Autoclaved aerated concrete plate production line and production method

Abstract

The application discloses an autoclaved aerated concrete plate production line, and relates to the technical field of concrete plate, which comprises a pulping module, a pouring module, a turnover cutting module, an autoclaving module and a packaging module. The pouring module adopts a pouring system to pour the finished product slurry into a pouring mold. The pouring system comprises a weighing device and a pouring machine. The weighing device is connected with a slurry storage tank. The weighing device is used to weigh and quantitatively convey the finished product slurry to the pouring machine. The pouring machine comprises a first pouring machine and a second pouring machine. The first pouring machine and the second pouring machine reciprocate between a discharge port of the weighing device and a pouring station. The first pouring machine and the second pouring machine are used to alternately convey the finished product slurry to the pouring mold. The pouring mold after pouring is completed is stored by a rolling and static placing device. Therefore, the production efficiency can be greatly improved.

Description

Technical Field

[0001] This invention belongs to the field of concrete slab production technology, specifically relating to an autoclaved aerated concrete slab production line and production method. Background Technology

[0002] Autoclaved aerated concrete (AAC-B) panels are a widely used building material made by highly mixing silica-based sand, lime, cement, aluminum powder, and other materials, then inserting a steel mesh cage into the mixture. In traditional AAC-B production lines, the production process was cumbersome, requiring extensive manual labor due to low automation, resulting in low production efficiency. Summary of the Invention

[0003] To address the low production efficiency of autoclaved aerated concrete (AAC) panels in existing technologies, this invention provides an AAC panel production line and production method that effectively improves the production efficiency of AAC panels.

[0004] To solve the above problems, the present invention adopts the following technical solution:

[0005] A production line for autoclaved aerated concrete (AAC) panels includes:

[0006] Pulping module: used to produce finished slurry, which is mainly composed of sand, limestone, cement, aluminum powder and water mixed by stirring, and the finished slurry is stored in a slurry storage tank;

[0007] Casting Module: The finished slurry is poured into the casting mold using a casting system. The casting system includes a weighing device and a casting machine. The weighing device is connected to the slurry storage tank and weighs a fixed amount of the finished slurry, which is then transported to the casting machine. The casting machine includes a first casting machine and a second casting machine. The first casting machine and the second casting machine alternately transport the finished slurry to the casting mold by moving back and forth between the outlet of the weighing device and the casting station. After casting is completed, the casting mold is rolled and stored by a rolling and stationary device.

[0008] Flip-and-cut module: The flip-and-cut module includes a flip-and-demold process and a cutting process. In the flip-and-demold process, the concrete slab is separated from the casting mold and sent to the cutting process, where the cutting machine cuts the concrete slab into the specified size.

[0009] Autoclaving module: The autoclaving module includes an autoclave, used for autoclaving the concrete slabs cut by the flip-cutting module;

[0010] Packaging module: Packages the concrete slabs after the autoclaving module has completed the autoclaving process.

[0011] Furthermore, the casting module includes a mold transport trolley for carrying the casting mold, and the mold transport trolley moves on the second track section.

[0012] Furthermore, the second track section passes through the mold oiling station, the casting station, and the probing station.

[0013] Furthermore, the casting module includes a settling area and a rolling settling device located in the settling area. The rolling settling device includes several parallel roller groups, with long strip tracks connected to the roller groups. A third track is fixed parallel to each track, and the third track rotates under the drive of the roller groups and aligns with the second track.

[0014] Furthermore, the autoclaving module includes an autoclaving preparation area, an autoclaving area, and an autoclaving parking area. Several autoclaves are placed parallel to each other above the ground in the autoclaving area. A fifth track segment is placed below each autoclave, and the two ends of the fifth track segment extend to the autoclaving preparation area and the autoclaving parking area.

[0015] Furthermore, it includes a steam curing cart, which comprises two pairs of wheel sets, the rollers of which are adapted to the fifth track section.

[0016] Furthermore, a support plate is installed on the wheel assembly, a lifting device is fixed on the support plate, a pad is fixed to the extended shaft end of the lifting device, the extended shaft is electrically driven to complete its lifting action, and the pad is used to place the concrete slab to be autoclaved.

[0017] Furthermore, three lifting devices are fixed on the support plate, and a pad is installed on each lifting device.

