SU1839655A3 - Transfer line for manufacture of building materials - Google Patents

Description

(57) Use: production of building ceramic products. The essence of the invention: the line contains an inclined conveyor 3 for supplying raw materials, a set of equipment for preparing raw materials for molding, a forming press 11. a device 15 for pressing and decorating a device 17, a cutting bar for workpieces, a slit drying kiln 19 with gas circulation systems, a divider 26 for workpieces on products and means of remote monitoring and control In the drying-firing unit 19, infrared emitters 22 are installed, high-frequency current emitters 21 and the core coating device 24 are hollow the mouthpiece 12 of the press 11 are included in the electrical circuit with a direct current source 14 8zl f-ly, 9 il

(1 ") SU (11) 1 839 655 AZ

The invention relates to the building materials industry, in particular to the production of tiles, bricks, blocks, beams, pipes, tiles, aggregate for concrete and other piece products.

A known method for the production of clay brick, including extraction, transportation of raw materials, preparing clay for molding, molding raw brick by cutting clay timber, laying on pallets, transportation to the drying chamber, drying, transportation from the drying chamber, removing raw brick from pallets, laying to a trolley, transportation to a kiln, laying, firing, cooling, transfer to a trolley, transportation to a warehouse of finished products and unloading (Chernyansky E.V. Brick production. M.: Literature publishing house on construction, 1966).

The disadvantages of this method are that the production is environmentally dirty, manual labor is used when loading and unloading bricks, a large number of reloading and transport operations, the duration of the process, low quality, difficulties in obtaining a textured and glazed brick surface, high consumption of thermal energy. A method of manufacturing ordinary clay clay brick of plastic pressing, including preparing the mixture for molding, steam heating, molding the clay beam, cutting into individual pieces cutting, laying raw brick on tunnel drying trolleys, transporting to a drying place, drying in a tunnel or chamber dryer, transporting to a firing place, manually loading raw brick in an oven or on trolleys, heating to 800 ° C, firing at 800 -1200 ° C, quick cooling to 600 ° C and slow to 130 ° C, unloading from the oven to pallets and exporting finished products to the warehouse (G. Burlakov, Fundamentals of ceramic technology and artificial porous aggregates. M.: Higher School, 1972).

The disadvantages of this method are that the technology is environmentally dirty, it takes a lot of manual labor, a lot of handling and transport operations, as a result of this heat loss after steam heating and drying, as well as the duration of the process and the low quality of the brick, the inability to expand the product range.

There is also a method for producing linear products from a sintered granular material, which involves passing this material through the mold while supplying heat to it so that this material has a sintering temperature before leaving the mold. The mass of the mixture is fed in a uniform flow through a fixed tubular form, providing extrusion with a given cross section. Inside the mold, the material is evenly heated in the feed direction. As the sintered mass is pulled out of the mold, the sintered porous material is continuously formed (US patent N14208367 M. CL. CB04 33/32, publ. 1980).

The disadvantage of this method is that the finished product is obtained in the form of broken porous blocks and gravel with a porous structure, not suitable as a facing material or brick.

Known slit furnace (VNIISTROM) with a length of 24x0.6x0.22 m. Rollers 076 mm are located along the entire length with a distance between the axles of 220-300 mm, which rotate freely in sliding bearings. Burn products on pallets. In these furnaces, the drying and firing processes of bricks and ceramic stones are easily combined. The firing time is reduced to 6 hours (N. Moroz. Technology of building ceramics. Kiev: Higher school, 1980, p. 129).

A disadvantage of the known slit furnace is the use of pallets, handling operations on the pallet and the pallets themselves with the products.

Known theoretical foundations of drying ceramic products, where it is recommended the use of high frequency current. This can be rational and cost-effective for the initial heating of products in combination with the evaporation of moisture due to the heat of the washing heated air. Combined drying of HDTV and heated air can be used in the construction ceramics industry. (K. Nokhratyan. Drying and firing in the building ceramics industry. M., 1962, p. 58-59).

