RU83024U1 - TECHNOLOGICAL COMPLEX FOR PRODUCTION OF PRODUCTS FROM CELLULAR CONCRETE OF AUTOCLAVE SOLID - Google Patents

Abstract

The technological complex for the manufacture of autoclaved aerated concrete products contains sections for preparing aerated concrete mixture, pouring and molding raw mass, aging arrays, stripping, tilting, a cutting line, an autoclave processing section, and a mold cleaning and assembly section. All technological sections are located on either side of the transfer platform travel path. The transfer platform is made with the possibility of transportation between sections of empty and filled molds and autoclave trolleys. The layout of technological equipment and the use of only two transporting devices as transport equipment: means of moving cut arrays and a transfer platform, allow to obtain a positive technical result, which consists in the compactness of the placement of technological equipment, low metal consumption and high load factor of transport equipment. 6 c.p. f-ly, 2 ill.

Description

The technical field to which the utility model relates.

The utility model relates to the production of building materials.

State of the art

Known conveyor line for the production of cellular concrete (see patent for utility model No. 41671, IPC: B28B 15/00, publ. 2004.11.10), containing posts for the preparation of the mixture, pouring and vibroforming, holding the arrays, formwork, tilting, line cutting, and the autoclave processing section, interconnected by transport ground and mounted bridges. In the known conveyor line, partial duplication of the equipment used is applied in order to increase the reliability of the line. The disadvantages of the line include a large number of transport equipment, the considerable production space occupied by it, and the implementation of the holding station of arrays in the form of a conveyor, along the rails of which molds with a hardening array move, because it is known that the shocking effects exerted on the hardening massif reduce its quality.

Known conveyor line for the manufacture of cellular concrete products (see patent for the invention No. 2054996, IPC: B28B 15/00, B28B 1/50, publ. 1996.02.27), containing a transport path along which in the technological sequence there are sections for preparing the raw material mixture, casting, molding of the array, aging of the array, formwork, cutting line and autoclave processing section. Parallel to the transport path, a mold return transport path is connected associated with the first by means of transmission platforms with rail guides. In the line transport trolleys are excluded and the massifs are transported in the mold, and then on the pallet from the mold, which excludes mechanical stress on the formed massif. Among the shortcomings of the known line can be noted its considerable length, the duration of the turnover of the molds and their rapid wear, due to the fact that the pallet from the mold is involved in autoclave (temperature) processing of products.

As the closest analogue to the claimed device adopted technological complex for the production of porous concrete, described in German patent DE 19632724, IPC: B28V 1/00, publ. 02/19/98

The complex contains a section for the preparation of aerated concrete mixture with a vertical arrangement of consumable silos for raw materials, dispensers and a mixer, a section for pouring and molding a raw array placed under it, an exposure section for arrays, a stripping area and a tilter located on the same track, connected with the cutting line , an autoclave treatment section with autoclaves and rail tracks for forming an autoclave train, a mold return line on which molds are cleaned, assembled and lubricated. The complex contains rail tracks to ensure technological flows, including the rail track of the sections of forming and holding the arrays, the rail track of the formwork and tilting section, the rail tracks of the cutting line and the preparation paths of the autoclave train. Communication between the said rail tracks and the movement of empty and filled molds, autoclave carts, cut arrays and finished products provides transport equipment in the form of transmission platforms and gantry cranes, which are mounted with the possibility of moving across sections of the rail tracks.

Among the shortcomings of the known technological complex, it is possible to distinguish the significant production space occupied by it, a large number of transport equipment and low coefficient of its use.

Utility Model Disclosure

The technical task of the claimed utility model is to save production space, reduce metal production, increase the intensity of use of transport equipment.

The problem is solved due to the fact that in the technological complex for the manufacture of autoclaved aerated concrete products containing a section for preparing aerated concrete mix with consumable containers for raw materials, dispensers and a concrete mixer, a section for pouring and molding a raw array, a holding section for arrays placed under it a stripping section and a tilter connected to a cutting line, an autoclave section including at least one autoclave and located on one rail track rail ways of forming an autoclave train, a section for cleaning and assembling forms, as well as transport equipment, including a transfer platform and means for moving cut arrays, mounted to move across the cutting line, the rail track of the stripping and tilting section and rail

ways of forming an autoclave train, according to the claimed utility model, the equipment is mounted on either side of the moving platform of the transfer platform with the location of the section for preparing aerated concrete mixture, the area for pouring and molding solid raw materials and the autoclave on one side, and the formwork, tilting, cutting line and formation paths an autoclave train - on the other side of the transfer platform travel path, and the holding section of the arrays is made in the form of preliminary hardening chambers placed along eim sides of the path of the transfer platform. The transfer platform is configured to move the filled molds from the casting and molding section of the raw mass to the holding section, from the holding section to the stripping section, with the possibility of returning empty molds to the said casting and forming section, and with the possibility of moving the autoclave trolleys from the autoclave forming paths trains to the autoclave and back. The cleaning and assembly section of the molds is combined with the formwork section. The casting and forming section is equipped with a vibratory compaction device.

