Module block installation device and module block installation method

Abstract

To provide an installation device of a module block which can reduce load swing quickly even if load swing occurs.SOLUTION: An installation device of a module block which installs a module block constituted of a plurality of bricks onto installed bricks has: a pair of gripping parts which grips a module block while sandwiching a side face of the block; a frame body which supports the pair of gripping parts; a guide part which is provided protruding below from the pair of gripping parts; and a load swing prevention part which is provided protruding from the pair of gripping parts further below the guide part.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a modular block installation device and a modular block installation method used in the construction or repair of a coke oven. [Background technology]

[0002] Metallurgical coke used in steelmaking is produced by carbonizing coal in a coke oven. A coke oven is composed of carbonization chambers and combustion chambers that supply heat to the carbonization chambers, arranged alternately across the width of the oven. In a coke oven, heat is supplied from the combustion chamber to the carbonization chamber through standard refractories such as firebricks that separate the two chambers, carbonizing the coal. Some coke ovens have more than 100 carbonization chambers, making them gigantic brick structures with a total length of more than 100 meters and a height of more than 10 meters.

[0003] Coke ovens have now become obsolete after 20 to 30 years of operation, and there is an urgent need to repair existing coke ovens and build new ones. Coke ovens are constructed by combining a complex array of standard refractory materials of various shapes and sizes. Due to the complexity of the shapes of the standard refractory materials, coke oven construction has long been carried out by kiln builders, who lay the materials by hand.

[0004] Since this type of manual construction takes a long time, a prefabricated construction method has been developed to shorten the construction time for coke ovens.The prefabricated construction method involves stacking multiple bricks to a specified size in an easy-to-work location away from the coke oven construction site, combining them with mortar to form modular blocks, and then stacking these modular blocks to build the coke oven.

[0005] As a technology related to prefabrication, Patent Document 1 discloses a coke oven construction device that has a gripping part that grips a brick block made up of multiple bricks and a pair of guide parts that protrude downward from the gripping part. According to Patent Document 1, by aligning the existing brick so that it is sandwiched between the guide parts, it is possible to install the brick block on top of the existing brick without causing individual differences in installation accuracy. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Patent Application Publication No. 2019-163351 Summary of the Invention [Problem to be solved by the invention]

[0007] Load swing occurs during the process of transporting modular blocks above the existing bricks. When load swing occurs in modular blocks, even when the coke oven construction device of Patent Document 1 is used, it is necessary to wait until the load swing amount becomes small enough to be guided by the guide section, and this waiting time results in an extended construction period. The present invention was made in consideration of these problems with the prior art, and its purpose is to provide a modular block installation device that can quickly stop load swing even if it occurs. [Means for solving the problem]

[0008] The means for solving the above problems are as follows. [1] A modular block installation device that installs a modular block consisting of multiple bricks on top of existing bricks, the modular block installation device having a pair of gripping parts that clamp and grip the sides of the modular block, a frame that supports the pair of gripping parts, a guide part that protrudes downward from the pair of gripping parts, and a load sway prevention part that protrudes further downward from the pair of gripping parts. [2] The module block installation device described in [1], wherein the guide portion is provided on one of the pair of gripping portions, and the load sway prevention portion is provided on the other of the pair of gripping portions. [3] The module block installation device described in [1] or [2], wherein the load sway prevention part can withstand a pushing force of at least 5 kN. [4] The modular block installation device according to [1] or [2], wherein the lower end of the guide section is provided with an inclined surface whose inner surface approaches the outer surface as it goes downward. [5] The modular block installation device described in [3], wherein the lower end of the guide portion has an inclined surface whose inner surface approaches the outer surface as it goes downward. [6] A modular block installation device as described in [4], wherein the length of the inclined surface projected horizontally is 100 mm or more, and the length projected vertically is at least twice the length projected horizontally. [7] A modular block installation device as described in [5], wherein the length of the inclined surface projected horizontally is 100 mm or more, and the length projected vertically is at least twice the length projected horizontally. [8] The modular block installation device described in [4], wherein a buffer material is provided on the inclined surface. [9] The modular block installation device described in [5], wherein a buffer material is provided on the inclined surface.

[10] The modular block installation device described in [6], wherein a buffer material is provided on the inclined surface.

[11] The modular block installation device described in [7], wherein a buffer material is provided on the inclined surface.

