RU2796339C1 - Dry mortar preparation system - Google Patents

Abstract

FIELD: construction equipment.

SUBJECT: mixers for the preparation of a dry building mix from components that differ in their physical properties. The system for preparing a dry mortar consists of a first stage mixer, a second stage mixer located below it, a control system consisting of a control panel (CP), an automatic control unit, a packaging machine control unit, a second stage mixer inverter, a second stage mixer motor and pneumatic discharge valves of finished products. The mixer of the first stage is made with the possibility for each loaded component of the mixture, in accordance with the commands received from the automatic control unit, to rotate for a certain amount of time, after which the material is dumped into the mixer of the second stage. The control panel is configured to send a sequence of control commands to the automatic control unit. The automatic control unit is configured to transmit control commands to the first stage mixer, the second stage mixer inverter, the second stage mixer motor and the finished product unloading pneumatic dampers. The packaging machine control unit is configured to transmit control commands to the automatic control unit.

EFFECT: improving the quality of the finished mixture and providing the possibility of flexible and quick adjustment of the production cycle when the characteristics of the raw materials change.

1 cl, 4 dwg

Description

The invention relates to construction equipment, and more specifically, to mixers for preparing a dry building mix from components that differ in their physical properties.

For the production of liquid wallpaper, many components are used.

The main ones are: cellulose, fiber, glue and decorative additives.

To qualitatively mix all the components, you need:

1. Grind the pulp well so that there are no large lumps.

2. Spin the chopped fiber so that there are uniform "cocoons", or, conversely, break them into very small fractions.

3. Add glue, which has a different fraction from 0 to 2 mm. In this case, glue with a fine fraction may crumble if the mixer shaft is slowly rotated. Or, on the contrary, it can scatter along the walls of the mixer if the mixer shaft is brought to higher rotational speeds.

4. Decorative additives should not be excessively crushed, but at the same time they should be well and evenly distributed.

Thus, some components of the mixture must be mixed intensively, others, on the contrary, with a minimum intensity, and others - at medium mixer speeds, but with an increased exposure time.

If all this is done in mixers, as recommended by various manufacturers, then obtaining the required quality of the mixture is not a trivial task.

In the production of dry building mixtures, a system is used from a set of dispensers, a mixer and a packaging line. In the production of liquid wallpaper, it is necessary to mix various components of different bulk density and with different physical properties.

Due to the fact that the production of liquid wallpaper requires several components that differ significantly from each other in physical properties, it is not possible to prepare a finished product of proper quality on such a standard system of equipment.

To solve this problem, pre-processing of components is usually used.

The closest in technical essence to the present invention is a unit for the preparation and supply of high-viscosity materials, described in patent RU 8632 U1, publ. 12/16/1998, containing a mixing apparatus, including an electric motor, a gearbox, a receiving hopper, a finished material supply system, a pre-mixing device installed above the receiving hopper of the mixing apparatus.

The disadvantage of the known solution is that the pre-mixing device does not involve separate processing of components that differ significantly from each other in physical properties. Another disadvantage is that the mixing apparatus in the known solution does not have the ability to maintain the mixture homogeneous, since it is possible for some fine components to spill down.

To solve the problem, according to the invention, it is proposed to use two mixers. The first is needed to prepare the required mixture. The second is used to feed this mixture to the packaging.

According to the proposed invention, the system for preparing a dry mortar contains a first-stage mixer, a second-stage mixer located below it, a control system consisting of a control panel (CP), an automatic control unit, a packaging machine control unit, a second-stage mixer inverter, a second-stage mixer motor and pneumatic dampers for unloading finished products. The mixer of the first stage is made with the possibility for each loaded component of the mixture, in accordance with the commands received from the automatic control unit, to rotate for a certain amount of time, after which the material is dumped into the mixer of the second stage. The control panel is configured to send a sequence of control commands to the automatic control unit. The automatic control unit is configured to transmit control commands to the first stage mixer, the second stage mixer inverter, the second stage mixer motor and the finished product unloading pneumatic dampers. The packaging machine control unit is configured to transmit control commands to the automatic control unit.

The mixers are positioned one above the other, which reduces the loss of materials (settling on conveyor belts, trays, tanks, etc.) and saves the time of loading components from the first mixer to the second.

The upper, main, mixer prepares the components, into which they are loaded in turn.