The disadvantage is the lack of real structures and lines,

From the literature it is known that the pressure value during pressing has a significant effect on the quality of ceramic products; therefore, it is advisable to use prepress (Cherny S.S. et al. Front brick. M., 1955, p. 85).

The disadvantage is the lack of real designs and lines,

The closest of these analogues to the claimed invention is a method for the production of bricks, including mass preparation, broaching a bar from a mouthpiece, cutting a bar into bars several times longer than a brick, drying the beam, firing and cutting the bars after firing in the longitudinal and transverse directions to individual bricks, and the waste when cutting fired bars is returned to production (Austria patent No. 376926, class B 28 B 11/16, publ. 1985).

The disadvantages of this method are the lack of an adjustable line and an integrated device that provides pressure testing of the beam, reducing the resistance that occurs when moving the beam, the large length of the horizontal section of the production line, the use of drying processes and products of combustion, the horizontal arrangement of the equipment in a straight line, large waste during sawing , the lack of integrated use of highly efficient energy sources that do not pollute the environment.

The aim of the invention is the automation of the process, expanding the range and improving the quality of products.

This goal is achieved by the fact that the line for the manufacture of building materials, containing an inclined conveyor belt for supplying raw materials installed in the technological sequence, a set of equipment for preparing raw materials for molding, a drive forming press with a mouthpiece containing core holders, a device that cuts a molded beam into blanks, drying and firing unit, transverse and longitudinal cutting devices separating the workpieces, and a roller conveyor transporting the bar and workpieces, sleep the wife is located behind the press with a device for pressing and decorating, the drying-firing unit is made in the form of a slit installation arranged obliquely in a spiral with means for processing high-frequency currents, infrared emitters and a device for applying glaze, while core-hollow core formers of the press mouthpiece are made in the form of an electrode, are included in an electric circuit, and a transverse cutting device separating the workpiece is made in the form of a guillotine mechanism with a synchronization unit, the line having distance means onnogo control, alarm management and technological operations.

The complex of equipment for preparing raw materials for molding consists of rotary distributor and consumables mounted sequentially vertically above the press. feeders, mash rollers, grinding rollers and continuous clay mixers.

The drive of the forming press is adjustable and connected to a direct current source.

The core holders of the mouthpiece of the press are included in the direct current circuit and isolated from the body of the mouthpiece.

The device for pressing and decorating is made in the form of two rollers with an ultrasonic vibrations source installed opposite on the opposite sides relative to the longitudinal axis of the press outlet.

The crevice drying and calcining plant is made with systems for supplying atmospheric air at its outlet and circulation of heated air.

The device for applying glaze is installed in the zone of maximum temperature of a slot-type drying-firing plant.

The transverse cutting device is made in the form of opposed blades, each of which is mounted on the movable core of the electromagnetic coil, in the electric circuit of which a contact device is included to synchronize the movement of the workpiece and the blades.

The crevice drying and calcining plant is located obliquely and rectilinearly or circumferentially.

In FIG. 1 shows a flow chart of a line for the production of building materials, which includes a quarry clay store 1, an excavator 2, a conveyor belt in an inclined gallery 3, a rotary distributor 4. consumables 5, feeders 6, stone rollers 7, grinding rollers 8, a continuous clay mixer 9, supply 10 steam, drive forming press 11, mouthpiece 12, core holders 13, direct current source 14, pressing and decorating device 15, ultrasound source 16, beam cutting device 17 for workpieces, workpieces 18, slit a drying and drying apparatus 19, movable under 20, a high-frequency current emitter 21, an infrared emitter 22, control and regulation devices 23, a glazing device 24, finished products 25, a transverse cutting device 26, bags 27, an atmospheric air supply system 28, smoke exhaust 29 and chimney 30.

In FIG. Figure 2 shows a general view of a line for the production of building materials, which is located in a straight line and includes an alumina refinery 1, an inclined gallery 2 for conveyor belts, a tower 3 with a complex of equipment for preparing raw materials for molding, a building 4 for a slit drying and calcining plant, a warehouse for 5 finished products.

In FIG. 3 shows a view of the line in the plan for the production of building materials, located around a circle or in a spiral and including clay storage 1, an inclined gallery 2, towers 3 with a set of equipment for preparing raw materials for molding, building 4 for a slotted drying kiln, warehouse 5.

