An automatic production system and method for autoclaved aerated concrete blocks

Abstract

The application discloses a full-process automatic production system and method for autoclaved aerated concrete blocks, and belongs to the technical field of special equipment for building material production. The system comprises a raw material pretreatment section, a batching and pouring section, a forming and cutting section and an autoclaving and curing section which are sequentially connected, and a control device which is signal-connected with each section. The control device comprises preset timing control logic, is used for sequentially triggering each section to start, run and stop according to the running tempo and material state of each section, and realizes automatic connection and full-process continuous running between each section. Through the cooperative matching of each section detection device and parameter linkage adjustment module, the full-process automatic continuous production from raw material crushing to finished product discharge is realized, manual intervention is effectively reduced, and the production efficiency and product qualification rate are improved.

Description

Technical Field

[0001] This invention relates to the field of specialized equipment for building material production, and in particular to a fully automated production system and method for autoclaved aerated concrete blocks. Background Technology

[0002] Currently, autoclaved aerated concrete (AAC) blocks, as a lightweight and porous new type of wall material, are widely used in the construction industry. Their production process typically includes multiple steps such as raw material crushing, ball milling, batching and mixing, pouring and gas generation, static curing and cutting, autoclaving, and finished product stacking. At present, the industry generally adopts a segmented operation mode, with each process equipped with independent equipment. Material flow between processes relies on manual handling or semi-automatic transfer devices. The equipment in each section operates in isolation, making it difficult to coordinate and unify production rhythms. Furthermore, the numerous manual operations not only result in high labor intensity and limited production efficiency but also easily lead to quality defects such as edge chipping and cracks during multiple transfers of the blocks, affecting the finished product qualification rate.

[0003] To address the aforementioned issues, some existing technologies attempt to automate localized processes by adding conveyor belts, automated guided vehicles (AGVs), or robotic arms to each section. For example, an automatic metering system could be installed in the batching section, or an automatic cutting machine could be used in the cutting section. However, these improvements mostly only optimize a single section locally. A unified scheduling control and sequential linkage mechanism between sections is still lacking. The material status after the completion of the previous section cannot be automatically detected to trigger the start of the next section, requiring manual intervention to connect and confirm the status between sections. Furthermore, due to the lack of a linkage adjustment mechanism that automatically adjusts the process settings of subsequent sections based on the actual operating parameters of the preceding sections, there is significant room for optimization in the matching of process parameters between sections, making it difficult to effectively guarantee the stability of the entire production line and the consistency of product quality. Summary of the Invention

[0004] The present invention aims to solve the technical problem of the lack of a unified scheduling control and timing linkage mechanism between different work sections in the prior art. To solve the above technical problem, the present invention proposes the following technical solution:

[0005] A fully automated production system for autoclaved aerated concrete (AAC) blocks includes:

[0006] The raw material pretreatment section is used to crush and grind lumpy siliceous raw materials and lime to obtain pretreated raw materials;

[0007] The batching and casting section is located at the discharge end of the raw material pretreatment section. It is used to mix and stir the pretreated raw materials with cement, gypsum, water and aluminum powder in a set ratio to form a foaming slurry. The foaming slurry is then poured into a mold and left to stand to generate gas and form a molded blank.

[0008] The forming and cutting section is located at the discharge end of the batching and casting section. It is used to statically harden the formed blank and cut the hardened blank to obtain fixed-length block blanks.

[0009] The autoclaving section is located at the discharge end of the forming and cutting section. It is used to introduce high-temperature and high-pressure saturated steam into the fixed-length block blanks for autoclaving to obtain finished blocks.

[0010] And a control device, which is signal-connected to the raw material pretreatment section, the batching and casting section, the molding and cutting section and the autoclaving section respectively;

[0011] The control device includes a preset timing control logic. The timing control logic triggers the raw material pretreatment section, batching and casting section, molding and cutting section and autoclaving section to start, run and stop in a preset sequence according to the running rhythm and material status of each section.

[0012] Furthermore, a material level sensor is installed at the discharge end of the raw material pretreatment section, a position sensor is installed at the casting mold of the batching and casting section, and a hardness tester is installed at the static stopping equipment of the forming and cutting section.

[0013] The material level sensor, position sensor, and hardness tester are respectively connected to the control device via signal transmission.

[0014] Furthermore, the control device also includes a parameter linkage adjustment module, the batching and casting section includes a batching control module, and the autoclaving section includes a curing control module;

[0015] The parameter linkage adjustment module is connected to the batching control module and the curing control module respectively;

[0016] The parameter linkage adjustment module calculates and adjusts the setting values ​​of the curing parameters for the autoclaving section based on the actual proportioning data fed back by the batching control module.

