Method and arrangement for providing a complete row of mineral fiber slabs

Abstract

The present invention relates to a method and arrangement for providing a complete row of mineral fiber slabs in a mineral fiber slab production process. In this method, a complete row of mineral fiber slabs is transported in the production process, with each row containing a predetermined number of mineral fiber slabs. Defective slabs are removed, thereby forming one or more incomplete rows of mineral fiber slabs. The complete and incomplete rows are transported on a conveyor along a common path in a first direction of movement, with one or more replacement slabs inserted into each incomplete row from at least one slab buffer before the stacker. The incomplete rows are thus made into a complete row containing a predetermined number of mineral fiber slabs.

Description

Technical Field

[0001] The present invention relates to a method and arrangement for providing a complete row of mineral fiber slabs as described in the preamble of the appended independent claims.

[0002] Mineral fibers are produced by melting a suitable mineral-rich raw material such as diabase, dolomite, limestone or slag in a melting furnace. The resulting melt is led to a fiberizing device where the mineral fibers are formed. A binder is added to the fibers and the fibers are collected to form a continuous mineral fiber web. After the desired product forming process, the continuous mineral fiber web is then transferred through a curing furnace where the binder is cured. After the curing furnace, the edges of the continuous web are usually cut off and the continuous web is cut into mineral fiber slabs in the transverse and longitudinal directions. The mineral fiber slabs are then stacked and packaged.

[0003] The production process of the mineral fiber slabs is continuous, which means that the continuous mineral fiber web and the cut mineral fiber slabs continuously advance through a continuous processing step from the collection of the fibers to the stacking of the slabs without pause or interruption. The fiber web and the mineral fiber slabs are transferred through the process by using a series of conveyors and the like. The mineral fiber web is typically cut into two, three or more adjacent rows of mineral fiber slabs which are transferred to the stacking. In the stacking process, the rows of slabs are placed on top of each other or stacked to form a stack of two, three or more slabs, and the stack contains a predetermined suitable number of slabs in preparation for packaging.

[0004] Before stacking, mineral fiber slabs undergo quality control. Incomplete or defective slabs must be discarded from the process. However, if only one slab is removed from a row, the row becomes incomplete, i.e., does not contain the correct number of slabs, which causes problems with stacking. Traditionally, if one slab in a row is considered defective, the entire row is discarded. This naturally increases the amount of waste generated during the process and reduces production efficiency.

[0005] European Patent No. 3615234 proposes a method and apparatus for removing defective mineral wool slabs. The proposed solution involves separating incomplete and complete rows onto different conveyor paths. The incomplete rows are sent to a buffer table where complete rows are assembled from defect-free slabs. This method uses multiple conveyor paths that must work together. This increases the complexity and spatial requirements of the proposed system.

[0006] Therefore, a simple, reliable, and effective solution is still needed to provide a complete row of mineral fiber slabs in the production process of mineral fiber slabs.

[0007] The objective of this invention is to minimize, or in some cases eliminate, the drawbacks present in the prior art.

[0008] Another object of the present invention is to provide a simple, versatile, and effective method for providing a complete row of mineral fiber slabs in the production process of mineral fiber slabs.

[0009] Another object of the present invention is to provide an arrangement that does not require much space and is easy to operate in order to provide a complete row of mineral fiber slabs in the mineral fiber slab production process.

[0010] These objectives are achieved by the present invention having the features described below in the feature portion of the independent claim. Some preferred embodiments of the present invention are presented in the dependent claims.

[0011] The embodiments referred to herein, where applicable, always relate to both all aspects, methods, and arrangements of the present invention, even if not specifically referred to otherwise.

[0012] In a typical method according to the present invention for providing a complete row of mineral fiber slabs in the production process of mineral fiber slabs, the method is as follows: - In the production process, the transfer of a complete row of mineral fiber slabs, each row containing a predetermined number of mineral fiber slabs, - During transport, defective slabs are removed from a complete row of mineral fiber slabs, thereby forming one or more incomplete rows of mineral fiber slabs. - To transport complete rows and incomplete rows of mineral fiber slabs along a common path on a conveyor in a first direction of movement, -The process includes inserting one or more substitute slabs from at least one slab buffer into each incomplete row before the stacker, thereby transforming an incomplete row of mineral fiber slabs into a complete row containing a predetermined number of mineral fiber slabs.

