RU2818201C1 - Technological complex for production of items of drainage systems and water disposal - Google Patents

Abstract

FIELD: hydraulic engineering.

SUBSTANCE: invention relates to equipment for production of items of drainage systems and water disposal. Process complex comprises a corrugated pipe winding device to produce a spiral workpiece and gluing its layers (1), unwinder (5), a geotextile cutting device (6), stiffening ribs gluing device (8), support trolley (2) and filter loading bin (9). Unwinder (5) contains a frame disk with guides diverging from the center, on which shelves are installed. Stiffening ribs gluing device (8) consists of movable frame with bearing support of cantilever type, platform with two-stage worm gear motor and limiter for installation of toroid-shaped workpieces. Support trolley (2) comprises a movable platform with a lifting scissor mechanism, having a drive in the form of a trapezoidal thread screw and a handle for rotation, and installed on movable platform with possibility of movement and fixation of rotary support rollers with support platform.

EFFECT: as a result, the range of products is increased with minimum replacement of tooling.

1 cl, 7 dwg

Description

The invention relates to a technology for the production of reinforced seamless products with a polymer matrix, which includes the continuous production of composite polymer pipes by extrusion, specifically, to equipment for the production of drainage and water disposal products made from corrugated and smooth plastic pipes by gluing a wound spiral.

Modern types of pipes are produced using the same technology; the difference is only in the design and layout of the main blocks of the line. The output is cylindrical or corrugated products with a cross section of 16-1600 mm.

Various methods for producing a composite reinforced polymer pipe are known from the prior art, according to which, at the first stage, threads or tapes of high-modulus fibers or metal wire are wound onto a mandrel in the form of a polymer pipe-blank, and at the second stage, the resulting semi-finished product is covered with an outer layer of polymer.

Unlike steel analogues, products made from polymer materials are characterized by lightness of construction, cost-effectiveness, chemical inertness and ease of installation.

Spiral pipes are products used in various industries, agriculture and public utilities, and in everyday life during installation:

- sewerage systems, drainage, storm water drainage, industrial wastewater - made of polyethylene (PE), polyvinyl chloride (PVC);

- air ducts - made of galvanized, stainless steel, aluminum.

Spiral pipes are manufactured on spiral-wound machines using the method of continuous spiral winding of a profile, which is connected to each other to form a single body (welded, rolled).

Known sets of equipment for the production of polymer and metal spiral (corrugated) pipe products of round cross-section of various diameters made in China (Eagle Machinery Co, Ltd) are highly efficient lines for the production of plastic pipes for various purposes: gas, sewer, water supply, drainage, electrical and others. Here a smooth water or gas pipe is glued together. The result is a continuous sealed wall.

The Polymer System Group is known for its line for the production of drainage pipes (https://www.all-upack.m/katalog/products/ekstmziormve-linii/proizvodstrub/drenazhnye-truby). The extrusion line is designed for the production of corrugated drainage pipes. Pipe diameters are specified by the customer.

The pipe has the following shape: single-layer, corrugated, there are holes on the walls, the pipe is protected by a geotextile coating.

The pipe has holes that perform a drainage function; water enters the pipe and then flows out at the end of the pipe. Geotextiles protect the drainage pipe holes from being clogged with earth. The drainage pipe production technology involves the following operations: the extruder die forms a pipe from the polymer melt, which is fed to corrugated tracks, where corrugation occurs. The resulting pipe is perforated. Up to 6 holes can be cut on one edge. Then the pipe enters the braiding zone, where it is covered with geotextile (spunbond). The finished drainage pipe is wound into coils.

The Politek company produces drainage pipes made of polyethylene in two versions: with and without perforation (not currently available for sale). Before laying in the ground, perforated drainage pipes can be additionally wrapped in filtering geofabric. If a geofabric filter is used, then a higher degree of efficiency of the system is noted, since this special material retains large and small particles of contaminants and sand, which significantly reduces the likelihood of rapid siltation of the drainage system from the inside. flittps://politek-ptk.ru/catalog/drenazhnve-truboprovodv/).

