RU2661484C1 - Forming stationary complex for production of concrete stones - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: invention relates to production of building materials by means of vibrating presses and concerns a forming stationary complex for production of concrete stones from semi-dry (hard) concrete with various fillers, allows to make wall stones, tile paving, side stones and other small items from semi-dry (hard) concrete mixtures with various fillers. Stationary forming complex for production of concrete stones comprises a frame with unbalanced vibrators, a vibrating table, a pallet, a matrix and a traverse with a punch, hydraulic cylinders. Central part of the complex is a mold block consisting of a universal vibrating press, a hydraulic unit and a control cabinet. Universal vibrating press consists of a frame, a loading module mounted on it, a traverse, a punch holder, guide rails, a guide matrix block, matrixes, a vibrating table with a rigidly synchronized vibrating unit. Main part, which unites all the working organs of the universal vibrating press, is a welded frame, which is conditionally divided into two zones – a forming zone and a loading zone. Molding zone is a vibrating press itself, the loading zone is a loading module. Conveyor is attached to the loading zone side of the universal vibrating press. Roller conveyor is attached to the molding side of the vibrating press. On the left (or on the right) side of the molding zone, next to the vibrating press, a hydraulic unit is installed, on the frame of which the control cabinet is fixed; for accumulation of a molding mixture the complex is equipped with a bunker.

EFFECT: increased productivity and wider range of manufactured products, expanded molding zone by the number and height of the molded products, increased density of mixture laying.

6 cl, 1 tbl, 1 dwg

Description

The claimed invention relates to the field of production of building materials using vibrating presses and relates to a stationary molding complex for the production of concrete stones from semi-dry (hard) concrete with various aggregates, it makes it possible to produce wall stones, paving slabs, side stones and other small piece products from semi-dry (hard) concrete mixtures with various fillers.

The Rifey-Buran vibropress equipment and the Rifey-Polyus vibropress complex are widely known, the drawback of which is the need for the vibropress operator to have specific skills and ability to determine the quality of the mixture visually and when compressing the finished mixture in a fist when mixing the components of the mixture.

Known Installation for pressing products mainly from semi-dry building mixtures (Patent for invention RU 2070109, IPC B28B 1/08, publ. 10.12.1996). Usage: in the building materials industry for the production of tiles, solid and hollow stones for various purposes. The inventive installation for pressing products, mainly from semi-dry building mixtures, contains a bed with a metering device in the form of a feed hopper and a drive horizontally movable drawer feeder placed below it, a thrust table on elastic supports with an exciter of vibration, located between the columns connected in the upper part of the cross member covered by the guide bushings of the auxiliary, upper and lower traverse. The upper and lower traverses are kinematically connected with the rods of the power cylinders and are connected through elastic elements, respectively, with a punch and a matrix, the latter being supported through a removable bottom on a thrust table. The removable bottom is mounted on an additional carriage in series with a removable tray. The additional carriage is supported by an auxiliary traverse mounted on the rods of the power cylinders, and the vectors of horizontal movements of the main and additional carriages of the feeder for removable pallets are mutually perpendicular and lie in the same plane. The total stiffness of the elastic supports and the vertical distance from the guides of the main carriage to the surface of the auxiliary beam in the extremely low position exceed, respectively, 1.2–4.5 and 1.5–4.5 times the total stiffness of the elastic elements and the matrix. A significant drawback is the bulkiness of the equipment and the difficulty of incorporation into automated production lines for the production of stones from building mixtures for various purposes.

A device for pressing products from building mixtures is known (Patent on the subway RU 111802, IPC B28B 1/08, B28B 3/00, publ. 12/27/2011). The utility model relates to the construction industry, namely, devices for pressing concrete products. A device for pressing products from building mixtures is proposed, including a fixed frame, a hopper, a table with vibrators, a traverse with a punch and a bottomless matrix closed around the perimeter that contacts the table surface through the pallet, vertical cylinders of the matrix and the punch traverse. The hopper is placed directly on the frame. Two eccentric vibrators are located symmetrically and perpendicular to the supporting ribs of the table. Two cylinders of vertical displacements of the matrix and a cylinder of vertical displacement of the punch are fixedly mounted on the transverse beam of the frame located between the traverse of the punch and the movable beam. Two movable guides are rigidly attached to the beam, in the lower part of each of which is a split key-ring connection of the brackets of the removable matrix. The claimed device is characterized by a simplified design, provides a reduction in metal consumption and cost. The disadvantages of this installation are the high cost of manual labor, low productivity and the difficulty of integrating it into in-line automated lines for the production of stones from building mixtures for various purposes.