[0013] A typical arrangement according to the present invention for providing a complete row of mineral fiber slabs in the production process of mineral fiber slabs, wherein a complete row of mineral fiber slabs containing a predetermined number of mineral fiber slabs is transported, defective slabs are removed from the complete row of mineral fiber slabs, resulting in one or more incomplete rows of mineral fiber slabs, and the arrangement is, - A conveyor for transporting complete rows and incomplete rows of mineral fiber slabs along a common path in a first direction of movement, - At least one slab buffer for the alternative slab, - comprising at least one insertion means for inserting one or more alternative slabs from a slab buffer into an incomplete column of slabs.

[0014] Surprisingly, it has been found that a complete row of mineral fiber slabs can be easily and effectively obtained by transporting a complete row of mineral fiber slabs and an incomplete row of mineral fiber slabs along a common path to a stacker, preferably from the cutting process to stacking, while inserting a replacement slab into the incomplete row from at least one slab buffer during transport to the stacker. There is no need to change the paths of the complete and incomplete rows of mineral fiber slabs, thereby saving considerable space. The present invention is thus suitable for retrofitting to existing production lines, as only space for the insertion means and slab buffers is required. Furthermore, the present invention can be easily adopted in different production settings where the number of slabs in a row is variable. The number of slab buffers required for the effective and rapid insertion of replacement slabs can be easily adapted to the variable production setting. Moreover, since the complete and incomplete rows of mineral fiber slabs are transported to the stacker along a common path, the coordination and difficulties associated with operating several cooperating conveyor paths can be avoided.

[0015] In the production process of mineral fiber slabs, a mineral fiber web is cut longitudinally and transversely, thereby forming a complete row of mineral fiber slabs. A continuous mineral fiber web is cut longitudinally and transversely in the direction of movement of the web by using a cutting means. Such cutting means are known to those skilled in the art. In this way, the cutting process creates the original complete row of mineral fiber slabs, and the continuous mineral fiber web is cut at least longitudinally and transversely as viewed in the direction of movement of the web. Typically, the edges of the continuous mineral web are also cut off in the cutting process. The continuous web is thus transformed in the cutting process into an original complete row of essentially rectangular mineral fiber slabs, each original complete row containing a predetermined number of mineral fiber slabs. The predetermined number of mineral fiber slabs in a complete row is preferably 2 to 4 or 2 to 3 slabs, but can vary depending on the width of the production line and the desired dimensions of the final product. According to one embodiment, the predetermined number of mineral fiber slabs in a complete row is 2 or 3 slabs. A continuous web of mineral fibers can be cut into rows containing four or five slabs, or possibly more. The original complete row of mineral fiber slabs is then further transported towards a stacker in the mineral fiber slab production process by a transport means such as a conveyor or rotary roller.

[0016] Following the cutting process, the mineral fiber slab production process includes a defect detection process and a defective slab removal process. This means that during the transfer of the mineral fiber slabs from the cutting process to the stacker, defective slabs are detected by detection means and removed from the original complete row of mineral fiber slabs by removal means. Reasons for removal may include visual defects, material defects, incorrect size, incorrect weight, incomplete curing, or any other defects that make the mineral fiber slab unsuitable for stacking, packaging, and / or end use. Defective mineral fiber slabs may be detected by any suitable method in the detection process of the production process. The arrangement according to the present invention may include detection means, such as sensors or arrays of sensors, for detecting defective mineral fiber slabs and / or incomplete rows of mineral fiber slabs. The detection means may include, for example, a visual sensor, a temperature sensor, a camera such as an IR camera, and / or weighing means. The defective mineral fiber slab detection process may be automated or performed according to the instructions of an operator.

[0017] Defective mineral fiber slabs are removed by the use of removal means. In the removal process, the removal of defective mineral fiber slabs may be carried out by any suitable removal means available that is configured to remove defective slabs. For example, defective mineral fiber slabs may be removed by using a removal conveyor equipped with adjacent swivelable parallel conveyors. The number of adjacent parallel conveyors is equal to the number of mineral fiber slabs in the complete row, and as a result, each slab in the row is carried and transported by its own swivelable conveyor. If a defective slab is detected in the detection process, a signal is generated automatically or manually and transported to the control unit of the removal conveyor. The adjacent parallel conveyor carrying the defective slab is swiveled downward or upward, preferably downward, thereby removing the defective mineral fiber slab from the row of slabs. Alternatively, the removal means may include a slab grabber, etc., attached to a large surface of the defective slab, which can lift the defective slab from the row of slabs. Removing a defective slab generates one or more incomplete rows of the original, defect-free mineral fiber slab. Therefore, these incomplete rows of defect-free mineral fiber slabs contain at least one empty space within the row from which the defective slab was removed.

