Process for manufacturing foam concrete sphere precast blocks

Abstract

The application relates to a foam concrete sphere prefabricated block manufacturing process and belongs to the technical field of foam concrete prefabricated block manufacturing, which comprises the following steps: S1, manufacturing a long-strip foam concrete prefabricated block; S2, rotatably arranging the long-strip foam concrete prefabricated block on a machining table; S3, driving the long-strip foam concrete prefabricated block to rotate rapidly; and S4, slowly moving a plurality of semicircular jigsaws on the machining table to the long-strip foam concrete prefabricated block until the long-strip foam concrete prefabricated block is turned into a plurality of sphere prefabricated blocks. The long-strip prefabricated block is turned into a plurality of sphere prefabricated blocks, and the foam concrete sphere prefabricated block production efficiency is improved.

Description

Technical Field

[0001] This invention belongs to the field of foamed concrete precast block manufacturing technology, specifically relating to a foamed concrete spherical precast block manufacturing process. Background Technology

[0002] Foamed concrete is a new type of lightweight thermal insulation material. Due to its advantages such as light weight, fast construction speed, and low price, it is widely used in construction, national defense, and disaster relief. In emergency filling of pits, to improve filling efficiency, precast foamed concrete spherical blocks are rolled into the pit, followed by foamed concrete grouting. The spherical rolling effect is good, enabling rapid, uniform, and dense filling, resulting in fast and effective emergency response. Traditionally, spherical precast blocks are made using spherical molds. However, when production demand is large but the number of molds is limited, and repeated demolding is required, production efficiency is low. Furthermore, different models of spherical precast blocks require different molds, leading to high mold costs.

[0003] Patent document CN 109987964 A discloses a type of piled foamed concrete and its construction method. The key feature is that it consists of 38-56 parts by weight of self-leveling foamed concrete slurry and 44-62 parts by weight of precast blocks. The self-leveling foamed concrete slurry is made by mixing cement, fly ash, polycarboxylate superplasticizer, carboxymethyl cellulose ether, water, and foam. The precast blocks are foamed concrete blocks with a particle size of not less than 40mm in a dry state, and are spherical or near-spherical in shape, or a combination of two of these shapes. During the construction of the piled foamed concrete, the precast blocks are naturally piled up in a site with templates or template substitutes, or in a site with natural barriers, to form a pile. Subsequently, the required self-leveling foamed concrete slurry is directly poured onto the surface of the pile, filling the voids in the pile itself without vibration to form the piled foamed concrete. The advantages are reduced labor costs, increased construction efficiency, improved construction environment, and improved quality of the cast concrete.

[0004] Patent document CN 103195070 A discloses a precast block for backfilling and a backfilling method using the precast block. The precast block is a block-shaped material made from hardened foamed lightweight soil slurry. It can be used for pipeline laying, trench backfilling, road emergency repair, road excavation and repair, and foundation or subgrade filling of buildings or structures, ensuring backfilling quality and reducing on-site workload. The backfilling method includes: S100, preparing foamed lightweight soil slurry; S200, filling the cavity with the prepared foamed lightweight soil slurry and the precast backfill block, so that the foamed lightweight soil slurry fills the gaps between the precast backfill blocks and the gaps between the inner surface of the cavity and the precast backfill block. Using this backfilling method, while achieving properties such as environmental friendliness, adjustable strength, load reduction, heat insulation, water absorption, noise absorption, fluidity, and self-compacting, it can control project costs and accelerate project progress. However, both inventions use molds to produce spherical prefabricated blocks, which cannot solve the aforementioned technical problems. Summary of the Invention

[0005] In view of this, the present invention addresses the shortcomings of the prior art by providing a manufacturing process for foamed concrete spherical precast blocks. By cutting long strip precast blocks into multiple spherical precast blocks, production efficiency is improved, and the number and cost of molds used are reduced.

[0006] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a process for manufacturing precast foamed concrete spheres, comprising the following steps:

[0007] S1: Produce long strip-shaped precast foamed concrete blocks;

[0008] S2: The long strip of precast foamed concrete block is rotatably placed on the processing table;

[0009] S3: Drive the long strip-shaped precast foamed concrete block to rotate rapidly;

[0010] S4: Multiple semi-circular lathes on the processing table slowly move toward the long strip of foamed concrete precast block until the long strip of foamed concrete precast block is machined into multiple spherical precast blocks.

