UA120658C2 - Device and method for producing solid and hollow gypsum wallboard elements in quick succession - Google Patents

Abstract

The invention relates to a device and a method for producing solid and hollow gypsum construction elements, comprising the following features: a) a gypsum silo (6) from which gypsum is conveyed to a gypsum mixer (4) where process water is also added, b) a moulding box (3) for moulding gypsum construction elements, comprising a plurality of parallel-lying moulding chambers (19) with grooved webs (23) on each of the two end faces, each moulding chamber (19) being provided with a displaceable bottom rail (24) and said bottom rail (24) additionally comprising web-like elevations tor die purpose of generating profiled structures, c) a number of drive cylinders (21) for the vertical displacement of cavity pins (17) in moulding chambers (19), d) a plane cross-bar (20) which can be guided in guiding units (13) over the moulding box (3), for smoothing the surface of the gypsum wallboard elements, e) a number of drive cylinders (22) for vertically ejecting finished gypsum wallboard elements, and f) a rotating device (26) allowing two moulding boxes (3) to be filled within a short time interval.

Description

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The invention relates to the device and method of manufacturing massive and hollow gypsum structural elements in the mode of rapid change.

Gypsum wall panels are structural elements made of massive plaster of paris for the construction of non-load-bearing internal partitions, shaft walls, cladding panels or cladding of supports in the interior of buildings.

The walls are built without a supporting structure using only plaster glue. Due to this fundamental difference, gypsum wall panels should not be confused with thinner plasterboard plates, which are used as cladding for frame partitions.

Among the prior art regarding gypsum wall panels from patent publications is known in particular the accepted application of Germany 1162 252. It relates to a hollow wall with a chrome coating for casting molds in molding machines for the production of gypsum boards.

Based on the prior art, according to this publication, a molded hollow wall for casting molds in molding machines for the production of gypsum boards with a high quality, non-deformable surface is chrome plated. The problem that needs to be solved according to this publication is a situation in which, with minor damage to the chrome coating of a molded hollow wall, due to the penetration of sulfur present in the gypsum, a corrosion ulcer is formed in the base of the chrome coating for a short time, which leads to the peeling of the chrome coating. To solve this problem, in the distinguishing part of the single claim of the invention, it is proposed to perform a molded hollow wall from an iron bearing plate that meets the requirements for strength, on which a plate made of stainless steel with a chrome coating applied to it by the galvanic method is glued.

In the current state of the art, reference is made to publication OE 697 11 644 T2. This publication relates to a method of manufacturing thin plates from a material suitable for processing by casting, in particular gypsum, a device for carrying out the method and a product manufactured by this method.

In this case, the basis is the method of manufacturing thin plates from a material suitable for processing by casting, in particular gypsum, which hardens with expansion during the molding process and hardens in the molding compartments of the molding chamber.

To prevent accumulation of material in the area around the mold opening or to avoid problems when removing air from the corresponding mixture when using material with

With glass fibers, in the distinguishing part of clause 1 of the claims of the invention, a method is claimed, which includes the following stages: 1. filling with poured material the corresponding molding compartments in the molding chamber; 2. vibration treatment of the material poured into the molding chamber to remove air present in it and distribute it evenly over the entire height of filling the mold; 3. formation of forming compartments inside the forming chamber; 4. enclosing the forming chamber to ensure that it withstands hardening and hardening of the formed plates without deformation during the forming process, for example, with a rigid outer frame that is installed around the forming chamber; 5. removal of the enclosure of the molding chamber after completion of molding by turning off the pressure on the molding compartments, which prevails during the molding of the material, and 6. removing the molding compartments and the molded material for further processing.

The invention is based on the task of developing a device and a method for fast and reliable production of gypsum structural elements with high stable quality with the possibility of quick change of massive and hollow plates.

This problem is solved in the device according to point 1 for the production of massive and hollow gypsum structural elements in the quick-change mode, which has the following features: a hopper (6) for transporting gypsum using a transport auger (5) through a scale (32) for gypsum using an additional transport auger to the gypsum mixer (4), into which process water from the water tank (7) is additionally supplied; a molding box (3) for molding gypsum structural elements (13) with a plurality of parallel-mounted, top-open molding chambers (19) with profiled partitions (23) on both ends, and each molding chamber (19) is equipped with a movable lower bar, which is optionally has a closed section and a section with holes for inserting rods (17) into it to form cavities, and the lower bar (24) can additionally have rib-like protrusions for forming profile structures; a set of drive cylinders (21) to ensure the possibility of vertical movement of the rods (17) for forming cavities in the forming chambers (19); made with the possibility of movement in the guide modules (18) above the molding box (3) a shear crossbar (20) for leveling the surface of gypsum structural elements,

moreover, profiled depressions can be made in the cutting crossbar (20) for the formation of groove and ridge structures; a set of drive cylinders (22) for lifting gypsum structural elements in the vertical direction; rotating device (26), made with the possibility of filling two molding boxes (3) with a short time interval.