Compared with the prototype and other well-known autoclaved aerated concrete production lines, the claimed complex is characterized by the compactness of the technological equipment, the reduced metal consumption of the production and the high load factor of the transport equipment.

The achievement of the above technical results was made possible thanks to the following distinctive points of the claimed technological complex.

In the claimed complex, all transport equipment providing communications between technological sections is made in the form of two conveying devices: a transfer platform and a means of moving cut arrays, which can be used as a multifunctional crane (bridge, portal, crane-beam, etc. )

All production equipment is arranged on the sides of the transmission platform. The sections or parts of the sections with the greatest length and containing rail tracks are located on one side of the platform, between the latter and the means of moving the cut arrays. This arrangement of equipment provides the greatest compactness and allows the most efficient use of production facilities.

The pre-casting preparation area for molds (i.e. cleaning, assembly and lubrication of molds) is combined with the stripping area, which also saves production space and helps to reduce the metal consumption of production.

In contrast to the known solutions, in the claimed complex, one transfer platform performs several functions: the functions of moving empty molds from the stripping / preparation of molds to the casting and molding section of the raw mass, the functions of moving the filled molds from the casting section and molding of the raw mass to the aging section and from the holding section to the stripping section, as well as the function of moving the autoclave carts from the paths of forming the autoclave train into the autoclave and vice versa.

The possibility of moving forms and autoclave trolleys with a transfer platform is realized due to the presence of rail guides on the surface of the platform, made in accordance with the track sections, and by equipping the transfer platform with a robotic arm that interacts with the said molds and autoclave trolleys and ensures the movement of the said forms and trolleys to and from the platform.

All operations carried out by the transfer platform have their priority status in the technological process for the production of autoclaved aerated concrete products. Priority status is an advantage - the right of first performance over other operations. This priority is set programmatically and monitored by the control system. The possibility of such work is confirmed by the current production and examples of the description.

The implementation of the site of exposure of arrays in the form of chambers of preliminary hardening helps to improve the quality of the ripened array. The shape in which the array swells is stationary in the chamber, which eliminates any shock or shock effects on the array during its maturation and protects the array from subsidence. A constant temperature is maintained in the chamber, which speeds up the process of curing the array.

The placement of cameras on both sides of the transfer platform travel path also contributes to the economical use of production facilities.

In the specific case of the implementation of the complex, the device for vibratory compaction of the mixture is made in the form of internal vibrators immersed by the working part in concrete

mixture and transmitting vibrations through the body. Due to the transfer of the concrete mixture to high-frequency vibrations (from 3-18 thousand vibrations per minute) and small amplitude, the mixture acquires the property of a heavy liquid, i.e. it is capable of filling the mold tightly, squeezing out excess water and air.

As such mixers can be used, for example, a high-frequency vibrator of the I-21A brand with a flexible shaft and a tip (Prince G. Burlakov, Technology of products from light concrete. M: Higher school, 1986, pp. 201-202) , or any other prior art deep centrifugal vibrators. The advantages of these vibrators include their compactness and mobility, low cost.

However, the use of internal vibrators is a special case of the implementation of the complex and does not limit the possibility of using other types of vibrators, for example vibratory platforms.

In the inventive complex can be used several internal vibrators, mounted in a single holding structure.

It is advisable to fix the vibrators on the same level as the concrete mixer with a vertical layout for the placement of sections for the preparation of aerated concrete mix and the formation of a raw array. In this case, the compaction of the mixture is carried out simultaneously with its filling.

The tilter ensures rotation of the array by 90 ° with its installation on a cutting trolley and the reverse tilting of the cut array with installation on an autoclave trolley.

The inventive complex can be used for the production of autoclaved aerated concrete according to the known technology based on sand and cement. However, it is preferable to use the complex for the production of aerated concrete products based on ash ash from thermal power plants.

In this case, the equipment of the site for the preparation of aerated concrete mixture includes consumables with dispensers for the components of the aerated concrete mixture: ash, cement, lime-ash mixture of binders (IZS), return sludge, water and a suspension of aluminum powder, and a mixer for mixing the above components.

The site is also equipped with a lime reception and crushing department, a lime-ash mixture preparation department, an aspiration system and an automatic control system for the preparation of aerated concrete mixture.

The vertical layout of equipment for sections for preparing aerated concrete mix, pouring and molding is the most technologically advanced, because components of the mixture and then the mixture itself is transported from top to bottom almost under its own weight. The vertical layout of equipment also contributes to the economical use of production facilities.