[12] The module block installation device described in [1] or [2], wherein the guide portion can move in a direction away from the gripping portion.

[13] A method for installing a modular block using the modular block installation device described in [1] or [2], wherein the load swing prevention part is collided with the side of the existing brick to reduce load swing, and then the modular block is installed on top of the existing brick. [Effects of the Invention]

[0009] According to the present invention, the load swing prevention unit can reduce load swings that occur in the modular block installation device, thereby shortening waiting times due to load swings. This shortens the time required to install modular blocks on existing bricks compared to conventional methods, thereby shortening the construction and repair times for coke ovens. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a schematic diagram showing an example of a modular block installation device according to this embodiment. [Figure 2] FIG. 2 is a schematic diagram of the guide portion. [Figure 3] FIG. 3 is a schematic diagram of the load sway prevention unit. [Figure 4] FIG. 4 is a schematic diagram showing a state in which a module block is gripped by a module block installation device. [Figure 5] FIG. 5 is a schematic diagram showing the process from gripping the module block to placing it on top of the existing bricks. DETAILED DESCRIPTION OF THE INVENTION

[0011] The present invention will be described below through embodiments of the present invention. In the following embodiments, the construction of a coke oven will be described as an example, but the present invention is not limited to this, and can also be applied to the repair of a coke oven using modular blocks and the construction of an oven other than a coke oven.

[0012] The modular block held by the modular block installation device according to this embodiment is constructed by stacking a plurality of bricks (standard refractories or unstandard refractories). The multiple standard or unstandard refractories that make up the modular block are integrated by mortar applied to the joints between each refractory.

[0013] The modular block is, for example, a rectangular parallelepiped with a height of 300 mm to 2000 mm, a longitudinal length of 500 mm to 3000 mm, and a transverse length of 800 mm to 1500 mm. The size of the modular block may be determined based on ease of work and the dimensions of the coke oven walls to be constructed.

[0014] Figure 1 is a schematic diagram showing an example of a modular block installation device 10 according to this embodiment. The modular block installation device 10 includes a frame 12 that surrounds the modular block, a pair of gripping sections 14a, 14b that grip the sides of the modular block, two guide sections 16, and a load sway prevention section 18. In explaining Figure 1, the directions shown in the upper right corner will be referred to as the front-to-back, left-to-right, and up-to-down directions. These directions are the same in Figures 1 to 5.

[0015] The frame 12 is sized to correspond to the size of the module block to be gripped. The grippers 14a, 14b are supported at the lower left-right end of the frame 12 so as to be movable relative to the frame 12 in a direction approaching each other. The frame 12 and the grippers 14a, 14b are made of, for example, steel plate (SS400). When gripping the sides of the module block, the grippers 14a, 14b move toward each other, and when releasing the module block, the grippers 14a, 14b move away from each other. When the bolts 19 are tightened, the grippers 14a, 14b move toward each other, and when the bolts 19 are loosened, the grippers 14a, 14b move away from each other.

[0016] The guide portion 16 is a plate-like member provided at the lower end of one of the pair of gripping portions, the gripping portion 14a. In the module block installation device 10 according to this embodiment, the two guide portions 16 are provided spaced apart in the front-to-rear direction. The guide portion 16 is fixed to the gripping portion 14a with bolts (not shown). The width of the guide portion 16 is preferably 50 mm or more, and it preferably protrudes 100 mm or more below the lower end of the gripping portion 14a.

[0017] FIG. 2 is a schematic diagram of the guide portion 16. As shown in FIG. 2, the lower end of the guide portion 16 is provided with an inclined surface whose inner surface approaches the outer surface as it extends downward. In this embodiment, the surface facing the module block to be gripped (to the right in FIG. 2) is the inner surface, and the surface opposite the inner surface (to the left in FIG. 2) is the outer surface. The inclined surface of the guide portion 16 preferably has a horizontally projected length a of 100 mm or more, and a vertically projected length b of at least twice the horizontally projected length a. In addition, it is preferable that a buffer material be provided on the inclined surface of the guide portion 16. This prevents the inclined surface from colliding with existing bricks and damaging them. The guide portion 16 is made of, for example, resin such as polyvinyl chloride, hard rubber, or steel plate, and the buffer material is made of, for example, polystyrene foam, sponge, or hard rubber.

