Control methods for concrete plants

Abstract

To provide a concrete plant, a concrete plant control method and a program which enable a mobile plant to produce special concrete, etc. manage to be of high quality at a construction site.SOLUTION: A concrete plant comprises: a transport vehicle 10; and a concrete plant unit 20 which is mounted on a loading platform 11 of the transport vehicle 10 and carried therewith. The concrete plant unit 20 has at least a mixer 50 and a control device 60 which executes drive control of the mixer. The control device 60 executes: primary mixing control which causes the mixer 50 to execute primary mixing to produce a primary mixed material; secondary mixing control which causes the mixer 50 to execute secondary mixing to mix the primary mixed material with an admixture to produce a secondary mixed material; and additional mixing control which causes the mixer to execute at least either additional primary mixing or additional secondary mixing when the primary and secondary mixing do not satisfy primary and secondary management standard values set for each thereof at time of completion of either or both of the primary and secondary mixing.SELECTED DRAWING: Figure 17

Description

Technical Field

[0001] The present invention relates to a concrete plant Regarding the control method and pertains to it

Background Art

[0002] In recent years, due to the increasing demand for high-performance concrete and the extension of the lifespan of existing structures, technologies for repairing and strengthening existing structures using, for example, high-performance concrete have been developed. Examples of such existing structures include reinforced concrete floor slabs in road bridges This high-performance concrete is a special type of concrete that is not generally supplied by ready-mix plants in urban areas. Even if repair and strengthening technologies have been established, there is a major problem in that special concrete cannot actually be supplied to construction sites. Here, in this specification, "high-performance concrete", "special concrete", "high-strength concrete", and "ultra-high-strength concrete" mean, for example, concrete having high compressive strength, toughness, and durability. As an example, ultra-high-performance fiber-reinforced concrete using special materials (premix powder obtained by mixing cement and admixtures, sand, fiber, water, admixtures, etc.) can be mentioned Therefore, in some cases, a mobile concrete plant (mobile plant) that moves to the construction site and manufactures concrete at the construction site is applied. However, since conventional mobile plants are intended for the production of ordinary concrete, problems can occur in the production (mixing) of special concrete such as ultra-high-strength concrete. Specifically, high-performance concrete and special concrete often have high viscosity, and there is no management know-how for mobile plants to manufacture special concrete such as high-quality controlled special concrete at the construction site

[0003] Here, Patent Document 1 proposes a ready-mix concrete manufacturing system that enables a stable supply of ready-mix concrete in accordance with the progress of construction work. This manufacturing system is a series of ready-mix concrete manufacturing systems consisting of at least a raw material storage process, a supply process and a mixing process, and each necessary equipment for each process is mounted on a separate vehicle so that all the processes necessary for the system can be moved. Here, the vehicles equipped with the necessary equipment for each process are a mixing mixer truck equipped with a ready-mix concrete raw material supply device having a weighing device and a mixing device and control panel connected thereto, a cement silo truck equipped with a cement storage silo, a water tank truck equipped with a water storage tank, and a conveyor truck equipped with a conveyor.

[0004] On the other hand, Patent Document 2 proposes a mobile batching plant that solves the noise problem. This mobile batching plant includes a powder storage device for storing pre-mixed powder materials, an aggregate storage device for storing aggregates, a water storage device for storing water, a mixing device for mixing powder materials, aggregates, and water, a powder conveying device, an aggregate conveying device, a water supply device, a control device for controlling the operation of each device, a support structure formed to support at least one of the devices and be mountable on a vehicle, and a noise reduction mechanism for reducing noise generated from at least one of the devices and the support structure. Here, each device is said to be installed on the cargo bed of a medium-sized truck. [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 7-52141 [Patent Document 2] Japanese Patent Publication No. 2020-142400 [Overview of the project] [Problems that the invention aims to solve]

[0006] Neither the ready-mix concrete manufacturing system described in Patent Document 1 nor the mobile batching plant described in Patent Document 2 envisions adding mixing materials such as fibrous materials in addition to aggregates and cement to the mixer equipped in the mobile plant to produce special concrete, and therefore, there is no disclosure of means for the mobile plant to produce high-quality, controlled special concrete at the construction site.