In FIG. 4 shows a section through a line of production of building materials, including alumina 1, an inclined belt conveyor 2 for supplying raw materials, a rotary distributor 3, a feed hopper 4, a feeder 5, stone extraction rollers 6, rollers 7 grinding, continuous clay mixers 8, a drive forming press 9, a slotted drying roasting plant 10. billet 11 products, transverse cutting device 12.

In FIG. 5 depicts a transverse cutting device including an electromagnetic coil 1, a movable core 2, a blade 3, a workpiece 4, an electrical contact device 5, and an article 6.

In FIG. 6 shows a prepress and decorating device with the influence of ultrasound, including a beam 1. rollers 2, a hopper 3 for a decorative composition and an ultrasound source 4.

In FIG. 7 shows a section through the body of the mouthpiece of a drive forming press. including core-core formers 1 on the bracket, body 2 of the mouthpiece, insulator 3. DC electric circuit 4.

In FIG. 8 shows a glazing application device including a preform 1, a hopper 2 for a glaze mixture, a glaze supply device 3, a housing 4 of a slit drying kiln, an icing 5 on the preform.

In FIG. 9 shows a functional diagram of the monitoring, signaling, regulation and control of the technological process of the production line of building materials: 1 - monitoring and signaling of the clay level, 2 - monitoring and control of the conveyor belt, 3 - monitoring and control of the rotary distributor, 4 - monitoring and control of the feeder, 5 monitoring and controlling the work of fine grinding rollers, 6 - monitoring and controlling the operation of a continuous clay mixer, 7 monitoring of wet clay, 8 - monitoring of air pressure in a slit pipe. 9 - temperature control and regulation, 10 - control and management of the press drive operation, 11 - monitoring, signaling and regulation of electric heating of the beam mass in the mouthpiece, 12 - monitoring and control of the pre-pressing rolls and ultrasound generator, 13 - temperature control, regulation and control depending on the speed of movement of the beam in a slot-hole drying-firing plant, 14 - control and management of an infrared radiation source, 15 control and management of a high-frequency current source, 16 - control, signal analysis and control of the device for applying the glazing composition on the surface of the beam, 17 - control, signaling and temperature control in the drying zone, 18 - control, monitoring according to technical specifications, signaling, regulation and control of the firing temperature, 19 - temperature control and regulation in the hardening zone, 20 - control, signaling and control of an automatic transverse cutting device dividing beams into blocks and bricks, 21 - control, signaling, metering and management of warehousing of finished products, 22 - video monitoring terminals for those technologically process and communication with the central control unit.

The invention is illustrated by the following examples.

Example 1, Performing operations of the technological scheme of the production line of building materials.

From the quarry or clay storage 1, clay is fed by a rotary excavator 2 by a system of conveyor belts along an inclined (Fig. 1) gallery 3 into a rotary distributor 4 and then into consumables 5, additives are also fed there. From the feed hopper by the feeder 6, the clay enters, to the stone extraction rollers 7, and then to the fine grinding rollers 8 and to the continuous clay mixer 9, where the clay is heated, mixed with additives and treated with steam. The mass prepared and heated to 30-50 ° C is fed to a press 11, where it is heated to 40-70 ° C from the body and is extruded at a controlled speed through the mouthpiece 12, in which core-core generators 13 electrically insulated from the body are installed, which simultaneously perform the functions of electrodes and connected to a source 24 of regulated electric direct current, as a result, electric heating occurs inside the extrudable timber to 50 ~ 80 ° C and the formation of gaps (hollow channels). After the mouthpiece, the continuously moving beam is simultaneously affected by pressure and ultrasound, using the device 15, which contains two rollers (Fig. 6) and ultrasound source 16 opposite to the longitudinal axis of the press outlet on the opposite side of the press, apply an ornament and press the decorative or glaze mixture. After that, the beam is cut with a cutting machine into workpieces 18, which are moved at a slit machine 19 with an adjustable speed in a continuous stream (Fig. 4) along a movable hearth 20 having drive, measuring and freely rotating rollers. Slit installation 19 is located with a slope to reduce the resistance to movement of the beams and create air traction in a straight line, or around a circle, or a circular spiral for compactness of the production line of building materials. Infrared emitters 22 and high-frequency current emitters (HDTV) 21, as well as devices 23 for controlling and regulating technological process parameters: humidity, temperature, pressure, speed of movement, etc. are installed in the slit drying and drying plant 19. All processes: heating, drying, firing, glazing, cooling - in a slot-hole drying and firing plant they are combined and flow as the beams move along the moving hearth, and the temperature changes gradually from 50 to 1100 and then to 80 ° C. An additional device 24 (FIG. 8) for applying the glaze in the form of a molten paste is further provided in the line in the zone with a maximum temperature. Next, the beams are cooled with cold air and after leaving the slot installation 19 in the form of finished products 25 are stacked on the pallets of the trolleys • or split into blocks, stones, bricks with a transverse cutting device 26 (Fig. 5) and then stacked in the form of finished products in bags 27, and the waste is ground and sent to production. From the atmospheric air supply system 28, the exhaust air is disposed of, and the exhaust fan 29 is sent to the chimney 30.