A device for forming circumferential reinforcement of a seamlessly drawn hollow product is known (RU, 2626039, F16L 9/128, B29S 63/24, published July 21, 2017), including a spool with circumferential reinforcement material, a support for laying circumferential reinforcement, a circumferential reinforcement stacker containing a guide roller and a pressure roller installed on the faceplate with the possibility of rotation around the longitudinal axis of the product being formed, characterized in that in front of the support for laying the circumferential reinforcement, a bypass roller is installed coaxially with it, and a coil with the material of the circumferential reinforcement is placed on the side of the bypass roller with the possibility of supplying the circumferential reinforcement to said bypass roller in a direction approximately perpendicular to the axis of the product being formed, and with the possibility of the circumferential reinforcement making at least one turn along the surface of said roller coaxially with the turns of the subsequent spiral winding.

A technological complex for corrugating a flame tube is known (RU, 2273539, B21D 15/06, 04/10/2006). The complex contains a device, fixedly installed on the base, for securing one end of a tubular billet with the possibility of its rotation around a longitudinal horizontal axis, a device for fixing the other end of a tubular billet, ensuring upsetting during rolling of each corrugation, a device for local heating of the area where each corrugation is made with high-frequency currents, and a corrugated rolling machine a mechanism for rolling corrugations during bending and upsetting of the metal of a tubular workpiece, while the device for local heating of the zone where each corrugation is made contains a ring inductor installed with the possibility of enveloping the tubular workpiece, transverse and longitudinal movement relative to it and fixing positions in the heating zones. The corrugated rolling mechanism includes a profiled roller for bending the metal of a tubular workpiece when rolling each corrugation, made with a profile of its working surface corresponding to the profile of the corrugation cavity in the range between the points of change in the sign of the curvature of the arc of this cavity or the law of its change, and the profiled roller is installed with the possibility of longitudinal movement along corrugated tubular workpiece with intermediate fixation of positions in the zones of rolling and transverse movement in a plane perpendicular to the longitudinal horizontal axis of the tubular workpiece. The complex is equipped with a hydraulic drive that ensures synchronous upsetting of the tubular billet and transverse movement of the profiled roller during the rolling process of each corrugation. Efficiency and manufacturability are increased, energy intensity and labor intensity of installation and operation are reduced, while simultaneously increasing environmental friendliness and improving the quality of manufactured products.

Technological complex for the production of corrugated pipes (RU, 43202, B21D 10/00, published 01/10/2005), characterized in that it contains a device fixedly installed on the base for securing one end of a tubular blank with the possibility of its rotation around the longitudinal horizontal axis and a device for fixing the other end of the tubular workpiece, ensuring upsetting of the tubular workpiece during rolling of each corrugation, a device for local heating of the area where each corrugation is made with high-frequency currents, and a corrugated rolling mechanism for rolling corrugations during bending and upsetting of the metal of the tubular workpiece, while a device for local heating of the area where each corrugation is made the corrugation is made in the form of a ring inductor installed with the possibility of enveloping the tubular workpiece, transverse and longitudinal movement relative to it, fixing positions in the heating zones and the inductor exiting the tubular workpiece, and the corrugated rolling mechanism includes a profiled roller for bending the metal of the tubular workpiece when rolling each corrugation, made with a profile of its working surface corresponding to the profile of the corrugation cavity in the range between the points of change in the sign of the curvature of the arc of this cavity or the law of its change, while the complex is equipped with a hydraulic drive that ensures synchronous upsetting of the tubular workpiece and transverse movement of the profiled roller.

The prototype was taken as equipment for the production of spirally wound profile pipes and fittings from PDN/PP KRAH, hatches from DN/ID300 mm to DN/ID 4500 mm. The main applications of KRAH profile wound pipes are non-pressure applications such as drainage, storm water, marine waterfalls, sewer piping systems, marine structured wall pipes and chemical storage tanks, as well as low-pressure applications such as irrigation systems. The big advantage of krah spiral extrusion technology is that production is very flexible. One machine can produce spiral profile pipes from DN300 to DN4500. The resizing time is very short. It can produce spiral wound profile pipes with various designs and ring stiffness classes from SN2 to SN16. (https://www.directindustry/com.ru/prod/eagle-machinery-co-ltd/product-231483-2358072.html).