[0011] Furthermore, in S1, the method for producing elongated precast foamed concrete blocks is as follows:

[0012] (1) Apply a release agent to the inside of the mold;

[0013] (2) A hollow support rod is placed at the center of the mold, the hollow support rod having multiple branch rods;

[0014] (3) Pour foamed concrete into the mold, let it solidify, demold, and obtain a long strip of foamed concrete precast block.

[0015] Furthermore, the processing table is provided with a front clamp, a rear clamp, and a drive motor. Both the front clamp and the rear clamp include a bearing seat, a shaft, and a clamping device. The shaft is provided on the bearing seat, and the clamping device is provided at one end of the shaft. The shaft of the front clamp is fixedly connected to the output shaft of the drive motor.

[0016] Furthermore, the front clamp is fixedly connected to the machining table, the rear clamp is slidably connected to the machining table, a slide rail is provided on the machining table, a slider is slidably connected on the slide rail, and the bearing seat of the rear clamp is fixedly mounted on the slider.

[0017] Furthermore, two lead screw slides are provided on the processing table, and support plates are slidably arranged on the two lead screw slides, with multiple semi-circular lathe saws arranged on the support plates.

[0018] Further, in S2, one end of the hollow support rod is connected and fixed to the clamping member of the front clamp, and then the rear clamp is slid so that the other end of the hollow support rod is connected and fixed to the clamping member of the rear clamp, and then the rear clamp is locked.

[0019] Furthermore, in S4, the two lead screw slides are activated, causing the multiple semi-circular lathe saws to slowly move toward the long strip of foamed concrete precast block.

[0020] Furthermore, it also includes S5: disconnecting the hollow support rod between two adjacent spherical prefabricated blocks to obtain the finished spherical prefabricated block.

[0021] Preferably, the elongated foamed concrete precast block is a cuboid or a cylinder.

[0022] Preferably, the clamping device is a manual chuck, a hydraulic chuck, or an electric chuck.

[0023] To improve the efficiency of backfilling and emergency repairs, those skilled in the art typically use precast spherical blocks for rapid backfilling, followed by concrete pouring. Patent document CN 103195070 A discloses a precast backfill block and a backfilling method using it. The precast backfill block is a block-shaped material made from hardened foamed lightweight soil slurry. It can be used for pipeline laying, trench backfilling, road emergency repairs, road excavation and repair, and foundation or roadbed filling of buildings or structures, ensuring backfill quality and reducing on-site workload. The backfilling method includes: S100, preparing foamed lightweight soil slurry; S200, filling the cavity with the prepared foamed lightweight soil slurry and the precast backfill block, so that the foamed lightweight soil slurry fills the gaps between the precast backfill blocks and the gaps between the inner surface of the cavity and the precast backfill block. For example, patent document CN 109987964 A discloses a type of foamed concrete and its construction method. The characteristic is that it consists of 38-56 parts by weight of self-leveling foamed concrete slurry and 44-62 parts by weight of precast blocks. The self-leveling foamed concrete slurry is made by mixing cement, fly ash, polycarboxylate superplasticizer, carboxymethyl cellulose ether, water, and foam. The precast blocks are foamed concrete blocks with a particle size of not less than 40mm in a dry state, and are spherical or quasi-spherical in shape, or a combination of two of these shapes. Therefore, it is clear that those skilled in the art typically use molds to manufacture spherical precast blocks of foamed concrete, mainly considering the composition of the foamed concrete. Furthermore, using molds to manufacture spherical precast blocks is convenient and cost-effective. Therefore, those skilled in the art would not easily conceive of the method used in this application: sawing long strip precast blocks into multiple spherical precast blocks.