Example 2. The implementation of the production line of building materials.

The raw material is clay, in which, to reduce the time by 2-3 times of drying and improve the quality of the raw material, they add introducers to 50%.

Clay and additives are fed through a conveyor belt located in an inclined gallery 3 to the tower, where a rotary distributor 4 and consumables 5 are installed, filling them. Bucota tower (Fig. 4) depends on the location of the press 11, i.e. beginning slit drying and calcining plant 19, and also from the height of the equipment located vertically (press, clay mixer, rollers, dispenser, feed hopper, rotary distributor, belt conveyor).

From the feed hopper 5, through the continuous feeder 6, clay and additives are fed to the stone extraction rollers 7, then to the fine grinding rollers 8 and then to the continuous clay mixer 9, where the ceramic mass is mixed, moistened and heated with steam and from the clay mixer body. When the mass is heated to 4060 ° C, the drying period is reduced by 40-50% or more.

From the continuous clay mixer 9, the mass is fed to the drive forming press 11, where it is additionally heated from the press body, and also electrically heated from the core-core generators 13 of the contact electrodes from the direct current source 14, and the constant heating by current leads to: decay into charged atoms and molecules - ions, which are then adsorbed on the surface of clay particles, causing them to coagulate and aggregate. Aggregation of clay particles improves the moisture conductivity of the mass.

As the contact electrodes, the press body 11, the mouthpiece 12 and core holders 13 are used, the latter are mounted on an electrically insulated bracket with core holders (Fig. 7). This allows you to combine the processes of electrical heating, electrical activation of the mass and the formation of slotted beams.

The drive of the forming press is made adjustable and connected to a constant current source, which allows using the electronic controller to control the speed of forming the beam, and therefore, to influence the drying and firing processes depending on the quality of the raw beam. From the press 11, a molded beam with an endless ribbon with a cross-section and a configuration determined by the opening of the mouthpiece of the press is fed to the movable one under 20, the press 11 and the crevice drying and calcining unit 19 being located obliquely, rectilinearly, or in a circle or in a spiral. This allows you to reduce the resistance to movement of the beam and air and place the slit installation in a straight line (Fig. 2), or around the circumference (Fig. 3), or in the form of two or more spirals, the turns of which are located one above the other in one span of an industrial building ( Fig. 4).

The next operation after molding is the extrusion and decoration of the beam (Fig. 6). This is done by rollers mounted opposite on opposite sides of the longitudinal axis of the press outlet, and mechanical pressure and ultrasound are used simultaneously, for this one of the rollers is a radiator, contains a piezoelectric battery consisting of Rochelle salt crystals, which converts electrical pulses into ultrasonic mechanical waves. Decoration of the surface of the beam is carried out by corrugated rollers, as well as by pressing the decorative layer onto the surface of the beam, and waste decorative composition is returned to production.