[0007] This invention relates to a concrete plant that can manufacture high-quality, controlled special concrete and the like at a construction site using a mobile plant. Control method The purpose is to provide this. [Means for solving the problem]

[0008] To achieve the above objective, one embodiment of the concrete plant according to the present invention is: Transport vehicles and It has a concrete plant unit which is mounted on the cargo bed of the transport vehicle and transported by the transport vehicle, The plant unit comprises at least a mixer and a control device that performs drive control of the mixer. The control device is Primary mixing control is performed to produce a primary mixed material by having the mixer perform a primary mixing of at least aggregate, powder and water, and secondary mixing control is performed to produce a secondary mixed material by having the mixer perform a secondary mixing of the primary mixed material and the mixing material. The method is characterized in that, if either or both of the primary and secondary mixing processes fail to meet the set management criteria at the time of completion, an additional mixing control is performed, which is at least one of an additional primary mixing or an additional secondary mixing.

[0009] According to this embodiment, a control device that controls the drive of a mixer constituting a plant unit, which is mounted on the cargo bed of a transport vehicle, performs primary mixing control to produce primary mixer and secondary mixing control to produce secondary mixer using primary mixer and mixing material. If the set control standard values ​​are not met at the completion of either primary mixing or secondary mixing or both, additional mixing control, which is at least one of additional primary mixing or secondary mixing, is performed, thereby enabling the production of special concrete, including mixing material, under high-quality control. Herein, "control standard values" in this specification include not only strict standard values ​​based on various specifications, etc., but also standard values ​​arbitrarily set based on in-house standards, etc.

[0010] In this embodiment, it is preferable that the mixer is not included in the plant unit when the concrete plant unit is loaded onto the cargo bed of the transport vehicle and transported, and that the mixer becomes a component of the plant unit during concrete production. That is, with this embodiment, by excluding the weight of the mixer during transport by the transport vehicle, the weight of the plant unit other than the mixer within the vehicle weight range that does not require special vehicle application can be made as large as possible, and the weight of the mixer that is transported separately can also be made as large as possible. As a result, a mixer with high mixing performance and concrete supply capacity can be applied without requiring special vehicle application, and a concrete plant with a high concrete supply capacity can be formed. By adopting a configuration in which a concrete plant unit is mounted on the cargo bed of a single transport vehicle, there is no risk of multiple vehicles or plant units occupying a large area at the construction site. For example, in the repair of road bridge decks, repair work can be carried out while the road remains in use, making it suitable for narrow construction sites, construction sites where the concrete manufacturing location changes frequently, and construction sites where concrete pouring is performed in a relatively short time. During concrete production, a mixer stand is provided at the rear of the plant unit, and the separately transported mixer is installed on the mixer stand. This configuration allows for the flexible formation of the plant unit, including the mixer.

[0011] At the construction site, when the mixer is installed on the mixer stand, a so-called vehicle-mounted concrete plant is formed, where the plant unit is mounted on the back of a transport vehicle and concrete is manufactured with it. A vehicle-mounted concrete plant can, for example, fit within one lane (for example, by designing the concrete plant within a lane width of 2.5m), and can be installed within one lane of a highway, for example, allowing other lanes to be used for road traffic.

[0012] Furthermore, in addition to this vehicle-mounted concrete plant, the present invention can also form a so-called stationary concrete plant in which the transport vehicle moves aside and the plant unit is installed on a road surface or the like while maintaining the configuration of the plant unit during transport. Moreover, by installing external aggregate storage devices and powder storage devices on the plant unit installed on a road surface or the like, the aggregate storage capacity and powder storage capacity can be increased, and another form of stationary concrete plant can be formed that can automatically produce more concrete. Thus, the concrete plant of this embodiment is a concrete plant whose functions can be expanded in various ways according to the needs of the construction site. A mobile plant equipped with multiple functions in this manner is a novel concrete plant that has not existed before, and possesses high mobility and expandability. Furthermore, due to its high mixing performance and concrete supply capacity, the concrete suitable for production includes not only ordinary concrete, but also special concretes such as ultra-high-strength fiber-reinforced concrete (UFC) and UHPFRC (Ultra-High Performance Fiber-Reinforced Concrete), which have high viscosity as described above, and environmentally friendly concrete (concrete that uses blast furnace slag (a by-product of steelmaking) and fly ash (coal ash), which are industrial by-products, instead of cement to reduce CO2 emissions).