[0018] Furthermore, the autoclave has a freely opening and closing opening at the bottom, the size of which is adapted to the size of the concrete slab.

[0019] A method for producing autoclaved aerated concrete (AAC) panels, comprising:

[0020] Pulping: In the pulping module, sand, limestone, cement, aluminum powder and water are mixed to form a finished slurry, which is then placed in a slurry storage tank for later use.

[0021] Casting: In the casting module, after applying oil to the casting mold, the finished slurry is injected, and the mold is inserted at the insertion station. After the insertion is completed, the casting mold is transported to the settling area by the rolling settling device for settling.

[0022] Flipping and cutting: After the casting mold is transported to the pin removal station and the pin is removed, it is transported to the flipping and mold removal station to remove the mold from the concrete slab; then, it is transported to the cutting station for cutting and placing the cut concrete slab on the curing cart.

[0023] Autoclaving: The autoclaving vehicle carrying the concrete slabs to be autoclaved is parked in the autoclaving preparation area to wait; after the autoclaving process is started, the autoclaving vehicle carrying the concrete slabs to be autoclaved enters the autoclaving area and is parked directly below the corresponding autoclave. The concrete slabs are then fed into the autoclave from the bottom for autoclaving; after autoclaving is completed, the autoclaving vehicle carrying the concrete slabs enters the autoclaving storage area to wait.

[0024] Packaging: After the autoclaved concrete slabs pass inspection, they are packaged.

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

[0026] (1) In the casting module, the casting system of the present invention includes a weighing device and a casting machine. The weighing device is connected to a slurry storage tank through a pipeline. The finished slurry in the slurry storage tank is transported to the weighing device through a pipeline for quantitative weighing. There are two casting machines, namely a first casting machine and a second casting machine. The first casting machine and the second casting machine are respectively connected to a lifting platform. The lifting platform drives the first casting machine and the second casting machine to move back and forth between the casting position and the discharge port of the weighing device. During operation, after the weighing device injects a quantitative amount of finished slurry into the first casting machine, the lifting platform drives the first casting machine to move to the casting position and inject the finished slurry into the mold waiting below the casting position. At the same time, during this process, the second casting machine moves to the discharge port of the weighing device to receive the quantitative amount of finished slurry released by the weighing device. During the process of the first casting machine returning to the discharge port of the weighing device after casting, the second casting machine can immediately move to the casting position to carry out the casting work. This pouring system can use the first and second pouring machines to alternate back and forth, eliminating the waiting time for the weighing device to inject material into the pouring machine and greatly improving the pouring efficiency.

[0027] (2) The static area of ​​the present invention is equipped with a rolling static placement device, which includes several parallel roller groups. A long strip track is connected to the roller groups, and several third tracks are fixed parallel to the track. The length of the third track can accommodate four mold transport trolleys. The several third tracks on the track rotate with the roller groups to achieve longitudinal displacement. One end of the bottom of the track is directly opposite the tail of the second track section on the insertion station. The track can be aligned with the tail of the second track on the insertion station by a positioning device. After the insertion is completed, the mold transport trolley carries the completed casting mold from the tail of the second track section into the third track section. When four mold transport trolleys have accumulated on the third track section, the rolling static placement device starts to roll, moving the third track section carrying four trolleys longitudinally, and at the same time rotating the next new (without mold transport trolleys) third track section to the position aligned with the tail of the second track section. After the mold transport trolleys on the second track enter the new third track and accumulate four, the rolling static placement device rolls cyclically. This rolling and settling device can automatically accumulate the prepared casting molds through a circulating rolling method and transport them to the settling area to wait for the board to solidify. The whole process is fully automated and does not require manual handling, saving time and effort and greatly improving production efficiency.

[0028] (3) The autoclave is located directly above the curing area of ​​the fifth track section, and the curing cart can move along the fifth track section to directly below the autoclave. The bottom of the autoclave has an opening that can be opened and closed freely. The size of the opening is adapted to the size of the concrete slab. After the curing cart moves under the autoclave, the opening opens. The pad plate along with the slab on it is sent into the autoclave through the opening using the lifting device on the curing cart. After the clamping device in the autoclave clamps the pad plate, the lifting device exits the autoclave, and then the autoclave opening closes, starting the autoclaving process. The curing cart remains under the autoclave while it is working. After the autoclaving is completed, the slab is removed and transported away from the autoclave using the above actions. In this process, the entire process is automated, eliminating the need for manual hoisting, greatly saving manpower and improving production efficiency. Attached Figure Description

[0029] Figure 1 This is a schematic diagram showing the location of each module in the autoclaved aerated concrete (AAC) panel production line.