The next operation after prepressing and decorating is cutting off the bars of a given length (billets 18) from an endless ribbon by a cutting machine, after which the billets 18 are moved along the movable hearth 20 along the line in the slotted drying and calcining plant 19, where they are dried, additionally heated throughout the entire volume from the inside HDTV, direct current irradiate the outer surface with infrared rays and blow hot air. When the mine is heated to 50 ~ 70 ° C, the surface tension of the water in the capillaries changes little, and its viscosity decreases by almost 85%, which facilitates the movement of water through the capillaries and provides better drying conditions. With convective dielectric drying, external moisture exchange is accelerated, and high-frequency energy provides internal moisture transfer. A high-frequency emitter 21 for heating dielectric materials (billets) in the conveyor line is located at certain intervals, powered by high-frequency energy from industrial generators DL1-40 or DL2-60. The frequency of oscillations generated by them is 13.56 MHz + 1%, the temperature in the center of the beam reaches 110 ° C (6.90-94). The heating of the HDTV allows you to create a temperature gradient between the surface of the beam and its internal volume. The drying time is halved compared to convective. Drying quality is much better due to a decrease in moisture difference. Infrared emitters 22 are located in the intervals between the plates of the emitters 21, individually represent a reflector with a radiation source made of high-resistance wire or silt rods, or gas burners, and hot air for drying from the atmospheric air supply system 28 is taken from the beam cooling path.

As the blanks 18 of the slit drying and calcining plant 19 move along the movable hearth 20, the critical moisture of the beam mass and the end of air shrinkage are achieved, then drying is carried out at higher (up to 600 ° C) temperatures and at a reduced relative humidity of the air heated from contact with hot beams, infrared emitters and installation enclosures.

At the end of drying, the moisture release weakens and completely stops, after which the stage of heating and firing from sources of infrared radiation at a temperature of up to 1100 ° C. In the first firing period, chemically bound water is removed, organic matter burns out, clay minerals are destroyed and transferred to new compounds - metakaolinite (560650 ° С). In the second period, a ceramic crock forms in the temperature range of 700-900 ° C, fire shrinks, followed by shrinkage at temperatures above 950-1100 ° C, the clay softens, low-melting compounds fill the pores between the grains of the skeleton, which are more refractory particles, resulting in firing the mass acquires a greater density — sintering. At this moment, a clay beam having a temperature of 850-1050 ° C is coated with a mixture of molten paste using a special device 24 (Fig. 8), covering the surface with a layer of glaze.

In the third period, the beams are cooled. After applying the glazing composition, the preform is blown with cold running air or steam, as a result of which the preform is subjected to thermal compression. Rapid cooling from a maximum firing temperature to 660 ° C with Steam or outside air, and then slow cooling controlled by dampers, air partially eliminates the harmful effects of polymorphic transformations of quartz. The billets are cooled to 130-80 ° C, it is impractical to cool products to a temperature of less than 80 ° C due to the fact that this will lead to an extension of the cooling tract and the production cycle.

Cooling the glazed blanks with a transverse cutting device is placed in bags and sent to the finished goods warehouse or divided into blocks, stones, bricks, for this the beams are fed to a pulsed percussion device in the form of a guillotine mechanism (Fig. 5), which is made in the form of opposed blades, each of which is mounted on the movable core of the electromagnetic coil, triggered synchronously from the electromagnet when the edge of the beam reaches the contact sensor set to the required size, or from grammnogo electric-roller, or a computer command, · and then placed on trays and trolleys direct to the warehouse.

It is also possible to cut the beams to the required sizes with abrasive wheels in the longitudinal and transverse directions, and sawing waste and splitting are sent to the technology.

Waste, warm, moist air is sent to heat exchangers, where heat and moisture are utilized. Condensate water is transported to the clay mixer to moisten the clay mass; condensate and steam improve the plastic properties of clay. Chilled air is supplied by a smoke exhauster 29 to the pipe 30, then to the atmosphere.

Example 3. Design features of the production line of building materials are shown in the table.