[0018] Referring again to Figure 1, the load sway prevention part 18 is a plate-like member provided at the lower end of the other of the pair of gripping parts, the gripping part 14b. In the modular block installation device 10 according to this embodiment, for example, one load sway prevention part 18 is provided and fixed to the gripping part 14b with a bolt 15. The width of the load sway prevention part 18 is preferably 50 mm or more, and the load sway prevention part 18 preferably protrudes downward from the lower end of the guide part 16 by a distance of 50 mm or more.

[0019] FIG. 3 is a schematic diagram of the load sway prevention unit 18. As shown in FIG. 3, the lower end of the load sway prevention unit 18 may also be provided with an inclined surface whose inner surface approaches the outer surface as it goes downward. In this embodiment, the surface facing the module block to be gripped (leftward in FIG. 3) is the inner surface, and the surface opposite the inner surface (rightward in FIG. 3) is the outer surface. It is preferable that the length c of the inclined surface of the load sway prevention unit 18 projected horizontally is 100 mm or more, and that the length d projected vertically is at least twice the length c projected horizontally. It is also preferable that the load sway prevention unit 18 is provided with a cushioning material. The load sway prevention unit 18 is made of, for example, steel plate (SS400), and the cushioning material is made of, for example, hard rubber, polystyrene foam, or sponge.

[0020] Fig. 4 is a schematic diagram showing a state in which a modular block 20 is gripped by the modular block installation device 10. As shown in Fig. 4, the modular block 20 is gripped by tightening the bolts 19, which moves the gripping parts 14a, 14b toward each other and clamps the left and right sides of the modular block 20 between the gripping parts 14a, 14b. The modular block installation device 10 is lifted by a crane (not shown) equipped with gripping devices that grip the modular block installation device 10 from the left and right, and is moved from the site where the modular blocks 20 are manufactured to the site where the coke oven is being constructed.

[0021] Next, a method for installing a modular block 20 on existing bricks 30 using the modular block installation device 10 will be described. The existing bricks 30 are, for example, refractories installed to form the furnace walls of a coke oven. Fig. 5 is a schematic diagram showing each stage from gripping the modular block 20 to installing it on the existing bricks 30.

[0022] 5(a) is a schematic diagram showing a state in which a modular block 20 held by a modular block installation device 10 is moved above existing bricks 30. The modular block 20, manufactured at a location away from the coke oven construction site, is moved, while held by the modular block installation device 10, above the existing bricks 30 to which mortar has been applied. This movement causes load swing in the modular block 20 and the modular block installation device 10.

[0023] When load swing occurs, the guide unit 16 is no longer able to guide the load to the target position, so conventionally, it was necessary to wait until the load swing amount settled to an amount that can be guided by the guide unit 16. In contrast, with the modular block installation device 10 according to this embodiment, when load swing occurs, the guide unit 16 is lowered to a position where it will not collide with the existing bricks 30, and the load swing prevention unit 18 is caused to collide with the side of the existing bricks 30. This state is shown in FIG. 5(b). This collision between the load swing prevention unit 18 and the side of the existing bricks 30 reduces the load swing of the modular blocks 20 and the modular block installation device 10. This significantly reduces the time it takes for the load swing amount to settle to an amount that can be guided by the guide unit 16.

[0024] In this way, in the modular block installation device 10 according to this embodiment, the load sway prevention section 18 is caused to collide with the existing bricks 30 to reduce load sway of the modular blocks 20 and the modular block installation device 10. For this reason, it is preferable that the load sway prevention section 18 be able to withstand the impact force of the collision with the existing bricks 30, and preferably be able to withstand a pressing force of at least 5 kN. Here, being able to withstand 5 kN means that the load sway prevention section 18 will not break or undergo plastic deformation even when a pressing force of 5 kN is applied to it using an autograph (precision universal testing machine).

[0025] After the swing of the modular blocks 20 and modular block installation device 10 has subsided to the point where they can be guided by the inclined surfaces of the guide sections 16, the modular block installation device 10 is lowered to a position where the guide sections 16 will collide with the existing bricks 30. The modular block installation device 10 is guided by the inclined surfaces of the guide sections 16, and its left-right position is positioned at the position of the existing bricks 30. This state is shown in Figure 5(c).

