Production system and production process of autoclaved aerated concrete member

Abstract

The production system comprises a pulping machine, an automatic welding machine, a drill rod inserting and pulling mechanism, a pouring stirring machine, a bubble finishing machine, a static curing chamber, a step-by-step cutting machine and an autoclave, the pulping machine comprises a feeding conveying belt, a pulping stirring machine, a rotary screen, a slurry tank and a slurry conveying pipeline, the automatic welding machine comprises a welding machine body, a longitudinal rib discharging wheel, a straightening machine, a transverse rib distributing wheel, a net welding machine, a net shearing machine and a dragging machine, and the drill rod inserting and pulling mechanism comprises a lifting machine, a lifting appliance, a mounting frame and a steel drill rod. According to the production system and the production process of the autoclaved aerated concrete member, by arranging the procedure of inserting and drilling the reinforcing mesh, the reinforcing mesh can be placed in the autoclaved aerated concrete member before precuring, and the procedure of pulling and drilling is completed before cutting, so that the structural strength, the tensile strength and the shear resistance of the autoclaved aerated concrete member are improved, and the production efficiency of the autoclaved aerated concrete member is improved. And the product quality is improved.

Description

Technical Field

[0001] The invention belongs to the technical field of autoclaved aerated concrete components, and in particular relates to a production system and a production process of autoclaved aerated concrete components. Background Art

[0002] In recent years, autoclaved aerated concrete has developed rapidly in my country's building materials market. Using it to replace clay solid bricks is the development trend of China's building materials industry. Autoclaved aerated concrete components are new wall materials. They are porous silicate components made by adding aluminum powder as an aerating agent to the ingredients of calcium and silicon materials, mixing with water, pouring and forming, gas expansion, pre-curing and cutting, and then curing with high-pressure steam. It has the characteristics of light weight, high strength, heat preservation, heat insulation, sound absorption, fire resistance, sawing and planing. It is mainly used for external wall filling and internal wall partition of frame structure and cast-in-place concrete structure buildings. It can also be used for the external wall or thermal insulation composite wall of multi-story buildings with earthquake-resistant ring beam structure. Sometimes it is also used for thermal insulation and heat insulation of building roofs. Compared with clay products and other new wall materials, the main advantages of autoclaved aerated concrete components are: large blocks, simple construction, low density, reduced weight, reduced foundation burden, low thermal conductivity, and good self-insulation materials. Vigorously developing autoclaved aerated concrete components can save a lot of land and energy, turn waste into treasure, purify the environment, save energy and reduce emissions, and have good economic and social benefits.

[0003] The structural strength, tensile strength and shear resistance of existing autoclaved aerated concrete components need to be improved, and waste materials, waste water and other wastes are still generated during the production process, causing environmental pollution and waste of resources. Therefore, it is urgent to design a production system and production process of autoclaved aerated concrete components to solve the above problems. Summary of the invention

[0004] The object of the present invention is to provide a production system and a production process for autoclaved aerated concrete components to solve the problems existing in the above-mentioned background technology.

[0005] To achieve the above object, the present invention provides the following technical solution: a production system of autoclaved aerated concrete components, comprising: a pulping machine, an automatic welding machine, a drill insertion and extraction mechanism, a pouring and mixing machine, a bubble finishing machine, a curing room, a step-by-step cutting machine and an autoclave;

[0006] The pulping machine comprises a feeding conveyor belt, a pulping mixer, a drum screen, a slurry tank, a slurry conveying pipeline, a stirring tank 1 and a stirring tank 2, one end of the feeding conveyor belt extends to the top of the pulping mixer feed hopper, the pulping mixer discharges slurry to the stirring tank 1 through a discharge port, the slurry in the stirring tank 1 is conveyed to the drum screen through a submersible pump, a stirring tank 2 is arranged below the discharge port of the drum screen, and the liquid slurry in the stirring tank 2 is conveyed to the slurry tank through a submersible pump and a slurry conveying pipeline;

[0007] The automatic welding machine includes a wire-releasing mechanism, a straightening mechanism, a traction mechanism, a material storage mechanism, a servo stepping mechanism, a welding host, a transverse reinforcement feeding mechanism, a shearing mechanism and a discharge mechanism which are sequentially arranged along the horizontal pay-off. The straightening mechanism is used to straighten the steel wire output by the wire-releasing mechanism, the traction mechanism is used to feed the longitudinal reinforcement into the material storage mechanism, the servo stepping mechanism drives the longitudinal reinforcement to step to a set transverse spacing, the welding host is used to weld the longitudinal reinforcement and the transverse reinforcement, the transverse reinforcement feeding mechanism is used to quickly feed the cut transverse reinforcement to the part to be welded, the shearing mechanism is used to shear the steel mesh output to the shearing position, and the discharge mechanism is used to pull the cut steel mesh out of the shearing mechanism;

[0008] The drill plugging and pulling mechanism comprises a hoist, a sling, a mounting frame and a steel drill, the hoist is connected to the sling through a steel wire rope and a pulley, the sling is connected to the mounting frame through a hook, and the steel drill is fixedly connected to the bottom of the mounting frame.