The objective of the present invention is to develop equipment to increase the range of products for the drainage system and water disposal (drainage wells, filter elements, etc.) with minimal replacement of equipment while simultaneously increasing the productivity of the finished product.

The problem is solved by the fact that the technological complex for the production of drainage and water disposal products, including a device for winding and gluing spiral blanks, an unwinder, a geofabric cutting device, a hopper for loading filters, is additionally equipped with a device for gluing stiffeners and a support trolley.

The set of equipment is designed to provide a line for the production of products from spiral-wound pipe blanks with equipment for the manufacture of products along the full technological cycle from unwinding to packaging.

The device for winding and gluing spiral blanks consists of a fixed frame, a shaft housing, a trimming module, thrust radials and an extruder for soldering.

The device for winding and gluing spiral blanks is installed on anti-vibration supports.

The frame is made of square pipes in the form of a support frame with a round-shaped frame drum installed and stiffening braces installed inside the drum. The frame also contains a power cabinet and a movable control console. The frame rests on vibration-damping supports.

The shaft housing is mounted on a frame and is made in the form of an octagonal pipe, made of bent profiles from sheet material of different thicknesses. A shaft is mounted in the center of the housing on bearing supports. Shaft rotation is ensured by a two-stage worm-type gear motor. The shaft is equipped with quick-release cones for installing drums depending on the diameter of the wound spiral workpiece.

The trimming module is designed for automatic trimming and trimming of the wound workpiece and is made in the form of square guides that allow the circular saw to move in two mutually perpendicular planes (along the winding direction and height). Movement is provided by belt drives.

The thrust radials are mounted directly on the frame and provide support for the spiral workpiece during the winding and gluing process. The radial is a block with guides and a ball screw pair installed in it, which ensures the movement of the moving part with the thrust roller.

The soldering extruder is made in the form of a separate element and provides the supply of heated adhesive mass to the mating zone of the elements of the spiral workpiece. The extruder consists of a screw pair with installed heating elements and a wired worm-type gear motor.

Loading of crushed raw materials for the adhesive mass is provided by the loading window.

The design of the extruder table allows adjustment of the position of the feed nozzle and ensures movement in two mutually perpendicular directions (in the horizontal plane)

The device operates in semi-automatic mode: the operator sets the task, for example, the diameter of the drainage well, its length, and quantity.

A drainage well is made by winding a corrugated pipe onto a drum corresponding to the diameter of the drainage well, with each subsequent layer of the well being glued to the previous layer. The gluing of the layers of the drainage well is carried out along the upper stiffening rib of the corrugated pipe; gluing is not carried out along the lower stiffening rib. Thus, holes are formed in the body of the drainage well to drain water into the ground.

The device independently glues and cuts the well based on the specified parameters.

The unwinder is a device consisting of a movable frame, a cantilever-type bearing support, and a frame disk with installed movable shelves, removable stops and a mechanism for adjusting the radial position of the shelves.

The frame is made of square pipes in the form of a square support, four racks arranged in the form of a pyramid, and a jib that ensures rigidity of the structure when exposed to bending loads.

The mobility of the movable frame is determined by the presence of four swivel rubber-coated rollers with brake mechanisms, rotating about an offset axis, which allows you to move the cart in any direction and lock it if necessary. Rubberized roller rims prevent spontaneous sliding. The bearing support ensures rotation of the conditional drum with the installed coil relative to the horizontal axis. The bearings in the support are installed at a certain distance, which makes it possible to absorb bending loads from the weight of the coil without causing residual deformations.

The frame disc is made of square pipes and consists of a rim and guides diverging from the center to the rim. Movable shelves move along the guides to ensure the required nominal installation diameter. The synchronization of movement is ensured by an adjustment mechanism consisting of a disk and leads connected to movable shelves.

The mechanism is equipped with a number of clamps, which allows for smooth adjustment of the diameter. The complex provides two such unwinders.

The geotextile cutting device contains drive rollers and a cutting machine.

The operator manually sets the required cut length and the number of cuts, the unit independently measures the length using drive rollers, and cuts it using a cutting machine. After cutting, the machine automatically returns to its original state.

