveyer configured in a thermally insulated chamber with heating, the second conveyor is provided with a post and a boot shape measuring weight and fasting vibromolding third conveyor is configured in the cooling chamber, and a fourth conveyor provided with fasting and fasting demoulding products installation forms.

The heat-insulated chamber is equipped with infrared heaters.

Infrared heaters are installed along the axis of the chamber in the immediate vicinity of the vertical walls of the mold.

The cooling chamber has front and rear ends open for air passage, and a collector with a suction fan is made in the middle of the chamber.

The post for loading and measuring the mass of molds contains a table mounted on four load cells.

The vibroforming station contains a table mounted on four vibration mounts, and electric vibrators are installed on the bottom of the table.

All conveyors are equipped with rails.

All conveyors are equipped with pushers with hinged stops.

A method of manufacturing concrete products involves moving molds in a closed conveying circuit, loading molds with concrete, vibroforming and stripping the products, while the closed conveying circuit is made of four sequentially installed and technologically connected conveyors, while the molds are heated on the first conveyor, and heated on the second conveyor molds load a predetermined amount of hot mass of concrete and are fed for vibroforming; on the third conveyor, loaded molds with hot mass of concrete are cooled air, and on the fourth conveyor, the products are stripped and transferred to the finished goods warehouse, while after the products are stripped, the molds are cleaned, lubricated, assembled and put into working condition to move the molds to the first conveyor and resume the product production cycle.

The first conveyor is installed in the heating chamber.

Forms are heated in a heating chamber using infrared heaters.

Forms are heated using infrared heaters to a temperature of 130 - 150ºС.

The amount of load mass is measured by a weighing system.

Vibroforming is carried out on a vibroforming post table mounted on vibration mounts using electric vibrators mounted on the bottom of the table.

The third conveyor is installed in the cooling chamber.

The molds with the concrete mixture are cooled by cold air using a fan.

The molds with concrete mixture are cooled to a temperature of 70 ºС.

In the manufacture of products as part of a loaded hot mass of concrete, technical sulfur is used as a binder.

Forms are moved on conveyors along rails with a given cycle of work for a fixed step.

Brief Description of the Drawings

Figure 1 - General diagram of the device.

Figure 2 - the design of the elements of conveyors and posts measuring the mass of forms and vibroforming.

In the figures, the numbers denote the following elements:

1 - conveyor heating chamber;

2 - molding conveyor;

3-conveyor cooling chamber;

4 - formwork conveyor;

5 - form;

6 - rails of conveyors moving forms;

7 - a pusher;

8 - a folding emphasis of movement of a form;

9 - drive pusher displacement form;

10 - heating chamber;

11 - infrared electric heaters;

12 - post mass measurement;

13 - vibration forming post;

14 - a table of a post of measurement of mass;

15 - strain gauges;

16 - table vibration post;

17 - vibration mounts;

18 - electric vibrator;

19 - cooling chamber;

20 - fan;

21 - post stripping products;

22 - post installation forms.

The implementation of the invention

The device consists of four sequentially installed and technologically connected conveyors 1; 2; 3 and 4, forming a horizontally closed loop. On conveyors are single or multi-seat forms 5.

All conveyors have rails 6 along which pushers 7 with hinged stops 8 move the forms 5. The reciprocating movement of the pushers is carried out by chain drives 9. The last stop of the pushers of all conveyors transfers the forms to the working area of the next conveyor, to its receiving table. All conveyors have the same level from the floor mark of the workshop.

The conveyor 1 is placed in a thermally insulated chamber 10, in which there are heaters 11, for example infrared, which can be located along the axis of the chamber above the molds. The conveyor 2 has a post 12 loading and measuring the mass of forms and post 13 vibroforming.

The post 12 for loading and measuring the mass of the molds is located in the gap of the rails of the conveyor 2. The pusher 7 passes through the post 12 without contacting it. After the pushing is completed, the form is on the table 14 mounted on four load cells 15.

The post 13 vibroforming is located in the gap of the rails of the conveyor 2. The pusher 7 forms passes through the post 13 without contacting it. After the pushing is completed, the form is on the table 16, mounted on four vibration mounts 17. From the bottom, electric vibrators 18 are installed on the table.

The conveyor 3 is placed in the cooling chamber 19, equipped with a cooling device, for example, fan 11. The conveyor 4 has a post 21 for stripping the products and a post 22 for installing the molds, where they clean, lubricate, assemble and set the molds in working condition to move them to the first conveyor and resume production cycle.