Also, according to the invention, the parts of the molding chambers (19) that are in contact with the gypsum mortar are made of synthetic material and/or other coatings are applied to them, and/or the molding boxes (3) are made with the help of transverse rails (27) and/or longitudinal the rail (28) is inserted into the magazine or removed from it, and/or the molding box (3) contains molding chambers (19) of different sizes for the production of various-sized gypsum structural elements, in addition, according to the invention, in the manufacture of hollow gypsum structural elements, different or replaceable rods for forming cavities (11), the subject of the invention according to point b is also a method of manufacturing massive and hollow gypsum structural elements in the mode of rapid change, which has the following features: a) forming boxes (3) open from above, made in accordance with the desired shape of concrete gypsum structural elements and/or wall panels, filled with gypsum solution from the gypsum mixer (4), and at least no two molding boxes (3) are served almost simultaneously with the help of one rotating device (26),

B) for this, in accordance with the specific task, the molding boxes (3) are moved from the store to the working area with the help of transverse rails (27) and longitudinal rails (28), after the hardening stage, the gypsum structural elements are pushed out of the molding box and directed to the dryer (10 ), c) after final drying, gypsum structural elements and/or formed wall structural elements (13) are transported using carriages (2), folded for shipment and packed in film or wrapped with tape or wire.

In addition, according to the invention, a part of the forming chambers (19) that is in contact with

With gypsum solution, made of synthetic material and/or have other coatings.

According to the invention, the molding boxes (3) in combination with the rotating device (26) with the help of transverse rails (27) and longitudinal rails (28) are installed next to each other for further optimization of the process, and sensors are used to control this process, in particular sensors ( 30) of the light field.

Likewise, according to the invention, in principle, instead of gypsum, other materials, such as, for example, cement or synthetic material, with known binders for the production of the corresponding structural elements, can also be treated.

Likewise, the invention relates to a computer program with program code for implementing a method when executing a program on a computer.

The subject of the invention is a machine-readable medium with the program code of a computer program for implementing a method when executing a program on a computer.

The device according to the invention is described in more detail below. The drawings show:

Fig. 1: The device according to the invention, top view

Fig. 2: Image of a hollow plaster wall panel in an isometric projection

Fig. 3: Separate image of the forming box C with inserts for the manufacture of hollow plates in an isometric projection

Fig. 4: Top view of a molding box with cavities

Fig. 5: Molding box with drive cylinders in section

Fig. 6: A series of cross-sectional images of the stages of the solid slab manufacturing process

Fig. 7: A series of cross-sectional images of the stages of the hollow plate manufacturing process

Fig. 8: Top view of the rotary device 26 of the double molding box

Fig. 9: Top view of transfer station for molding boxes

In fig. 1 shows a top view of the corresponding inventive installation.

The central element of the installation, in fig. 1, shown in the center right in a top view, is a molding box 3. This drawing shows a top view of a molding box 3, which is mainly used for the manufacture of gypsum structural elements. In fig. This molding box C is shown separately in an isometric projection. To the left and to the right of the molding box C, two long crane tracks 1 are shown for moving grippers for transporting finished gypsum structural elements from the area 60 of the molding box C to the area of transport carriages 2, with the help of which they are moved, for example, to a dryer. For loading the molding box With gypsum as the main material, a transport auger 5 is assigned, which transports gypsum from the transport hopper b through the gypsum scale 32 with the help of an additional transport auger to the gypsum mixer 4, in which this gypsum is mixed with water supplied from the water tank 7 , obtaining a plaster solution. Block 8 of power supply and control of the technological process is provided for power supply and generation of production impulses for the forming box Z. The hydraulic unit 9 provides the working pressure necessary for the technological process. In the dryer zone 10, plates still wet after the production process are dried until the desired humidity is reached.