[0026] In the modular block installation device 10 according to this embodiment, the guide unit 16 is provided on one of the pair of gripping units, the gripping unit 14a, and the load sway prevention unit 18 is provided on the other of the pair of gripping units, the gripping unit 14b. By providing the guide unit 16 and the load sway prevention unit 18 so that they face each other with the modular block 20 in between, the load sway prevention unit 18 can function as a guide unit. This makes it possible to position the modular block installation device 10 in the left-right direction relative to the existing bricks 30 without providing the guide unit 16 on the gripping unit 14b.

[0027] With the modular block installation device 10 positioned laterally at the same position as the existing bricks 30, the device 10 is further lowered, and the modular block 20 is installed on top of the existing bricks 30 to which mortar has been applied. This state is shown in FIG. 5(d). Then, the bolts 19 are loosened, causing the gripping sections 14a, 14b to move away from each other, thereby releasing the gripping sections 14a, 14b from the modular block 20. To install the next modular block on top of the existing bricks 30, the modular block installation device 10 is moved to the location where the modular blocks 20 are being manufactured, and the device 10 grips the next modular block again. The operations described with reference to FIGS. 5(a) to 5(d) are then repeated, stacking modular blocks on top of the existing bricks 30 to construct the coke oven's carbonization chamber and combustion chamber.

[0028] As described above, the modular block installation device 10 according to this embodiment has guide sections 16 that protrude downward from the pair of gripping sections 14a, 14b, and a load sway prevention section 18 that protrudes further downward than the guide sections 16. By having the load sway prevention section 18 that protrudes further downward than the guide sections 16, even if load sway occurs due to the movement of the modular blocks 20 and modular block installation device 10, the load sway of the modular blocks 20 and modular block installation device 10 can be reduced by having only the load sway prevention section 18 collide with the side of the existing bricks 30, and waiting time due to load sway can be significantly reduced.

[0029] The present invention is not limited to the above-described embodiment, and various modifications can be made. In the present embodiment, an example has been shown in which the guide portion 16 is directly fixed to the gripping portion 14a, but the present invention is not limited to this. For example, the guide portion 16 may be fixed by sandwiching a shim (a plate-shaped member with a specific thickness) between the gripping portion 14a and the guide portion 16. By changing the thickness of the sandwiched shim, the guide portion 16 can be moved in a direction away from the gripping portion 14a, and the distance between the guide portion 16 and the load sway prevention portion 18 can be adjusted.

[0030] In the construction of a coke oven, the horizontal dimensions of the existing bricks are not necessarily the same as the horizontal dimensions of the modular blocks to be installed on them. Therefore, if the distance between the guide unit 16 and the load swing prevention unit 18 can be adjusted, the modular block installation device 10 according to this embodiment can be used to install a modular block by aligning it with the existing bricks, even if the horizontal dimensions of the existing bricks are larger than the horizontal dimensions of the modular block. This improves the versatility of the modular block installation device 10. Furthermore, in this embodiment, the gripping units 14a and 14b grip the modular block 20 by tightening the bolts 19, and release the gripping of the modular block 20 by loosening the bolts 19. However, other devices may be used instead of the bolts 19 as long as they can fix the positions of the gripping units 14a and 14b. [Example]

[0031] Next, examples of the present invention will be described. Using the module block installation device 10 shown in Figure 1, module block installation devices of invention examples 1 and 2 and comparative examples 1 and 2 were fabricated. The configurations of invention examples 1 and 2 and comparative examples 1 and 2 are as follows.

[0032] Example 1: Modular block installation device 10 shown in Figure 1 (unmodified) Example 2 of the invention: A device in which the guide portion 16 of the module block installation device 10 shown in FIG. 1 is changed to a guide portion without an inclined surface. Comparative Example 1: A device in which the load sway prevention section 18 of the module block installation device 10 shown in FIG. Comparative Example 2: A device in which the guide section 16 and the load sway prevention section 18 are removed from the modular block installation device 10 shown in FIG. Module block size: height 626mm x long side 1836mm x short side 850mm Module block weight: 1.3 tons Length of protrusion of guide 16 from the lower end of the grip: 200 mm, width: 150 mm, inclined surface: horizontal 40 mm, vertical 100 mm Length of protrusion from the bottom end of the grip of the load sway prevention part 18: 300 mm, width: 150 mm

[0033] Using the modular block installation devices of Examples 1 and 2 and Comparative Examples 1 and 2, modular blocks were installed from a predetermined position onto existing bricks, and the time required for installation and the positioning accuracy in the left-right direction were confirmed. This operation was repeated five times, and the average installation time and positioning accuracy in the left-right direction were calculated. The results are shown in Table 1 below.