[0009] Furthermore, the pouring mixer includes a mixer barrel, a stirring device bracket, a stirring motor, a belt drive system, a stirring shaft, a spoiler and a steam injection pipe. The stirring device bracket is fixed to the top of the mixer barrel, the stirring motor is fixed to the top of the stirring device bracket and is connected to the stirring shaft through the belt drive system, the spoiler is fixed to the inner wall of the mixer barrel, and one end of the steam injection pipe extends to the inner bottom of the mixer barrel.

[0010] Furthermore, the bubble sorting machine includes a frame, a chain arranged on the top of the frame, a sprocket meshing with the chain, a driving cylinder fixed at one end of the chain and a vibrating rod fixed at the bottom of the frame, and the other end of the chain is fixedly connected to the frame.

[0011] Furthermore, the curing room includes a conveying track, a pre-curing table, a connecting track, a residual steam injection pipe, a heat dissipation fan and a temperature sensor. The conveying track is arranged in the middle of the bottom surface of the curing room, the pre-curing table is arranged on both sides of the conveying track, the connecting track is arranged on the upper part of the pre-curing table, the residual steam injection pipe is connected to the heat dissipation fan, and the heat dissipation fans are evenly distributed on the pre-curing table.

[0012] Furthermore, the step-by-step cutting machine includes a cutting machine track, a longitudinal cutting trolley, a pre-cutting unit, a longitudinal cutting machine, a blank lifting device, a cross-cutting machine, a vacuum suction hood, a waste cleaning machine and a cross-cutting cutting trolley. The longitudinal cutting trolley and the cross-cutting trolley are movably connected to the two ends of the cutting machine track, the pre-cutting unit, the longitudinal cutting machine, the cross-cutting machine and the waste cleaning machine are arranged in sequence along the cutting machine track, the blank lifting device is arranged at the bottom of the cross-cutting machine, and the vacuum suction hood is arranged at the top of the cross-cutting machine.

[0013] Furthermore, a steam inlet and a steam exhaust port are provided at the top of the autoclave, a temperature sensor and a pressure sensor are provided inside the autoclave, and a water outlet is provided at the bottom of the autoclave.

[0014] A production process of an autoclaved aerated concrete component, the production process of the autoclaved aerated concrete component is completed by the production system of the autoclaved aerated concrete component, and comprises the following steps:

[0015] S1: Prepare raw materials, deliver cement, lime and other powders to the silo through the compressed air delivery system, deliver sand and gypsum to the slurry mixer through the feeding conveyor belt, add water and stir during the process, and then make liquid slurry through the drum screen, and then deliver it to the slurry tank through the submersible pump, weld the steel mesh through the automatic welding machine, and then immerse the steel mesh in the anti-corrosion immersion tank for anti-corrosion treatment, dry it in the steam dryer, and then hoist it to the designated location by the drill insertion crane for drill insertion;

[0016] S2: Measuring and mixing the ingredients to make slurry. According to the given formula, the liquid slurry, lime, cement, aluminum paste and water are measured by metering equipment respectively, and then the measured materials are put into the pouring mixer in sequence. After stirring at a speed of not less than 80 rpm and a stirring time of not less than 3 minutes, ensure that the mixed slurry is fully and evenly stirred;

[0017] S3: pouring and tidying bubbles, injecting the mixed slurry in the pouring mixer into the mold through the pouring head, and then removing bubbles through the bubble tidying machine;

[0018] S4: Inserting the steel bar, moving the mold poured with the mixed slurry to the bottom of the steel bar inserting crane, and then controlling the installation frame to move downward by the steel bar inserting crane until the steel bar and the steel mesh fixed on the steel bar are inserted into the designated position of the mold;

[0019] S5: Pre-curing. Then the mold with the steel mesh inserted is sent to the curing room by a shuttle bus for constant temperature pre-curing. After the pre-curing temperature is 50℃~70℃ and the pre-curing time is 2~4 hours, it is ensured that the blank meets the cutting requirements;

[0020] S6: After the pre-curing is completed, the mold is moved to the bottom of the steel bar pulling crane, and then the steel bar is pulled out by the steel bar pulling crane, so that the steel mesh is left inside the blank;

[0021] S7: demoulding, the mold is moved to the step-by-step cutting machine position by turning the transfer cart and flipping it 90 degrees, then the side panels of the mold are separated, and the mold is separated from the blank by turning the transfer cart;

[0022] S8: Cutting: The green body is cut longitudinally and transversely by a step-by-step cutting machine. The cut green body is transported to the semi-finished green body transfer car. After the waste is removed by the ground turning table edge cleaning machine, the semi-finished green body is hoisted to the marshaling steaming car. At the same time, the cut waste and the waste removed by the ground turning table edge cleaning machine are sent to the slurry tank and mixed with the waste slurry generated by the cleaning pouring mixer to form waste slurry for reuse;

[0023] S9: Autoclave curing: the cut green bodies are grouped one by one, and after forming a row, they are sent into the autoclave for curing. The curing cycle is 10 to 14 hours, the steam temperature is 192°C, and the steam pressure is 12.5MPa. The condensed water generated by the autoclave curing is pumped to the ball milling and stirring process by a water pump, and all the condensed water is recycled;

[0024] S10: Finished product packaging. The finished products that have completed autoclave curing are transported to the post-autoclave section by the autoclave shuttle vehicle for packaging. The finished products are then lifted to the plate packaging line by the finished product transfer machine and transported to the finished product yard by a forklift for inspection and sale.