[0017] When the actual silicon raw material ratio is higher than the preset value, the parameter linkage adjustment module controls the curing control module to extend the heat preservation time of autoclaving and / or increase the curing temperature.

[0018] When the actual silicon raw material ratio is lower than the preset value, the parameter linkage adjustment module controls the curing control module to shorten the heat preservation time of autoclaving and / or reduce the curing temperature.

[0019] Furthermore, the batching and pouring section includes a mixer, and a consistency meter is installed at the mixer, the consistency meter being signal-connected to a control device;

[0020] The control device calculates the expected hardening rate of the preform based on the consistency value, and dynamically adjusts the static dwell time setting of the forming and cutting section according to the expected hardening rate:

[0021] When the consistency value is higher than a preset range, the static pause time is shortened; when the consistency value is lower than a preset range, the static pause time is extended.

[0022] Furthermore, the batching and casting section is equipped with a circular track, on which multiple sets of casting molds are mounted, and the multiple sets of casting molds circulate along the circular track.

[0023] Multiple station detection sensors are installed on the circular track, and each station detection sensor is connected to the control device for signal transmission.

[0024] The control device acquires the position information of each group of casting molds on the circular track in real time through the detection sensors at each workstation, and controls the driving mechanism of each workstation section according to the preset mold flow scheduling rules.

[0025] The preset mold flow scheduling rules include: priority rules for pouring stations, allocation rules for stationary stops, and queuing rules for cutting stations.

[0026] Furthermore, the autoclaving section is equipped with multiple autoclaves, and the feeding end of the autoclave section is equipped with an inlet shuttle car and the discharging end is equipped with an outlet shuttle car.

[0027] The autoclave is equipped with an autoclave door status detection sensor and an autoclave internal pressure detection sensor. The autoclave inlet shuttle car, autoclave outlet shuttle car, autoclave door status detection sensor and autoclave internal pressure detection sensor are respectively connected to the control device.

[0028] The control device automatically assigns inlet and outlet tasks based on the state of the autoclave door and the pressure inside the autoclave.

[0029] Furthermore, the raw material pretreatment section includes a crusher, a ball mill, a silo, and a feeder connected in sequence;

[0030] The batching and casting section includes a metering device, a mixer, and a casting mold;

[0031] The forming and cutting section includes a stationary equipment and a cutting machine;

[0032] The autoclaving section includes an autoclave and a boiler.

[0033] Furthermore, the discharge end of the autoclaving section is equipped with a palletizer and a packaging machine;

[0034] Both the raw material pretreatment section and the batching and casting section are equipped with dust removal devices.

[0035] Furthermore, this includes the following steps:

[0036] Step 1: The control device controls the raw material pretreatment section to crush and grind the lumpy siliceous raw materials and lime according to the preset timing control logic to obtain pretreated raw materials.

[0037] Step 2: When the pre-treated raw material reaches the preset material level, the control device controls the batching and pouring section to mix the pre-treated raw material with cement, gypsum, water and aluminum powder in the set ratio to form a foaming slurry. The foaming slurry is then poured into the mold and left to stand to generate gas and form a molded blank.

[0038] Step 3: When the molded blank reaches the preset hardness threshold, the control device controls the molding and cutting section to demold the molded blank, allow it to stand still for hardening, and then cut it to obtain a fixed-length block blank.

[0039] Step 4: When the cutting is detected to be complete, the control device controls the autoclaving section to introduce high-temperature and high-pressure saturated steam into the fixed-length block blank for autoclaving to obtain the finished block.

[0040] Furthermore, in step two, the set proportions are: lime 10%-20%, cement 5%-15%, gypsum 2%-5%, siliceous raw materials 60%-80%, and aluminum powder added at 0.05%-0.15% of the total mass of all raw materials;

[0041] In step three, the static curing temperature is 40℃-50℃, and the time is 1-3 hours;

[0042] In step four, the autoclaving temperature is 180℃-200℃, the pressure is 1.0MPa-1.3MPa, and the time is 8-12 hours.

[0043] Compared with the prior art, the beneficial effects of the present invention are as follows: The present invention sets up a raw material pretreatment section, a batching and casting section, a molding and cutting section, and an autoclaving section connected in sequence, and sets up a control device that is signal-connected to each of the above sections. The control device contains a preset timing control logic, which can trigger each section to start, run, and stop in a preset sequence according to the running rhythm and material status of each section. This realizes the fully automated continuous operation of the entire process from raw material crushing to finished product output, effectively solving the technical problems of isolated operation of equipment in each process and reliance on manual connection between sections in the existing segmented production mode. It also improves the problems of logistics interruption and production rhythm incoordination caused by manual intervention, and avoids quality defects such as edge bumps and cracks in the billet during multiple manual transfers, effectively improving the finished product qualification rate and production efficiency.