[0024] Furthermore, even if those skilled in the art conceive of the above method, the following difficulties need to be overcome in order to cut a long strip precast block into multiple spherical precast blocks: First, the manufacturing method of the long strip precast block to ensure its high-speed and stable rotation during lathe sawing; second, the structure of the long strip precast block to enable its high-speed rotation driven by a motor or other structure; and third, the structure of the lathe saw and the cutting method to cut the long strip precast block into multiple spherical precast blocks. These problems are insurmountable for those skilled in the art. Therefore, this application adopts a technical solution of pre-installing rigid plastic tubes and branch rods inside the long strip precast block, setting front and rear clamps on the lathe, and designing multiple semi-circular lathe saws and their moving mechanisms to cut multiple spherical precast blocks from a high-speed rotating long strip precast block. This solution is not easily conceived or implemented by those skilled in the art.

[0025] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0026] 1. The present invention relates to a process for manufacturing precast foam concrete spherical blocks. A hollow support rod is embedded in the center of a long, rectangular precast block. Both ends of the hollow support rod are connected to a front clamp and a rear clamp, respectively. A drive motor rotates the long, rectangular precast block at high speed. Simultaneously, support plates on two lead screw slides drive multiple semi-circular saws to approach the long, rectangular precast block until it is cut into multiple spherical precast blocks. Then, the hollow support rods at the joints are cut off, resulting in multiple independent spherical precast blocks. This invention, by cutting multiple spherical precast blocks from a long, rectangular precast block, significantly reduces the number of molds compared to spherical mold manufacturing methods. It also facilitates changing the model of the spherical precast blocks, resulting in high production efficiency.

[0027] 2. The manufacturing process of the foamed concrete spherical precast blocks of the present invention involves placing a hollow support rod at the center of the mold when making long strip precast blocks. The hollow support rod is equipped with multiple branch rods, which makes the connection between the hollow support rod and the foamed concrete more secure and more stable when rotating. The use of hollow support rods facilitates connection with the clamping chuck and makes it easier to disconnect after multiple spherical precast blocks are machined from the long strip precast blocks.

[0028] 3. The manufacturing process of the foamed concrete spherical precast blocks of the present invention involves first connecting and fixing one end of the hollow support rod to the clamping fastener of the front clamp when installing the long strip precast block on the processing table, then sliding the rear clamp so that the clamping fastener on it is connected and fixed to the other end of the hollow support rod, and then locking the rear clamp, thereby conveniently and quickly rotatably installing the long strip precast block on the processing table. The shaft on the front clamp is connected to the drive motor, and the long strip precast block is rotated at high speed through the drive motor.

[0029] 4. By changing the long strip precast blocks of different sizes, different models of lathe saws, and adjusting the various parts on the processing table, different models of spherical precast blocks can be produced, which is highly flexible. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the mold structure in Embodiment 1 of the present invention;

[0031] Figure 2 This is a front view of the processing table in Embodiment 1 of the present invention;

[0032] Figure 3 This is a top view of the processing table in Embodiment 1 of the present invention;

[0033] Figure 4 This is a front view of the processing table in Embodiment 2 of the present invention;

[0034] Among them, 1-base plate, 2-slot, 3-semi-circular groove, 4-hollow support rod, 5-baffle, 6-branching rod, 7-bearing seat, 8-shaft, 9-clamping fastener, 10-drive motor, 11-processing table, 12-coupling, 13-slide rail, 14-slider, 15-screw slide rail, 16-support plate, 17-semi-circular lathe saw, 18-vertical rod, 19-long strip-shaped precast foam concrete block, 20-base plate, 21-lifting rod, 22-top plate, 23-screw, 24-moving block, 25-guide rod, 26-fixed block, 27-gear motor, 28-screw sleeve. Detailed Implementation

[0035] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. All other embodiments obtained by those skilled in the art based on the described embodiments of the present invention are within the scope of protection of the present invention.

[0036] Example 1

[0037] A process for manufacturing precast foamed concrete spheres includes the following steps:

[0038] S1: Produce long strip-shaped precast foamed concrete blocks with dimensions of 300×300×1500mm;

[0039] (1) Apply a release agent to the inside of the mold;

[0040] (2) A hollow support rod 4, specifically a rigid PVC pipe, is placed in the center of the mold. The hollow support rod 4 has five branch rods 6.