[0025] The technical effects and advantages of the present invention are as follows: the production system and production process of the autoclaved aerated concrete component can place the steel mesh inside the autoclaved aerated concrete component before pre-curing by setting the process of inserting the steel mesh, and complete the process of pulling out the steel mesh before cutting, so as to increase the structural strength, tensile strength and shear resistance of the autoclaved aerated concrete component and improve the product quality. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Figure 1 is a process flow chart of the present invention;

[0027] Figure 2 A vertical cross-sectional view of the pulping machine of the present invention in the main viewing direction;

[0028] Figure 3 A vertical cross-sectional view of the automatic welding machine of the present invention in the main viewing direction;

[0029] Figure 4 It is a front view of the drill inserting and extracting mechanism of the present invention;

[0030] Figure 5 A vertical cross-sectional view of the pouring mixer of the present invention in the main viewing direction;

[0031] Figure 6 A vertical cross-sectional view of the bubble finishing machine of the present invention in the main viewing direction;

[0032] Figure 7 A vertical cross-sectional view of the main viewing direction of the resting room of the present invention;

[0033] Figure 8 A top view of the step-by-step cutting machine of the present invention;

[0034] Fig. 9 It is a vertical cross-sectional view of the autoclave of the present invention in the main viewing direction.

[0035] In the figure: 100, pulping machine; 101, feeding conveyor belt; 102, pulping mixer; 103, drum screen; 104, slurry tank; 105, slurry conveying pipeline; 106, stirring tank 1; 107, stirring tank 2; 200, automatic welding machine; 201, wire release mechanism; 202, straightening mechanism; 203, traction mechanism; 204, material storage mechanism; 205, servo stepping mechanism; 206, welding host; 207 , cross-rib feeding mechanism; 208, shearing mechanism; 209, unloading mechanism; 300, plug-in and pull-out mechanism; 301, hoist; 302, sling; 303, mounting frame; 304, steel drill; 400, pouring mixer; 401, mixer barrel; 402, stirring device bracket; 403, stirring motor; 404, belt drive system; 405, stirring shaft; 406, inspection hole; 407, spoiler; 408, steam Steam injection pipe; 409, double impeller; 410, discharge valve; 411, pouring head; 500, bubble sorting machine; 501, frame; 502, chain; 503, sprocket; 504, drive cylinder; 505, vibrating rod; 600, rest room; 601, conveying track; 602, pre-curing table; 603, connecting track; 604, residual steam injection pipeline; 605, cooling fan; 606, temperature sensor; 700, Step-by-step cutting machine; 701, cutting machine track; 702, longitudinal cutting trolley; 703, pre-cutting unit; 704, longitudinal cutting machine; 705, blank lifting device; 706, cross-cutting machine; 707, vacuum suction hood; 708, waste cleaning machine; 709, cross-cutting trolley; 800, autoclave; 801, steam inlet; 802, steam exhaust port; 803, temperature sensor; 804, pressure sensor; 805, water outlet. DETAILED DESCRIPTION

[0036] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0037] In the description of the present invention, it should be noted that the terms "upper", "lower", "inner", "outer", "front end", "rear end", "two ends", "one end", "the other end" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance.

[0038] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "provided with", "connected", etc. should be understood in a broad sense. For example, "connected" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0039] The present invention provides Figure 1-9 A production system of autoclaved aerated concrete components shown in the figure comprises: a pulping machine 100, an automatic welding machine 200, a drill insertion and extraction mechanism 300, a pouring and mixing machine 400, a bubble finishing machine 500, a curing room 600, a step-by-step cutting machine 700 and an autoclave 800;

[0040] The pulping machine 100 includes a feeding conveyor belt 101, a pulping mixer 102, a drum screen 103, a slurry tank 104, a slurry conveying pipeline 105, a stirring tank 106 and a stirring tank 2 107. One end of the feeding conveyor belt 101 extends to the top of the feed hopper of the pulping mixer 102. The pulping mixer 102 discharges the slurry into the stirring tank 106. The slurry in the stirring tank 106 is conveyed to the drum screen 103 by a submersible pump. The drum screen 103 A stirring tank 107 is provided below the discharge port, and the liquid slurry in the stirring tank 107 is transported to the slurry tank 104 through a submersible pump and a slurry transport pipeline 105, so that sand or fly ash or subway sand and gypsum can be transported to the slurry mixer 102 for breaking up. Water is added for stirring during the breaking up process, so that the broken and stirred raw materials can be transported to the drum screen 103, and large particles (with a particle size greater than 3 mm) in the slurry can be filtered out through the drum screen 103;