[0044] Furthermore, this invention installs a material level sensor at the discharge end of the raw material pretreatment section, a position sensor at the casting mold in the batching and casting section, and a hardness detector at the static stopping device in the forming and cutting section. These sensors are then connected to a control device, enabling the control device to automatically trigger the start-up of the next section based on the material state of each section, thus achieving automatic connection between sections. A parameter linkage adjustment module connected to the batching control module and the curing control module allows curing parameters to be automatically adjusted according to actual ratio fluctuations. Finally, a consistency meter at the mixer detects the slurry consistency and dynamically adjusts the static stopping time accordingly, preventing unstable cutting quality caused by slurry consistency fluctuations.

[0045] This invention also enables the control device to acquire the position information of each group of casting molds in real time and schedule them according to preset rules by setting up a circular track and multiple station detection sensors in the batching and casting section, thus avoiding production line stagnation caused by multiple groups of molds arriving at the same station at the same time; by setting up multiple autoclaves and autoclave inlet and outlet shuttle cars in the autoclave curing section, and automatically allocating autoclave inlet and outlet tasks according to the autoclave door status and pressure status of each autoclave, the invention achieves efficient utilization and automatic scheduling of autoclaves, effectively shortens production waiting time, and improves equipment utilization and overall production line capacity. Attached Figure Description

[0046] Figure 1 This is a system flowchart of the present invention;

[0047] Figure 2 This is a flowchart of the production process steps of the present invention. Detailed Implementation

[0048] To better understand the purpose, structure, and function of this invention, the following detailed description, in conjunction with the accompanying drawings, provides an automated production system and method for autoclaved aerated concrete blocks.

[0049] Example 1

[0050] like Figure 1-2 As shown in the figure, this embodiment provides a fully automated production system for autoclaved aerated concrete (AAC) blocks, including: a raw material pretreatment section for crushing and grinding blocky siliceous raw materials and lime to obtain pretreated raw materials; a material level sensor is installed at the discharge end of the raw material pretreatment section, a position sensor is installed at the casting mold of the batching and casting section, and a hardness tester is installed at the static stopping equipment of the forming and cutting section; the material level sensor, position sensor, and hardness tester are respectively connected to the control device.

[0051] In this embodiment, the batching and casting section is located at the discharge end of the raw material pretreatment section. It is used to mix and stir the pretreated raw materials with cement, gypsum, water, and aluminum powder according to a set ratio to form a foaming slurry. The foaming slurry is then poured into a mold and allowed to stand to generate gas and form a molded green body. The batching and casting section includes a mixer, and a consistency meter is installed at the mixer. The consistency meter is connected to a control device. The control device calculates the expected hardening rate of the green body based on the consistency value and dynamically adjusts the static stop time setting value of the molding and cutting section according to the expected hardening rate: when the consistency value is higher than a preset range, the static stop time is shortened; when the consistency value is lower than a preset range, the static stop time is extended. The batching and casting section is equipped with a circular track, on which multiple sets of casting molds are mounted and circulate. Multiple station detection sensors are installed on the circular track, each connected to a control device. The control device acquires the real-time position information of each set of casting molds on the circular track through the station detection sensors and controls the drive mechanism of each station section according to preset mold flow scheduling rules. These preset mold flow scheduling rules include: casting station priority rules, static stop station allocation rules, and cutting station queuing rules. The forming and cutting section, located at the discharge end of the batching and casting section, is used to statically harden the formed blank and cut the hardened blank to obtain fixed-length block blanks.

[0052] The autoclaving section, located at the discharge end of the forming and cutting section, is used to introduce high-temperature, high-pressure saturated steam into the fixed-length block blanks for autoclaving to obtain finished blocks. The autoclaving section is equipped with multiple autoclaves. The feeding end of the autoclave is equipped with an inlet shuttle car, and the discharge end is equipped with an outlet shuttle car. Each autoclave is equipped with an autoclave door status detection sensor and an autoclave internal pressure detection sensor. The inlet shuttle car, outlet shuttle car, autoclave door status detection sensor, and autoclave internal pressure detection sensor are respectively connected to a control device. The control device automatically allocates inlet and outlet tasks based on the autoclave door status and internal pressure status of each autoclave.