Figure 2 shows a hollow gypsum wall panel in an isometric projection as an example of a wall structural element 13. Such a panel equipped with profile elements can be used as an independent wall structural element, since several panels can be connected to each other with power locking. The side surfaces of such a wall structural element 13 are usually subjected to a special additional treatment as visible surfaces 12. These wall structural elements can be made in the form of a monolithic material or, as shown in Fig. 2, they can have cavities 11.

Cavities, in addition to the round shape shown in the drawing, can also have a rectangular or oval cross-section.

In fig. 3 in an isometric projection shows a separate image of the molding box 3 with inserts for the manufacture of hollow plates. The foundation of such a molding box C in this example is the main supports 14, and the drawing shows the left and middle of them. As shown also in fig. 4, the molding box C contains numerous molding chambers 19 installed next to each other, each of which corresponds to the external dimensions of the gypsum structural element. Gypsum solution is poured into these forming chambers 19 from above, which, after drying, forms gypsum structural elements. Rods 17 necessary for the manufacture of hollow plates are shown in one molding chamber 19 located in the molding box on the left. Since the upper side of the manufactured gypsum structural elements is subjected to processing to achieve a certain surface structure, and it also needs to be cleaned of excess gypsum mortar, a shear crossbar 20 is provided , which

Zo is moved over the parallel installed forming chambers 19.

As shown in fig. 3, for this purpose, it is possible to use a shear crossbar 20 with a defined profile shape, which, when moved over the corresponding ready-made gypsum structural elements, gives them a shape complementary to its profile, like a negative matrix. Guide modules 18 oriented parallel to the molding chambers 19 and perpendicular to the longitudinal direction of the molding box are provided to guide the shown shear crossbar 20. Since the gypsum structural elements are ready to be pushed out of the molds after a certain time of hardening, they must be transported from the molding chambers in a vertical direction for further processing, for each molding chamber 19 is provided with a corresponding ejector 16, and all ejectors are actuated together by two parallel crossbars 15. In general, drive cylinders 22 are used to actuate the device for pushing out gypsum structural elements, which through the crossbar 15 provide the necessary lifting force. When making hollow plates and forming the necessary cavities before filling the forming chambers 19 with gypsum mortar, the drive cylinders 21 are activated, and to form the cavities, they push the rods 17 into the forming chambers in the vertical direction upwards.

Unlike the EM 12859 standard, molding boxes can have such dimensions that allow the production of profiled and non-profiled gypsum structural elements with special geometric parameters (thickness, length, width) and shapes.

In fig. 4 shows a top view of a molding box with multiple cavities. In this drawing, to the left and to the right of the transversely oriented molding box are the guide modules 18 for the shear bar 20. The individual molding chambers 19 are shown in detail, and the molding chamber on the left of the molding box is specially shown on both ends of the profiled partitions 23. Several plaster structural elements are also shown 13 and individual cavities 11.

The materials from which the parts of the molding chambers that are in contact with the gypsum solution, such as the bottom bars and side profiles, are made, can be made mainly of synthetic material and/or other coatings can be applied to them.

The corresponding inventive installation can also be equipped with molding boxes 60 suitable for the production of gypsum structural elements as panels combined with other materials. So, for example, Styrofoam rods can be used for cavities 11. Structural elements can also be made of other building materials, such as, for example, cement, combined wood fiber materials, foam concrete, or similar building materials. In addition, the molding box can contain molding chambers, which are suitable for the production of products of different thicknesses and shapes according to their dimensions, and replaceable rods for cavities 11 can also be used.

In fig. 5 shows a cross-section of a molding box with drive cylinders. In the isometric projection, a fragment of fig. With in cross-section. Along with the main supports 14, in the lower part of the drawing, the driving cylinders 21 for the rods 17 for forming cavities and the driving cylinders 22 for the ejector device are shown, and they act directly on the depicted cross member 15. In addition, this drawing shows a partially perforated bottom bar 24 that is moved in the horizontal direction This lower bar 24, which provides the possibility of closing the bottom zone of the forming chambers, has a section without round holes and a section with round holes for inserting rods 17 for forming cavities.

In the case when cavities are to be formed in the manufactured gypsum structural elements along the entire length or in some areas of the molding box, this area allows inserting the rods 17 to form the cavities from below through the lower bar 24.