A device for molding concrete products is known (Patent for invention RU 2366572, IPC B28B 1/08, publ. 09/10/2009). The invention relates to the field of molding. A device for molding concrete products includes a molding table with supports, a vibration exciter having a drive located on the site in the loading zone and a crank pair kinematically connected to the molding table, an elastic element and placed on the molding table and removably associated with it. The mold is made with a removable bottom in the form of a pallet and is equipped with at least two clamps, the molding table has at least three supports that are equipped with wheels, two of which are mounted coaxially. The elastic element is made in the form of a cylindrical compression spring and is integrated into the connecting rod of the vibration exciter, which provides vibration of the molding table with a frequency in the range of 1.0-2.5 Hz and amplitude in the range of 0.020-0.070 m. The connecting rod is made of two axially movable parts, kinematically closed through an elastic element. The butt ends of the connecting rod have helical grooves that engage with the end sections of the compression spring, and the connecting part of the connecting rod of the vibration exciter is detachably connected to the molding table from the side of the supports with coaxial wheels. The technical result is to improve the quality of manufactured products. Significant disadvantages of the known invention is the dependence of the amplitude of the horizontally directed oscillatory movement of the molding table on its mass and on the oscillation frequency, which leads to the deviation of the accelerations of the molding table from their specified optimal values, as well as the difficulty of incorporation into automated production lines for the production of stones from building mixtures for various purposes .

The closest in technical essence to the claimed object is a device for pressing products from building mixtures (Patent for invention RU 2230659, B28B 1/08, B28B 3/00, publ. 06/20/2004). The invention relates to the manufacture of building products by the method of semi-dry vibrocompression. The device consists of a vibrating table, a frame with unbalanced vibrators, a pallet, a matrix and a traverse with a punch, hydraulic cylinders, the matrix being bottomless and mounted on brackets and in contact with the table surface through the pallet, the device is equipped with a bed, which is equipped with fixed table supports and elastic guides provided bushings with vibration-isolating column supports located in the upper part of the bed; in addition, the matrix and punch are connected directly to the table by cylinders of vertical displacements appearing on the table. Significant disadvantages of the known device are: excessive complexity of the design, in addition, the device has large overall dimensions that require appropriate areas for placement, the disadvantages of the prototype include the lack of a control panel for the working bodies of the device, as well as the difficulty of incorporation into in-line automated stone production lines of building mixtures for various purposes and the inability to include additional equipment in the complex, dimogo for its greater mechanization in a user-friendly sequence.

The technical task of the claimed invention is to eliminate these disadvantages, which will allow, while maintaining vibrational safety, due to the design solution, to increase productivity and expand the range of manufactured products, reduce the cost of manufactured products, by reducing the drying time of the finished product due to manufacturing by vibrocompressing a semi-dry mixture, expand molding area according to the number and height of the molded products, increase the density of the mixture, the implementation of Troll for the working bodies of the complex.

The technical task is achieved by creating a stationary molding complex for the production of concrete stones, whose technical and ergonomic characteristics guarantee a longer service life, increased productivity due to the design solution and the expansion of the range of products.

The problem is solved by creating a stationary molding complex for the production of concrete stones, which consists of a frame with unbalanced vibrators, a vibrating table, a pallet, a matrix and a crosshead with a punch, hydraulic cylinders, the central part of the complex being a molding block consisting of a universal vibrating press, a hydraulic unit and a control cabinet, universal vibrating press consists of a frame, a loading module mounted on it, a traverse, a punch holder, guide rods, a block of matrix guides, a matrix, brostola with tightly synchronized vibroblokom; the main part, uniting all the working bodies of the universal vibrating press, is a welded frame, which is conditionally divided into two zones - the molding zone and the loading zone; the forming zone is the vibropress itself, the loading zone is the loading module; a conveyor is attached to the universal vibrating press from the side of the loading zone, a roller table is attached to the universal vibrating press, a hydraulic unit is installed on the left (or right) side of the forming zone near the vibrating press, on the frame of which the control cabinet is fixed; to control the position of the executive bodies contactless induction switches are provided, the complex is equipped with a hopper for accumulating the molding sand; automatic cycle of the complex is possible.

Technical characteristics of the proposed facility are shown in table 1.

The essence of the claimed invention is illustrated by graphic material (drawings), where a general view of the claimed technical solution and a top view for a better understanding are arranged.