[0053] The system includes a control device, which is signal-connected to the raw material pretreatment section, the batching and casting section, the molding and cutting section, and the autoclaving section, respectively. The control device includes a preset timing control logic, which, according to the operating rhythm and material status of each section, sequentially triggers the raw material pretreatment section, the batching and casting section, the molding and cutting section, and the autoclaving section to start, run, and stop according to the preset timing sequence. The control device further includes a parameter linkage adjustment module. The batching and casting section includes a batching control module, and the autoclaving section includes a curing control module. The parameter linkage adjustment module is signal-connected to both the batching control module and the curing control module. Based on the actual batching data fed back by the batching control module, the parameter linkage adjustment module calculates and adjusts the curing parameter settings of the autoclaving section: when the actual silicon raw material ratio is higher than the preset value, the parameter linkage adjustment module controls the curing control module to extend the holding time and / or increase the curing temperature during autoclaving; when the actual silicon raw material ratio is lower than the preset value, the parameter linkage adjustment module controls the curing control module to shorten the holding time and / or decrease the curing temperature during autoclaving.

[0054] The raw material pretreatment section of this embodiment includes a crusher, a ball mill, a silo, and a feeder connected in sequence; the batching and casting section includes a metering device, a mixer, and a casting mold; the forming and cutting section includes a static stopping device and a cutting machine; and the autoclaving section includes an autoclave and a boiler. The discharge end of the autoclaving section is equipped with a palletizer and a packaging machine; both the raw material pretreatment section and the batching and casting section are equipped with dust removal devices.

[0055] This embodiment provides a fully automated production method for autoclaved aerated concrete (AAC) blocks, comprising the following steps: Step 1: A control device, according to a preset timing control logic, controls the raw material pretreatment section to crush and grind lumpy siliceous raw materials and lime to obtain pretreated raw materials; Step 2: When the pretreated raw materials are detected to have reached a preset material level, the control device controls the batching and pouring section to mix the pretreated raw materials with cement, gypsum, water, and aluminum powder according to a set ratio to form a foaming slurry, and pours the foaming slurry into a mold for static aeration and molding to obtain a molded blank; In Step 2, the preset timing control logic... The mixing ratio is: lime 10%, cement 5%, gypsum 2%, siliceous raw materials 60%, and aluminum powder added at 0.05% of the total mass of all raw materials. Step three: When the molded blank reaches the preset hardness threshold, the control device controls the molding and cutting section to demold, allow static hardening, and cut the molded blank to obtain a fixed-length block blank. In step three, the static hardening temperature is 40℃, and the time is 1 hour. Step four: When cutting is detected as complete, the control device controls the autoclaving section to introduce high-temperature, high-pressure saturated steam into the fixed-length block blank for autoclaving to obtain the finished block. In step four, the autoclaving temperature is 180℃, the pressure is 1.0 MPa, and the time is 8 hours.

[0056] Example 2

[0057] like Figure 1-2 As shown in this embodiment, an automated production system for autoclaved aerated concrete (AAC) blocks is provided. The system includes a raw material pretreatment section, a batching and pouring section, a molding and cutting section, an autoclaving section, and a control device. These sections are sequentially connected to form a complete automated production line. The control device is signal-connected to each of the raw material pretreatment, batching and pouring, molding and cutting, and autoclaving sections. It stores preset timing control logic to sequentially trigger each section to start, run, and stop according to the preset timing based on the operating cycle and material status of each section, achieving automatic connection between sections and continuous operation throughout the entire process.

[0058] I. Raw Material Pretreatment Section

[0059] The raw material pretreatment section includes a crusher and a ball mill. Lumpy siliceous raw materials (such as sand and fly ash) and lime are first fed into the crusher for coarse crushing. After being crushed to a certain particle size, they are conveyed by a conveyor belt into the ball mill for grinding to a fine powder state. Preferably, the ball mill is a dry ball mill or a wet ball mill, which can be selected according to the characteristics of the raw materials and production requirements.

[0060] After grinding, the raw materials are vertically conveyed to silos via bucket elevators for zoned storage. A feeder is installed at the outlet of each silo to quantitatively transport the stored raw materials to the downstream batching process. Preferably, the feeder is a vibrating feeder or a screw conveyor, which can be adjusted according to the flowability of the raw materials and the production cycle.

[0061] A level sensor is installed at the discharge end (i.e., the discharge port of the silo) of the raw material pretreatment section. This sensor is signal-connected to the control device and is used to detect the level of the pretreated raw material in the silo in real time, sending the detected level value to the control device. When the level reaches a preset high threshold, the control device automatically starts the feeding device of the batching and casting section to begin supplying the pretreated raw material. When the level is below a preset low threshold, the control device automatically starts the crusher and ball mill of the raw material pretreatment section to replenish the material. Through this level detection and automatic replenishment mechanism, automatic connection between the raw material pretreatment and batching / casting sections is achieved, preventing interruptions in batching or overflows due to an empty silo, thus ensuring the continuity and stability of material supply.

