Manufacturing equipment for producing masonry blocks

Abstract

To provide a production apparatus for producing laminated blocks provided with a structure in which burrs or the like generated by a suspending board do not interfere upon lamination.SOLUTION: A production apparatus for producing laminated blocks comprises: a body flask 100 molding a front wall, a rear wall and side walls of each laminated block; an upper press part for compacting laminated blocks from above; and a hollow flask 300 molding a hollow part surrounded by the front wall, the rear wall and the side walls of each block. The hollow flask 300 is suspended and fixed by a suspending board 400 fitted to an upper end side of the body flask 100. The upper press part comprises an insertion part inserting the suspending board 400 when, for compacting and molding each laminated block, it drops toward the main flask 100 and presses the same. In the upper press part, a part adjacent to the insertion part is provided with a projection part projecting downward, and a recessed part capable of storing burrs generated around the insertion part is formed at each laminated block by the projection part.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a manufacturing apparatus for manufacturing masonry blocks that are stacked in multiple stages and installed on the slopes of rivers, roads, etc. [Background technology]

[0002] Traditionally, masonry blocks have a hollow center to improve the block's strength and weight, as well as to allow concrete to be poured and fixed in place after stacking. While various forms are used for masonry blocks manufactured using the pouring method, masonry blocks manufactured using the quick-release method have a hollow center formed by a hollow formwork, which is suspended and fixed by a hanging plate to the main formwork that forms the block's outer wall. However, due to the influence of the hanging plate, burrs and other imperfections can form on the top edge of the masonry blocks after the formwork is formed. When stacking the blocks, the burrs can get in the way and become pinched, creating gaps between the blocks. Conventionally, these burrs and other imperfections can be removed by air treatment to create a flat surface, but this is time-consuming and difficult to completely remove. DISCLOSURE OF THE INVENTION [Problem to be solved by the invention]

[0003] Therefore, the present invention provides a manufacturing device for manufacturing masonry blocks that has a structure in which burrs and the like generated by the hanging plates do not get in the way when stacking. [Means for solving the problem]

[0004] The manufacturing apparatus of the present invention is particularly a manufacturing apparatus for manufacturing masonry blocks using an instant demolding method, and comprises a main formwork that forms the front wall, rear wall, and side walls of the masonry block, an upper press section that compacts the masonry block from above, and a hollow formwork that forms the hollow section surrounded by the front wall, rear wall, and side walls of the masonry block, wherein the hollow formwork is suspended and fixed by a hanging plate attached to the upper end side of the main formwork, and the upper press section has an insertion section through which the hanging plate is inserted when it is lowered toward the main formwork and pressed to compact and mold the masonry block, and the upper press section has a protrusion that protrudes downward at a location adjacent to the insertion section, and the protrusion forms a recess in the masonry block that can accommodate burrs that occur around the insertion section.

[0005] According to the above feature, a recess can be formed in the stacking block by the protrusion adjacent to the insertion portion of the upper press part, and even if there is a certain size of burr, it can be prevented from becoming a hindrance when the stacking blocks are stacked.

[0006] Furthermore, in the manufacturing apparatus of the present invention, the lower end surface of the hanging plate is positioned below the upper end surface of the main formwork.

[0007] According to the above feature, since the lower end face of the hanging plate is positioned lower than the upper end face of the main formwork, recesses can be formed in the masonry blocks, preventing imperfectly formed parts from getting in the way when the masonry blocks are stacked.

[0008] Furthermore, in the manufacturing apparatus of the present invention, the hanging plate is made of a long plate member, and the lower end surface of the hanging plate is arranged facing the main formwork side.

[0009] According to the above features, it is possible to reduce the contact area with the poured concrete while providing the strength to withstand the weight of the hollow formwork, thereby minimizing molding defects that may occur around the hanging plate.

[0010] Furthermore, in the manufacturing apparatus of the present invention, the upper press section is configured to chamfer the edges of the upper ends of the lamination blocks.