[0041] The automatic welding machine 200 includes a wire-releasing mechanism 201, a straightening mechanism 202, a traction mechanism 203, a material storage mechanism 204, a servo stepping mechanism 205, a welding host 206, a transverse reinforcement feeding mechanism 207, a shearing mechanism 208 and a discharge mechanism 209 which are sequentially arranged along the horizontal line. The straightening mechanism 202 is used to straighten the steel wire output by the wire-releasing mechanism 201, the traction mechanism 203 is used to feed the longitudinal reinforcement into the material storage mechanism 204, the servo stepping mechanism 205 drives the longitudinal reinforcement to step to a set transverse spacing, the welding host 206 is used to weld the longitudinal reinforcement and the transverse reinforcement, the transverse reinforcement feeding mechanism 207 is used to quickly feed the cut transverse reinforcement to the part to be welded, and the shearing mechanism 208 is used to shear the steel output to the shearing position. The unloading mechanism 209 is used to pull the cut steel mesh out of the shearing mechanism 208, wherein the wire feeding mechanism 201 includes a base, a feeding tray, a brake mechanism, a wire rack and a material shortage detection mechanism, a bearing is installed between the base and the feeding tray, so that the feeding tray can rotate flexibly when working, and the brake mechanism can adjust the flexibility of the feeding tray when there is no material discharge, so that the parked steel bar coil material will not automatically disperse; the straightening mechanism 202 includes a base, a frame, a straightening wheel and a guide mechanism, the straightening wheel includes a horizontal straightening wheel and a vertical straightening wheel, half of which are installed on the slider, and the purpose of straightening the steel bar can be achieved by adjusting the wheel to a suitable position; the traction mechanism 203 includes a traction motor, a reducer and a clamping wheel, which are moved up and down Two sets of clamping wheels clamp the steel wire, which is driven by a traction motor to pull the steel wire into the material storage mechanism 204; the material storage mechanism 204 includes a roller, a grid tube and a threading tube; the servo stepping mechanism 205 includes a servo motor, a fine straightening plate and a wire tube, the servo motor drives the longitudinal reinforcement to step to the set lateral spacing, and the fine straightening plate is used for fine straightening of the longitudinal reinforcement; the welding host 206 includes a welding cylinder, a welding transformer, a lifting mechanism and an electrode main part, the electrode main part is used for clamping, lifting, powering on welding and other actions during welding, the lifting mechanism is used to move synchronously with the welding electrode to prevent the longitudinal reinforcement from rubbing against the electrode when moving, the welding transformer is located below the welding main part, which shortens the welding distance and improves the welding quality. By adjusting the columns on both sides The adjusting nut is used to change the position of the upper beam to adjust the opening distance between the upper electrode and the lower electrode; the transverse reinforcement feeding mechanism 207 includes a wire-releasing drum, a straightening wheel, a powder mechanism, a cutter cylinder and a material-throwing cylinder. The wire-releasing drum is provided with a swing rod for wire-releasing buffering. Two sets of straightening wheels are distributed at 90 degrees to straighten the steel bars in two directions. The material-splitting mechanism is used to divide the transverse reinforcement to be dropped each time. The cutter cylinder is used to cut the steel bars. The material-throwing cylinder is used to quickly deliver the cut transverse reinforcement to the part to be welded; the shearing mechanism 208 includes a shearing tool; the unloading mechanism 209 includes a net-pulling mechanism, a turning mechanism and a stacking trolley. The net-pulling mechanism pulls the cut steel mesh out of the shearing mechanism 208 and puts it into the stacking trolley through the turning mechanism for transportation;

[0042] The drill inserting and extracting mechanism 300 includes a hoist 301, a sling 302, a mounting frame 303 and a steel drill 304. The hoist 301 is connected to the sling 302 through a wire rope and a pulley, the sling 302 is connected to the mounting frame 303 through a hook, and the steel drill 304 is fixedly connected to the bottom of the mounting frame 303. When in use, the hoist 301 drives the sling 302 to move in the vertical direction, and then drives the mounting frame 303 to move together, and finally drives the steel drill 304 to move in the vertical direction to complete the drill inserting and extracting operations.

[0043] For example, see Figure 5 As shown, the pouring mixer 400 includes a mixer barrel 401, a stirring device bracket 402, a stirring motor 403, a belt transmission system 404, a stirring shaft 405, a spoiler 407 and a steam injection pipe 408. The stirring device bracket 402 is fixed to the top of the mixer barrel 401, the stirring motor 403 is fixed to the top of the stirring device bracket 402, and is connected to the stirring shaft 405 through the belt transmission system 404, the spoiler 407 is fixed to the inner wall of the mixer barrel 401, and one end of the steam injection pipe 408 extends to the inner bottom of the mixer barrel 401.

[0044] In the technical solution, an inspection hole 406 is provided on the top of the stirring device bracket 402, a double-layer impeller 409 is keyed to the bottom end of the stirring shaft 405, a pouring head 411 is provided at the bottom of the mixer barrel 401, and a discharge valve 410 is provided on the pouring head 411. After the electronic metering scale completes the metering, the pouring mixer 400 is started, the stirring motor 403 rotates the stirring shaft 405 through the belt transmission system 404, and the double-layer impeller 409 rotates accordingly, the discharge valve of the slurry electronic metering scale is opened, and the slurry enters the mixer barrel 401, rotates under the action of the double-layer impeller 409, and passes through the spoiler 410. 07, the slurry is impacted and dispersed, and the dispersed slurry is rotated again by the double-layer impeller 409, and is mixed and stirred with other slurries again, the discharge valve of the electronic powder metering scale is opened, and the screw conveyor at the bottom of the scale is started, and the powder is evenly conveyed to the mixer barrel 401, and under the action of the double-layer impeller 409 and the spoiler 407, the powder is gradually mixed with the slurry evenly. After the slurry and powder are evenly mixed, steam is added from the steam injection pipe 408, and the steam is injected into the mixed slurry along the holes on the surface of the steam injection pipe 408, and is fully mixed with the slurry and releases heat, so that the temperature of the slurry gradually rises.