[0062] II. Batching and Casting Section

[0063] The batching and casting section includes a metering device, a mixer, and casting molds. The metering device is a fully automatic metering system controlled by a microcomputer, and its inlet is connected to the outlet of each silo. During production, the feeder quantitatively discharges each raw material from the silo and sends it to the metering device via a bucket elevator. The metering device then weighs lime, cement, gypsum, water, and each siliceous raw material in sequence according to a preset ratio.

[0064] After weighing, the raw materials are added to the mixer in a set order, along with aluminum powder, for mixing. Preferably, the mixer is a twin-shaft horizontal mixer, and its mixing time and speed are automatically controlled by the mixing control module of the control device according to preset parameters. After the raw materials are fully mixed in the mixer, a uniform foamed slurry is formed.

[0065] A consistency meter is installed at the mixer, and the consistency meter is signal-connected to the control device. It detects the consistency value of the foamed slurry after mixing and sends the consistency value to the control device. The control device calculates the expected hardening rate of the green body based on the consistency value and dynamically adjusts the static dwell time setting of the forming and cutting section according to the expected hardening rate: when the consistency value is higher than a preset range, it indicates that the water content in the slurry is low and the hardening rate is fast, and the control device shortens the static dwell time setting accordingly; when the consistency value is lower than the preset range, it indicates that the water content in the slurry is high and the hardening rate is slow, and the control device extends the static dwell time setting accordingly. Through this consistency detection and static dwell time linkage adjustment mechanism, the green body enters the cutting process in the optimal hardening state, avoiding unstable cutting quality caused by slurry consistency fluctuations.

[0066] The foaming slurry is poured into the casting mold through the discharge port of the mixer. The casting mold includes a mold frame, a mold base plate, and a mold carriage, which together form a closed molding cavity. A position sensor is installed at the casting mold, and the position sensor is signal-connected to the control device to detect whether the casting mold has reached the casting position and send the detected arrival signal to the control device. When the position sensor detects that the casting mold has reached the casting position, the control device automatically activates the discharge valve of the mixer, allowing the foaming slurry to be poured into the casting mold; after casting is completed, the control device automatically closes the discharge valve and controls the transfer carriage to transport the casting mold to the next position. The foaming slurry undergoes gas generation while standing in the molding cavity. The aluminum powder reacts with the alkali in the cement and lime in an alkaline environment to produce hydrogen gas, causing the slurry to expand in volume and form a porous structure.

[0067] In this embodiment, the batching and casting section is further equipped with multiple sets of casting molds and a circular track. The multiple sets of casting molds are arranged on the circular track and circulate along the track. Multiple station detection sensors are installed on the circular track, and each station detection sensor is signal-connected to the control device. The control device acquires the position information of each set of casting molds on the circular track in real time through the station detection sensors, and controls the drive mechanism of each station section according to a preset mold flow scheduling rule. The preset mold flow scheduling rule includes: a casting station priority rule—when a set of casting molds arrives at a casting station, the control device controls the mixer to prioritize casting to that set of casting molds; a static stop station allocation rule—after casting is completed, the control device allocates the casting molds to currently idle static stop stations; and a cutting station queuing rule—when multiple sets of casting molds complete hardening simultaneously, the control device controls the cutting machine to cut each set of blanks sequentially according to a preset priority order. The above-mentioned mold transfer scheduling mechanism effectively avoids workstation conflicts and production line stagnation caused by multiple sets of molds arriving at the same workstation at the same time, thereby improving the smoothness and efficiency of the entire line operation.

[0068] III. Forming and Cutting Section

[0069] The forming and cutting section includes a static curing device and a cutting machine. After the casting and gas generation are completed, the casting mold containing the formed billet is transferred to the static curing device by a hoist. Preferably, the static curing device is a static curing chamber or a pre-curing kiln, the internal temperature of which is controlled at 50°C, and the billet is statically cured for 3 hours to allow the billet to initially harden to a cuttable strength.

[0070] A hardness detector is installed at the static hardening device. This hardness detector is signal-connected to the control device and is used to detect the surface hardness value of the billet during static hardening. The detected hardness value is then sent to the control device. The control device compares the hardness value with a preset hardness threshold. When the hardness value reaches or exceeds the preset threshold, the control device automatically issues demolding and cutting commands, controlling the demolding device to remove the billet from the casting mold and controlling the cutting machine to start the cutting action. When the hardness value does not reach the preset threshold, the control device controls the static hardening device to continue static hardening of the billet. Through this hardness detection and automatic triggering mechanism, the cutting timing is accurately determined based on the hardness value, replacing traditional manual experience-based judgment or timed cutting methods. This avoids problems such as billet breakage during cutting due to insufficient hardening or accelerated wear of the cutting tool due to over-hardening.