[0018] After a removal process in which defective mineral fiber slabs are removed, complete rows and incomplete rows of mineral fiber slabs are transported on a conveyor along a common path to a stacker in a first direction of movement. In the context of the present invention, the term “conveyor” may include one conveyor or a series of several conveyors arranged sequentially before and after each other. The term “common path” means that complete rows and incomplete rows of mineral fiber slabs are transported sequentially to the stacker on the same conveyor. This means that complete rows and incomplete rows are transported sequentially to the stacker along a common path on the conveyor. To make an incomplete row of mineral fiber slabs a complete row, the required number of replacement slabs are inserted into each incomplete row from at least one slab buffer in front of the stacker. The arrangement according to the present invention therefore comprises at least one slab buffer for replacement slabs, positioned in front of the stacker.

[0019] Preferably, the replacement slabs are inserted one by one into the incomplete rows.

[0020] This arrangement can comprise multiple slab buffers, for example, two or three slab buffers, arranged continuously along the conveyor in a first direction of movement. By using several slab buffers, it is possible to insert several alternative slabs one by one into a single incomplete row. By using multiple slab buffers, the size required for each slab buffer can also be reduced, which is particularly advantageous when the arrangement according to the present invention is retrofitted to an existing production line where available space may be limited.

[0021] According to one embodiment of the present invention, at least one slab buffer is located or positioned next to the conveyor in a first direction of movement, where complete and incomplete columns are transported. The slab buffer may be a buffer table having capacity for at least one alternate slab, but may also have capacity for two or three slabs. The slab buffer may be positioned to hold a stack of alternate slabs, with the top slab of the stack being used to insert into the empty space of the incomplete column.

[0022] If the arrangement includes two or more slab buffers, the slab buffers can be placed on both sides of the conveyor, adjacent to the conveyor. In this way, the insertion of alternative slabs can be performed more quickly, especially to create a complete column with three or more slabs. The slab buffers can be placed alternately on both sides of the conveyor. It is also possible to place all slab buffers on the same side of the conveyor.

[0023] The arrangement according to the present invention is positioned in front of the stacker and comprises at least one insertion means for inserting one or more replacement slabs from a slab buffer into an incomplete row of slabs. The replacement slabs may be inserted into the incomplete row by any suitable method and using any suitable insertion means. For example, the replacement slab can be lifted from the slab buffer into the empty space of the incomplete row by using a lifting means or slab grabber that is attached to a large surface of the replacement slab and can lift it into the incomplete row. According to a preferred embodiment, the replacement slab may be inserted into the incomplete row by a lateral feeder or lateral pusher that pushes the replacement slab laterally with respect to a first direction of movement. Thus, the insertion means preferably comprises a lateral feeder or pusher that moves laterally with respect to a first direction of movement and is arranged to push the replacement slab laterally onto the conveyor. Thus, the lateral feeder is arranged to move in a second direction laterally with respect to a first direction of movement.

[0024] The replacement slab can be directly inserted into the empty space of the incomplete column, or the replacement slab can fill the empty space by pushing the original, defect-free slab of the incomplete column, or the replacement slab can replace the original, defect-free slab of the column.

[0025] Typically, each slab buffer is associated with one insertion device. However, it is possible for two or more insertion devices to be associated with a single slab buffer, especially when an insertion device such as a slab grabber lifts a replacement slab from the slab buffer into an incomplete column.

[0026] By removing an incomplete row of mineral fiber slabs from a conveyor to a slab buffer, a replacement slab can be obtained within the slab buffer, thereby creating a slab buffer. This means that the insertion means may be configured to remove one or more incomplete rows of mineral fiber slabs from a conveyor to a slab buffer, with the removed slabs becoming replacement slabs for the next incomplete row. For example, when the slab buffer is empty, i.e., when no replacement slabs are placed in the slab buffer, the next incomplete row on the conveyor can be removed from the conveyor and transferred to the slab buffer. Thus, the correct slab of an incomplete row becomes a replacement slab that can be inserted into a subsequent incomplete row. According to another embodiment of the present invention, the slab buffer may be created independently, for example, from previously created correct mineral fiber slabs, which can be used as replacement slabs.