[0013] Here, a "special vehicle" refers to a special vehicle subject to the special vehicle passage permit system, and "without special vehicle application" means that it can run without applying the special vehicle passage permit system. Regarding this special vehicle application, an application is required when exceeding 20 tons outside the designated road. When the maximum weight of the plant unit is about 9 tons, by setting the vehicle weight to about 10 tons (10-ton vehicle), the application becomes unnecessary. Strictly speaking, in addition, by further meeting other vehicle width limits (2.5 m), height limits in the state of mounting the plant unit on the loading platform (3.8 m (4.1 m on the designated road)), vehicle length limits (12 m), etc., the application becomes unnecessary.

[0014] Also, in another aspect of the concrete plant according to the present invention, The management reference value is characterized in that it is at least a management reference value related to the mixer load value.

[0015] According to this aspect, as the management reference value, since the management reference value related to the mixer load value is included, it is possible to prevent the mixer from going down due to high load and the failure of related equipment when charging and kneading the kneaded material, and by ensuring the initial kneading time, it becomes possible to manufacture high-quality special concrete and the like.

[0016] Also, in another aspect of the concrete plant according to the present invention, The management reference value is characterized in that it is a management reference value related to the mixer load value and the flow test value.

[0017] According to this aspect, as the management reference value, since both the management reference value related to the mixer load value and the management reference value related to the flow test value are included, it becomes possible to manufacture high-quality special concrete and the like while preventing the mixer from going down due to high load when charging and kneading the kneaded material.

[0018] Also, in another aspect of the concrete plant according to the present invention, The control device is provided with a display screen, The display screen is characterized in that time-series data of the mixer load value and the management reference value related to the mixer load value are displayed.

[0019] According to this aspect, by displaying the time-series data of the mixer load value and the management reference value related to the mixer load value on the display screen provided in the control device, the administrator can clearly and easily confirm whether the mixer can be shut down and the quality of the concrete to be produced through the display screen.

[0020] In addition, one aspect of the concrete plant control method according to the present invention is A concrete plant control method having at least a concrete plant unit including a mixer and a control device that executes drive control of the mixer, The control device Performs primary kneading control for causing the mixer to perform primary kneading of at least aggregate, powder, and water to produce a primary kneaded material, Performs secondary kneading control for causing the mixer to perform secondary kneading of the primary kneaded material and the kneaded material to produce a secondary kneaded material, When either one or both of the primary kneading and the secondary kneading do not satisfy the management reference values set for each at the completion time, additional primary kneading and / or additional secondary kneading are executed by causing the mixer to perform either one or both of them, characterized by executing additional kneading control.

[0021] According to this aspect, by a control device that executes drive control of a mixer constituting a plant unit, which is mounted on and transported on the loading platform of a transport vehicle, primary kneading control for producing a primary kneaded material and secondary kneading control for producing a secondary kneaded material with the primary kneaded material and the kneaded material are executed. When either one or both of the primary kneading and the secondary kneading do not satisfy the management reference values set for each at the completion time, additional kneading control, which is at least one of additional primary kneading and secondary kneading, is executed, so that special concrete containing the kneaded material can be produced under high-quality management.

[0022] Furthermore, one embodiment of the program according to the present invention is: A concrete plant having a concrete plant unit comprising at least a mixer and a control device that performs drive control of the mixer, wherein a program causes the control device to perform the following control: A primary mixing control system is used to manufacture a primary mixed material by having the mixer perform a primary mixing process in which aggregate, powder, and water are mixed together. A secondary mixing control system is used to manufacture a secondary mixing material by having the mixer perform a secondary mixing process in which the primary mixing material and the mixing material are mixed together. The system is characterized by performing additional mixing control, which causes the mixer to perform either an additional primary mixing or an additional secondary mixing, if the set management standard values ​​are not met at the completion of either or both of the primary mixing and the secondary mixing processes.