[0071] After static curing, the billet is removed from the casting mold through a demolding process and transported to the cutting station of the cutting machine by a transfer vehicle. Preferably, the cutting machine is an air-turning cutting machine or a ground-turning cutting machine. The cutting machine performs vertical and horizontal cuts on the billet according to preset dimensions, dividing it into fixed-length block billets that meet the specifications. During the cutting process, the cutting control module of the control device automatically controls the accuracy and sequence of the cutting actions according to the preset dimensions.

[0072] IV. Autoclaving Section

[0073] The autoclaving section includes an autoclave and a boiler. After the blocks are cut to size, they are transferred from the cut blocks to the autoclave by a transfer car, and the autoclave moves along the track to deliver the blocks into the autoclave.

[0074] The boiler includes a boiler body, a steam distribution cylinder, steam pipes, and a safety valve. High-temperature, high-pressure saturated steam generated by the boiler body is distributed by the steam distribution cylinder and then sent to the autoclave through the steam pipes. The curing conditions inside the autoclave are: temperature 200℃, pressure 1.3MPa, and curing time 12 hours. Under these conditions, silica and calcium oxide in the block blank undergo a hydrothermal synthesis reaction to form tobermorite crystals, allowing the block to reach its final strength. The curing control module of the control device automatically controls the autoclaving temperature, pressure, and time according to a preset curing curve.

[0075] In this embodiment, the control device further includes a parameter linkage adjustment module, which is signal-connected to the batching control module of the batching and casting section and the curing control module of the autoclaving section. The batching control module sends the actual weighed raw material ratio data to the parameter linkage adjustment module. Based on the received actual ratio data, the parameter linkage adjustment module calculates and adjusts the curing parameter settings of the autoclaving section: when the actual siliceous raw material ratio is higher than the preset value, the parameter linkage adjustment module controls the curing control module to extend the heat preservation time of autoclaving and / or increase the curing temperature to ensure that the hydrothermal synthesis reaction between the siliceous raw material and lime proceeds fully; when the actual siliceous raw material ratio is lower than the preset value, the parameter linkage adjustment module controls the curing control module to shorten the heat preservation time of autoclaving and / or decrease the curing temperature to avoid over-curing leading to a decrease in masonry strength and energy waste. By using the above proportions and curing parameters, we can solve the problem that the curing parameters in traditional curing processes are fixed and cannot adapt to fluctuations in the raw material proportions. This ensures the consistency of product quality and enables the on-demand use of energy.

[0076] Furthermore, in this embodiment, the autoclaving section is equipped with multiple autoclaves, with an inlet shuttle car at the feed end and an outlet shuttle car at the discharge end. Each autoclave is equipped with an autoclave door status detection sensor and an autoclave internal pressure sensor. The inlet shuttle car, outlet shuttle car, autoclave door status detection sensor, and autoclave internal pressure sensor are respectively connected to the control device. The control device automatically allocates inlet and outlet tasks based on the door status and internal pressure of each autoclave: when the door of an autoclave is open and the internal pressure drops below a safe value, the control device controls the outlet shuttle to remove the finished blocks from the autoclave and controls the inlet shuttle to deliver the blocks to be cured into the autoclave; when the door of an autoclave is closed and the internal pressure is within the curing pressure range, the control device marks the autoclave as running and does not allocate new inlet tasks; when the curing time of an autoclave reaches the preset curing duration, the control device automatically issues an outlet command. Through the above-mentioned automatic inlet and outlet scheduling mechanism for multiple autoclaves, efficient utilization and automatic scheduling of autoclaves are achieved, effectively shortening production waiting time and improving equipment utilization and overall production line capacity.

[0077] After curing is completed, the steam curing vehicle pulls the finished blocks out of the autoclave and into the next process.

[0078] V. Finished Product Processing Procedures

[0079] The finished product processing section is located at the discharge end of the autoclaving section and includes a palletizer and a packaging machine. The finished blocks taken from the autoclave are first inspected and approved, then automatically stacked by the palletizer, and finally packaged by the packaging machine to form finished products ready for direct shipment.

[0080] In addition, the system also includes dust removal devices installed in the raw material pretreatment section and the batching and casting section. The dust removal devices include silo top dust collectors and dust removal systems, which are used to collect and treat the dust generated during the production process to ensure that the production environment meets environmental protection requirements.