The hopper for loading filters is a chain of interconnected devices, consisting of a hopper for filling, a screw conveyor with a flexible shaft, a supporting frame, a flexible hose for filling and a stand for the filter housing.

The elements of the hopper for loading filters are rigidly attached to the floor and walls with anchor bolts.

The bunker consists of a frame made of square pipes and a rectangular container made of galvanized steel 0.55 mm thick with a window for loading into a screw conveyor. The supporting frame ensures the required position of the conveyor relative to the hopper and takes on the load from the weight of the body and the conveyor drive, and the material being transferred.

The flexible hose is installed directly on the conveyor and allows you to direct the flow of backfill material. The hose consists of a rectangular to round adapter, a large cross-section hose and a handle to control the position of the hose.

The stand for the housing is made in the form of a cylinder, with stops installed on it and a clamp for fixing the filter housing. The pressure is controlled by a pedal through an extension spring. The clamping force is adjusted by the tensioner.

The operator fixes the filter housing in the drum, and using a foot switch, fills the sorbent inside the filter housing; the equipped ventilation hood completely eliminates the ingress of dust into the operator’s working area.

It is known that the degree of rigidity of corrugated pipes is regulated by thickening the ribs. The higher the rigidity of the corrugation, the greater the load it can experience and is suitable for laying in a ditch. In order to increase the rigidity of the corrugated product, the complex includes the installation of gluing stiffeners.

The gluing device for stiffeners is a device consisting of a movable frame, a cantilever-type bearing support, a rotating platform with a two-stage worm gear motor and a limiter for installing torus-shaped workpieces.

The frame is made of square pipes in the form of a square support and four racks arranged in the form of a pyramid. The mobility of the movable frame is determined by the presence of four swivel rubber-coated rollers with brake mechanisms, rotating about an offset axis, which allows you to move the cart in any direction and lock it if necessary. Rubberized roller rims prevent spontaneous sliding. The bearing support ensures rotation of the platform with installed workpieces relative to the horizontal axis.

The bearings in the support are installed at a certain distance, which allows them to absorb bending loads from the weight of the platform without causing residual deformations.

The rotating platform is made of a shaft with welded guides diverging from the center, and a sheet of round plywood screwed to them. A limiter, designed double-sided, is attached to the front part of the sheet with screws to allow adjustment of the installation diameter of the smallest torus-shaped ring.

The operator installs pre-prepared corrugated pipe elements into the templates and glues the seams in stages, manually, directing the extruder into the grooves. The support trolley is a device consisting of a movable platform, a scissor-type lifting mechanism with a screw drive with a trapezoidal thread, a traction screw control handle, a support platform on rotary locking rollers.

On the movable platform there are movable support rollers elongated along the axis, which are moved across the movable platform to ensure stability depending on the spiral workpiece being produced.

Rearrangement is carried out by lifting the support roller from the guide bushings with a sharp jerk (to remove the axles from the internal locking rings) and installing them in the required position by pressing with a little force.

Lifting is provided by a scissor mechanism using interconnected folding legs in a criss-cross pattern and operated by turning a traction screw with a handle.

The mobility of the trolley is determined by the presence of four swivel rubber-coated rollers with brake mechanisms, rotating about an offset axis, which allows you to move the trolley in any direction and lock it if necessary.

Rubberized roller rims prevent spontaneous sliding.

The unwinder, the device for gluing the stiffeners and the support trolley are made with the ability to move and lock. The complex is intended for the production of:

- drainage wells and filter elements for cleaning storm drains;

- spiral pipes.

Drainage pipes are manufactured with diameters of 325, 360, 420, 600, 720, 800, 900, 1000, 1200 mm, up to 8 meters in length and are used to drain stormwater into the ground locally, in places where flooding occurs. Spiral pipes are manufactured with diameters of 325, 360, 420, 600, 720, 800, 900, 1000, 1200 mm. The following pipes are made from:

- communication cable wells;

- caissons;

- storage tanks;

- for laying in a ditch under the road to drain storm water; - inspection wells for deep drainage and drainage tunnels;

-pontoon modules for sea and river piers.