[0011] According to the above feature, even if a small burr forms around the edge of the upper end of the masonry block, the burr is contained within the chamfered space and does not protrude upward from the upper end, so the burr does not get in the way when stacking the masonry blocks. [Effects of the Invention]

[0012] As described above, the manufacturing apparatus of the present invention can manufacture masonry blocks having a structure in which burrs and the like generated by the hanging plates do not get in the way when stacking. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 2(a) is a plan view of a main body form of the manufacturing apparatus of the present invention, and FIG. 2(b) is a front view of the main body form. [Figure 2] 1A is a cross-sectional view taken along line AA in FIG. 1, and FIG. 1B is a cross-sectional view taken along line BB in FIG. [Figure 3] 1A is a bottom view of an upper press unit of the manufacturing apparatus of the present invention, and FIG. 1B is a front view of the upper press unit. [Figure 4] 3(a) is an enlarged view of the CC end face of FIG. 3(a), and FIG. 3(b) is an enlarged view of the DD end face of FIG. 3(a). [Figure 5] FIG. 1 is a front view of a manufacturing apparatus according to the present invention. [Figure 6] FIG. 1 is a front view of a manufacturing apparatus according to the present invention. [Figure 7] 5A is a cross-sectional view showing an enlarged view of the vicinity of the insertion part, similar to FIG. 4, when the upper press part is pressing the stacking block, and FIG. 5B is a cross-sectional view showing an even further enlarged view of the vicinity of the insertion part. [Figure 8] FIG. 1 is a front view of a manufacturing apparatus according to the present invention. [Figure 9] FIG. 1 is a front view of a manufacturing apparatus according to the present invention. [Figure 10]FIG. 1 is a front view of a manufacturing apparatus according to the present invention. [Figure 11] 11(a) is an overall perspective view of a masonry block manufactured by the manufacturing apparatus of the present invention, and FIG. 11(b) is an enlarged cross-sectional view taken along the line PP of FIG. 11(a). [Figure 12] FIG. 10 is an enlarged front view of the burrs and their surroundings in a state where blocks of the same configuration are stacked one on top of the other. [Explanation of symbols]

[0014] 100 Main body formwork 200 Upper Press Section 240 Insertion part 300 Hollow Formwork 400 hanging board 800 stacked blocks 810 Front wall 820 Back wall 830 Side wall 840 Hollow part 850 Hollow section at both ends 900 Manufacturing equipment DETAILED DESCRIPTION OF THE INVENTION

[0015] The following describes embodiments of the present invention with reference to the drawings. Note that the shapes, materials, etc. of the components of the manufacturing apparatus in the embodiments described below are merely examples and are not intended to limit the scope of the present invention.

[0016] First, Figures 1 and 2 show a main body form 100 of a manufacturing apparatus 900 of the present invention. Figure 1(a) is a plan view of the main body form 100, Figure 1(b) is a front view of the main body form 100, Figure 2(a) is a cross-sectional view taken along line A-A in Figure 1, and Figure 2(b) is a cross-sectional view taken along line B-B in Figure 1. Also, Figure 11(a) is an overall perspective view of a masonry block 800 manufactured by the manufacturing apparatus 900, and Figure 11(b) is an enlarged cross-sectional view taken along line P-P in Figure 11(a).

[0017] First, with reference to FIG. 11(a), the configuration of a masonry block 800 manufactured by the manufacturing apparatus 900 of the present invention will be described. As shown in FIG. 11(a), the masonry block 800 is a concrete structure that is stacked in multiple layers and installed on the slope of a river, road, or the like. The masonry block 800 includes a long, plate-like front wall 810, a short, plate-like rear wall 820 parallel to the front wall 810, and two side walls 830 connecting the front wall 810 and the rear wall 820. The center of the masonry block 800 defines a hollow portion 840 surrounded on all four sides by the front wall 810, the rear wall 820, and the side walls 830. When installing the masonry block 800 on a slope, other masonry blocks 800 are stacked and fixed on top of the upper end 801 of the masonry block 800. Then, concrete is poured into the hollow portion 840 and the hollow portions 850 at both ends, thereby firmly fixing the stacked masonry blocks 800 to each other.

