WO1994017969A2

WO1994017969A2 - Improvements to sawing machines and methods for cutting stones

Info

Publication number: WO1994017969A2
Application number: PCT/ES1994/000009
Authority: WO
Inventors: Luis Castro Gomez
Original assignee: Luis Castro Gomez
Priority date: 1993-02-02
Filing date: 1994-02-01
Publication date: 1994-08-18
Also published as: AU6039794A; WO1994017969A3

Abstract

The improvements to saw machines and sawing methods to cut stones consist in modifying of the hoops (4), the tensioners (2), the frames (3), the tensioning systems and other parts of the machines, in order to take better advantage of the machines and to increase the feed. The collective hydraulic tensioning is set. A better use is made of the hoops (4) and of the shot. The down-times for substituting and changing the hoops (4) are reduced. The beginning and the end of the saw-cutting are made easier. A reduced flow of sludge per groove is used. The sludge consists of calcic ferrite. The machine has to operate in conditions where the sludge adheres to the extremities of the hoops (4) which project from the block. The amount of the cuttings is limited in the sludge. An economical, silent and high-production machine is provided.

Description

IMPROVEMENTS IN THE MACHINES AND METHODS OF SAWING STONES State-of the prior art.

From the years 20 to 1975 approximately it was sawn with average advances of the order of 55 mm / h and costs far superior to the current ones. From that date there were improvements until reaching average advances of the order of 28 mm / h, sawing pink Porrino, stone type three meters long, two cm thick, with the shot of 3 to 5 tenths of a mm. with flat strips, making 50 cm routes 70 times round trip per minute, and with 23 mm machine arrow, with the following average technical costs, per square meter, shot, 2 kg; strapping 0.8 kh; energy, lOkwh; lime, 4 kh; human work, O'l hour and amortization, O'l hh. Perforated and grooved strips were devised, which increased the advances but raised the specific costs, reaching up to 25% elevation in the case of perforations, so they have been discarded.

The improvements that have allowed to increase the advance from 6 to 28 mm / h consist in the increase of shot blast concentration on the side, increase of the pressure of the strap on the stone, increase of the arrow of the machine and of the travel and drag of the strip; better control and maintenance of the optimum characteristics of the sludge, increased tension of the strap and better control of its permanence. Explanation.

In the patent we describe, the use of the machine's arrow is optimized, which goes from approximately 24% to 59%, and the characteristics and use of the sludge are improved, improving the Spanish patents numbers 525.314-4 and 545.142 -6, which allows to increase the advance and reduce the cost of sawing. The new strap does not require perforations in the

SUBSTITUTED SHEET ends for tensioning and scission, so that its length is better used. It is tensioned by the edges of the four ears that remain when lowered near the ends, to compensate for the less wear in these areas. At the same length of stones, it means an average increase of 2%, because strips and frames can be shorter than other circumstances, and therefore the sawing pressure on which the advance depends can be higher. In figure 1 you can see the ends of a strap, in which 1 are the ears, 2 are the recesses and 4 the edges to tighten the strapping.

The most important improvement is to avoid vertical displacement of the ends of the straps to better take advantage of the machine's arrow; This results in an increase in sawing pressure of approximately 60%. To do this, we fit the ends of the strips between two auxiliary beams at each end of the strips, supported by parts of the carrier frame, without impeding the rotation of the ends of the strips, for which the ears of these end in arches with the center on the main axis of the strip, about 2 °, followed by tangents to them, as seen in figure 1 mark 3. By leaving freedom of rotation, harmful tensions are avoided.

To take advantage of the length of the strap, the dividers between strips to obtain the stone plates of the desired thicknesses, will stick to the strips at their ends, where, in addition to not spending strap length, they will avoid buckling their ends. These separate glued joints facilitate the assembly, alignment and plumbing of the straps and, making them smooth, facilitate the rotation of the ends between them and in relation to the stops located on the racks. The ends of these separators are as seen in Figures 2 and 3, mark 3, to facilitate the entry of the clamps, and recessed, mark 2, to accommodate them. The mark 1 is the separators and the mark 4 the strips. With this situation of the separators, the average advance of the sawing can be increased by another 2%, approximately.