[0027] According to one embodiment, the insertion means can be configured to receive a signal when at least one defective mineral fiber slab is removed in the removal process and an incomplete row of mineral fiber slabs is formed. The insertion means may comprise a control unit configured to receive a signal each time an adjacent parallel conveyor of the removal conveyor is rotated for the removal of defective mineral fiber slabs. The generated signal can include not only information regarding the formation of the incomplete row but also information regarding the position of the formed empty spaces within the incomplete row. If there are two or more insertion means in the arrangement, they may all be communicatively connected to each other. For example, all the insertion means may be connected to a central control unit, and the central control unit is configured to calculate an optimal pattern for inserting replacement slabs into the incomplete row based on the signals received from the removal conveyor. According to one preferred embodiment, this arrangement comprises two slab buffers and two insertion means communicatively connected to each other.

[0028] According to one embodiment of the present invention, this arrangement comprises a stacking table arranged between the stacker and the slab buffer, behind the conveyor for transporting complete and incomplete rows, when viewed in the first moving direction. The complete rows of mineral fiber slabs and the incomplete rows of mineral fiber slabs are conveyed along a common path to the stacking table located between the stacker and the slab buffer, when viewed in the first moving direction. The replacement slabs are inserted into the incomplete rows on the stacking table by using any suitable insertion means as described above, before the rows are conveyed to the stacker. According to one preferred embodiment, one or more replacement slabs are inserted into the incomplete rows of mineral fiber slabs on the stacking table by a lateral feeder to form complete rows of mineral fiber slabs, and then the complete rows of mineral fiber slabs are pushed by the lateral feeder to the stacker. Thus, the lateral feeder can be used not only for inserting replacement slabs into the incomplete rows but also for transporting the complete rows to the stacker.

Brief Description of the Drawings

[0029] Some embodiments of the present invention are described in the attached schematic diagrams.

[0030] [Figure 1] One embodiment of the present invention described above is shown. [Figure 2] An embodiment of the slab buffer and the insertion means as viewed from the first moving direction is shown. [Figure 3] One embodiment of the present invention having the two slab buffers described above is shown. [Figure 4] Another embodiment of the present invention described above is shown.

[0031] FIG. 1 shows one embodiment of the present invention described above. The continuous mineral fiber web 1 is cut along the longitudinal cutting line 1' and the transverse cutting line 1'' using the schematically shown cutting means 11, 11'. The moving direction of the mineral fiber web 1 is indicated by the arrow A in FIG. 1. The cutting of the mineral fiber web 1 forms the original complete rows 2, 2' of mineral fiber slabs. In the embodiment shown in FIG. 1, each complete row includes three mineral fiber slabs. In the original row 2, two of the slabs contain defects indicated by dots.

[0032] Possible defects in the mineral fiber slabs are detected by the detecting means 3. When a defect is detected, the defective slab is removed using a removing means (not shown), and incomplete rows 4, 4' of mineral fiber slabs are formed. The complete rows 2, 2', 5 and the incomplete rows 4, 4' of mineral fiber slabs are conveyed in the moving direction A along a common path on the same conveyor.

[0033] The alternative slab 6 is inserted from the slab buffer 7 into the incomplete row 4' to make the incomplete row 4' of mineral fiber slabs a complete row by using the insertion means 8 that pushes the alternative slab 6 in a direction transverse to the first moving direction A. The next alternative slab 6' located in the slab buffer 7 is shown by a dashed line. The reciprocating lateral movement of the insertion means 8 in the second direction transverse to the first direction is indicated by a double-headed arrow.

[0034] Figure 2 shows one embodiment of a slab buffer and insertion means as viewed from a first direction of movement. An incomplete row 24 containing one mineral fiber slab 100 is transported on a conveyor 101. A slab buffer 27 containing a stack of alternative slabs 26, 26' is positioned next to the conveyor 101. A lateral feeder 28 functions as an insertion means and is positioned to push the alternative slab 26'' laterally from the stack onto the conveyor 101, thereby forming a complete row containing two mineral fiber slabs 100, 26''.

[0035] Figure 3 shows an embodiment of the present invention having two slab buffers, viewed from above. In the illustrated embodiment, the direction of movement of the slab rows is indicated by arrow A, and a complete row of mineral fiber slabs 32 includes three adjacent slabs. Two slab buffers 37, 37', having lateral feeders 38, 38' as insertion means, are positioned adjacent to the conveyor 101. The slab buffers 37, 37' are positioned on both sides of the conveyor 101 when viewed in the direction of movement A. The lateral feeders 38, 38' insert replacement slabs 36, 36' into the incomplete row of mineral fiber slabs 34, 34', where a complete row of slabs is formed.