The operation of the device is as follows. On all conveyors, molds 5 are moved with pushers 7 with hinged stops 8 with a given cycle of work for a fixed step. On conveyors 1 and 3, the step of moving the molds is the same. Each conveyor for providing reciprocating motion of the pushers is equipped with an electromechanical drive 9. Forms 5 on the conveyor 1 during the movement in the chamber 10 are heated by infrared heaters 11 to a temperature of 140 ± 10ºС. It is also possible to heat the molds with hot gases produced in a heat generator, but such a system is more complex, more expensive and less efficient than electric heating. The heaters 11 are located on the axis of the molds, in the immediate vicinity of the vertical walls of the mold, which ensures maximum heat transfer from the heaters to the molds 5. Heated molds arrive on the conveyor 2, where they are moved to the table 14 of the post 12 and they load a predetermined amount of hot mass of concrete prepared using technical sulfur as an astringent. The amount of the loaded mass is measured by load cells 15 included in the weight measuring system of station 12. The presence of the weight measuring system allows the use of single or multi-seat forms loaded with concrete from the paver. After the concrete is loaded, the mold 5 is fed to the table 16 of the vibration molding station 13. The electric vibrators 18 are turned on, the table 16 mounted on the vibration mounts 17 starts to vibrate, and the mixture is distributed over the mold 5 and compacted. After passing the conveyor 2, the molds fall onto the conveyor 3 located in the cooling chamber 19. The cooling chamber has front and rear ends open for air passage, and a collector with a suction fan 20 is made in the middle of the chamber. Concrete in molds 5 is cooled with cold air to 70 ºС, after whereby the concrete in the molds acquires strength sufficient to remove products from the conveyor and transfer to the finished product warehouse. After passing the conveyor 3, the molds 5 get onto the conveyor 4, where at the post 21 the formwork is removed and the products are removed, and at the post 22 the molds are cleaned, lubricated and assembled in working condition and the molds are installed to move them to the first conveyor and resume the product production cycle.

Thus, the production line allows to obtain, with a high level of automation and in compliance with the requirements of the technology, concrete products using technical sulfur as an astringent.

The advantages of sulfur concrete are: increased quality characteristics; the possibility of using a wide range of raw materials; lack of need for water and cement; quick set of strength; the possibility of re-processing by remelting.

The properties of sulfur allow the use of the mixture and forms in the temperature range 114-150ºС. When lowering the lower temperature level to this value, there is a danger of concrete setting in places where the temperature drops below 114 ° C, and heating the mixture to higher temperatures requires additional heat, which will negatively affect the cost of the final product. Every 10ºС temperature increase requires for an item weighing 250 kg additional heat costs of the order of 1000 kcal, or 200 kg of standard fuel.

The optimum temperature range of the concrete mixture using technical sulfur as a binder when loading it into the mold was obtained experimentally, using the installation for the preparation of concrete mixture.

The table shows the properties of the mixture obtained at the outlet of the installation for the preparation of concrete mix, at different temperatures.

Npp. The temperature of the concrete mixture, ° C. Product Formation Result Concrete strength compression, MPa on a bend, MPa one 110 products could not be formed, crumbled - - 2 130 products received 41.3 9.9 3 140 products received 42.5 9.6 four 160 products received 28.9 4,5

At a temperature of 110 ºС, sulfur did not melt, concrete mixture was not obtained, and, therefore, further molding of products from such a mixture on the claimed production line was impractical.

At a temperature of 130 ° C, a concrete mixture was obtained with a uniform distribution of components throughout the volume. Due to this, high physical and mechanical properties of the obtained concrete were obtained, which allowed for further molding of products from such a mixture on the claimed production line.

At a temperature of 140 ° C, a concrete mixture was also obtained with a uniform distribution of components in volume with high physical and mechanical properties, which also allowed further molding of products from such a mixture on the claimed production line.

At a temperature of 160 ° C, the high viscosity of sulfur did not allow to obtain a homogeneous mass, due to this there were unmixed areas in the volume of the mixture, which sharply reduced the physical and mechanical properties of the products. Further molding of products from such a mixture on the claimed production line was impractical.

If molded products from a concrete mixture having a temperature of 130-140 ºС, in cold forms, then the first portions of the mixture, falling into a cold form, harden and do not allow to obtain high-quality products. While it is known that the melting point of sulfur is 114 ºС, and the high mobility of the mixture is maintained up to 150 ºС, it follows that it is advisable to have a mold heating range in the range of 120-130 ºС, therefore, taking into account mold cooling when transferring them from conveyor 1 to conveyor 2 it is advisable to heat the molds in the chamber 10 to a temperature of 140 ± 10 ° C.