[0081] VI. Operating Mode of the Control System

[0082] The control device includes a batching control module, a mixing control module, a cutting control module, and a curing control module. The batching control module is located at the metering device and is used to automatically control the proportion and feeding sequence of each raw material according to a preset formula. The mixing control module is located at the mixer and is used to control the mixing time and speed. The cutting control module is located at the cutter and is used to control the cutting action according to a preset size. The curing control module is located at the autoclave and is used to control the autoclaving temperature, pressure, and time according to a preset curing curve.

[0083] The aforementioned control modules communicate with each other via industrial Ethernet or fieldbus, forming a distributed control network. Throughout the production process, the control device collects the operating parameters of each section in real time (such as temperature, pressure, time, proportioning accuracy, material level, consistency value, hardness value, etc.), and issues control commands to each section according to the preset timing control logic, realizing the timing linkage control between each section of the entire production line and the fully automated continuous operation of the entire process.

[0084] VII. System Specific Workflow

[0085] When using the above-mentioned fully automated autoclaved aerated concrete (AAC) block production system for block production, the specific workflow is as follows:

[0086] Step 1: The control device controls the raw material pretreatment section to crush and grind the lumpy siliceous raw materials and lime according to the preset timing control logic to obtain pretreated raw materials.

[0087] Step Two: When the material level sensor detects that the pre-treated raw material has reached the preset material level, the control device controls the batching and pouring section to mix the pre-treated raw material with cement, gypsum, water, and aluminum powder according to the set ratio to form a foaming slurry. The foaming slurry is then poured into a mold and allowed to stand to aerate and form a molded blank. The set ratio is: lime 20%, cement 15%, gypsum 5%, siliceous raw materials 80%, and the amount of aluminum powder added is 0.15% of the total mass of all raw materials.

[0088] Step 3: When the hardness tester detects that the molded blank has reached the preset hardness threshold, the control device controls the molding and cutting section to demold the molded blank, allow it to undergo static hardening, and then cut it to obtain a fixed-length block blank. The static hardening temperature is 50℃, and the time is 3 hours.

[0089] Step 4: When the cutting is detected as complete, the control device controls the autoclaving section to introduce high-temperature, high-pressure saturated steam into the fixed-length block blank for autoclaving to obtain the finished block. The autoclaving temperature is 200℃, the pressure is 1.3MPa, and the time is 12 hours.

[0090] Step 5: The control device controls the palletizer and packer to stack and package the autoclaved finished blocks.

[0091] During the above process, the control device monitors and controls the operating parameters of each section in real time via an industrial Ethernet or fieldbus through a batching control module, a stirring control module, a cutting control module, and a curing control module. At the same time, the parameter linkage adjustment module adjusts the autoclaving parameters in real time according to the actual proportion data fed back by the batching control module, ensuring that the entire production line operates automatically and continuously according to the preset sequence.

[0092] Although the present invention has been described in detail above with reference to preferred embodiments, those skilled in the art will understand that various modifications and substitutions can be made to these embodiments without departing from the principles and spirit of the invention. For example, the type of hinge, the specific form of the locking device, and the selection of materials can all be adjusted according to actual needs. Therefore, the scope of protection of the present invention should be defined by the content of the appended claims.

Claims

1. A fully automated production system for autoclaved aerated concrete (AAC) blocks, characterized in that, include: The raw material pretreatment section is used to crush and grind lumpy siliceous raw materials and lime to obtain pretreated raw materials; The batching and casting section is located at the discharge end of the raw material pretreatment section. It is used to mix and stir the pretreated raw materials with cement, gypsum, water and aluminum powder in a set ratio to form a foaming slurry. The foaming slurry is then poured into a mold and left to stand to generate gas and form a molded blank. The forming and cutting section is located at the discharge end of the batching and casting section. It is used to statically harden the formed blank and cut the hardened blank to obtain fixed-length block blanks. The autoclaving section is located at the discharge end of the forming and cutting section. It is used to introduce high-temperature and high-pressure saturated steam into the fixed-length block blanks for autoclaving to obtain finished blocks. And a control device, which is signal-connected to the raw material pretreatment section, the batching and casting section, the molding and cutting section and the autoclaving section respectively; The control device includes a preset timing control logic. The timing control logic triggers the raw material pretreatment section, batching and casting section, molding and cutting section and autoclaving section to start, run and stop in a preset sequence according to the running rhythm and material status of each section.

2. The fully automated production system for autoclaved aerated concrete blocks according to claim 1, characterized in that, A material level sensor is installed at the discharge end of the raw material pretreatment section, a position sensor is installed at the casting mold of the batching and casting section, and a hardness tester is installed at the static stopping equipment of the forming and cutting section. The material level sensor, position sensor, and hardness tester are respectively connected to the control device via signal transmission.