[0045] For example, see Figure 6 As shown, the bubble sorting machine 500 includes a frame 501, a chain 502 arranged on the top of the frame 501, a sprocket 503 meshingly connected to the chain 502, a driving cylinder 504 fixed at one end of the chain 502 and a vibrating rod 505 fixed at the bottom of the frame 501, and the other end of the chain 502 is fixedly connected to the frame 501.

[0046] In this technical solution, by controlling the extension and retraction of the driving cylinder 504, the chain 502 can be controlled to be retracted and extended, and then the height of the frame 501 and the vibrating rod 505 can be controlled to ensure that the vibrating rod 505 can be fully inserted into the mold poured with the mixed slurry, and then ensure that the vibrating rod 505 fully vibrates the mixed slurry. The vibrating rod 505 adopts a motor-built-in vibrating rod, which has the advantages of light weight, strong exciting force, high vibration frequency, low noise, and long life. It can break up large bubbles, effectively reduce pores and cracks on the surface of aerated bricks, make the surface of aerated bricks smooth, reduce missing corners, and improve product quality.

[0047] For example, see Figure 7 As shown, the curing room 600 includes a conveying track 601, a pre-curing table 602, a connecting track 603, a residual steam injection pipeline 604, a heat dissipation fan 605 and a temperature sensor 606. The conveying track 601 is arranged in the middle of the bottom surface of the curing room 600, the pre-curing table 602 is arranged on both sides of the conveying track 601, the connecting track 603 is arranged on the upper part of the pre-curing table 602, the residual steam injection pipeline 604 is connected to the heat dissipation fan 605, and the heat dissipation fan 605 is evenly distributed on the pre-curing table 602.

[0048] In this technical solution, the mold that has completed the soldering operation enters the designated position of the curing chamber 600 through the conveying track 601, and then is conveyed to the pre-curing table 602 through the connecting track 603. At this time, the remaining steam in production is injected into the heat dissipation fan 605 through the residual steam injection pipe 604, and the temperature around the pre-curing table 602 is monitored in real time through the temperature sensor 606 to ensure that the mixed slurry in the mold can be pre-cured at a constant temperature.

[0049] For example, see Figure 8 As shown, the step-by-step cutting machine 700 includes a cutting machine track 701, a longitudinal cutting trolley 702, a pre-cutting unit 703, a longitudinal cutting machine 704, a blank lifting device 705, a cross-cutting machine 706, a vacuum suction hood 707, a waste cleaning machine 708 and a cross-cutting trolley 709. The longitudinal cutting trolley 702 and the cross-cutting trolley 709 are movably connected to both ends of the cutting machine track 701, the pre-cutting unit 703, the longitudinal cutting machine 704, the cross-cutting machine 706 and the waste cleaning machine 708 are arranged in sequence along the cutting machine track 701, the blank lifting device 705 is arranged at the bottom of the cross-cutting machine 706, and the vacuum suction hood 707 is arranged at the top of the cross-cutting machine 706.

[0050] In this technical solution, the aerial turning blank transfer car places the side panel of the mold car that has been turned 90 degrees flat on the longitudinal cutting car 702, the demoulding device is activated to loosen the side panel, the aerial turning blank transfer car is lifted up a small amount and then moves toward the bottom of the mold to separate the mold from the side panel and the blank. The blank is ready to be cut. After the step-by-step cutting machine 700 sends a signal to allow cutting, the longitudinal cutting car 702 carries the side panel and the blank to run toward the step-by-step cutting machine 700. When passing through the pre-cutting unit 703, the pre-cutting steel wire pre-cuts the "bread head" of the blank and the excess material on the bottom of the mold frame, so that the large surface of the blank is scraped off. The cutting thickness of the blade is reduced (within about 5mm) to ensure that the surface of the blank is flat and smooth after being cut by the scraper on the large surface of the blank. After being cut by the scraper on the large surface of the blank, the longitudinal cutting trolley 702 continues to carry the side plate and the blank forward. If the blank is a plate product, the scraper on the large surface of the blank will control the cutting size of the blank between the two large surfaces according to the size of the plate. In the process of moving forward, the plate notching knife will cut the two large surfaces of the blank into long strip notches for stacking multiple plates according to the required specifications and shapes. After reaching the required plate length, the notching knife will automatically retract the knife, and the scraper on the large surface of the bread head side blank will automatically retract to form the block cutting size;If the blank is a block product, the blank large surface scraper directly cuts the size between the two large surfaces into the required size of the block, and the plate notch knife does not perform cutting. After the pre-cutting unit 703 completes the cutting, the longitudinal cutting trolley 702 continues to move forward, and the cutting wire laid by the longitudinal cutting machine 704 performs horizontal layered cutting on the blank to cut the blank into a long long plate. At this time, it should be noted that the notch position should be aligned with the horizontal cutting position of the wire. After the longitudinal cutting machine 704 completes the cutting, the longitudinal cutting trolley 702 continues to move forward. The machine then moves forward to the position of the blank lifting device 705, which lifts the side panels and the blank upward, and the longitudinal cutting trolley 702 returns to its original position to wait for the next mold. At the same time, the transverse cutting trolley 709 moves to the position below the transverse cutter 706 to wait for the cut blank and side panels to be loaded. When the blank lifting device 705 rises, the transverse cutter 706 vertically cuts the blank into the required plate shape according to the set plate (or block) size, and the vacuum suction cover 707 on the top of the transverse cutter 706 is closed. 07 sucks up the waste material on the top of the blank, and after the cutting is completed, the blank lifting device 705 moves the side plate and the blank downward to the cross-cutting trolley 709. When the cross-cutting trolley 709 carries the blank out of the cross-cutting machine 706 station, the vacuum suction cover 707 is released, and the waste material on the top falls into the waste slurry channel under the cutting machine. The cross-cutting trolley 709 moves towards the semi-finished blank transfer car. When passing the waste cleaning machine 708, low-pressure compressed air is blown on the large surface and top surface of the blank after cutting, and the steel wire and the notch knife are removed. The adhered garbage formed by cutting is blown away to make the surface of the plate (block) clean. The blank and side plate cleaned by the waste cleaning machine 708 are carried by the cross-cutting cutting trolley 709 to the bottom of the semi-finished blank transfer vehicle, and the semi-finished blank transfer vehicle lifts the side plate and blank away. The step-by-step cutting unit can realize the six-sided cutting and forming of the blank in the aerated concrete production process. It is the most core and critical equipment in the aerated concrete production workshop, which greatly improves the production efficiency and product qualification rate of aerated concrete components. ;