Stationary molding complex for the production of concrete stones consists of a molding block consisting of a universal vibrating press (hereinafter - UVP), a hydraulic unit 28 and a control cabinet 26. The UVP consists of a vibrating press 7 and a loading module 13 mounted on its frame. To the UVP from the side of the loading zone is connected a conveyor 19 for supplying an empty pallet 21 from the store of pallets 20 to the forming zone. The filled pallet with freshly molded products is pushed onto the carriage 3 of the rolling table 2. From the side of the molding zone, the roller table 2 is attached to the UVP, to which the pallets with molded products come after they are molded and move along it further into the accumulation zone of the pallets - rack 1, which is mounted on racks with its supports live rolls. The receiving surface of the rack is located below the surface of the rollers of the roller table 2, which provides free movement of pallets on the rollers of the roller table 2 above the rack. In vibrating press 7 is the molding of products. The products are molded in a forming tooling (set “matrix-punch”), which during the molding cycle moves progressively up / down. Its fastening is made to the movable elements of the vibropress: the matrix - to the guide blocks 6, and the punch - to the punch holder 9. The movement of the guide blocks 6 and the punch holder 9 is provided by hydraulic cylinders 22 and 10, respectively. Rods 8 are guides when moving blocks of guides and punch holder. To ensure the pressing of "low" products (products up to 90 mm high), a frame with a punch is attached to the punch holder 9. The surface of the product molding is the pallet 21, which is installed on the vibrating table 24. When the punch 31 is moved down into the die, the products are finally molded (pressed). The hopper 12 is a reservoir of sand. When opening the shutter 16, the molding mixture fills the loader box, which moves it into the matrix. Filling the hopper 12 with molding sand can be done in any mechanized way. The mutual movement of the loader relative to the die and the punch during the molding cycle (blocking) is controlled by non-contact induction switches (hereinafter the sensor). For this purpose, the sensors are installed on the vibrating press frame (2 pcs.) And the boot module frame (1 pc.). On the left side of the molding zone, a hydraulic unit 28 is installed next to the vibrating press, which is designed to supply the working fluid under working pressure to the hydraulic system of the complex and control the hydraulic cylinders of the complex. High-pressure hoses connect the hydraulic unit to the hydraulic cylinders of the working bodies of the vibrating press, conveyor and roller table. A control cabinet 26 is mounted on the valve body frame 28, in which the electrical circuits of the complex are located that control the operation of electric drives. Management is carried out from the front control panel 29, which is displayed on the door of the control cabinet and is an electric control panel. The control of hydraulic cylinders: guide blocks, punch holder, loader, dispenser flap, conveyor trolley and roller conveyor carriage is carried out by supplying control pressure from the control valve 27 to the corresponding hydraulic cylinder of the complex. The control is carried out by the handles 30. The control valve 27 acts as a hydraulic control panel. On the panel located below the valve, opposite each of its sections are marked with symbols (symbols) corresponding to the movement of the working bodies.

Works Complex molding stationary for the production of concrete stones as follows.

Turn on the valve body by pressing the START PUMP STATION button. Check the installation of the working bodies of the complex in the initial position:

- the loader is on the stop under the hopper (the sensor is on),

- punch - in the upper position (the sensor is on),

- the matrix is in the upper position (the sensor is disabled),

- conveyor trolley - in the extreme rear position,

- roller conveyor carriage in front position.

The molding mixture is loaded into the hopper by any mechanized method. With the handle of the CONVEYOR (onto itself), push the rear pushers out of the empty pallets from the pallets store onto the conveyor trolley and, moving it with the trolleys pushers, set them on the vibrating table. Using the MATRIX handle (towards yourself), move the matrix down to the stop and press the pallet to the vibrating table. Using the BUNKER handle (onto yourself), open the shutter and fill the loader with the molding mixture. Use the BUNKER handle (away from you) to close the shutter. Using the LOADER handle (towards yourself), the loader moves forward onto the matrix, filling the matrix with the molding mixture to its upper plane. The required amount of the molding sand during loading is determined from the condition that the voids of the matrix are completely filled with the molding sand with the addition of a small amount of excess mixture in order to prevent underfilling of the internal cavities of the matrix with the molding sand after vibration is completed. In the process, the operator determines from his work experience how much it is necessary to load the molding sand into the matrix so that there are not too many surpluses.