They are also loaded into the lower mixer in turn, when they are prepared by the upper, main mixer. After all ready-made components get into the lower mixer, it makes a general, summing batch and starts distributing the material for packaging.

The second stage mixer has a triple purpose.

- preparation of the total summing batch;

- maintaining the overall uniform composition of the mixture;

- supply of material to the packaging line.

In order for the lower mixer to work in two modes, the speed of rotation of the working shaft is changed. When it is necessary to direct the material to the package, it operates at a reduced speed. When you need to do a summing batch, its speed increases. All this happens automatically by changing its operating parameters on command from the automatic control unit.

This ensures the quality preparation of the components of the mixture, mixed properly, and the ability to send to the finished mixture for packaging.

When applying the proposed solution using a system of mixers, an increase in the quality of the product is achieved due to the fact that the mixer of the first stage prepares each component or mixture separately and independently of other components that differ in physical properties in turn. Further, the prepared components enter the mixer of the second stage, which is switched on in the appropriate mode and prepares the total batch. An improvement in the quality of the finished mixture is further ensured by the fact that the second stage mixer keeps the mixture homogeneous. The second stage mixer also provides a uniform supply of the mixture to the packaging line, as well as the ability to flexibly and quickly adjust the production cycle when the characteristics of the raw materials change.

In FIG. 1 shows a diagram of the mixer system with symbols, side view.

In FIG. 2 shows a diagram of the mixer system with designations top view.

In FIG. 3 shows a diagram of the mixer system with front view designations.

In FIG. 4 shows a diagram of the operation and control of the mixer.

The system for preparing a dry mortar contains a mixer 1 of the first stage, a mixer 2 of the second stage, a gear motor 3 and a drive shaft of the first stage mixer, a gear motor 4 and a drive shaft of the second stage mixer, dosing windows 5, 6 mixture components for the first stage mixer, cooling fan 7 of the motor-reducer, damper 8 of the first-stage mixer, funnel 9 of the first-stage mixer, additional pneumatic damper 10 of the first-stage mixer, inspection doors 11 of the first-stage mixer, drive cabinet 12 of the first-stage mixer, inspection door 13 of the second-stage mixer, support shaft support 14 of the mixer of the second stage, gas outlets 15 for removing excess pressure, disintegrators 16 of the mixer of the first stage (disintegrators are displaced along the path 17 during dismantling), pneumatic blowing 18 of the mixer shafts, pneumatic damper 20 for unloading finished products, mounting supports 21 of the mixer system, outlet for aspiration connections 22, hatch 24 of the mixer of the first stage.

Mixer 1 of the first stage is used for the sequential preparation of the components of the mixture.

Mixer 2 of the second stage is used to prepare a general batch, maintain a uniform composition of the mixture, and supply material to the packaging line.

Dosing windows 5, 6 components of the mixture for the mixer of the first stage include an actuator with a pneumatic cylinder.

The damper 8 of the mixer of the first stage is used to supply the components of the mixture.

Funnel 9 of the mixer of the first stage is used to supply the components of the mixture.

An additional pneumatic damper 10 is used to feed the finely dispersed components of the mixture into the first stage mixer.

Inspection doors 11 of the mixer of the first stage are used for servicing the mixer.

In the drive cabinet 12 of the first stage mixer, there is a drive for the unloading hatch of the first stage mixer.

The inspection door 13 of the mixer of the second stage is used for servicing the mixer.

Pneumatic purge of 18 mixer shafts is designed to eliminate stagnant zones.

Description of the operation of the system.

The control system consists of the following main elements: a control panel (CP), an automatic control unit, a packaging machine control unit, a second stage mixer inverter, a second stage mixer motor, and finished product discharge pneumatic dampers.

With the help of the control panel, the operator sets the mode of operation - the sequence of execution of commands and the duration of each stage of work. Also, the operator has the ability to give control commands at each stage and control the workflow. The control panel and automatic control unit also send commands to the first stage mixer.

The automatic control unit can be implemented on any logic controller, for example, Aries PLC 110-30. This block receives commands and issues control signals to the actuators.

The control unit of the packaging machine issues control signals to the control panel and the automatic control unit and receives a signal about the start of the packaging process from these devices.

The inverter controls the operating modes of the working shaft of the mixer and changes it at the right time.