[0051] For example, see Fig. 9 As shown, a steam inlet 801 and a steam exhaust port 802 are provided at the top of the autoclave 800 , a temperature sensor 803 and a pressure sensor 804 are provided inside the autoclave 800 , and a water outlet 805 is provided at the bottom of the autoclave 800 .

[0052] In this technical solution, a steam inlet 801 is provided to facilitate the addition of steam into the autoclave 800 during autoclave curing, a steam exhaust port 802 is provided to facilitate the discharge of steam in the autoclave 800 after the autoclave curing is completed, a temperature sensor 803 and a pressure sensor 804 are provided to facilitate the monitoring of the temperature and pressure in the autoclave 800, and a water outlet 805 is provided to facilitate the discharge of condensed water in the autoclave 800.

[0053] A production process of an autoclaved aerated concrete component, the production process of the autoclaved aerated concrete component is completed by the production system of the autoclaved aerated concrete component, and comprises the following steps:

[0054] S1: Prepare raw materials, deliver cement, lime and other powders to the silo through the compressed air delivery system, deliver sand and gypsum to the slurry mixer through the feeding conveyor belt, add water and stir during the process, and then make liquid slurry through the drum screen, and then deliver it to the slurry tank through the submersible pump, weld the steel mesh through the automatic welding machine, and then immerse the steel mesh in the anti-corrosion immersion tank for anti-corrosion treatment, dry it in the steam dryer, and then hoist it to the designated location by the drill insertion crane for drill insertion;

[0055] S2: Measuring and mixing the ingredients to make slurry. According to the given formula, the liquid slurry, lime, cement, aluminum paste and water are measured by metering equipment respectively, and then the measured materials are put into the pouring mixer in sequence. After stirring at a speed of not less than 80 rpm and a stirring time of not less than 3 minutes, ensure that the mixed slurry is fully and evenly stirred;

[0056] S3: pouring and tidying bubbles, injecting the mixed slurry in the pouring mixer into the mold through the pouring head, and then removing bubbles through the bubble tidying machine;

[0057] S4: Inserting the steel bar, moving the mold poured with the mixed slurry to the bottom of the steel bar inserting crane, and then controlling the installation frame to move downward by the steel bar inserting crane until the steel bar and the steel mesh fixed on the steel bar are inserted into the designated position of the mold;

[0058] S5: Pre-curing. Then the mold with the steel mesh inserted is sent to the curing room by a shuttle bus for constant temperature pre-curing. After the pre-curing temperature is 50℃~70℃ and the pre-curing time is 2~4 hours, it is ensured that the blank meets the cutting requirements;

[0059] S6: After the pre-curing is completed, the mold is moved to the bottom of the steel bar pulling crane, and then the steel bar is pulled out by the steel bar pulling crane, so that the steel mesh is left inside the blank;

[0060] S7: demoulding, the mold is moved to the step-by-step cutting machine position by turning the transfer cart and flipping it 90 degrees, then the side panels of the mold are separated, and the mold is separated from the blank by turning the transfer cart;

[0061] S8: Cutting: The green body is cut longitudinally and transversely by a step-by-step cutting machine. The cut green body is transported to the semi-finished green body transfer car. After the waste is removed by the ground turning table edge cleaning machine, the semi-finished green body is hoisted to the marshaling steaming car. At the same time, the cut waste and the waste removed by the ground turning table edge cleaning machine are sent to the slurry tank and mixed with the waste slurry generated by the cleaning pouring mixer to form waste slurry for reuse;

[0062] S9: Autoclave curing: the cut green bodies are grouped one by one, and after forming a row, they are sent into the autoclave for curing. The curing cycle is 10 to 14 hours, the steam temperature is 192°C, and the steam pressure is 12.5MPa. The condensed water generated by the autoclave curing is pumped to the ball milling and stirring process by a water pump, and all the condensed water is recycled;

[0063] S10: Finished product packaging. The finished products that have completed autoclave curing are transported to the post-autoclave section by the autoclave shuttle vehicle for packaging. The finished products are then lifted to the plate packaging line by the finished product transfer machine and transported to the finished product yard by a forklift for inspection and sale.