[0023] According to this embodiment, a control device that controls the drive of a mixer constituting a plant unit, which is mounted on the cargo bed of a transport vehicle, is instructed to perform primary mixing control to produce primary mixer, and secondary mixing control to produce secondary mixer using primary mixer and other mixing materials. If the set management standard values ​​are not met at the completion of either primary or secondary mixing, or both, additional mixing control, which is at least one of additional primary or secondary mixing, is performed, thereby enabling the production of special concrete and the like, including mixing materials, under high-quality control. [Effects of the Invention]

[0024] Concrete Plant of the Invention Regarding the control method Therefore, a mobile plant can manufacture high-quality, controlled special concrete and other materials at the construction site. [Brief explanation of the drawing]

[0025] [Figure 1]This is a perspective view showing the state of a vehicle-mounted concrete plant, which is an example of a concrete plant according to the first embodiment, while it is traveling on a public road. [Figure 2] This is a perspective view showing a plant unit sliding backward on the loading platform of a transport vehicle. [Figure 3] This diagram illustrates the situation where a mixer is being towed to the mixing position on the rails of a mixer stand. [Figure 4] This is a magnified view of an example of a sliding jig attached to a mixer. [Figure 5] This diagram shows the mixer fixed to the rail in the mixing position. [Figure 6] This is a perspective view showing the state of a vehicle-mounted concrete plant during concrete production. [Figure 7] This figure shows a mixer stand supported by an example of support legs. [Figure 8] This figure shows the mixer stand being supported by another example of support legs. [Figure 9] This is a block diagram schematically showing each component of the plant unit that makes up a vehicle-mounted concrete plant. [Figure 10] This is a perspective view showing a stationary concrete plant, which is an example of a concrete plant according to the second embodiment, in a self-supporting state with its outriggers extended. [Figure 11] This is a perspective view showing the state after the transport vehicles have been evacuated and a stationary concrete plant has been formed. [Figure 12] This is a perspective view showing a stationary concrete plant with an external fiber storage device and an external fiber conveying device installed. [Figure 13] This is a perspective view showing a stationary concrete plant, which is an example of a concrete plant according to the third embodiment. [Figure 14] This is a block diagram schematically showing the various components of a plant unit that makes up a stationary concrete plant. [Figure 15] This figure shows an example of the hardware configuration of a control device. [Figure 16] This figure shows an example of the functional configuration of a control device. [Figure 17] This flowchart shows an example of a control flow for a concrete plant control method according to the present invention. [Figure 18A] This figure shows an example of a selection screen in the design operation screen of a control device. [Figure 18B] This figure shows an example of the main screen in the design operation screen of a control device. [Figure 18C] This figure shows an example of the mixing timer setting screen in the design operation screen of a control device. [Figure 18D] This figure shows an example of an operation screen in the design operation screen of a control device. [Figure 19] This figure shows an example of time-series data of mixer load values ​​and management reference values ​​on the control device's display screen. [Figure 20] This is a perspective view showing an example of a kneading material supply system, which consists of a fiber storage device and a fiber conveying device. [Figure 21] This diagram shows the structure in which a fiber storage device is housed inside the safety measures that make up the mixing material supply device. [Figure 22] Following Figure 20, this figure shows the container moving upwards and rotating above the mixer. [Figure 23] Following Figure 22, this figure shows the container rotating further to feed the mixing material into the mixer. [Modes for carrying out the invention]

[0026] The concrete plants and control methods for each embodiment of the concrete plants described below will be explained with reference to the attached drawings. In this specification and the drawings, substantially identical components may be denoted by the same reference numerals to avoid redundant explanations.