The sets of pieces for tensioning the strips by the edges of the ears can be seen in figures 6 and 7, where 1 is a semi-cylinder that is in contact with the flat edge of the ear of the strap and on the symmetrical surface receives the effort of the clamp 2, which in turn receives it from the yoke 3 through its semi-cylindrical parts, whose yoke rests on the beam 5 of the frame or the interpu¬ 4 supplements. The piece 1 is glued or welded to the piece 2. The piece 2 can have ears as in figure 4 and be grooved as in figure 5. This tensioning system allows more tension in the lower ears, at least when the strap is deformed by sawing, achieving a slight embedment or a shortening of length for the calculation of the arrow, whereby a higher sawing pressure can be applied and a greater estimated advance can be achieved by an average of 16%. achieve this purpose by making the lower clamps of greater section, or shorter, or moving them away, or in any other way. Other pieces prevent the fall and movement of the clamps and yokes, figure 6 mark 5.

The frame whose patent is requested consists of three amounts instead of two as before. It has the advantages that the horizontal and vertical arrows are much smaller, also hanging them with six points. The arrows are reduced to a 19th. The resulting small differences in the horizontal arrows are corrected with supplements between the yokes and the beams, as seen in figures 6, 7 and 8 with the mark 4. These supplements will have the appropriate profiles to the distribution of the strips and the tension. By keeping the support areas of the beams straight, the straps can be tensioned collectively, moving the beams away from each other, due to the effect of the jacks housed in the uprights, at homologous ends. Once the straps are tensioned, six wedges are pulled and hydraulic tension is not required during sawing work. This modification lightens the frame, makes it cheaper and reduces the cost of sawing, but does not increase the feed. But the advance if it increases significantly in relation to the machines in use, when hanging the six-point frame, since the vertical arrow on those machines is 3 + 1.5 mm. that in this new frame can be easily reduced to a few tenths of mm. achieving a greater estimated average advance of the sawing of 20% The system has the disadvantage that the measurement A of the strips, figure 1, must be very precise in all of them, error less than 3% of the elongation, but this does not make them more expensive appreciably. In figure 8 we see a frame of this type, in which 1 is the central upright, 2 are the extreme uprights, 3 are the beams and 4 are the supplements profiled two or not. These supplements are seen in figures 6 to 8 with the mark 4. In figures 8 and 9 the expenses are marked with 5, and the wedges with 6. The force in expenses and central uprights must be 3 '5 times greater than at the ends, approximately, to ensure that the three support points of the beams are almost in a straight line.

The guidance of the vertical movement of the platforms of the four-frame sawing machines so far presented the problem of difficult adjustment between fixed and mobile parts, due to construction or assembly deficiencies or different thermal variations, so between two sliders and the platform we interspersed an elastic system like a spring or a i s.to hydraulic with gas ampoule, leaving the guidance entrusted to the opposite guides homologas, one on each side of the machine. In figures 10 and 11, the platform is marked with 1, with 2 the markers, with 3 the sliders, with 4 the elastic systems, with 5 the guiding planes, with 6 the contraguided ones and with the 7 the structures of the guides.

The tensioning system described also allows to reduce the machine stop time and the human effort required to replace and turn the straps using grills on cars, as follows; the cats are relaxed, the main beams approach each other with the help of other small removable cats, screws or levers, the beams move away from each other, mark 5 figures 2 and 3, about 2 per cm and lower about 3 cm, the ears are removed from the ears and the lower clamps are retracted, the tacos for packing the strips are dried, the machine frame is raised and the strips are left on the grill on a car that had previously been fitted underneath; if the strips removed are to be replaced, they are taken to the workshop and the new ones are brought on another grill and the reverse process is done; if the strips have been disassembled to flip, it is assumed that they are already in a car that allows flipping, they are covered with the second inverted grill, they show solidarity, they put the tacos that the package had on the machine, turn around, turn Remove the upper grill, lower the frame until the straps fit, the lower clamps are pulled, the beams mark 5, Figure 2 and 3 are replaced, the ends of the straps are pressed, the tacos are retained, the beams 5 and 6 are pressed, figures 2 and 3, the straps are tensioned with the three main jacks, the six wedges mark 6, figure 4 are pulled and the main jacks are released. In figure 12 you can see a car with a grille for mounting strips, in which 1 is the longitudinal carriage. 2 the tracks for the lateral displacement, 3 are rollers for this displacement, 4 are the frames for the rest of the lowered area of the strips, 5 are the soft material coated poles and 6 the folding end frames. Figure 13 shows a carriage with the two grills for the turn, in which 7 is a laterally movable superstructure without grill, with rollers to facilitate the turn, 8 are the grills, 9 the circular tracks connected to the grills and each. The longitudinal carriage is the same as the replacement car.