[0064] The present invention is a production system and production process of autoclaved aerated concrete components. When in use, the raw materials are first prepared, that is, sand or fly ash or subway sand and gypsum are added with water by a pulping machine 100 to form a liquid slurry, and powders such as lime and cement are transported to a silo by an air compression system. A steel mesh is produced by an automatic welding machine 200, and anti-corrosion treatment is carried out in an anti-corrosion immersion tank. After drying in a steam dryer, the steel mesh is hoisted to a designated position by a drill insertion crane to be drilled, and then each raw material is weighed and added to a pouring mixer 400 for stirring. The mixed slurry after stirring is poured into a mold and passed through a bubble finishing machine 50. 0 to remove bubbles, the inserting crane inserts the steel mesh into the cast mold, and then the shuttle car sends it to the curing room 600 for constant temperature pre-curing until it meets the cutting requirements. After the pre-curing is completed, the steel bar is removed by the pull-out crane, and after demoulding, the step-by-step cutting machine 700 performs longitudinal and transverse cutting. The cut waste is sent to the slurry pool and mixed with the waste slurry generated by the cleaning pouring mixer 400 to form waste slurry for reuse. After the cut green bodies are organized into a series by car, they are sent to the autoclave for high temperature and high pressure curing. After the autoclave curing is completed, the finished product is hoisted to the plate packaging line by the finished product transfer machine, and transported to the finished product yard by forklift for inspection and sale. The production system and production process of the autoclaved aerated concrete component can place the steel mesh inside the autoclaved aerated concrete component before pre-curing by setting the process of inserting the steel mesh, and complete the pull-out process before cutting, so as to increase the structural strength, tensile and shear resistance of the autoclaved aerated concrete component and improve the product quality.

[0065] Finally, it should be noted that the above is only a preferred embodiment of the present invention and is not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, it is still possible for those skilled in the art to modify the technical solutions described in the aforementioned embodiments or to make equivalent substitutions for some of the technical features therein. Any modifications, equivalent substitutions, improvements, etc. made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A production system for autoclaved aerated concrete components, characterized in that: include: A pulping machine (100), an automatic welding machine (200), a drill insertion and extraction mechanism (300), a pouring and mixing machine (400), a bubble sorting machine (500), a resting room (600), a step-by-step cutting machine (700) and an autoclave (800); The pulping machine (100) comprises a feeding conveyor belt (101), a pulping mixer (102), a drum screen (103), a slurry tank (104), a slurry conveying pipeline (105), a stirring tank 1 (106) and a stirring tank 2 (107); one end of the feeding conveyor belt (101) extends to the top of the feed hopper of the pulping mixer (102); the pulping mixer (102) discharges slurry to the stirring tank 1 (106); the slurry in the stirring tank 1 (106) is conveyed to the drum screen (103) by a submersible pump; a stirring tank 2 (107) is arranged below the feeding outlet of the drum screen (103); the liquid slurry in the stirring tank 2 (107) is conveyed to the slurry tank (104) by a submersible pump and a slurry conveying pipeline (105); The automatic welding machine (200) comprises a wire-releasing mechanism (201), a straightening mechanism (202), a traction mechanism (203), a material storage mechanism (204), a servo stepping mechanism (205), a welding host (206), a cross-rib feeding mechanism (207), a shearing mechanism (208) and a material discharge mechanism (209) which are sequentially arranged along a horizontal line, wherein the straightening mechanism (202) is used to straighten the steel wire output by the wire-releasing mechanism (201), and the traction mechanism (203) is used to The longitudinal reinforcement is fed into the storage mechanism (204), the servo stepping mechanism (205) drives the longitudinal reinforcement to step to a set transverse spacing, the welding host (206) is used to weld the longitudinal reinforcement and the transverse reinforcement, the transverse reinforcement feeding mechanism (207) is used to quickly feed the cut transverse reinforcement to the position to be welded, the shearing mechanism (208) is used to shear the steel mesh output to the shearing position, and the unloading mechanism (209) is used to pull the cut steel mesh out of the shearing mechanism (208). The drill plugging and pulling mechanism (300) comprises a hoist (301), a sling (302), a mounting frame (303) and a steel drill (304); the hoist (301) is connected to the sling (302) via a steel wire rope and a pulley; the sling (302) is connected to the mounting frame (303) via a hook; and the steel drill (304) is fixedly connected to the bottom of the mounting frame (303).

2. The production system of autoclaved aerated concrete components according to claim 1, characterized in that: The pouring mixer (400) comprises a mixer barrel (401), a stirring device support (402), a stirring motor (403), a belt transmission system (404), a stirring shaft (405), a spoiler (407) and a steam injection pipe (408), wherein the stirring device support (402) is fixed to the top of the mixer barrel (401), the stirring motor (403) is fixed to the top of the stirring device support (402) and is connected to the stirring shaft (405) through the belt transmission system (404), the spoiler (407) is fixed to the inner wall of the mixer barrel (401), and one end of the steam injection pipe (408) extends to the inner bottom of the mixer barrel (401).