[0027] [Concrete plant according to the first embodiment] First, an example of a concrete plant according to the first embodiment will be described with reference to Figures 1 to 9. Here, Figure 1 is a perspective view showing a vehicle-mounted concrete plant, an example of a concrete plant according to the first embodiment, in a state when traveling on a public road. Figure 2 is a perspective view showing the plant unit sliding backward on the cargo bed of a transport vehicle, and Figure 3 is a diagram illustrating the situation where the mixer is being towed to the mixing position on the rails of the mixer stand. Figure 4 is an enlarged view of an example of a sliding jig attached to the mixer, and Figure 5 is a diagram showing the state in which the mixer is fixed to the rails at the mixing position. Furthermore, Figure 6 is a perspective view showing the state of the vehicle-mounted concrete plant during concrete production, and Figure 9 is a schematic block diagram showing each component of the plant unit that constitutes the vehicle-mounted concrete plant.

[0028] Each concrete plant according to the respective embodiment is equipped with a control device for driving and controlling each device. The hardware configuration and functional configuration of the control device will be described in the section on the concrete plant according to the third embodiment. In addition, the vehicle-mounted concrete plant shown in the illustration is described as a configuration without a fiber storage device or fiber transport device, but a vehicle-mounted concrete plant may be equipped with these devices.

[0029] The concrete plant 100 shown in Figure 1 is a vehicle-mounted concrete plant that moves to the construction site with the plant unit 20 mounted on the cargo bed 11 of a transport vehicle 10, and manufactures concrete at the construction site with the plant unit 20 still mounted on the cargo bed 11.

[0030] Here, the vehicle-mounted concrete plant 100 shown in the illustration, and the stationary concrete plants 200 and 300 described below, are applicable to construction sites and projects such as the RC deck slabs of highway bridges, the superstructure of bridge girders constructed as cantilevers on bridges, the RC structure of the middle and upper floors of high-rise buildings under construction, the lining concrete on the tunnel face and sides in mountain tunnels, and the RC structure of the underground section in large box culvert construction.

[0031] The transport vehicle 10 is, for example, a 10-ton truck (large truck), with the plant unit 20 mounted on the cargo bed 11, and the total weight with the crew on board is set to 20 tons or less. Therefore, the vehicle-mounted concrete plant 100 is a concrete plant with a total weight that does not require special vehicle application when traveling on public roads.

[0032] Regarding "special vehicle applications," an application is required if the weight exceeds 20 tons on roads other than designated roads. However, if the maximum weight of the plant unit 20 is around 9 tons, an application is not required because the transport vehicle 10 is a 10-ton truck. More precisely, an application is not required if the transport vehicle 10 also meets other requirements, such as the width limit of the transport vehicle 10 (2.5m), the height limit with the plant unit 20 loaded on the cargo bed 11 (3.8m (4.1m on designated roads)), and the length limit of the transport vehicle 10 (12m).

[0033] The plant unit 20 that constitutes the vehicle-mounted concrete plant 100 for use on public roads, as shown in Figure 1, has a frame structure 21 equipped with a work stage 22 on its uppermost surface and a mixer stand 25 at its rear.

[0034] As shown in Figure 9, the frame structure 21 houses a coarse aggregate storage device 31A (an example of an aggregate storage device), a fine aggregate storage device 31B (an example of an aggregate storage device), a belt conveyor for coarse aggregate transporting devices 34A (an example of an aggregate transporting device) and a belt conveyor for fine aggregate transporting devices 34B (an example of an aggregate transporting device), a powder storage device 35, a screw conveyor for powder transporting devices 38, a water tank 41, an additive tank 45, and a control device 60 that controls each device.

[0035] The work stage 22 is equipped with a coarse aggregate input port 32A (an example of an aggregate input port), a fine aggregate input port 32B (an example of an aggregate input port), and a powder input port 36. Each input port is fitted with an opening / closing lid, which is closed when materials are not being added.

[0036] Furthermore, the plant unit 20 that constitutes the vehicle-mounted concrete plant 100 for use on public roads does not include a mixer. The mixer 50 shown in Figure 3, etc., is transported to the construction site by another transport vehicle (not shown) and installed on the mixer stand 25 at the construction site, thereby becoming a component of the plant unit 20.

[0037] As shown in Figure 2, after the transport vehicle 10 arrives at the construction site, the vehicle-mounted concrete plant 100 is changed to a position for concrete production. The frame structure 21 that constitutes the plant unit 20 is slidably mounted on the loading platform 11 of the transport vehicle 10, and when the plant unit 20 slides backward in the X1 direction, the mixer stand 25 located at the rear of the frame structure 21 extends outwards to the rear of the loading platform 11, forming a support position for the mixer 50.