[0018] Next, we will explain the main body formwork 100 of the manufacturing apparatus 900 that produces the masonry block 800. As shown in Figures 1 and 2, the main body formwork 100 includes a front wall mold 110 that forms the front wall 810 of the masonry block 800, a rear wall mold 120 that forms the rear wall 820 of the masonry block 800, and a side wall mold 130 that forms the side wall 830 of the masonry block 800. The front wall mold 110, the rear wall mold 120, and the side wall mold 130 form a continuous, communicating space, and as described below, concrete is poured into this space, compacted, and then allowed to harden, thereby forming each wall portion that surrounds the outside of the masonry block 800. In addition, a hollow formwork 300 that forms the hollow portion 840 of the masonry block 800 is provided near the center of the main body formwork 100. This hollow formwork 300 is suspended by a suspension plate 400 as will be described later, and therefore has a hollow interior to reduce weight.

[0019] Here, since the hollow portion 840 of the masonry block 800 is in the form of a hole with a completely closed periphery, the hollow formwork 300 that forms the hollow portion 840 needs to be installed in a floating state independent of the surrounding molds (front wall mold 110, rear wall mold 120, side wall mold 130). Therefore, the hollow formwork 300 is suspended and fixed by a plate-like hanging plate 400. Specifically, the hanging plate 400 is a long plate-like member, and a front end 401 side of the hanging plate 400 is fixed to the front wall mold 110 side, and a rear end 402 of the hanging plate 400 is fixed to the rear wall mold 120 side, and the hanging plate 400 is attached to the upper end surface 101 of the main formwork 100 so as to cross from the front wall mold 110 to the rear wall mold 120 from front to rear.

[0020] Furthermore, the hanging plate 400 is installed upright so that the side surface 403 of the hanging plate 400 is perpendicular to the horizontal plane (in other words, aligned vertically). Because the hanging plate 400 suspends and supports the hollow formwork 300, it needs to be strong enough to withstand the weight of the hollow formwork 300. Therefore, by making the hanging plate 400 a long plate member, high strength is achieved. Furthermore, the end surface 404 of the hanging plate 400 is narrower and has a smaller surface area than the side surface 403. By placing the end surface 404 facing downward, i.e., toward the main formwork 100, as described below, the contact area with the poured concrete is reduced and molding defects around the hanging plate 400 are minimized. Note that while the hanging plate 400 is a long plate member, it is not limited to this and may be any shape, such as a long round bar, as long as it is strong enough to withstand the weight of the hollow formwork 300.

[0021] Furthermore, the upper end 301 of the hollow formwork 300 is connected to the lower end surface 404 of the hanging plate 400 and is suspended, but the lower end 302 of the hollow formwork 300 is not fixed anywhere and is in a floating state. However, as will be described in detail later, when the masonry block 800 is manufactured using the manufacturing apparatus 900, the lower end of the main body formwork 100 is closed with a flat lower mounting plate 500, so the lower end 302 of the hollow formwork 300 comes into contact with the lower mounting plate 500. Furthermore, because the lower end 302 of the hollow formwork 300 comes into contact with the lower mounting plate 500, when concrete is poured into the main body formwork 100, the concrete does not flow into the hollow formwork 300, and the hollow portion 840 of the masonry block 800 can be neatly formed.

[0022] Next, Figures 3 and 4 show the upper press section 200 of the manufacturing apparatus 900 of the present invention. Figure 3(a) is a bottom view of the upper press section 200, Figure 3(b) is a front view of the upper press section 200, Figure 4(a) is an enlarged view of the CC end face of Figure 3(a), and Figure 4(b) is an enlarged view of the DD end face of Figure 3(a).

[0023] As shown in Figure 3, the upper press section 200 presses concrete poured into the main body formwork 100 from above to compact it, and includes a front-wall press section 210 that presses the upper part of the front wall mold 110 of the main body formwork 100, a rear-wall press section 220 that presses the upper part of the rear wall mold 120 of the main body formwork 100, and a side-wall press section 230 that presses the upper part of the side-wall mold 130 of the main body formwork 100. The front-wall press section 210, the rear-wall press section 220, and the side-wall press section 230 are fixed so as to protrude downward from the base section 201, and as the base section 201 moves up and down, the front-wall press section 210, the rear-wall press section 220, and the side-wall press section 230 also move up and down integrally. In addition, an insertion section 240 that crosses the front-to-rear direction is provided near the center of the front-wall press section 210. Similarly, an insertion portion 240 that crosses the front-to-rear direction is provided near the center of the rear wall pressing portion 220. This insertion portion 240 is arranged in a straight line from the front wall pressing portion 210 to the rear wall pressing portion 220, and as will be described later, the insertion portion 240 is a space of a width that allows the hanging plate 400 to be inserted therethrough.