3. The fully automated production system for autoclaved aerated concrete blocks according to claim 1, characterized in that, The control device also includes a parameter linkage adjustment module, the batching and pouring section includes a batching control module, and the autoclaving section includes a curing control module; The parameter linkage adjustment module is connected to the batching control module and the curing control module respectively; The parameter linkage adjustment module calculates and adjusts the setting values ​​of the curing parameters for the autoclaving section based on the actual proportioning data fed back by the batching control module. When the actual silicon raw material ratio is higher than the preset value, the parameter linkage adjustment module controls the curing control module to extend the heat preservation time of autoclaving and / or increase the curing temperature. When the actual silicon raw material ratio is lower than the preset value, the parameter linkage adjustment module controls the curing control module to shorten the heat preservation time of autoclaving and / or reduce the curing temperature.

4. The fully automated production system for autoclaved aerated concrete blocks according to claim 1, characterized in that, The batching and pouring section includes a mixer, and a consistency meter is installed at the mixer. The consistency meter is connected to a control device via a signal connection. The control device calculates the expected hardening rate of the preform based on the consistency value, and dynamically adjusts the static dwell time setting of the forming and cutting section according to the expected hardening rate: When the consistency value is higher than a preset range, the static pause time is shortened; when the consistency value is lower than a preset range, the static pause time is extended.

5. The fully automated production system for autoclaved aerated concrete blocks according to claim 1, characterized in that, The batching and casting section is equipped with a circular track, on which multiple sets of casting molds are mounted, and the multiple sets of casting molds circulate along the circular track. Multiple station detection sensors are installed on the circular track, and each station detection sensor is connected to the control device for signal transmission. The control device acquires the position information of each group of casting molds on the circular track in real time through the detection sensors at each workstation, and controls the driving mechanism of each workstation section according to the preset mold flow scheduling rules. The preset mold flow scheduling rules include: priority rules for pouring stations, allocation rules for stationary stops, and queuing rules for cutting stations.

6. The fully automated production system for autoclaved aerated concrete blocks according to claim 1, characterized in that, The autoclaving section is equipped with multiple autoclaves. The feeding end of the autoclave section is equipped with an inlet shuttle car, and the discharging end is equipped with an outlet shuttle car. The autoclave is equipped with an autoclave door status detection sensor and an autoclave internal pressure detection sensor. The autoclave inlet shuttle car, autoclave outlet shuttle car, autoclave door status detection sensor and autoclave internal pressure detection sensor are respectively connected to the control device. The control device automatically assigns inlet and outlet tasks based on the state of the autoclave door and the pressure inside the autoclave.

7. The fully automated production system for autoclaved aerated concrete blocks according to claim 1, characterized in that, The raw material pretreatment section includes a crusher, a ball mill, a silo, and a feeder connected in sequence; The batching and casting section includes a metering device, a mixer, and a casting mold; The forming and cutting section includes a stationary equipment and a cutting machine; The autoclaving section includes an autoclave and a boiler.

8. The fully automated production system for autoclaved aerated concrete blocks according to claim 1, characterized in that, The discharge end of the autoclaving section is equipped with a palletizer and a packaging machine; Both the raw material pretreatment section and the batching and casting section are equipped with dust removal devices.

9. A fully automated production method for autoclaved aerated concrete (AAC) blocks, characterized in that, Includes the following steps: Step 1: The control device controls the raw material pretreatment section to crush and grind the lumpy siliceous raw materials and lime according to the preset timing control logic to obtain pretreated raw materials. Step 2: When the pre-treated raw material reaches the preset material level, the control device controls the batching and pouring section to mix the pre-treated raw material with cement, gypsum, water and aluminum powder in the set ratio to form a foaming slurry. The foaming slurry is then poured into the mold and left to stand to generate gas and form a molded blank. Step 3: When the molded blank reaches the preset hardness threshold, the control device controls the molding and cutting section to demold the molded blank, allow it to stand still for hardening, and then cut it to obtain a fixed-length block blank. Step 4: When the cutting is detected to be complete, the control device controls the autoclaving section to introduce high-temperature and high-pressure saturated steam into the fixed-length block blank for autoclaving to obtain the finished block.

10. The fully automated production method for autoclaved aerated concrete blocks according to claim 9, characterized in that, In step two, the set proportions are: lime 10%-20%, cement 5%-15%, gypsum 2%-5%, siliceous raw materials 60%-80%, and aluminum powder added at 0.05%-0.15% of the total mass of all raw materials. In step three, the static curing temperature is 40℃-50℃, and the time is 1-3 hours; In step four, the autoclaving temperature is 180℃-200℃, the pressure is 1.0MPa-1.3MPa, and the time is 8-12 hours.

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