The technical and economic advantages of the proposed line for the production of building materials are:

the ability to fully automate all technological operations;

large assortment and high quality products;

buildings built of beams, blocks, stones, glazed, do not require further decoration, aesthetic, durable;

the location of the line with a slope allows you to reduce energy consumption for moving the beams along the moving hearth and moving the air, arrange the line in a straight line, or in a circle, or in a spiral in the same production room at several levels, and use the internal area to accommodate an inclined gallery, clay storage, warehouse of finished products and domestic premises;

the combination of the processes of formation, heating, pre-pressing, drying, firing, cooling with the simultaneous action of a constant dock, ultrasound, infrared radiation, high-frequency current, heated (from the cooling line) air and glazing with spread paste in the zone with maximum temperature eliminates heat loss, accelerates the drying and firing process, to improve the quality of products and reduce cycle time, and chopping at the final stage to the required dimensions eliminates the formation of waste that inevitably occurs when cutting abr zivnymi circles.

(56) Austrian patent No. 376926. cl. B 28 B 11/16, 1985.

Parameter One, rev. Minimum see 446 Max. see 142 Avg see 277 Productivity of one press (SM-446, SM-142, t. one 10 5 SM-277) brick per hour meters per hour 70 700 350 1 line million pcs brick per year 7.2 72 36 Cycle time h 8 48 24 Line length m 560 5600 2800 The diameter of the spiral m 178 . 360 260 Workshop Width m 3 6 4.5 Workshop Height m 2.7 4,5 3.2 Line slope m 0.0075 0.015 0.01 The length of the spiral m 560 1130 785

Table continuation

Parameter One, rev. Minimum see 446 Max. see 142 Average, see 277 The number of turns of the spiral PC. one 4.9 3.5 Line height m 8 fifteen 10.5

Note. The cycle time depends on the composition of the raw materials, the content of thinning additives, the heating temperature, the speed of forming the beam, the power of the HDTV and infrared radiation sources, and other parameters that are selected experimentally.

feed bins, feeders, stone extraction rollers, grinding rollers and continuous clay mixer.

3. The line according to claim 1, characterized in that the drive of the forming press is made adjustable and connected to a constant current source.

4. The line according to claim 1, characterized in that the core hollow core

Claims (2)

Formulas 1. LINE FOR THE PRODUCTION OF BUILDING MATERIALS, content -. sheathing inclined belt 5 feed conveyor installed in the technological sequence, a set of equipment for preparing raw materials for molding, a drive forming press with a mouthpiece having hollow core cores, _________________ developers, a device for cutting the press are included in the direct current circuit of the drying beam firing longitudinal cutting divisions of workpieces for both timber and workpieces, characterized in that, in order to automate the process, expand the range and improve quality, the line is equipped with with a prepress and decorating device behind the press, the drying-firing unit is made in the form of a slit installation inclined along a spiral with processing means of high-frequency currents, infrared emitters and a coating device, while core holders of the press mouth are made in the form of electrodes included in an electric the chain, and the transverse cutting device separating the billet> is made in the form of a guillotine mechanism with a synchronization unit, and the line has: of control, signaling and control technology; operations. 'and are isolated from the body of the mouthpiece. 5. The line according to claim 1, characterized in that the extrusion and decorating device is made in the form of two oppositely mounted opposite sides of the longitudinal axis of the press outlet of the press with a source of ultrasonic vibrations. 6. The line according to claim 1, characterized in that the slit drying and firing plant is made with systems for supplying atmospheric air at its outlet and circulation of heated air. 25 7. The line according to claim 1, characterized in that. the device for applying glaze is installed in the zone of maximum temperature of the drying and calcining plant. 8. The line according to claim 1, characterized in that the transverse cutting device is made in the form of opposed blades, each of which is mounted on a moving core of an electromagnetic ---------- '· _ _ coil, which is included in the electrical circuit operations. _itp ³⁵ contact device for synchronization 2 Line according to claim 1, characterized in that; ^{7 to} 5 movement of the workpiece and the blade, a set of equipment for preparing] ^{g of} raw material for molding consists of a set-up 9. The line according to claim 1, characterized in that the flax consistently vertically above ; 40P ^is positioned obliquely and rectilinearly. on workpieces, assembly, cross and devices for cutting an egg conveyor