The engine (motor-reducer) of the mixer of the second stage receives commands from the inverter and directly drives the working shaft of the mixer into rotation.

Pneumatic gates for unloading finished products receive signals from the automatic control unit for opening/closing for unloading finished products.

Control commands to the automatic control unit come in the form of discrete signals with a duration of 0.3-0.6 seconds from the control panel.

The control unit operates in several modes depending on the work cycle:

1. Preparation of the total summing batch.

The first stage mixer prepares the mixture in terms of the optimal quality of its components in accordance with the technological map. Each time it rotates for a certain amount of time, after which the material is discharged on command from the PU into the mixer of the second stage. After the end of the reset, the control panel receives a signal that the reset is over and the control unit sends a signal to the inverter, which turns on the rotation at an operating frequency of 15 Hz for 15 seconds. This is necessary to level the material on the bottom of the mixer.

After preparing the next component, the procedure is repeated.

After the final reset of the premixes of the first stage mixer and its emptying, the process of preparing the general batch in the second stage mixer begins. The control unit sends a signal to the inverter, and it turns on the motor at a frequency of 60 Hz for 40 seconds. At the end of this time, the mixer automatically stops and waits for a command from the control unit of the packaging machine about its readiness.

2. Maintaining the overall uniform composition of the mixture.

In the event that the packaging machine does not pack the material, or this process stops, the automatic control unit switches the mixer into the mode of maintaining a homogeneous composition. To do this, the control unit has a timer that is triggered if the packaging machine is idle for more than 20 seconds. At the same time, the control unit closes the loading hatches and blocks their opening.

The control unit generates commands to the inverter to rotate the mixer motor at a frequency of 10 Hz in the forward and reverse direction for 10 seconds in each direction. After the end of the procedure, the timer is reset. If the timer is triggered again after the set time, the procedure is repeated until the control unit receives a command from the packaging machine to start packaging.

3. Supply of material to the packaging line

When a command is received from the packaging machine to start packaging, the automatic control unit opens the shipping hatches and sends a command to the inverter to operate the motor at a frequency of 1 Hz. In this case, it is possible to achieve a uniform supply of material to the packaging machine. After the end of the material in the mixer of the second stage, the packaging machine gives a signal that the material has run out. After a signal is received, information about this is displayed on the control panel (information lamp lights up), and the control unit turns on the exposure timer for the next batch. The operator can force the start of the next batch. After the end of the exposure timer (15 seconds), the command to start the next batch will be automatically generated by the control unit and the control unit closes the loading hatches. The work cycle is repeated.

4. If it is necessary to clean the mixer after changing the article numbers of products, when opening the working hatches, the control unit blocks the operation of the inverter to ensure safety.

A detailed example of the preparation of a general batch.

The operator on the PU sets the mode of operation - the sequence of execution of commands and the duration of each stage of work. Then PU gives the command to start the batch.

The signal about the start of mixing is sent to the dosing system. The loading hatch 6 opens and the raw materials for the preparation of the mixture enter the mixer of the first stage. This hatch is used for bulk materials of various densities, pre-dosed in accordance with the technological map, including adhesives, thickeners and fillers. A screw conveyor (not shown) can be used as transportation. After the dosing is completed, the information light on the control panel goes out and the dosing system closes the loading hatch 6. The control panel gives a command to rotate the mixer, and it starts working for 60 seconds. For high-quality preparation of the mixture, the PU additionally includes disintegrators 16. After the end of the required time in accordance with the technological map, in this case 60 seconds, the PU gives a command to stop the rotation of the mixer working shaft. This opens the hatch 24 of the mixer of the first stage and the signal about the readiness of the first portion is sent to the control unit of the mixer of the second stage. After receiving this signal, the control unit switches it to the mode of preparing a general summing batch. After the end of emptying the mixer of the first stage, the PU closes the discharge hatch 24, and the control unit sends a signal to the inverter of the mixer of the second stage, which turns on the motor-reducer 4 of the mixer of the second stage for 15 seconds at a frequency of 15 Hz to equalize the batch according to the volume of the mixer.

After the end of the alignment process, the rotation of the motor-reducer 4 ends automatically.