The technical result provided by the given set of features is to increase efficiency, manufacturability, and reduce the labor intensity of manufactured products.

Thus, the claimed complex is used for the manufacture of:

- drainage wells and filter elements for cleaning storm drains.

Drainage pipes are manufactured with diameters of 325, 360, 420, 600, 720, 800, 900, 1000, 1200 mm, up to 8 meters in length and are used to drain stormwater into the ground locally, in places where flooding occurs.

- inspection wells for deep drainage and drainage tunnels;

Uniqueness of the development:

- for the manufacture of drainage pipes, corrugated pipes with diameters of 25 mm, 32 mm, 40 mm, 50 mm, 63 mm are used;

- to increase the rigidity of the structure from lateral loads, a stiffening rib has been developed, which is inserted inside the well and fixed using a manual extruder;

- the complex is designed with the ability to transform corrugated pipes into different sizes with minimal replacement of equipment.

The invention is illustrated by the following drawings:

Fig. 1 - Schematic representation of the technological complex for the production of drainage and sanitation products, where

1 - device for winding and gluing spiral blanks,

2 - support trolley,

3 - tool table,

4 - equipment storage rack,

5 - unwinder,

6 - geotextile cutting device,

7 - geotextile storage rack,

8 - gluing device for stiffeners,

9 - hopper for loading filters,

10 - area for gluing stiffeners into the product;

Fig. 2 - device for winding and gluing spiral blanks;

Fig. 3 - unwinder;

Fig. 4 - geotextile cutting device;

Fig. 5 - gluing device for stiffeners;

Fig. 6 - hopper for loading filters;

Fig. 7 - Support trolley.

The technological complex for the production of drainage and water disposal products includes the following main production units: a device for winding and gluing spiral blanks (1), a support trolley (2), an unwinder (5), a device for cutting geotextiles (6), a device for gluing stiffeners (8) , hopper for loading filters (9),

The device for winding and gluing spiral blanks (1) consists of a fixed frame (11), a shaft housing (12), a trimming module (13), thrust radials (14) and an extruder for soldering (15).

The frame is made of square pipes in the form of a support frame with a round-shaped frame drum installed and stiffening braces installed inside the drum. The frame also contains a power cabinet and a movable control console. The frame rests on vibration-damping supports.

The shaft housing is mounted on a frame and is made in the form of an octagonal pipe, made of bent profiles from sheet material of different thicknesses. A shaft is mounted in the center of the housing on bearing supports. Shaft rotation is ensured by a two-stage worm-type gear motor. The shaft is equipped with quick-release cones for installing drums depending on the diameter of the wound spiral workpiece.

The trimming module is designed for automatic trimming and trimming of the wound workpiece and is made in the form of square guides that allow the circular saw to move in two mutually perpendicular planes (along the winding direction and height). Movement is provided by belt drives.

The thrust radials are mounted directly on the frame and provide support for the spiral workpiece during the winding and gluing process. The radial is a block with guides and a ball screw pair installed in it, which ensures the movement of the moving part with the thrust roller.

The soldering extruder is made in the form of a separate element and provides the supply of heated adhesive mass to the mating zone of the elements of the spiral workpiece. The extruder consists of a screw pair with installed heating elements and a wired worm-type gear motor.

Loading of crushed raw materials for the adhesive mass is provided by the loading window.

The design of the extruder table allows adjustment of the position of the feed nozzle and provides movement in two mutually perpendicular directions (in the horizontal plane).

The support trolley (2) is a device consisting of a movable platform (16), a scissor-type lifting mechanism (17) with a screw drive with a trapezoidal thread, a control handle (18) with a traction screw, a support platform (19) on rotary locking rollers (20 ).

On the movable platform there are movable support rollers elongated along the axis, which are moved across the movable platform to ensure stability depending on the spiral workpiece being produced.

Lifting is provided by a scissor mechanism using interconnected folding legs in a criss-cross pattern and operated by turning a traction screw with a handle.

The mobility of the trolley is determined by the presence of four swivel rubber-coated rollers with brake mechanisms, rotating about an offset axis, which allows you to move the trolley in any direction and lock it if necessary. Rubberized roller rims prevent spontaneous sliding.