Additionally, such a lower bar 24 according to fig. 2 in the middle may have a profiled protrusion projecting upward to form a longitudinal profile in the finished gypsum structural element. The cross-section in this drawing also shows the individual gypsum structural elements 13. The shear crossbar 20 is shown in both guide modules 18 in cross-section. To measure the temperature of each individual gypsum structural element 13, at least one corresponding temperature sensor 31 is provided. Thus, by means of temperature profile control in time, by measuring, it is possible to monitor the hardening process of each gypsum structural element 13, and at the same time, the entire molding box 3.

In fig. 6 in cross-section shows a series of images of the stages of the manufacturing process of massive plates.

At the same time, fig. ba) the cross-section shows the forming chamber 19, and the section is closed

From the bottom panel 24 covers the bottom of the molding chamber in the downward direction, and the plaster mixer 4 does not work. In fig. 65) shows the loading of the liquid gypsum mixture 25 from the gypsum mixer 4 into the forming chamber. In fig. bs) the plaster mixer again stops working, and the plasterboard in the form of a wall panel 13 is pushed out of the chamber by means of an ejector.

In fig. 7 is a cross-sectional view of a series of images of the stages of the hollow plate manufacturing process.

At the same time, fig. 7a) also shows the molding chamber 19 in section, and the closed section of the lower panel 24 also covers the bottom of the molding chamber in the downward direction, and the plaster mixer 4 is not working. In fig. 75) the liquid gypsum mixture 25 is loaded from the gypsum mixer 4 into the forming chamber 19, however, at the same time, the perforated section of the lower panel 24 with through holes is preliminarily pushed under the forming chamber 19, as a result of which the rods 17 can be inserted through these through holes to form cavities. In fig. 7c) the gypsum mixer 4 does not work, and the gypsum structural element in the form of a wall panel 13 with cavities is pushed out of the forming chamber after the completion of the hardening stage.

In fig. 8 shows a top view of the rotary device 26 of the double molding box.

To increase the productivity of the installation for the production of gypsum structural elements according to the invention, a device with a double molding box is provided.

Such a double molding box is fixed on a rotating device 26, and its two parts can be alternately installed under the gypsum mixer 4. It goes without saying that the construction of the foundation with the main supports 14 and the drive cylinders 21 and 22 in this case is also double. In the case of the need for an additional increase in the productivity of the installation for the production of gypsum structural elements, it is also possible to install additional molding boxes, as well as the corresponding rotating devices 26.

In fig. 9 shows a top view of a system of cross rails and longitudinal rails with intersection points, which to some extent represents a transfer station as a magazine for forming boxes. The store depicted in this drawing provides the possibility of flexible and prompt response to order changes.

For the production of gypsum structural elements with different dimensions and intended purposes, it is necessary to use molding boxes of different designs with different molding chambers 19.

Thus, in Fig. 9 examples of the implementation of the installation offer an improvable concept of rapid optimization of the changing technological process.

For this, in the middle of fig. 9In the area of the gypsum mixer 4 on the left is shown a double molding box with a rotating device 26, to which transverse rails 27 are laid on both sides. The intended cross connection of transverse rails 27 on two longitudinal sides with longitudinal rails 28. Molding boxes C can be moved along the rails shown with the help of drive and running wheels 29 in any direction. Cross connections between transverse rails 27 and longitudinal rails 28 in this example are only formally marked to explain the possibilities of movement. The appropriate design of the drive and running wheels 29, as well as the intersection points and arrows and the positions of the arrows are well known to those skilled in the art.

In order to control the position and loading status of individual molding boxes Z, along with the usual electronic registration elements, a number of sensors are provided, in particular sensors 30 of the light field.

With regard to the applied sensors 30 of the light field, reference is made to the development of so-called minilenses, since according to this development, the principle of the light field provides for the collection of optical information with the help of hundreds of minilenses, on the basis of which it is then possible, through data processing, to form an image with the desired resolution and/or the desired point of view With the help of such minilenses, you can create ZO images; the process of their production does not require large costs; they work on the principle of an insect's eye. Thus, with the help of these sensors 30 of the light field, in addition to the usual possibility of rotation, it is possible to set the desired viewing angle and/or the desired magnification of the image fragment using exclusively electronic technology.

After the final drying of the plate elements in the dryer 10, they must be transported to a station not shown in the drawings, and then packed for shipment. Reference is made to the fact that, in principle, instead of gypsum, other materials, such as, for example, cement or synthetic material, with known binders for the production of the corresponding structural elements, can also be treated. For example, it is possible to make combined materials from wood and synthetic material or from cement and cement fibers.

Complex management of the described transfer processes requires the use of a special program.