By controlling the LOADER handle, the loader makes several reciprocating movements with an amplitude of 100-200 mm, leveling the surface of the molding mixture with the loader agitator and at the same time turn on the vibrators for 3-5 seconds by pressing the VIBRATOR button or by pressing the PEDAL, and pre-press the products. The time of preliminary pressing depends on the shape and height of the product, the rigidity and composition of the mixture and is selected experimentally in the process of preliminary moldings. Turn off the VIBRATOR or PEDAL and use the LOADER (from yourself) to move the loader to its original position under the hopper. Using the PUNCH handle (toward you), move the punch into the matrix while turning on the vibrator with the START VIBRATOR button or by pressing the PEDAL, and make the final pressing of the products. Usually it is 4-10 seconds. After that, the product is additionally kept in vibrocompression mode to obtain accurate geometric parameters. The time required for prepress is determined empirically.

Turn off the VIBRATOR or PEDAL, leaving the punch in the lower position. “Molding” of the molded products is carried out, for which the MATRIX handle (away from me) lifts the matrix up until the stones are completely released (the gap between the bottom of the matrix and the top of the product is at least 15 mm), while the punch remains in the lower position, pressing the molded products to the pallet. After that, with the handle of the PUNCH (from myself) they lift the punch up. Using the CONVEYOR handle (towards you), move the conveyor carriage forward and push the carts with the pushers of the molded products from the vibrating table to the roller table carriage, while simultaneously installing an empty pallet on the vibrating table. Using the ROLANG handle (towards you), grabbing the pallet with the rollers of the roller table carriage, move the pallet further along the roller table. With further molding of the products, each subsequent pallet moves the previous pallet along the live table until the rack is filled with pallets. Filling the rack with pallets and using a load-gripping mechanism, they transfer it to the aging zone, and an empty rack is installed in its place. The cycle of molding products is repeated.

The proposed stationary molding complex for the production of concrete stones is characterized by a new set of essential features and satisfies the criterion of "inventive step", since the proposed set of essential features is not used in installations of a similar purpose, known from the patent and technical literature and not solving the problem of increasing productivity and quality of molded products while reducing the complexity of manufacturing the latter.

The use of the proposed stationary molding complex for the production of concrete stones, while maintaining vibration safety, is technically and economically feasible, since it will allow:

- reduce the cost of manufactured products by reducing the drying time of the finished product due to the fact that the manufacture is carried out by vibropressing a semi-dry mixture;

- monitor the entire process of vibrocompression using the control panel of the working bodies of the installation;

- include in the composition of the complex additional equipment necessary for its greater mechanization in a sequence convenient for the consumer;

- operate the vibrocompression cycle automatically.

The analysis of the prior art shows that the technical solution is not known, which has inherent features identical to all the essential features of this technical solution, which indicates its unknownness and, therefore, novelty.

Claims (6)

1. Stationary molding complex for the production of concrete stones consists of a frame with unbalanced vibrators, a vibrating table, a pallet, a matrix and a crosshead with a punch, hydraulic cylinders, characterized in that the central part of the complex is a molding block, consisting of a universal vibrating press, a hydraulic unit and a control cabinet, and universal vibrating press consists of a frame, a loading module, a traverse, a punch holder, guide rods, a guide block of a matrix, a matrix, a vibrating table with tightly synchronized nym vibroblokom; the main part, uniting all the working bodies of the universal vibrating press, is a welded frame, which is conditionally divided into two zones - the molding zone and the loading zone; the forming zone is the vibropress itself, the loading zone is the loading module; a conveyor is attached to the universal vibrating press from the side of the loading zone, a roller table is attached to the universal vibrating press, a hydraulic unit is installed on the left (or right) side of the forming zone near the vibrating press, on the frame of which the control cabinet is fixed; the complex is equipped with a hopper to accumulate the molding sand. 2. Stationary molding complex for the production of concrete stones according to claim 1, characterized in that it combines a set of devices, such as a loading module, rolling table, rack, conveyor, valve body with a control cabinet. 3. The stationary molding complex for the production of concrete stones according to claim 1, characterized in that the rod guides of the punch and die (4 pcs.) Are fixed in the frame and are not movable. 4. The stationary molding complex for the production of concrete stones according to claim 1, characterized in that the vibrating table is equipped with a vibrating unit with unbalanced shafts rigidly synchronized through gears. 5. The stationary molding complex for the production of concrete stones according to claim 1, characterized in that contactless induction switches are provided for monitoring the position of the executive bodies. 6. The stationary molding complex for the production of concrete stones according to claim 1, characterized in that an automatic cycle of the complex is possible.

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