[0038] A generator 18 is mounted at the front of the loading platform 11 to supply power to each device during concrete manufacturing. When the transport vehicle 10 is traveling on public roads, the generator 18 is housed inside the frame structure 21. As shown in Figure 2, when the plant unit 20 slides backward at the construction site, the generator 18 on the loading platform 11 is exposed to the outside and made available for use.

[0039] Here, although not shown in the diagram, the frame structure 21 does not slide on the loading platform 11, the mixer stand is housed in the loading platform 11 when the transport vehicle 10 is traveling on public roads, and at the construction site, the mixer stand may be configured to extend outwards from the rear of the loading platform 11 by rotating or sliding from its housed position.

[0040] A handrail 23 is provided around the work stage 22 so as to be able to move up and down or be attached, and as shown in Figure 2, the handrail 23 is installed around the work stage 22 when concrete is manufactured. For example, the handrail 23 may be extended upward by an actuator such as a cylinder mechanism (not shown), or it may be installed by a worker manually.

[0041] In the vehicle-mounted concrete plant 100, workers on the work stage 22 load materials such as coarse aggregate, fine aggregate, and cement (powder) in batches through various input ports. During this material loading operation and other various operations, the work stage 22 is surrounded by handrails 23, ensuring worker safety.

[0042] Furthermore, when the transport vehicle 10 is traveling on public roads, the handrail 23 does not protrude upward as shown in Figure 1. This eliminates the risk of exceeding the height limit for special vehicle applications due to the upward protrusion of the handrail 23, and makes it possible to set the height of the work stage 22 to the limit of the height limit.

[0043] After the mixer stand 25 extends to the rear of the loading platform 11, as shown in Figure 3, the mixer 50, which has been transported to the construction site by another transport vehicle, is lifted via a wire W by heavy machinery such as a crane and lowered in the X2 direction onto the mixer stand 25 that extends to the rear of the loading platform 11.

[0044] Two rails 26, formed from H-shaped steel or the like, are installed on the mixer stand 25. Meanwhile, endless rollers 55 (an example of a sliding jig) are attached to the underside of the mixer 50 at positions corresponding to each rail 26.

[0045] As shown in Figure 4, the endless roller 55 is a jig in which a plurality of steel rollers 55b are installed in an endless manner inside a steel jig body 55a, and each roller 55b rotates on its own axis while the whole system revolves, thereby reducing frictional resistance and moving the object placed on top. Here, as the sliding jig, materials other than the endless roller 55 that can reduce frictional resistance, such as a sheet of Teflon® material, may be used.

[0046] The side of the endless roller 55 is provided with a fall prevention means 56 to prevent the endless roller 55 from engaging with or disengaging from the rail 26.

[0047] Returning to Figure 3, a lever block (registered trademark) L is installed at any point on the frame structure 21, and a chain C extending from the lever block L is attached to the mixer 50. By using the lever block L to pull the mixer 50 in the direction of X3, which is the loading platform side, the mixer 50 is moved along the rail 26 to a predetermined mixing position.

[0048] As shown in Figure 5, after the mixer 50 is moved to the mixing position on the rail 26, the stopper 57 is fixed to the rail 26, thereby preventing the endless roller 55 from moving and completing the installation of the mixer 50 in the mixing position.

[0049] As shown in Figure 9, the top surface of the mixer 50 is provided with a receiving port 52a for receiving coarse aggregate supplied from the coarse aggregate conveying device 34A, a receiving port 52b for receiving fine aggregate supplied from the fine aggregate conveying device 34B, a receiving port 52c for receiving cement supplied from the powder conveying device 38, a receiving port 52e for receiving water supplied from the supply pipe 42 leading to the water tank 41, and a receiving port 52f for receiving additives supplied from the supply pipe 47 leading to the additive tank 45. In addition, the top surface of the mixer 50 is equipped with receiving ports for receiving mixing materials, air vents, a camera for imaging the mixing process inside the mixer 50, and lighting equipment for illuminating the inside of the mixer 50 when imaging is being performed.