Positional designations 1 Under-crane track for a gripper for slabs 2 Carriage for transporting gypsum structural elements

C Molding box 4 Gypsum mixer 5 Transportation auger for gypsum (in Hopper for gypsum 7 Tank for process water 8 Power supply unit and control of the production process 9 Hydraulic unit 10 Dryer 11 Cavities 12 Visible surface of the slab 13 Gypsum structural element 14 Main supports 15 Pusher crossbar 16 Ejector 17 Rods for making cavities 18 Guide module for shearing crossbar 20 19 Forming chamber 20 Shearing crossbar 21 Drive cylinders for cavity forming rods 22 Drive cylinders for pusher device 23 Profiled partitions in forming chambers 24 Bottom bar in molding box 25 Liquid gypsum mixture 26 Rotary device of a double molding box 27 Cross rails for a rotary device 26

28 Longitudinal rails of the transfer station 23 Drive and running wheels of the molding box

Control sensors (light field sensors)

З1 Temperature sensors 32 Scales for gypsum with a transport auger

Claims (10)

FORMULA OF THE INVENTION 1. A device for the production of massive and hollow gypsum structural elements in the mode of sequential change, containing: a) a hopper (6) for gypsum, made with the possibility of supplying gypsum with the help of a transport screw (5) through a scale (32) for gypsum with another transport screw in a gypsum mixer (4), additionally connected to a tank (7) for process water, B) a store with at least two molding boxes (3) for molding gypsum structural elements (13), containing a plurality of parallel-mounted, open-top molding chambers (19) with profiled partitions (23) on both ends, and each forming chamber (19) is equipped with a movable lower bar (24), which optionally has a closed section and a perforated section with holes for inserting rods (17) for forming cavities, and the lower bar ( 24) made with the possibility of installing additional rib-like protrusions for the formation of profiled structures, c) a set of drive cylinders (21), made them with the possibility of vertical movement of the rods (17) for forming cavities in the forming chambers (19), a) a shear crossbar (20), made with the possibility of movement in the guide modules (18) above the forming box (3) and leveling the surface of the gypsum structural elements, and the shear crossbar (20) is made with the possibility of forming profiled recesses for the formation of groove and ridge structures, e) a set of drive cylinders (22), made with the possibility of lifting gypsum structural elements in the vertical direction, a rotating device (26), made with the possibility of sequential filling at least two molding boxes (3). 2. The device according to point 1, which is characterized by the fact that the parts of the forming chambers (19) that are in contact with the plaster solution are made of synthetic material. 3. The device according to item 1 or 2, which is characterized by the fact that the forming boxes (3) are made with the possibility of being inserted into the store or removed from it using transverse rails (27) and/or longitudinal rails (28). 4. The device according to any of the preceding points, which is characterized by the fact that the molding box (3) contains molding chambers (19) of different sizes for the production of various-sized gypsum structural elements. 5. The device according to any of the preceding points, which is characterized by the fact that it contains various replaceable rods for forming cavities (11) for the manufacture of hollow gypsum structural elements. 6. The method of manufacturing massive and hollow gypsum structural elements in the mode of sequential change using the device according to any of items 1-5, which includes the following stages: a) filling from above with gypsum solution from the gypsum mixer (4) open-top molding boxes (3) , the shape of which corresponds to the desired shape of the specified gypsum structural elements and/or gypsum wall panels, and at least two molding boxes (3) are sequentially serviced with the help of a rotating device (26), e) moving for this purpose the corresponding molding boxes (3) according to a specific task from the store into the working area with the help of transverse rails (27) and longitudinal rails (28), pushing out gypsum structural elements after the hardening stage from the molding box and directing them to the dryer (10), І) transportation of gypsum structural elements and/or gypsum formed wall structural elements elements (13) using carriages (2) after final drying , their assembly for shipment and packing in film or wrapping with tape or wire. 7. The method according to item b, which is characterized by the fact that the parts of the forming chambers (19) that are in contact with the gypsum solution are made of synthetic material. 8. The method according to claim 7, which is characterized in that the forming boxes (3) in combination with the rotating device (26) by means of transverse rails (27) and longitudinal rails (28) are installed next to each other for additional optimization of the production process, and sensors are used to control this process, in particular sensors (30) of the light field. 9. The method according to point 6, which is characterized by the fact that, in addition to plaster, other materials are also used, such as cement or synthetic material treated with known binders, for the manufacture of corresponding structural elements. 10. 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