In the processes of sawing up until now in practice an excess of mud is pumped that falls by the four sides of the block, which is not used. The delivery tube that we have devised conducts a stream of mud to each slot or little else. It has in its lower generatrix a row of perforations of adequate diameter, separated from each other just like the strips or less. If necessary, a deflector is installed inside so that the internal velocity of the sludge does not disorient the jets and that all are vertical. This tube is replaced by another with great ease and also easily adjusts to the situation of the straps. In figures 14 and 15 this tube is seen in which the mark 1 is the tube, the 2 the perforations, the 3 a plug, the 4 a position limiter of the toric joint, with clamp; 5 the o-ring, 6 the tube where the mud comes from, 7 the inner deflector, 8 a deflector positioner, 9 a tube position adjusting block and 10 a support. Using this tube saves installation, energy, shot, which does not oxidize so much, and splashes on the mechanisms and parts of the machine.

Until now the blocks are mounted on cars with continuous platform and the spaces between them are filled with concrete or mortar to the edges of the platforms. ways so that the shot does not stay in it.

The cars described below have only two short support platforms at the longitudinal ends of the cars and on them the long blocks of the stones are supported, with mortar or concrete. In the intermediate spaces the cars have rafts of sufficient height to flood the highest gaps in the lower part of the blocks, which by the longitudinal ends are closed with said mortars plus any other material up to the side walls of the rafts. These rafts are filled with sustaining mud to the edge, before the strips reach sawn to their level, so that the sludge cannot leave the grooves through the bottom holes. In figure 16, the support platforms are marked with 1, with 2 the block, with the three side walls of the rafts, with 4 the bottoms, with 5 the mortars or concrete support, with 6 the side fillings. With this method, the preparation and application of mortars on the platforms is saved and debris and the jobs involved are saved.

To facilitate the beginning of sawing a raft is constituted at the top of the block, with transverse edges that are very easy to saw, so that, filled with mud, any projection of the stone is bathed in mud and the strips do not work in the stone without the presence of shot. In figure 16 you can see this raft marked with 7.

The improvements related to change and flip of straps, and lower and upper rafts do not modify the advance of the machine, but save wasted time, which with these reforms can reach 3 hours a day, and deterioration of sawn material at the beginning and end . The sludge is accurate when shot sawing to extract the detritus produced from the rushes, to keep the shot in suspension and to evacuate the heat produced in the sawing, but the less mud, the lower the cost of sawing, due to savings in pumping and purification facilities, and in energy . In addition, at the same concentration of shot blasting in the mud, the less sludge, less shot blasting grass by oxidation. On these premises we have investigated for years to achieve the method of driving the saw that we now describe. The sludge must have the appropriate viscosity to keep the shot, even attached to the strap outside the block, in motion, while not being excessive so that it does not stop lowering between the rough stone plates of each slot, until it reaches the moving strap. The lime is used to prevent the stone from staining when the strips and the shot are oxidized. Chemical processes develop as follows:

2 Fe0 ₂

OH - * 2 H ₂ 0

Ca0 ₂ H ₂ * ^ Ca ⁺⁺ - 2 OH ^" Fe0 ⁼ + Ca ⁺⁺ - Fe0 ₂ Ca |

and these equilibria are very much displaced towards the formation of calcium ferrite, FeO Ca, which is insoluble and precipitates, keeping the content of ferrous acid dissolved in water very low, which could lead to the formation of Fee0a, 'causing the spots. Calcium ferrite has so far been eliminated from the process of sawing with dissolved and suspended lime, with lime carbonate formed with the C0 of the air, with water, with the detritus of the sawn and with the fine particles of iron not yet oxidized. The new method of conducting sawing is intended to use calcium ferrite as a sustainer without adding any powdery product I miss the sawed, since we have verified that the Ferrito behaves very well to this end, supporting the shot and flowing well through the grooves of the sawed. Thus, the sludge that reaches the grooves of the sawmill is composed of non-selenite water, which would catalyze the oxidation of the shot and the strips, dissolved lime up to approximately 2% and non-harmful impurities. Approximately 70% by volume, on the one hand, and on the other, mainly calcium ferrite, with undissolved calcium hydroxide and calcium carbonate formed with the C0e of the air, ' ¹ constitutes the sustaining sludge, approximately 21% by volume. It may also contain some small-scale sawing detritus, which slightly impairs the sawing process. This mud does not depend on the nature of the stone.