[0024] 4, the underside 211 of the front wall pressing unit 210 is flat, and when the upper pressing unit 200 presses from above toward the main body formwork 100, the underside 211 compacts and hardens the concrete evenly, resulting in a flat upper end 801 of the masonry block 800. A protrusion 250 protruding downward from the underside 211 is provided at a location adjacent to the insertion unit 240. Similarly, the underside 221 of the rear wall pressing unit 220 is flat, and when the upper pressing unit 200 presses from above toward the main body formwork 100, the underside 221 compacts and hardens the concrete evenly, resulting in a flat upper end 801 of the masonry block 800. A protrusion 250 protruding downward from the underside 211 is provided at a location adjacent to the insertion unit 240.

[0025] Next, the steps of manufacturing the laminated block 800 by the manufacturing apparatus 900 will be described with reference to Figures 5 to 10. Figures 5 and 6 are front views of the manufacturing apparatus 900.

[0026] First, as shown in FIG. 5, the lower end of the main body formwork 100 is placed on a flat lower support plate 500 to close the lower end of the main body formwork 100. Then, a container N containing concrete M is moved onto the main body formwork 100, and concrete M is poured into the front wall mold 110, rear wall mold 120, and side wall mold 130 of the main body formwork 100, filling it up to the upper end surface 101. Since the lower end of the main body formwork 100 is closed by the lower support plate 500, concrete M does not leak below. Next, the container N is moved to the side of the main body formwork 100, and the upper press unit 200 is lowered toward the main body formwork 100. Then, as shown in FIG. 6, the upper press unit 200 presses the upper end of the concrete M poured into the main body formwork 100 to compact it and form a masonry block 800.

[0027] At this time, as shown in Figure 7, the hanging plate 400 fixed to the main body formwork 100 is inserted into the insertion portion 240 of the upper press unit 200, so there is no interference between the lowered upper press unit 200 and the hanging plate 400. Then, the flat lower surface 211 of the upper press unit 200 is lowered to a specified height below the upper end surface 101 of the main body formwork 100 and compacted, thereby forming the upper end portion 801 of the lamination block 800 flat. Note that Figure 7(a) is an enlarged cross-sectional view of the vicinity of the insertion portion 240, similar to Figure 4, when the upper press unit 200 is pressing the lamination block 800, and Figure 7(b) is a further enlarged cross-sectional view of the vicinity of the insertion portion 240.

[0028] 7(b), the lower end surface 404 of the hanging plate 400 is positioned lower than the upper end surface 101 of the main body formwork 100, so that a recess 803 recessed downward from the flat upper end portion 801 is formed in the lamination block 800. Furthermore, a protrusion 250 is provided on the lower surface 211 of the upper press unit 200 at a location adjacent to the hanging plate 400. When the upper press unit 200 is pressing the lamination block 800, this protrusion 250 protrudes below the upper end surface 101 of the main body formwork 100, so that a recess 804 recessed downward from the flat upper end portion 801 is formed in the lamination block 800.

[0029] The insertion portion 240 of the upper press unit 200 needs to smoothly insert the hanging plate 400 fixed to the main formwork 100. For this reason, as shown in Figure 7(b), the opening width of the insertion portion 240 is slightly wider than the thickness of the hanging plate 400, and a small gap X is created between the insertion portion 240 and the hanging plate 400 so that they do not interfere with each other. When the upper press unit 200 presses the masonry block 800, the concrete that makes up the masonry block 800 enters the gap X and protrudes upward, causing burrs 809.