[0036] Figure 4 shows a further embodiment of the present invention as viewed from above. The direction of movement of the slab is indicated by arrow A. The slab buffer 37 is located next to the stacking table 40, which is positioned behind the conveyor 101. The stacking table 40 is positioned between the stacker 41 and the slab buffer 37. The lateral feeder 48 functions as an insertion means and also as a pusher to transport a complete row from the stacking table 40 to the stacker 41. When an incomplete row arrives at the stacking table 40, the lateral feeder 48 is positioned to first insert a replacement slab 46 into the incomplete row, and then push the complete row to the stacker 41 to form two stacks 42, 42' of mineral fiber slabs.

[0037] Although the present invention has been described with reference to what appears to be the most practical and preferred embodiment at present, it should be understood that the present invention is not to be limited to the embodiments described above, and that the present invention is intended to encompass different modifications and equivalent technical solutions within the scope of the appended claims.

Claims

1. A method for providing a complete row of mineral fiber slabs in the production process of mineral fiber slabs, wherein the method is - In the production process described above, the transfer of a complete row of mineral fiber slabs, each row containing a predetermined number of mineral fiber slabs, - During the transfer, the process includes removing defective slabs from a complete row of mineral fiber slabs, thereby forming one or more incomplete rows of mineral fiber slabs. - To transport the complete row and the incomplete row of mineral fiber slabs along a common path on the conveyor in a first direction of movement, A method comprising inserting one or more substitute slabs from at least one slab buffer into each incomplete row in front of the stacker, thereby making the incomplete row of mineral fiber slabs a complete row containing a predetermined number of mineral fiber slabs.

2. The method according to claim 1, characterized in that at least one slab buffer is positioned next to the conveyor as viewed in the first direction of movement, and the replacement slab is inserted into the incomplete row by a lateral feeder that pushes the replacement slab laterally with respect to the first direction of movement.

3. The method according to claim 1 or 2, characterized in that at least one slab buffer is created by removing an incomplete row of mineral fiber slabs from the conveyor to the slab buffer.

4. The method according to claim 1, 2, or 3, characterized in that the complete row and the incomplete row of mineral fiber slabs are transported along the common path to a stacking table located between the stacker and the slab buffer, as viewed in the first direction of movement.

5. The method according to claim 4, characterized in that one or more alternative slabs are inserted by the lateral feeder into an incomplete row of the mineral fiber slabs on the stacking table to form a complete row of the mineral fiber slabs, and then the complete row of mineral fiber slabs is pushed into the stacker by the lateral feeder.

6. The method according to any one of claims 1 to 5, characterized in that the predetermined number of mineral fiber slabs in the complete row are two or three slabs.

7. An arrangement for providing a complete row of mineral fiber slabs for a mineral fiber slab production process, wherein a complete row of mineral fiber slabs containing a predetermined number of mineral fiber slabs is transported, and the arrangement is, - Removal means configured to remove defective slabs from a complete row of mineral fiber slabs, resulting in one or more incomplete rows of mineral fiber slabs, - A conveyor for transporting complete rows and incomplete rows of mineral fiber slabs along a common path in a first direction of movement, - At least one slab buffer for the alternative slab, - At least one insertion means for inserting one or more alternative slabs from the slab buffer into the incomplete row of slabs, An arrangement that includes such features.

8. The arrangement according to claim 7, characterized in that at least one slab buffer is positioned next to the conveyor when viewed in the first direction of movement.

9. The arrangement according to claim 8, wherein the insertion means comprises a lateral feeder positioned to push the alternative slab laterally onto the conveyor.

10. The arrangement according to claim 7, 8, or 9, characterized in that the insertion means is arranged to remove one or more incomplete rows of mineral fiber slabs from the conveyor to the slab buffer.

11. The arrangement according to any one of claims 7 to 10, characterized in that, viewed in the first direction of movement, the arrangement includes a stacking table positioned behind the conveyor and between the stacker and the slab buffer.

12. The arrangement according to any one of claims 7 to 11, characterized in that the slab buffer is a buffer table having capacity for at least one alternative slab.

13. The arrangement according to any one of claims 7 to 12, characterized in that the arrangement comprises detection means for detecting defective mineral fiber slabs and / or incomplete rows of mineral fiber slabs.

14. The arrangement according to any one of claims 7 to 13, characterized in that the insertion means is configured to receive a signal when at least one defective slab is removed and an incomplete row of mineral fiber slabs is formed.

15. The arrangement according to any one of claims 7 to 14, characterized in that it comprises two slab buffers and two insertion means connected to each other in a communicative manner.

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