Calcium ferrite mud, as described with the highest proportion of shot blast allowed by the machine, the stone, and the strips, is made to reach the sawing grooves at the minimum possible flow, but that is sufficient for the strips they are surrounded by mud to the upper edge, inside the stone, and so that the increase in concentration in sawing detritus that occurs from the center of the groove, where between the mud, to the exits, does not cause reasoning between detritus , stone, shot and strips, which significantly increase energy consumption, shot and strap. In experiences carried out, it has been proven that up to 25% of shot blast plus detritus, in volume, the expense is very low and almost proportional to the concentration, but that if the volume is exceeded 44%, the cost of sawing is triggered by three concepts and it is slower. Another cause of the greater progress of this method and savings is that the mud is sticky, so that it is attached to the strips when they leave the block and when entering again they saw as much as when leaving, by taking the shot attached to the lower edge, while the muds currently used do not adhere and the strips only saw when leaving, while entering they rub against the stone, making noise and are spent on the areas that leave the block. For this reason this machine is silent, and advances almost double.

Another improvement of method refers to the saving of shot, consisting of separating the smaller one that is recovered from the detritus that is thrown to the landfill or taken to silos, and that smaller shot does not return to the sawing sludge as the largest, and is stored for later use in suitable containers.

The smaller shot is not useful for sawing along with the larger one because the straps cannot press on it, having it greater than prevents it. This results in an additional saving of shot blasting from 10 to 30% depending on the relationship between the diameters of the larger grille and the maximum of the separated one, although it has little impact on the cost of sawing.

In figures 17, 18 and 19 three schemes of possible application of these sawing method improvements are shown. In all of them 0 is the sawing process; 1 is a sludge lift pump, which may be in that situation or another, or there may be more pumps in series or in parallel in the process; 2 is a size separator; 3 is one or more density separators, which separate sawing debris from one side and another shot; 4 is a regulating tank and ho ogeinazor of the mixture of shot and mud; 5 is a diluent or sludge mixer with water; 6 is a separator by deities and sizes; 7 is a sludge concentrator up to the proper density and viscosity; 8 is a fine shot silo, alone or mixed with debris of equal size; 9 is one or several silos of detritus of sawn, and 10 is a silo of Ferrito mud with or without detritus. In addition to the indicated devices there will be detectors of level, density and concentration of shot blast valves; lime, shot and powder feeders; transitory or regulatory deposits and other devices commonly used in this and other activities none of them subject to this patent.

With all these improvements in sawing machines and methods, not yet tested together, we hope that the Porrino rose can be sawn under the conditions indicated on page 2, with an advance of up to 15 cm / h, with a much lower cost to the current one.

Claims

R E I V I N D I C A C I O N E S

1§- Improvements in machines and methods of sawing stones consisting of strapping without perforations, equipped with four ears in the corners to tighten them, ears that result when making the necessary recesses to compensate for the less wear of the nearby strips of the ends, without lowering the ends, and consistent in that the ears have the normal inner edges to the main axes of the curved strips and agreements, and consistent in that the tension to the strapping is applied in the inner edges of the ears, by the flat part of semi-cylindrical or more cylindrical pieces, which receive it in turn by its semi-cylindrical parts of strap clamps, closed as chain links, which in turn receive it from the semi-cylindrical parts of vertical plate yokes, which they rest or receive the tension of the main rafters of the racks, or of intercalated supplements, and also consistent in that the lower clamps that tension the fl axes are of greater section than the upper ones or shorter than those or are further apart than the upper ones by supplements between the lower part of the beams and the yokes, or in any other way exert greater tension. 2§.- Improvements in the machines and methods of sawing stones consisting in that the ends of the ears of the strips are small arcs of circumference centered in the main axes of the strips, followed by tangents to them, and in which the The ends of the strips fit between horizontal auxiliary beams, below and above, supported on the frame pieces, with the particularity that these beams are mounted in contact with the arches of the ends of the ears of the straps, allowing their rotation, but preventing or limiting its vertical displacement relative to racks, and consistent in that one or two pieces of thickness adequate to that of the plates to be obtained are attached or fitted to the ends of the strips and in which these supplements are beveled at the ends and recessed in the areas close to they.