[0050] When the mixer 50 is installed in the mixing position, each material is positioned to be received into the corresponding receiving port of the mixer 50, thereby forming a concrete manufacturing plant unit 20.

[0051] Figure 6 shows a vehicle-mounted concrete plant 100 at a construction site, where the mixer 50 is a component of the plant unit 20 and ready for concrete production. As shown in Figures 6 and 7, multiple support legs 27 (two in the illustrated example) are installed below the mixer stand 25 that extends to the rear, eliminating the cantilevered state of the mixer stand 25 and providing stable support for the mixer 50.

[0052] As shown in Figure 7, a splash-proof cover 58 is attached to the rear of the mixer 50 to prevent concrete discharged from an unillustrated outlet located below from scattering to the sides. The concrete discharged from the mixer 50 can be received in various ways, such as by bringing a wheel loader close to it or by setting up a receiving container such as a bucket. The splash-proof cover 58 can be removed as needed if it gets in the way of receiving the concrete.

[0053] Here, as shown in Figure 8, the mixer stand 25 may be supported by support legs 28 equipped with wheels 29. Because the mixer stand 25 is supported by these movable support legs 28, when the transport vehicle 10 moves at a low speed at the construction site, the mixer stand 25 can move along with the transport vehicle 10 while supporting the mixer 50. Therefore, it becomes possible to respond to the need to move the concrete plant 20 in accordance with changes in the concrete pouring location at the construction site.

[0054] Next, referring to Figure 9, we will explain the individual components of the plant unit 20 that make up the vehicle-mounted concrete plant 100, and the control details of each device by the control device 60.

[0055] The coarse aggregate storage device 31A has a storage hopper whose cross-section decreases in diameter as it goes downwards. This storage hopper serves as a weighing tank and, for example, weighs and stores one batch of coarse aggregate. Below the coarse aggregate storage device 31A, a belt conveyor, the coarse aggregate transport device 34A, is connected. The coarse aggregate transported in the Y1 direction by the coarse aggregate transport device 34A falls downward in the Y2 direction at the downstream end of the coarse aggregate transport device 34A and is received by the receiving port 52a of the mixer 50. An on-off valve 53a is provided between the receiving port 52a and the mixer body 51. When coarse aggregate is supplied to the mixer body 51, the on-off valve 53a opens and the coarse aggregate is supplied.

[0056] The fine aggregate storage device 31B has a storage hopper whose cross-section decreases in diameter as it goes downwards. This storage hopper serves as a weighing tank and, for example, weighs and stores one batch of fine aggregate. Below the fine aggregate storage device 31B, a fine aggregate conveying device 34B, which is a belt conveyor, is connected. The fine aggregate conveyed in the Y3 direction by the fine aggregate conveying device 34B falls downward in the Y4 direction at the downstream end of the fine aggregate conveying device 34B and is received into the receiving port 52b of the mixer 50. An on-off valve 53b is provided between the receiving port 52b and the mixer body 51. When fine aggregate is supplied to the mixer body 51, the on-off valve 53b opens and the fine aggregate is supplied.

[0057] The powder storage device 35 has a storage hopper whose cross-section narrows as it goes downwards. This storage hopper serves as a weighing tank and weighs and stores, for example, one batch of powder (cement). Below the powder storage device 35, a screw conveyor, which is a powder transport device 38, is connected. The powder transported in the Y5 direction by the powder transport device 38 falls downward in the Y6 direction at the downstream end of the powder transport device 38 and is received by the receiving port 52c of the mixer 50. An on-off valve 53c is provided between the receiving port 52c and the mixer body 51. When powder is supplied to the mixer body 51, the on-off valve 53c opens and fine aggregate is supplied.

[0058] The water tank 41 is connected to the receiving port 52e of the mixer 50 via a supply pipe 42 such as a hose. The supply pipe 42 includes a supply pump 43a, a flow meter 43b, and an on-off valve 43c, which are driven when water is supplied. For example, when supplying the water required for one batch of concrete production to the mixer 50, the on-off valve 43c opens, the supply pump 43a is driven, and a predetermined amount of water is supplied from the water tank 41 in the direction of Y7.