The presence of the cooling chamber 19 allows you to quickly cool the products in the molds to a safe temperature of 70 ° C for workers, which reduces the number of molds and improves the efficiency of production. The presence of a weighing system complete with a paver allows you to expand the range of products molded on the device, to increase its effectiveness. The vibrating platform at the vibroforming station allows to obtain high-quality products that are not achieved on concrete based on cement and other traditional types of binders.

Based on the foregoing, the optimum temperature of the concrete mixture was adopted when loading it into the mold within 130-140ºС. The temperature of the molds should be above 120ºС. Given that all processes are carried out in the open air, there is a continuous loss of heat in the environment and a decrease in the temperature of the molds and concrete. This will occur especially quickly in forms having a large cooling surface. Therefore, the molds that get into molding 15-20 minutes after leaving the heating chamber are heated in the chambers to a higher temperature, so that after heat loss to the environment their temperature does not drop below 120 ° C. Unfortunately, it is impossible to make the mold body with thermal insulation, since after molding the concrete in the mold must cool down and set.

The temperature for cooling molds to 70 ° C was selected, including from safety conditions, 70 ° C is the temperature at which the painted surface does not burn hands during formwork. The temperature inside the product will be higher than on its surface, but lower than the melting temperature of sulfur. Cooling of the entire mass of the product occurs during storage in the warehouse.

Thus, due to the production of concrete products, using technical sulfur as an astringent, the above-described production line and the above-described method provide an increase in the quality of products, the efficiency and safety of their production, and the range of molded products is expanding.

Claims (19)

1. A technological line for the production of concrete products, comprising a closed conveying circuit formed by conveyors, equipped with a concrete loading station, a vibroforming station, and a product stripping station, characterized in that the closed conveying circuit is made of four series-mounted and technologically connected conveyors, on which molds are installed, made with the possibility of movement on conveyors, while the first conveyor is made in a heat-insulated chamber equipped with heating firs, second conveyor is provided with a post and a boot shape measuring weight and fasting vibromolding third conveyor is configured in the cooling chamber, and a fourth conveyor provided with a demoulding fasting and fasting products installation forms. 2. The production line according to claim 1, characterized in that the insulated chamber is equipped with infrared heaters. 3. The production line according to claim 2, characterized in that the infrared heaters are installed along the axis of the chamber in the immediate vicinity of the vertical walls of the form. 4. The production line according to claim 1, characterized in that the cooling chamber has front and rear ends open for air passage, and a collector with a suction fan is made in the middle of the chamber. 5. The production line according to claim 1, characterized in that the post loading and measuring the mass of the forms contains a table mounted on four load cells. 6. The production line according to claim 1, characterized in that the vibroforming station comprises a table mounted on four vibration mounts, and electric vibrators are installed on the bottom of the table. 7. The production line according to claim 1, characterized in that all conveyors are equipped with rails. 8. The production line according to claim 1, characterized in that all conveyors are equipped with pushers with folding stops. 9. A method of manufacturing concrete products, including moving molds in a closed conveying circuit, loading molds with concrete, vibrating and stripping products, characterized in that the closed conveying circuit is made of four sequentially installed and technologically connected conveyors, while the molds are heated on the first conveyor, on the second conveyor, a predetermined amount of hot mass of concrete is loaded into the heated molds and fed to vibroforming, on the third conveyor, loaded forms with a hot mass of concrete they are cooled by cold air, and on the fourth conveyor, the products are stripped off and transferred to the finished product warehouse, while after the products are stripped off, the molds are cleaned, lubricated, assembled and put into working condition to move the molds to the first conveyor and resume the product production cycle. 10. The method according to claim 9, characterized in that the first conveyor is installed in the heating chamber. 11. The method according to claim 9, characterized in that the heating of the molds is carried out in the heating chamber using infrared heaters. 12. The method according to claim 11, characterized in that the heating of the molds using infrared heaters is carried out to a temperature of 130 - 150 ° C. 13. The method according to claim 9, characterized in that the amount of load mass is measured by a weighing system. 14. The method according to claim 9, characterized in that the vibroforming is carried out on the table of the vibroforming station mounted on the vibration mounts using electric vibrators mounted on the bottom of the table. 15. The method according to claim 9, characterized in that the third conveyor is installed in the cooling chamber. 16. The method according to claim 9, characterized in that the cooling of the molds with the concrete mixture is carried out with cold air using a fan. 17. The method according to claim 9, characterized in that the cooling of the molds with the concrete mixture is carried out to a temperature of 70 ° C. 18. The method according to claim 9, characterized in that in the manufacture of products, as part of the loaded hot mass of concrete, technical sulfur is used as the binder. 19. The method according to claim 9, characterized in that the molds are moved on conveyors along rails with a given cycle of work for a fixed step.

Images