3§.- Improvements in the machines and methods of sawing stones consisting of the racks having four fixed stops for each bundle of strips, aligned two to two, which allow the strapping package to be automatically aligned and plumbed, attaching it to two stops aligned and pressing it from the other two stops with jacks or with wedges or otherwise, after having fitted the clamps and having fitted the joints between the limiting beams, of vertical displacements of the ends of the straps, and consisting in that the frames portaflejes are composed of two beams of one piece each, supported by three uprights, horizontal as the beams, subject to understanding between the beams, that of the center 3.5 times more resistant than those of the ends, approximately , between two uprights and beams being two spaces for the placement of strips, to saw two separate blocks and also characterized in that the beams can be double, a on another, the couples separated by three uprights or more, and consistent that the straps are all tensioned at once, moving the rafters away from each other, with three hydraulic jacks located at homologous ends of the three stanchions, fixed or removable, so that the force in the central jack is 3.5 times greater than that exerted at each of the ends, approximately, and consistent in that it is achieved that the elongations and tensions of all the strips are equal, outlining the faces of the beams where the yokes are supported or inserting supplements between these faces and the yokes, with the suitable profile in each case, to compensate for the differences in the arrow of the beams in the support areas of the yokes, or in any other way to achieve equal tension in the straps, and also consisting in that, with two wedges in each stile, maintains the tension of the straps without pressure on the jacks.

4§.- Improvements in the machines and methods of sawing stones consisting in which the vertical movement guidance of the large platforms from which the four racks hang, in machines of this type, is carried out by two vertical guides, located at both machine sides, consisting of two flat surfaces of precision, strong and rigid, vertical, both located in the same geometric plane, on which two skates, rolling or sliding, attached to the platform with minimal elasticity in the direction of the longitudinal axis of the machine, and so that these skates do not separate from the guides, there are two other planes, also vertical and strong, parallel to the previous ones and to both sides of the machine, with other similar skates, but attached to the platform by a longitudinally mechanical or hydraulic elastic system, capable of absorbing differences in expansion and inaccuracies, without significantly changing guiding forces.

5§.- Improvements in the machines and methods of sawing stones consisting in that the carriages for the assembly and turning of the strips are composed of rollers and structures for the longitudinal displacements, on which there are transverse rails for the displacements in this direction of superstructures, on wheels or rollers, with grills, which in the case of the assembly of strips with at least two low porches open upwards, where the lowered parts of the strips and one or more intermediate gantries will be supported covered with a thick layer of a soft and non-slip material, and two more portals at the ends, folding overcoming the pressure of springs, which fit the ends of the strips with bonded supplements when the machine frame is lifted and released when it comes down, and consistent in that the turning grills are like those described above and can be in solidarity with other inverted equals, which have intermediate portals slightly displaced two along and also are provided with two semicircular tracks each, with axes in the longitudinal of the bundle of strips, which rest and can roll on four rollers mounted on the superstructure with transverse displacement. 6§._ Improvements in machines and methods of sawing stones consisting in that the carriages have, in the longitudinal ends according to the strips, rigid areas to support the blocks with the help of concrete or mortar, and, among them, a raft watertight, closed at the longitudinal ends by concrete or mortar support and by more materials such as these or others, filling up the side walls of the rafts, whose side walls reach near the end of the rigid areas and have more than enough height to overcome the highest gaps that may be in the bases of the blocks to be sawn, and consistent in that, before the strips reach the lower gaps of the blocks, said rafts of mud are filled as well as sawing, and consisting also that, before taking the blocks to the sawing machine, its upper part is prepared so that a raft is formed which, once flooded with mud, cuibra the parts m s of high block using materials easily attachable and the lengthwise ends dinales also easily sawed and not despren- they occur when they are sawn, and they are also consistent in that the most protruding parts of the block where the strips are going to pass are covered with paste or mortar of easy sawing and difficult detachment. 7§.- Improvements in the machines and methods of sawing stones consisting of the fact that the sludge that sustains the shot and debris that is sawn into the grooves is mainly constituted by calcium ferrite, FeO „Ca, self-generated in the process, and impure - flush, all suspended in lime water, may contain small proportions of small iron particles and sawing debris.

8§.- Improvements in machines and methods of sawing stones consisting of the minimum possible amount of sustaining sludge being delivered to the sawing slots, from a groove drilling or little more, located in the lower generatrix of a distributor tube, horizontal, and transverse, without the concentration of debris plus shot in the whole of the mud, at the exit of the grooves reaches 40% in volume, and also consistent in that the sludge must have the viscosity necessary for that adheres to the ends of the strips that leave the grooves, so that the shot is adhered to the strap laterally and below, despite the acceleration to which it is subjected by the movement of the strips.

9§.- Improvements in the machines and methods of sawing stones consisting in the fact that the smaller shot separated from the debris that is sent to the landfill or silo is not reincorporated into the sawing circuit, but is separated from the larger one and stored .