[0030] Figure 2 A schematic diagram showing the location of the rolling and stationary placement device for the casting module;

[0031] Figure 3 This is a schematic diagram of the autoclaving module;

[0032] Figure 4 This is a schematic diagram of the casting system structure in the casting module;

[0033] Figure 5 This is a schematic diagram of the steam curing cart structure;

[0034] Figure 6 This is a side view of the structure of the rolling and stationary placement device for casting modules.

[0035] In the picture:

[0036] 1. Pulping module; 11. Pulp storage tank;

[0037] 2. Casting module; 21. Mold oiling station;

[0038] 22. Pouring station; 221. First pouring machine; 222. Second pouring machine; 223. Weighing device; 224. Elevator;

[0039] 23. Insertion station; 24. Second track section; 25. Fourth track section; 26. Third track section;

[0040] 27. Rolling stationary device; 271. Roller group; 272. Track;

[0041] 28. Settling area; 29. ​​Mold transport trolley; 291. Casting mold;

[0042] 3. Flip-cutting module;

[0043] 4. Autoclaving module; 41. Fifth track section; 42. Autoclaving cart; 421. Wheel set; 422. Support plate; 423. Lifting device; 424. Pad; 43. Autoclaving preparation area; 44. Autoclave; 45. Autoclaving area; 46. Autoclaving parking area;

[0044] 5. Packaging module;

[0045] 6. Concrete slabs. Detailed Implementation

[0046] The following detailed description of exemplary embodiments of the invention is taken with reference to the accompanying drawings, which form part of the description and illustrate exemplary embodiments in which the invention may be practiced. While these exemplary embodiments have been described in sufficient detail to enable those skilled in the art to practice the invention, it should be understood that other embodiments may be implemented and various changes may be made to the invention without departing from the spirit and scope thereof. The more detailed description of embodiments of the invention below is not intended to limit the scope of the claimed invention, but is merely illustrative and not restrictive of the description of the features and characteristics of the invention, to suggest the best mode for carrying out the invention, and is sufficient to enable those skilled in the art to practice the invention. Therefore, the scope of the invention is defined only by the appended claims.

[0047] To address the above issues, the following explanation is provided in conjunction with the accompanying drawings:

[0048] This invention provides a production line for autoclaved aerated concrete (AAC) panels. It includes a pulping module 1, a casting module 2, a flipping and cutting module 3, an autoclaving module 4, and a stacking and packaging module 5.

[0049] Pulping Module 1:

[0050] The pulping module 1 includes a pulping area, a batching area, and a pulp storage area. The raw materials in the batching area are automatically transported to the pulping area through a feeding pipe. The cement pulp that has been mixed in the pulping area is then sent to the storage area for later use.

[0051] The batching area includes sand and gravel silos, lime silos, cement silos, and aluminum powder lift shafts. The lime silos store a quantity of limestone, the cement silos store a quantity of cement powder, and the aluminum powder lift shafts are located within the mixing tank of the slurry preparation area. The feeding pipes are automatically fed by an automatic pump according to preset parameters.

[0052] The pulping area has at least one ball mill, which is used to grind limestone into powder and then convey it to the mixing tank for pulping. During the pulping process, sand, cement powder, limestone powder, phosphogypsum slurry, and aluminum powder are automatically fed into the mixing tank. Sand accounts for 70% of the total pulp mass, cement powder accounts for 15%, limestone powder accounts for 10%, phosphogypsum slurry accounts for 5%, and aluminum powder is added in appropriate amounts according to the type of board being manufactured, at a rate of 300~400g / m². 3 The mixing temperature in the mixer is set to 40°C and mixed for 5 minutes. The mixed slurry is then sent to six 100-cubic-meter slurry storage tanks 11 in the slurry storage area for later use.