[0041] (3) Pour foamed concrete into the mold, let it solidify, demold, and obtain a long strip of foamed concrete precast block;

[0042] like Figure 1 As shown, the mold includes a base plate 1, front and rear side plates, left and right side plates, and slots 2 are provided on the inner edges of the front and rear side plates. Semicircular slots 3 are provided on the top of the left and right side plates. The two ends of the hollow support rod 4 are respectively inserted into the semicircular slots 3 on the top of the left and right side plates. Then, two baffles 5 are respectively inserted into the slots 2 on both sides. The bottom of the baffles 5 is also provided with semicircular slots to connect with the left and right side plates.

[0043] S2: The long strip of precast foamed concrete block is rotatably placed on the processing table;

[0044] like Figures 2-3As shown, the processing table 11 is equipped with a front clamp, a rear clamp, and a drive motor 10. Both the front clamp and the rear clamp include a bearing seat 7, a shaft 8, and a clamping device 9. The clamping device 9 is a manual chuck. The shaft 8 is mounted on the bearing seat 7, and the clamping device 9 is mounted on one end of the shaft 8. The shaft of the front clamp is connected to the output shaft of the drive motor 10 via a coupling 12. The front clamp is fixedly connected to the processing table 11, and the rear clamp is slidably connected to the processing table 11. A slide rail 13 is provided on the processing table 11, and a slider 14 is slidably connected to the slide rail 13. The bearing seat of the rear clamp is fixedly mounted on the slider 14.

[0045] Connect and fix one end of the hollow support rod 4 to the clamping part of the front clamp, then slide the rear clamp so that the other end of the hollow support rod 4 is connected and fixed to the clamping part of the rear clamp, and then manually lock the slider 14 to fix the rear clamp.

[0046] S3: Drive the long strip-shaped precast foamed concrete block to rotate rapidly;

[0047] S4: Multiple semi-circular lathes on the processing table slowly move toward the long strip of foamed concrete precast block until the long strip of foamed concrete precast block is machined into multiple spherical precast blocks.

[0048] Two lead screw slide rails 15 are provided on the processing table 11, and a support plate 16 is slidably provided on the two lead screw slide rails 15. Multiple semi-circular saws 17 are fixed on the support plate 16 by three vertical rods 18. The two lead screw slide rails 15 are activated to make the multiple semi-circular saws 17 slowly move toward the long strip of foamed concrete precast block 19.

[0049] S5: Disconnect the hollow support rod between two adjacent spherical precast blocks to obtain five finished spherical precast blocks with a diameter of 300mm.

[0050] Example 2

[0051] like Figure 4 As shown, the manufacturing process of the foamed concrete spherical precast block in this embodiment of the invention differs from that in embodiment 1 in that: in S2, in order to further improve the installation convenience and efficiency of the elongated precast block, an auxiliary support mechanism is also provided on the processing table. The auxiliary support mechanism includes a base plate 20, a base plate translation drive component, a lifting rod 21, and a top plate 22. The base plate 20 is located on the lower side of the processing table 11, and an opening is provided on the processing table 11. The lifting rod 21 and the top plate 22 can extend out of the opening to support the elongated precast block 19.

[0052] The substrate translation drive component includes a screw 23, a moving block 24, a guide rod 25, a fixed block 26, and a reduction motor 27. The fixed block 26 is rotatably mounted at both ends of the screw 23. The moving block 26 is provided with a screw hole and is connected to the screw 23. Guide holes are provided on both sides of the screw hole, and the guide rod 25 passes through both guide holes. The two ends of the guide rod 25 are respectively fixed to the two fixed blocks 26. One end of the screw 23 is connected to the reduction motor 27.

[0053] Two lifting rods 21 are provided on the base plate 20, and the top plate 22 is provided at the upper end of each of the two lifting rods 21;

[0054] Both sides of the bottom surface of the substrate 20 are provided with screw sleeves 28, and both screw sleeves 28 are threadedly connected to the screw 23.

[0055] The manufacturing process of the foamed concrete spherical precast blocks of this invention involves the operator placing the long strip precast block on the two top plates and then starting the reduction motor to align one end of the long strip precast block with the front clamp. By setting an auxiliary support mechanism, the long strip precast block can be horizontally supported during installation, making installation convenient. In addition, when the model and size of the long strip precast block are adjusted, the hollow support rod is aligned with the manual chuck position by controlling the lifting rod, thereby facilitating the connection.