Brief Description of the Drawings

The work and the device of the technological complex for the manufacture of products from aerated concrete autoclaved hardening is illustrated by drawings, where

figure 1 - schematically shows a General view of the claimed complex, (view in plan);

figure 2 - shows the plot of preparation of aerated concrete mixture.

Utility Model Implementation

The technological complex for the manufacture of autoclaved aerated concrete cellular products (see Fig. 1) contains a section 1 for preparing aerated concrete mix, a section 2 for pouring and molding a raw mass, a block 3 for holding arrays with pre-hardening chambers 4, a section 5 for form stripping and their pre-casting preparation (hereinafter simply the stripping area) and tilter 6, cutting line 7, autoclaves 8 and paths 9 of forming the autoclave train, transfer platform 10 and multi-function crane 11.

Rail guides 12 and a robotic arm 13 are mounted on the surface of the transfer platform 10, providing movement of the molds 14 and autoclave trolleys 15 to and from the platform.

The transmission platform 10 is installed on the rail 16, located as well as the guides of the working carriage of the crane 11 across the cutting line 7, the rail 17, along which the equipment of the stripping section 5 and tilter 6 are sequentially mounted, as well as across the rail tracks 9 for preparing the autoclave train.

Section 1 of the preparation of aerated concrete mixture, section 2 of pouring and molding a raw mass and autoclaves 8 are mounted on one side of the path 16 of the transfer platform 10. Section 5 formwork, tilter 6, cutting line 7 and path 9 of the formation of the autoclave train - on the other side of path 16. Pre-hardening chambers 4 are placed on both sides of the path 16 of the transfer platform 10.

The equipment of section 1 for preparing aerated concrete mixture is mounted (see figure 2) in a vertical diagram, which involves the placement of this equipment at several levels vertically, according to the technological process. Consumption tanks 18 for ash, cement, lime-ash mixture, recirculated sludge, water and a suspension of aluminum powder with appropriate batchers 19 are mounted in the upper level of the NZ. In the second level Н2, a mixer 20 for preparing aerated concrete mixture and a device for vibration compaction of the mixture in the form of internal vibrators 21. In the lower level H1, under the concrete mixer, form 14 is installed.

Section 1 is equipped with a lime receiving and crushing compartment 22, which includes a hopper 23, a conveyor belt 24 with a metal detector and a rotary crusher 25, a lime-ash mixture preparation section 26, as well as an aspiration system and an automatic control system for the preparation of aerated concrete mixture (in the drawing not shown).

The lime-ash mixture preparation section 26 contains containers 27 for lime and ash, each of which is equipped with a bottom vibration activator and level indicator, screw conveyors 28, hopper scales 29, a ball mill 30 for co-grinding ash and lime to a specific surface of 4500 cm ² / g and at least one storage hopper 31 for the lime-ash mixture.

The technological complex works as follows.

The transfer platform 10 moves to position A and sets in section 2 an empty mold 14, prepared for pouring aerated concrete mixture.

The components of the cellular concrete mixture from the supply containers 18 are fed into the corresponding weighing batchers 19 and from there, according to the given recipe, are sequentially loaded into the mixer 20 in the following order: sludge with water, ash, then cement and lime-ash mixture, aluminum suspension last.

As soon as aluminum mixes well with the other components, the cellular concrete mixture is poured into mold 14. During the pouring process, the mixture is compacted by means of vibrators 21.

The transfer platform 10 either waits while standing in position A opposite the molding section 2, or it is moved to the aforementioned position. The manipulator 13 captures the mold 14 filled with the cellular concrete mixture and moves it to the platform 10, which moves the mold 14 to the holding section 3 (in the drawing - conditional position B, conditional, since the platform 10 is installed opposite any of the preliminary hardening chambers 4).

By means of the manipulator 13, the mold with the raw mass moves into one of the preliminary hardening chambers 4.

The production process involves the sequential filling of the pre-hardening chambers 4 in a similar manner.

As soon as the first array (or one of the arrays) reaches the required size and the specified formwork strength, the transfer platform 10 also with the help of the manipulator 13 picks up the mold 14 with the array from the preliminary hardening chamber 4 and moves it to the formwork section 5 (also position A). In this section, the tooling of mold 14 is opened and the open mold is pushed into the tilter 6, which rotates the array 90 ° into a vertical position and sets it on the trolley of the cutting line 7.

Empty form 14 is returned by tilter 6 to its original position (tilts back). In the future, the mold will be subjected to cleaning, assembly and lubrication and will be immediately waiting for re-filing.

The array mounted in a vertical position on the trolley of the cutting line is sequentially calibrated in length, cut in height and thickness. The cut array is returned by tilter 6 to its original position, after which the bottom layer is removed. Cutting waste is collected and fed to the sludge pool, where it is steamed, crushed, mixed and adjusted to the desired moisture and density parameters.