[0053] Casting Module 2:

[0054] The casting module 2 includes a steel mesh fabrication area, a mold storage area, and mold transport trolleys 29. In the steel mesh fabrication area, steel bars from the steel mesh discs are placed on a steel bar straightening and cutting machine to form several steel bars of the same length. The mold storage area has a track on which several mold transport trolleys 29 are sequentially connected and rolled. Casting molds 291 slots are fixed on the mold transport trolleys 29. The track includes a first track section and a second track section 24. The first track section has several parallel rails and can store a large number of casting mold slots with mold transport trolleys 29. The second track section 24 passes through a mold oiling station 21, a casting station 22, and a pinning station 23. During casting, the mold transport trolleys 29 lead the casting molds 291 slots out of the mold storage area. When passing the mold oiling station 21, an automatic oiling machine automatically applies oil to the molds. Subsequently, the casting mold 291 is driven into the casting station 22, where the casting machine (connected to the slurry storage tank) pours the finished slurry into the mold. After casting is completed, the mold transport trolley 29 leads the casting mold 291 into the insertion station 23, where the insertion machine inserts the reinforcing bars into the finished slurry in the casting mold 291. The casting mold 291, after insertion, is sent to the settling area 28 for shaping.

[0055] At the pouring station 22, this invention provides a pouring system including a weighing device 223 and a pouring machine. The weighing device 223 is connected to a slurry storage tank 11 via a pipeline. The finished slurry in the slurry storage tank 11 is transported to the weighing device 223 for quantitative weighing via the pipeline. There are two pouring machines, namely a first pouring machine 221 and a second pouring machine 222. The first pouring machine 221 and the second pouring machine 222 are respectively connected to a lifting platform 224. The lifting platform 224 drives the first pouring machine 221 and the second pouring machine 222 to move back and forth between the pouring station 22 and the outlet of the weighing device 223. During operation, after the weighing device 223 injects a quantitative amount of finished slurry into the first pouring machine 221, the lifting platform 224 drives the first pouring machine 221 to move to the pouring station 22 and inject the finished slurry into the mold waiting below the pouring station 22. Simultaneously, during this process, the second pouring machine 222 moves to the outlet of the weighing device 223 to receive the quantitative finished slurry released by the weighing device 223. While the first pouring machine 221 is returning to the outlet of the weighing device 223 after pouring, the second pouring machine 222 can immediately move to the pouring position 22 to perform the pouring work. This pouring system, through the alternating pouring of the first pouring machine 221 and the second pouring machine 222, eliminates the waiting time for the weighing device 223 to inject material into the pouring machines, greatly improving the pouring efficiency.

[0056] The static area 28 of this invention is equipped with a rolling static placement device 27, which includes several parallel roller groups 271. A long strip track 272 is connected to each roller group 271, and several third tracks are fixed parallel to each track 272. The length of the third tracks is sufficient to accommodate four mold transport trolleys 29. The third tracks on the track 272 rotate with the roller groups 271 to achieve longitudinal displacement. One bottom end of the track 272 faces the tail of the second track section 24 on the insertion station 23. A positioning device allows the third tracks fixed on the upper part of the track 272 to align with the tail of the second track on the insertion station 23. After insertion is completed, the mold transport trolley 29 carries the completed casting mold 291 from the tail of the second track section 24 into the third track section 26. After four mold transport trolleys 29 have accumulated on the third track segment 26, the rolling placement device 27 begins to roll, moving the third track segment 26 carrying the four trolleys longitudinally. Simultaneously, it rotates the next new third track segment 26 (without mold transport trolleys 29) to align with the tail of the second track segment 24. The mold transport trolleys 29 on the second track then enter the new third track, and after four trolleys have accumulated, the rolling placement device 27 continues to roll in a cycle. This rolling placement device 27 automatically accumulates the prepared casting molds through a cyclical rolling process and transports them to the placement area 28 to await solidification of the sheet metal. The entire process is fully automated, eliminating the need for manual handling, saving time and labor, and greatly improving production efficiency.