[0030] After that, when the pressed lamination block 800 is completed, it is removed from the manufacturing apparatus 900. At that time, as shown in FIG. 8, the main body formwork 100 first moves upward to remove the lamination block 800 from the main body formwork 100. At that time, the upper press unit 200 is stopped in the pressing position, so the top and bottom of the lamination block 800 are sandwiched and fixed between the upper press unit 200 and the lower mounting plate 500. Therefore, the lamination block 800 can be easily removed from the main body formwork 100. Note that FIGS. 8 to 10 are front views of the manufacturing apparatus 900.

[0031] Next, as shown in Figure 9, when the upper press unit 200 moves upward, the lamination block 800 is completely removed from the main formwork 100 and the upper press unit 200. The removed lamination block 800 is placed on the lower loading plate 500, and can be moved together with the lower loading plate 500 to another storage location or the like.

[0032] 10, the manufacturing apparatus 900 moves another lower mounting plate 500A below the main body formwork 100 to continuously manufacture new masonry blocks 800. The lower end of the main body formwork 100 is then placed on the flat lower mounting plate 500A so as to cover the lower end of the main body formwork 100, and the manufacturing apparatus 900 is set to a state in which manufacturing of the masonry blocks 800 can begin. Thereafter, concrete is poured into the main body formwork 100 and compacted by the upper press unit 200 in the same manner as the manufacturing method described with reference to FIGS. 5 to 9, thereby repeatedly manufacturing masonry blocks 800. Note that the manufacturing method for the masonry blocks 800 is not limited to the method described with reference to FIGS. 5 to 9, and any method may be used.

[0033] As shown in FIG. 11 , a burr 809 is formed in the completed masonry block 800 near the location where the hanging plate 400 is placed. As described with reference to FIG. 7( b), a recess 804 is formed on one side of the burr 809. Furthermore, a recess 803 is formed on the other side of the burr 809. Because the recess 803 is in contact with the end surface 404 of the hanging plate 400, it is not directly subjected to the pressing force of the upper press unit 200. Furthermore, because the recess 803 is located below the end surface 404 of the hanging plate 400, concrete (material) does not easily enter the recess 803. Therefore, when the masonry block 800 is released from the main formwork 100, the area around the recess 803 may be dragged by the end surface 404 of the hanging plate 400 or may be prone to a shortage of material, resulting in an unevenly formed defective portion 805 (see FIG. 11( b)). However, since the recess 803 is recessed downward from the upper end 801 , the defective molding portion 805 occurring in the recess 803 is accommodated within the recess 803 and can be prevented from protruding upward from the upper end 801 .

[0034] Next, the state in which the completed masonry blocks 800 are stacked in multiple layers and installed will be described with reference to Fig. 12. Fig. 12 shows an enlarged front view of the periphery of burrs 809 in a state in which masonry blocks 800 and 800A of the same configuration are stacked one on top of the other.

[0035] 12, when stacking the lamination blocks 800 in multiple stages, the lower end 802 of the upper lamination block 800A is placed on the upper end 801 of the lower lamination block 800. The lower end 802 is held down by the flat lower mounting plate 500 during the manufacturing process, and therefore has a flat surface. Therefore, the flat lower end 802 of the upper lamination block 800A is placed on the flat upper end 801 of the lower lamination block 800, and no gaps are created between the upper lamination block 800A and the lower lamination block 800, allowing for stable stacking.

[0036] 11(b), burrs 809 protrude above the upper end 801. Therefore, when stacking the laminated blocks 800A on the laminated blocks 800, if the laminated blocks 800A are flat rather than concave like the recesses 804, even a small amount of burr will get caught and get in the way, resulting in a gap between the lower end 802 of the upper laminated block 800A and the upper end 801 of the lower laminated block 800. However, in the present invention, as shown in FIG. 12, a recess 804 recessed downward from the upper end 801 is formed in a location adjacent to the burr 809. Therefore, the burr 809 crushed by the lower end 802 of the upper laminated block 800A escapes to the recess 804 and is contained within the recess 804. Therefore, the crushed burr 809 does not protrude above the upper end 801 and does not get in the way when stacking the laminated blocks 800A on the laminated blocks 800. As described above, with the manufacturing apparatus 900 of the present invention, the protrusion 250 adjacent to the insertion portion 240 of the upper press unit 200 can form the recess 804 in the masonry block 800, preventing the burrs 809 from interfering with stacking the masonry blocks 800. As shown in FIG. 11(b), the height (depth) H of the recess 804 should be as low as possible to prevent leakage of concrete material (the height must be equal to or less than 5 mm, the minimum diameter of the coarse aggregate, and approximately 3 mm (millimeters) is preferable). Also, as shown in FIG. 11(b), the size of the recess, consisting of the overall width L and height H including the recesses 804 on both sides, should be large enough to accommodate the burrs 809 and should be as small as possible to prevent leakage of concrete material.