The array 32 cut into blocks is transferred by a crane 11 to an autoclave trolley 15 mounted on tracks 9 to form an autoclave train.

As soon as one of the molds 14 is ready for filling, the control system starts the process of preparing the next portion of aerated concrete mix in section 1. The platform 10 transfers the mold 14 to the molding section 2. The casting and molding process is repeated. At this time, the transfer platform 10 moves the next form with an array that has reached the formwork strength, from the preliminary hardening chamber 4 to the formwork section 5.

An autoclave train is formed from autoclave trolleys 15 with cut arrays 30 mounted on them on tracks 9. Once the autoclave train is formed, the control system sends a signal to the transfer platform 10, and the latter moves and is installed in position C opposite the corresponding autoclave 8. Autoclave trolleys 15 with cut arrays are moved to the autoclave 8.

The autoclave treatment time for arrays is no more than 12 hours at a pressure of 14 bar and t = 190 ° C.

During the time when the autoclave hardening of products occurs, the platform 10 performs other operations to move empty and filled forms 14 in accordance with the importance, status of the operation, compliance with which is provided by the control system software.

Upon completion of the autoclave process, also through the transfer platform 10, the autoclave carts 15 with finished products are unloaded from the autoclave 8 on the path 9. The autoclaves 8 operate alternately.

The crane 11 moves the cut arrays from the cutting line 7 on the path 9 to form an autoclave train, as well as finished products after autoclaving to the finished product section, from where they are taken, for example, by an auto-loader 33, and transferred to the packaging operation (not shown in the drawing).

The advantages of the claimed complex:

1. The compactness of equipment placement, which allows the use of the complex for the production of building products in small enterprises.

2. Simplification of the design of the complex and its metal consumption by reducing transport routes and the number of auxiliary conveying equipment.

3. High load factor of conveying equipment.

4. Placement of forms in the preliminary exposure chambers, which ensures constant temperature during the maturation of the massif and the absence of any shocks and shocks, which helps to improve the quality of the ripened massif.

Claims (7)

1. Technological complex for the manufacture of autoclaved aerated concrete products, comprising a section for preparing aerated concrete mixture with consumables for raw materials, dispensers and a concrete mixer, a section for pouring and molding a raw array underneath it, a holding section for arrays placed on a single rail track formwork and tilter associated with the cutting line, an autoclave treatment section including at least one autoclave and rail tracks for forming an autoclave the building, a cleaning and assembly section of molds, as well as transport equipment, including a transfer platform and means for moving cut arrays, mounted to move across the cutting line, the rail track of the stripping and tilting section, and the rail tracks for forming the autoclave train, characterized in that the equipment is mounted on to the sides of the transfer platform moving path with the location of the section for preparing the cellular concrete mixture, the section for pouring and molding the raw mass and the autoclave along one side, and the stripping area, the tilter, the cutting line and the autoclave train forming paths - on the other side of the transfer platform moving path, the array holding section is made in the form of preliminary hardening chambers placed on both sides of the transfer platform moving path, the latter being made with the possibility of moving filled forms from the casting and molding section of the raw mass to the holding section, from the holding section to the stripping section, with the possibility of returning empty forms to a crumpled casting and forming section, and with the possibility of moving autoclave trolleys from the paths of forming the autoclave train into the autoclave and vice versa, while the cleaning and assembly section of the molds is combined with the stripping section, and the filling and molding section is equipped with a vibratory compaction device. 2. The complex according to claim 1, characterized in that the device for vibro-compaction of the mixture is made in the form of internal vibrators fixed at the same level with the concrete mixer. 3. The complex according to claim 1, characterized in that the transfer platform is equipped with a robot manipulator interacting with the forms. 4. The complex according to claim 1, characterized in that the section for preparing aerated concrete mixture contains consumables for ash, cement, lime-ash mixture, recirculated sludge, water and a suspension of aluminum powder, while the section is equipped with a lime receiving and crushing section, a preparation section lime-ash mixture, aspiration system and automatic control system for the preparation of aerated concrete mixture. 5. The complex according to claim 4, characterized in that the lime-ash mixture preparation department contains containers for lime and ash, each of which is equipped with a bottom vibration activator and level indicator, screw conveyors, hopper scales, a ball mill for joint grinding of ash and lime to specific surface area of 4,500 cm ² / g and at least one storage hopper for lime-ash mixture. 6. The complex according to claim 1, characterized in that the tilter is configured to rotate the array 90 ° and install it on the cutting trolley of the cutting line and with the possibility of reverse tilting the cut array with installation on an autoclave trolley. 7. The complex according to claim 1, characterized in that the means of moving the cut arrays is made in the form of a multifunctional crane.