3. The production system of autoclaved aerated concrete components according to claim 1, characterized in that: The bubble sorting machine (500) comprises a frame (501), a chain (502) arranged on the top of the frame (501), a sprocket (503) meshingly connected to the chain (502), a driving cylinder (504) fixed at one end of the chain (502) and a vibrating rod (505) fixed at the bottom of the frame (501), and the other end of the chain (502) is fixedly connected to the frame (501).

4. The production system of autoclaved aerated concrete components according to claim 1, characterized in that: The resting room (600) comprises a conveying track (601), a pre-curing table (602), a connecting track (603), a residual steam injection pipeline (604), a heat dissipation fan (605) and a temperature sensor (606); the conveying track (601) is arranged in the middle of the bottom surface of the resting room (600); the pre-curing table (602) is arranged on both sides of the conveying track (601); the connecting track (603) is arranged on the upper part of the pre-curing table (602); the residual steam injection pipeline (604) is connected to the heat dissipation fan (605); and the heat dissipation fans (605) are evenly distributed on the pre-curing table (602).

5. The production system of autoclaved aerated concrete components according to claim 1, characterized in that: The step-by-step cutting machine (700) comprises a cutting machine track (701), a longitudinal cutting trolley (702), a pre-cutting unit (703), a longitudinal cutting machine (704), a blank lifting device (705), a cross-cutting machine (706), a vacuum suction hood (707), a waste cleaning machine (708) and a cross-cutting trolley (709). The longitudinal cutting trolley (702) and the cross-cutting trolley (709) are movably connected to the two ends of the cutting machine track (701). The pre-cutting unit (703), the longitudinal cutting machine (704), the cross-cutting machine (706) and the waste cleaning machine (708) are arranged in sequence along the cutting machine track (701). The blank lifting device (705) is arranged at the bottom of the cross-cutting machine (706), and the vacuum suction hood (707) is arranged at the top of the cross-cutting machine (706).

6. The production system of autoclaved aerated concrete components according to claim 1, characterized in that: The top of the autoclave (800) is provided with a steam inlet (801) and a steam outlet (802), the interior of the autoclave (800) is provided with a temperature sensor (803) and a pressure sensor (804), and the bottom of the autoclave (800) is provided with a water outlet (805).

7. A process for producing autoclaved aerated concrete components using the production system for autoclaved aerated concrete components according to any one of claims 1 to 6, characterized in that: The following steps are involved: S1: Prepare raw materials, deliver cement, lime and other powders to the silo through the compressed air delivery system, deliver sand and gypsum to the slurry mixer through the feeding conveyor belt, add water and stir during the process, and then make liquid slurry through the drum screen, and then deliver it to the slurry tank through the submersible pump, weld the steel mesh through the automatic welding machine, and then immerse the steel mesh in the anti-corrosion immersion tank for anti-corrosion treatment, dry it in the steam dryer, and then hoist it to the designated location by the drill insertion crane for drill insertion; S2: Measuring and mixing the ingredients to make slurry. According to the given formula, the liquid slurry, lime, cement, aluminum paste and water are measured by metering equipment respectively, and then the measured materials are put into the pouring mixer in sequence. After stirring at a speed of not less than 80 rpm and a stirring time of not less than 3 minutes, ensure that the mixed slurry is fully and evenly stirred; S3: pouring and tidying bubbles, injecting the mixed slurry in the pouring mixer into the mold through the pouring head, and then removing bubbles through the bubble tidying machine; S4: Inserting the steel bar, moving the mold poured with the mixed slurry to the bottom of the steel bar inserting crane, and then controlling the installation frame to move downward by the steel bar inserting crane until the steel bar and the steel mesh fixed on the steel bar are inserted into the designated position of the mold; S5: Pre-curing. Then the mold with the steel mesh inserted is sent to the curing room by a shuttle bus for constant temperature pre-curing. After the pre-curing temperature is 50℃~70℃ and the pre-curing time is 2~4 hours, it is ensured that the blank meets the cutting requirements; S6: After the pre-curing is completed, the mold is moved to the bottom of the steel bar pulling crane, and then the steel bar is pulled out by the steel bar pulling crane, so that the steel mesh is left inside the blank; S7: demoulding, the mold is moved to the step-by-step cutting machine position by turning the transfer cart and flipping it 90 degrees, then the side panels of the mold are separated, and the mold is separated from the blank by turning the transfer cart; S8: Cutting: The green body is cut longitudinally and transversely by a step-by-step cutting machine. The cut green body is transported to the semi-finished green body transfer car. After the waste is removed by the ground turning table edge cleaning machine, the semi-finished green body is hoisted to the marshaling steaming car. At the same time, the cut waste and the waste removed by the ground turning table edge cleaning machine are sent to the slurry tank and mixed with the waste slurry generated by the cleaning pouring mixer to form waste slurry for reuse; S9: Autoclave curing: the cut green bodies are grouped one by one, and after forming a row, they are sent into the autoclave for curing. The curing cycle is 10 to 14 hours, the steam temperature is 192°C, and the steam pressure is 12.5MPa. The condensed water generated by the autoclave curing is pumped to the ball milling and stirring process by a water pump, and all the condensed water is recycled; S10: Finished product packaging. The finished products that have completed autoclave curing are transported to the post-autoclave section by the autoclave shuttle vehicle for packaging. The finished products are then lifted to the plate packaging line by the finished product transfer machine and transported to the finished product yard by a forklift for inspection and sale.

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