[0037] Furthermore, since the defective molding portion 805 is accommodated in the recess 803 recessed below the upper end portion 801, it does not get in the way when stacking the laminated blocks 800A on the laminated blocks 800. As described above, according to the manufacturing apparatus 900 of the present invention, the lower end surface 404 of the hanging plate 400 is positioned below the upper end surface 101 of the main formwork 100, so that the recess 803 can be formed in the laminated block 800, and the defective molding portion 805 can be prevented from getting in the way when the laminated blocks 800 are stacked. Furthermore, since the recess 803 is adjacent to the burr 809, a portion of the burr 809 crushed by the lower end portion 802 of the upper laminated block 800A escapes into the recess 803 and is also accommodated within the recess 803. Therefore, the burr 809 can be more reliably prevented from getting in the way when the laminated blocks 800 are stacked.

[0038] Furthermore, as shown in FIG. 11( a), the outer edge 891 of the top end 801 of the masonry block 800 is chamfered. This chamfering of the edge 891 is formed when the upper press unit 200 compacts the concrete. Similarly, the inner edge 892 of the top end 801 of the masonry block 800 is also chamfered. This edge 892 is also chamfered when the upper press unit 200 compacts the concrete. Even if small burrs are formed around the outer edge 891 or the inner edge 892 of the top end 801 of the masonry block 800 during manufacturing, the burrs are contained within the chamfered space and do not protrude upward from the top end 801 of the masonry block 800. Therefore, the burrs do not get in the way when stacking the masonry block 800A on the masonry block 800. Furthermore, even if a burr protrudes upward from the upper end 801 of the stacked block 800, the burr is crushed by the lower end 802 of the upper stacked block 800A and escapes into the chamfered space and is contained therein, so the burr does not get in the way when stacking the stacked block 800A on the stacked block 800.

[0039] Furthermore, the manufacturing apparatus of the present invention is not limited to the above examples, and various modifications and combinations are possible within the scope of the claims and the scope of the embodiments, and these modifications and combinations are also included in the scope of rights.

Claims

1. A manufacturing apparatus for manufacturing masonry blocks, a main body form for forming the front wall, rear wall, and side walls of the masonry block; an upper press section for compressing the lamination blocks from above; a hollow formwork for forming a hollow portion surrounded by the front wall, rear wall, and side walls of the masonry block; The hollow formwork is suspended and fixed by a hanging plate attached to the upper end side of the main body formwork, The upper press unit has an insertion portion through which the hanging plate is inserted when the upper press unit descends toward the main formwork to press the masonry blocks to compact them, a protrusion protruding downward is provided at a location of the upper press portion adjacent to the insertion portion, A manufacturing device characterized in that the protrusion forms a recess in the lamination block that can accommodate burrs that occur around the insertion portion.

2. 2. The manufacturing apparatus according to claim 1, wherein a lower end surface of the hanging plate is positioned below an upper end surface of the main formwork.

3. The manufacturing device according to claim 1 or 2, characterized in that the hanging plate is made of a long plate member, and the lower end surface of the hanging plate is arranged facing the main formwork side.

4. 3. The manufacturing apparatus according to claim 1, wherein the upper press section is configured to chamfer the edges of the upper ends of the lamination blocks.

5. 4. The manufacturing apparatus of claim 3, wherein the upper press section is configured to chamfer the edges of the upper ends of the lamination blocks.

Images