[0057] Flip-cutting module 3:

[0058] The flipping and cutting module includes a flipping demolding process and a cutting process. The demolding process includes a fourth track section 25, whose starting point connects to the third track section 26 on the rolling device. The fourth track section 25 passes through the pin-removal station and the flipping demolding station. The completed casting mold 291 is driven into the fourth track section 25 via the mold transport trolley 29 and enters the pin-removal station, where the pin-removal machine performs the pin-removal operation. After pin-removal, the casting mold 291 moves along the fourth track section 25 via the mold transport trolley 29 to the flipping demolding station, where demolding is performed (removing the mold from the concrete slab 6). After demolding, the concrete slab 6 is sent to the cutting station for cutting. The cutting machine cuts the concrete slab 6 to the specified size, and the cutting is divided into horizontal cutting and transverse cutting. After cutting, the cut slab is further sent by a crane to the peeling mechanism to remove excess covering film from the surface of the slab before being sent to the curing car 42.

[0059] Autoclaving module 4:

[0060] The autoclaving module 4 includes an autoclaving preparation area 43, an autoclaving zone 45, and an autoclaving storage area 46. Several autoclaves 44 are placed parallel to each other off the ground in the autoclaving zone 45. A fifth track section 41 is placed below each autoclave 44, extending to both ends of the fifth track section 41 into the autoclaving preparation area 43 and the autoclaving storage area 46. The peeled concrete slabs are stacked on a curing cart 42 via a crane. The curing cart 42 then enters the autoclaving preparation area 43 along the fifth track, awaiting entry into the autoclave 44 for aeration and autoclaving. During autoclaving, the curing cart 42 carries the neatly stacked concrete slabs 6 to the autoclave 44 corresponding to the autoclave in the autoclave zone 45. A lifting device 423 delivers the concrete slabs 6 into the autoclave 44, which is then closed for autoclaving treatment. The temperature of the autoclave 44 is set to 250°C and the pressure to 1.5 MPa during autoclaving. During the autoclaving process, the curing cart 42 waits below the autoclave 44. After the autoclaving is completed, the concrete slab 6 is taken out by the lifting device 423 and placed back on the curing cart 42. The curing cart 42 then transports the autoclaved concrete slab 6 away from the autoclave 44 into the autoclaving storage area 46 to await the next process.

[0061] The steam curing cart 42 includes two pairs of wheel sets 421, whose rollers are adapted to the fifth track section 41, allowing movement on the fifth track section 41. Support plates 422 are mounted on the two pairs of wheel sets 421, and three sets of lifting devices 423 are fixed to the support plates 422. A pad 424 is fixed to the extended shaft end of each lifting device 423, and the extended shaft is electrically driven to complete its lifting action. Concrete slabs to be steam-cured can be placed on the pads 424. Three concrete slabs 6 can be placed on one steam curing cart 42.

[0062] The autoclave 44 is located directly above the curing area of ​​the fifth track section 41, and the curing cart 42 can move along the fifth track section 41 to directly below the autoclave 44. The autoclave 44 has an opening at its bottom that can be freely opened and closed, the size of which is adapted to the size of the concrete slab 6. After the curing cart 42 moves under the autoclave 44, the opening opens. Using the lifting device 423 on the curing cart 42, the pad 424, along with the slab on it, is passed through the opening and sent into the autoclave. After the clamping device in the autoclave 44 clamps the pad 424, the lifting device 423 retracts from the autoclave 44, and then the opening of the autoclave 44 closes, initiating the autoclaving process. The curing cart 42 remains stationary under the autoclave 44 during the autoclave's operation. After curing is complete, the cured slab is removed using the above actions and transported away from the autoclave 44. In this invention, there are several autoclaves 44, the specific number depending on the size of the site. The entire process is automated, eliminating the need for manual hoisting, which greatly saves manpower and improves production efficiency.

[0063] Packaging Module 5:

[0064] The concrete slabs 6 in the storage area are transported to the stacking station by a gantry crane. After being stacked by a double-mold stacking machine, they are stored in the side plate storage area. The concrete slabs 6 that have passed inspection are ready for packaging.

[0065] The present invention and its embodiments have been described above illustratively. This description is not restrictive, and the figures shown are only one embodiment of the present invention; the actual structure is not limited thereto. Therefore, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the present invention, such designs should fall within the protection scope of the present invention.