The unwinder (5) is a device consisting of a movable frame (21), a cantilever-type bearing support (not shown), and a frame disk (22) with installed movable shelves (23), removable stops and a mechanism for adjusting the radial position of the shelves (24).

The frame is made of square pipes in the form of a square support, four racks arranged in the form of a pyramid, and a jib that ensures rigidity of the structure when exposed to bending loads.

The mobility of the movable frame is determined by the presence of four swivel rubber-coated rollers with brake mechanisms, rotating about an offset axis, which allows you to move the cart in any direction and lock it if necessary.

Rubberized roller rims prevent spontaneous sliding. The bearing support ensures rotation of the conditional drum with the installed coil relative to the horizontal axis. The bearings in the support are installed at a certain distance, which makes it possible to absorb bending loads from the weight of the coil without causing residual deformations.

The frame disc is made of square pipes and consists of a rim and guides diverging from the center to the rim. Movable shelves move along the guides to ensure the required nominal installation diameter. The synchronization of movement is ensured by an adjustment mechanism consisting of a disk and leads connected to movable shelves.

The mechanism is equipped with a number of clamps, which allows for smooth adjustment of the diameter.

The complex provides two such unwinders.

The geotextile cutting device (6) contains drive rollers (25) and a cutting machine (26).

The gluing device for stiffeners (8) is a device consisting of a movable frame (27), a cantilever-type bearing support (28), a rotating platform with a two-stage worm gear motor (29) and a limiter (30) for installing torus-shaped workpieces.

The frame is made of square pipes in the form of a square support and four racks arranged in the form of a pyramid. The mobility of the movable frame is determined by the presence of four swivel rubber-coated rollers with brake mechanisms, rotating about an offset axis, which allows you to move the cart in any direction and lock it if necessary. Rubberized roller rims prevent spontaneous sliding.

The bearing support ensures rotation of the platform with installed workpieces relative to the horizontal axis. The bearings in the support are installed at a certain distance, which allows them to absorb bending loads from the weight of the platform without causing residual deformations.

The rotating platform is made of a shaft with welded guides diverging from the center, and a sheet of round plywood screwed to them. A limiter, designed double-sided, is attached to the front part of the sheet with screws to allow adjustment of the installation diameter of the smallest torus-shaped ring.

The hopper for loading filters (9) is a chain of interconnected devices: a hopper for filling (31), a screw conveyor (32) with a flexible shaft (not marked), a supporting frame (33), a flexible sleeve (34) for filling and supports for the filter housing (35).

The bunker consists of a frame made of square pipes and a rectangular container made of galvanized steel 0.55 mm thick with a window for loading into a screw conveyor. The supporting frame ensures the required position of the conveyor relative to the hopper and takes on the load from the weight of the body and the conveyor drive, and the material being transferred.

The flexible hose is installed directly on the conveyor and allows you to direct the flow of backfill material. The hose consists of a rectangular to round adapter, a large cross-section hose and a handle to control the position of the hose.

The stand for the housing is made in the form of a cylinder, with stops installed on it and a clamp for fixing the filter housing. The pressure is controlled by a pedal through an extension spring. The clamping force is adjusted by the tensioner.

Thus, the implementation of the invention solves the problems set by the author.

Claims (1)

A technological complex for the production of drainage wells, and filter elements of drainage systems, and spiral pipes for drainage, characterized in that it contains a device for winding a corrugated pipe to produce a spiral blank and gluing its layers, an unwinder, a geofabric cutting device, a device for gluing stiffeners, a trolley supports and a hopper for loading filters, while the unwinder contains a frame disk with guides diverging from the center, on which shelves are installed with the ability to move to ensure the required installation diameter, the gluing device for the stiffeners consists of a movable frame with a cantilever-type bearing support, a platform with a two-stage worm a gear motor and a limiter for installing torus-shaped workpieces, installed with the possibility of rotation using a bearing support, and the support trolley contains a movable platform with a lifting scissor mechanism having a drive in the form of a traction screw with a trapezoidal thread and a handle for rotating the traction screw, and mounted on the movable platform with the ability to move and fix rotating support rollers with a support platform.