[0056] In this embodiment, the clamping device is an electric chuck. The electric chuck, drive motor, and reduction motor are all controlled by a PLC controller. A pressure sensor can be installed on the top plate. After the elongated precast block is placed on it, the pressure sensor detects the weight change and transmits the information to the PLC. The PLC controls the reduction motor to rotate, causing the elongated precast block on the moving block to move forward onto the electric chuck on the clamp. A contact switch is installed on the upper side of the electric chuck to determine whether the hollow support rod is engaged with the jaws on the electric chuck. Then, the PLC controls the electric chuck to move and fix the front end of the hollow support rod. Subsequently, the rear clamp is controlled to slide to the rear end of the hollow support rod and is engaged and fixed in the same way. Next, the two lifting rods are controlled to descend, and the drive motor is turned on to make the elongated precast block rotate at high speed. At the same time, the lead screw slide rail is controlled to start, causing the five semi-circular saws on the support plate to move toward the elongated precast block, thereby turning the elongated precast block into five spherical precast blocks. The whole process has a high degree of automation and further improves production efficiency.

[0057] The above description represents the preferred embodiments of the present invention. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A manufacturing process for precast foamed concrete spheres, characterized in that, Includes the following steps: S1: Produce long strip-shaped precast foamed concrete blocks; S2: The long strip of precast foamed concrete block is rotatably placed on the processing table; S3: Drive the long strip-shaped precast foamed concrete block to rotate rapidly; S4: Multiple semi-circular lathes on the processing table slowly move toward the long strip of foamed concrete precast block until the long strip of foamed concrete precast block is machined into multiple spherical precast blocks. In S1, the method for producing long strip-shaped precast foamed concrete blocks is as follows: (1) Apply a release agent to the inside of the mold; (2) A hollow support rod is placed at the center of the mold, and the hollow support rod has multiple branch rods; (3) Pour foamed concrete into the mold, let it solidify, demold, and obtain a long strip of foamed concrete precast block.

2. The manufacturing process of precast foamed concrete spheres as described in claim 1, characterized in that: The processing table is equipped with a front clamp, a rear clamp, and a drive motor. Both the front clamp and the rear clamp include a bearing seat, a shaft, and a clamping device. The shaft is mounted on the bearing seat, and the clamping device is mounted on one end of the shaft. The shaft of the front clamp is fixedly connected to the output shaft of the drive motor.

3. The manufacturing process of precast foamed concrete spheres as described in claim 2, characterized in that: The front clamp is fixedly connected to the machining table, the rear clamp is slidably connected to the machining table, a slide rail is provided on the machining table, a slider is slidably connected on the slide rail, and the bearing seat of the rear clamp is fixedly mounted on the slider.

4. The manufacturing process of precast foamed concrete spheres as described in claim 3, characterized in that: Two lead screw slides are provided on the processing table, and a support plate is slidably mounted on the two lead screw slides. Multiple semi-circular lathe saws are mounted on the support plate.

5. The manufacturing process of precast foamed concrete spheres as described in claim 4, characterized in that: In step S2, one end of the hollow support rod is connected and fixed to the clamping fastener of the front clamp, and then the rear clamp is slid to connect and fix the other end of the hollow support rod to the clamping fastener of the rear clamp, and then the rear clamp is locked.

6. The manufacturing process of precast foamed concrete spheres as described in claim 5, characterized in that: In S4, the two lead screw slides are activated, causing the multiple semi-circular lathe saws to slowly move toward the long strip of foamed concrete precast block.

7. The manufacturing process of precast foamed concrete spheres as described in claim 6, characterized in that, It also includes S5: disconnecting the hollow support rod between two adjacent precast spherical blocks to obtain the finished precast spherical block.

8. The manufacturing process of precast foamed concrete spheres as described in claim 1, characterized in that: The elongated foamed concrete precast blocks are cuboids or cylinders.

9. The manufacturing process of precast foamed concrete spheres as described in claim 2, characterized in that: The clamping device is a manual chuck, a hydraulic chuck, or an electric chuck.

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