Claims

1. A production line for autoclaved aerated concrete (AAC) panels, characterized in that, include: Pulping module (1): used to produce finished slurry, which is mainly made of sand, limestone, cement, aluminum powder and water through stirring and mixing. The finished slurry is stored in slurry storage tank (11). Casting Module (2): The finished slurry is poured into the casting mold (291) using a casting system. The casting system includes a weighing device (223) and a casting machine. The weighing device (223) is connected to the slurry storage tank (11) and weighs a fixed amount of the finished slurry and delivers it to the casting machine. The casting machine includes a first casting machine (221) and a second casting machine (222). The first casting machine (221) and the second casting machine (222) move back and forth between the outlet of the weighing device (223) and the casting station (22) to alternately deliver the finished slurry to the casting mold (291). After the casting is completed, the casting mold (291) is rolled and stored by a rolling static placement device (27). Flip-cutting module (3): The flip-cutting module includes a flip-demolding process and a cutting process. In the flip-demolding process, after the concrete slab and the casting mold (291) are separated, they are sent to the cutting process, where the cutting machine cuts the concrete slab into the specified size. Autoclaving module (4): The autoclaving module (4) includes an autoclave (44) for autoclaving the concrete slabs cut by the flip-cutting module (3); the autoclaving module (4) includes an autoclaving cart (42), an autoclaving preparation area (43), an autoclaving area (45), and an autoclaving parking area (46). Several autoclaves (44) are placed parallel to each other on the autoclaving area (45), and a fifth track segment (41) is placed below each autoclave (44). The two ends of the fifth track segment (41) extend to the autoclaving preparation area (43) and the autoclaving parking area (46); the autoclaving cart (42) includes two pairs of wheel sets (421). The rollers of the autoclave (421) are adapted to the fifth track section (41); a support plate (422) is installed on the wheel set (421), a lifting device (423) is fixed on the support plate (422), a pad (424) is fixed to the extended shaft end of the lifting device (423), the extended shaft is electrically driven to complete its lifting action, and the pad (424) is used to place the concrete slab to be autoclaved; three lifting devices (423) are fixed on the support plate (422), and a pad (424) is installed on each lifting device (423); the autoclave (44) has a freely opening and closing opening at the bottom, and the size of the opening is adapted to the size of the concrete slab; Packaging module (5): Packaging the concrete slabs after the autoclaving module (4) has finished autoclaving.

2. The autoclaved aerated concrete (AAC) panel production line according to claim 1, characterized in that, The casting module (2) includes a mold transport trolley (29) for carrying the casting mold (291), and the mold transport trolley (29) moves on the second track section (24).

3. The autoclaved aerated concrete (AAC) panel production line according to claim 2, characterized in that, The second track section (24) passes through the mold oiling station (21), the casting station (22) and the pin insertion station (23).

4. The autoclaved aerated concrete (AAC) panel production line according to claim 3, characterized in that, The casting module (2) includes a static area (28) and a rolling static placement device (27) located in the static area (28). The rolling static placement device (27) includes several parallel roller groups (271). A long strip track (272) is connected to the roller group (271). A third track is fixed parallel to each track (272). The third track rotates under the drive of the roller group (271) and aligns with the second track.

5. A method for producing autoclaved aerated concrete (AAC) panels, characterized in that, include: Pulping: Sand, limestone, cement, aluminum powder and water are mixed in the pulping module (1) to form finished slurry, which is then placed in the slurry storage tank (11) for storage. Casting: In the casting module (2), after applying oil to the casting mold (291), the finished slurry is injected, and the pin is inserted at the pin insertion station (23). After the pin is inserted, the casting mold (291) is transported to the settling area (28) by the rolling settling device (27) for settling. Flipping and cutting: After the casting mold (291) is transported to the pin removal station to remove the pin, it is transported to the flipping and demolding station to remove the mold on the concrete slab; then, it is transported to the cutting station for cutting and placing the cut concrete slab on the steam curing car (42). Autoclaving: The autoclaving vehicle (42) carrying the concrete slabs to be autoclaved is parked in the autoclaving preparation area (43) and waits; after the autoclaving process is started, the autoclaving vehicle (42) carrying the concrete slabs to be autoclaved enters the autoclaving area (45) and is parked directly below the corresponding autoclave (44), and the concrete slabs are sent into the autoclave (44) from the bottom of the autoclave (44) for autoclaving; after the autoclaving is completed, the autoclaving vehicle (42) carrying the concrete slabs enters the autoclaving parking area (46) and waits; Packaging: After the autoclaved concrete slabs pass inspection, they are packaged.

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