PU includes the mode of the second dosing of raw components. For their entry into the mixer, a pneumatic damper 22 opens. This damper is used to supply fillers with a low bulk density, such as pneumotextured threads and fibers. Their supply can be carried out both by screw conveyors and by gravity from large-capacity hoppers, into which these additives are pre-dosed, both with preliminary preparation and with the help of dispensers (not shown). Also, the necessary finely dispersed components, such as, for example, dyes, marble or sand fillers, decorative flocks, mica, in accordance with the technological map, are added through the damper 8 of the first stage mixer or the pneumatic damper 10. 5 closes. Next, the PU gives a command to start rotation and the motor-reducer of the mixer of the first stage 3 starts rotating the working shaft. This also turns on the cooling fan 7 of the geared motor. After the end of the time in accordance with the technological map, in this case 40 seconds, the PU stops the rotation. At the same time, the hatch of the mixer of the first stage 24 opens, and the signal about the readiness of a portion of the raw material is sent to the control unit of the mixer of the second stage. After the end of emptying, the mixer of the second stage repeats the procedure for leveling the batch and stops automatically, at the same time, a signal is sent to the operator's control panel that the mixer of the second stage is ready.

Next, the PU gives a control command to start unloading, because. all the necessary components of the mixture are prepared and added to the mixer of the second stage.

The control unit receives this signal and, through the inverter, turns on the gear motor 4 of the mixer of the second stage for 40 seconds at a speed of 60 Hz. After this time has elapsed, the rotation stops and the control unit waits for a ready signal from the dosing system. If the signal is not received for more than 20 seconds, the procedure for maintaining the overall uniform composition of the working mixture begins. The control unit sends a signal to the inverter motor reducer to rotate the working shaft of the mixer of the second stage for 10 seconds in the forward and reverse direction with a frequency of 10 Hz.

After receiving the ready signal of the packaging machine, the unloading of the finished product begins. The control unit generates a pulse to open the unloading pneumatic dampers 20, as well as a signal to the inverter, which drives the mixer gear motor of the second stage at a frequency of 10 Hz.

After the unloading of finished products is completed, the control unit receives a signal from the packaging machine, it turns off the inverter, the motor-reducer 4 and the working shaft of the mixer stops, the control unit closes the pneumatic gates for unloading 20 finished products.

After 15 seconds, the control unit generates a signal to the control panel about the end of the work cycle and readiness for the next cycle.

The mixer cycle is repeated.

When using the traditional method of general kneading, large particles larger than 5 mm remained in the pulp, the binder was not distributed evenly, and decorative additives were excessively crushed. The dye did not evenly color the fibers and the cellulose component, since the fibers in disintegrated form have the cumulative effect of fine powders and accumulate the dye. The accumulated dye highlights them, and the mixture loses its property of uniformity.

When implementing the proposed solution, the components were divided into two groups of materials, which were prepared separately and alternately in the first stage mixer. After preparation, they were redirected to the second stage mixer, where they were mixed together until a homogeneous mixture.

After making a number of production lots, a sample was taken from each of them. Next, the samples were deposited on one surface end-to-end. The result was obtained that all samples are identical in appearance and in the properties of applying materials.

This confirmed that this solution made it possible to solve the problem of mixing dissimilar components successfully.

The advantages of the proposed solution are as follows:

- due to the independent preparation of the components of the mixture, the finished product (in particular, liquid wallpaper) is of higher quality;

- flexible and quick adjustment of the production cycle is possible when the characteristics of raw materials change if they are detected at the input control or one of the components is replaced;

- the use of the mixer of the second stage in different modes of operation allows to reduce the cost of equipment due to universalization without loss of performance.

Claims (5)

A system for preparing a dry building mixture, containing a first-stage mixer, a second-stage mixer located below it, a control system consisting of a control panel PU, an automatic control unit, a packaging machine control unit, a second-stage mixer inverter, a second-stage mixer motor and pneumatic discharge valves products, and the mixer of the first stage is made with the possibility for each loaded component of the mixture, in accordance with the commands received from the automatic control unit, to rotate for a certain amount of time, after which the material is dumped into the mixer of the second stage, the control panel is configured to send a sequence of control commands to the automatic control unit, the automatic control unit is configured to transmit control commands to the first stage mixer, the second stage mixer inverter, the second stage mixer motor and the finished product unloading pneumatic dampers, the packaging machine control unit is configured to transmit control commands to the automatic control unit.

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