[0034] [Table 1]

[0035] In Example 1 of the invention, which used the modular block installation device 10, the load sway prevention unit 18 was able to reduce load sway caused by movement, and the modular block was able to be installed on top of the existing bricks in an installation time of 2 minutes with a positioning accuracy of ±1 mm. In Example 2 of the invention, the guide unit 16 did not have an inclined surface, so it took time to position it with the guide unit 16, but the load sway prevention unit 18 was able to reduce load sway, and the modular block was able to be installed on top of the existing bricks in an installation time of 3 minutes with a positioning accuracy of ±1 mm.

[0036] On the other hand, in Comparative Example 1, since the load sway prevention unit 18 was not provided, load sway could not be reduced, and although the positioning accuracy was the same as in Invention Examples 1 and 2, the installation time was 5 minutes, which was longer than Invention Examples 1 and 2. In Comparative Example 2, since the guide unit 16 and the load sway prevention unit 18 were not provided, load sway could not be reduced, and it took time to position the modular blocks on the existing bricks. For this reason, the installation time for Comparative Example 2 was 15 minutes, which was significantly longer than Invention Examples 1 and 2. Furthermore, since positioning was not performed using the guide unit 16 in Comparative Example 2, the positioning accuracy was ±2 mm, resulting in a result inferior to Invention Examples 1 and 2 and Comparative Example 1.

[0037] From the above results, it was confirmed that by using the modular block installation device 10 of this embodiment, which has a guide section 16 and a load swing prevention section 18, it is possible to reduce load swing caused by movement, and to install modular blocks on existing bricks in a shorter time and with higher positioning accuracy than conventional devices. [Explanation of symbols]

[0038] 10. Module block installation device 12 Frame 14a, 14b grip part 15 volts 16 Guide section 18 Load swing prevention part 19 volts 20 module blocks 30 Existing bricks

Claims

1. A modular block installation device that installs a modular block composed of a plurality of bricks on existing bricks, a pair of gripping portions that sandwich and grip the side surfaces of the module block; a frame supporting the pair of gripping portions; guide portions provided to protrude downward from the pair of grip portions; A load sway prevention portion provided to protrude further downward from the pair of gripping portions than the guide portion; A modular block installation device having:

2. 2. The modular block installation device according to claim 1, wherein the guide portion is provided on one of the pair of gripping portions, and the load sway prevention portion is provided on the other of the pair of gripping portions.

3. 3. The modular block installation device according to claim 1, wherein the load sway prevention portion can withstand a pushing force of at least 5 kN.

4. 3. The modular block installation device according to claim 1, wherein the lower end of said guide portion is provided with an inclined surface whose inner surface approaches the outer surface as it goes downward.

5. 4. The modular block installation device according to claim 3, wherein the lower end of said guide portion is provided with an inclined surface whose inner surface approaches the outer surface as it goes downward.

6. 5. The modular block installation device according to claim 4, wherein the length of the inclined surface projected in the horizontal direction is 100 mm or more, and the length projected in the vertical direction is at least twice the length projected in the horizontal direction.

7. 6. The modular block installation device according to claim 5, wherein the length of the inclined surface projected in the horizontal direction is 100 mm or more, and the length projected in the vertical direction is at least twice the length projected in the horizontal direction.

8. 5. The modular block installation device according to claim 4, wherein a buffer material is provided on the inclined surface.

9. 6. The modular block installation device according to claim 5, wherein a buffer material is provided on the inclined surface.

10. 7. The modular block installation device according to claim 6, wherein a buffer material is provided on the inclined surface.

11. 8. The modular block installation device according to claim 7, wherein a buffer material is provided on the inclined surface.

12. 3. The modular block installation device according to claim 1, wherein said guide portion is movable in a direction away from said gripping portion.

13. 3. A method for installing modular blocks using the installation device for modular blocks according to claim 1 or 2, comprising: A modular block installation method in which the load swing prevention unit is caused to collide with the side of the existing bricks to reduce load swing, and then the modular block is installed on top of the existing bricks.

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