[0059] The water tank 41 can store, for example, about 500 liters of water (enough for several batches), and water is supplied to the water tank 41 by means of a pump or by a hose connected to a water supply.

[0060] The additive tank 45 contains additives such as setting retarders and water-reducing agents, depending on the type of concrete being manufactured. The additive tank 45 is connected to the receiving port 52f of the mixer 50 via a supply pipe 46. The supply pipe 46 includes a supply pump 47a, a flow meter 47b, and an on-off valve 47c, which are driven when additives are supplied. For example, when supplying the additives required for one batch of concrete to the mixer 50, the on-off valve 47c opens, the supply pump 47a is driven, and a predetermined amount of additives is supplied from the additive tank 45 in the direction of Y8.

[0061] The mixer 50 includes a mixer body 51, a load cell 51b for measuring the total weight and the weight of the materials when various materials are put into the mixer body 51, various receiving ports 52a, 52b, 52c, 52e, 52f and corresponding on-off valves 53a, 53b, 53c, 53e, 53f, a blade 51a located inside the mixer body 51 for kneading the various materials that have been put in, and a mixing motor 54 for rotating the blade 51a in the Y10 direction.

[0062] The control device 60 is installed, for example, inside the plant unit 20 as an operation panel or control panel, and receives input such as mix design data for concrete production and control data for sequentially controlling each device when various materials are put into the mixer 50 and mixed. Through the control of the control device 60, the plant unit 20 executes, for example, the production of one batch of concrete.

[0063] Here, the sequence of steps in the production of one batch of concrete includes loading and weighing the materials into each storage device (weighing tank), loading the materials into the mixer 50, mixing by the mixer 50, and discharging the produced concrete. In this specification, a production method in which, for example, a worker loads the materials for one batch, and the other processes are performed automatically, is referred to as "semi-automatic production." On the other hand, a production method in which, for example, materials for two or three batches have been loaded, and all processes related to the production of each batch of concrete are carried out sequentially and automatically, is referred to as "automatic production."

[0064] The vehicle-mounted concrete plant 100 and the stationary concrete plant 200 described below are semi-automatic concrete plants because workers on the work stage 22 input materials, for example, one batch's worth, through each input port. On the other hand, the stationary concrete plant 300 described below is equipped with external aggregate storage devices and external powder storage devices, and is a concrete plant that can continuously produce, for example, three batches' worth of concrete. Since the production of the second and third batches of concrete is carried out continuously without material input, it is an automated concrete plant.

[0065] The above-mentioned mix design data includes, for example, the type of cement, aggregate dimensions, concrete slump, air content, water-cement ratio, fine aggregate ratio, unit water content, and additive amounts. The above-mentioned control data includes the flow rate from supply pumps 43a and 47a, the opening and closing timings of valves 53a to 53f, 43c, and 47c, the material transport timings by screw conveyors 38 and belt conveyors 34A and 34B, and the drive timing and drive time of mixer 50.

[0066] According to the illustrated vehicle-mounted concrete plant 100, when the concrete plant unit 20 is loaded onto the cargo bed 11 of the transport vehicle 10 and transported, the mixer 50 is not included in the plant unit 20, and the mixer 50 becomes a component of the plant unit 20 during concrete production. In other words, by excluding the weight of the mixer 50 during transport by the transport vehicle 10, the weight of the plant unit 20 other than the mixer 50 within the vehicle weight range that does not require special vehicle application can be made as large as possible, and the weight of the mixer 50 that is transported separately can also be made as large as possible. As a result, a mixer 50 with high mixing performance and concrete supply capacity can be applied without requiring special vehicle application, and a concrete plant with a high concrete supply capacity can be formed.

[0067] For example, while conventional mobile plant mixers generally have a capacity of 250L and a maximum of 500L, the mixer 50 equipped in the vehicle-mounted concrete plant 100 can achieve a capacity of approximately 750L. Furthermore, the mixing motor 54 can be fitted with a mixing motor that has more than 1.5 times the performance of conventional motors, enabling the production of special concretes such as highly viscous UFC and UHPFRC that place a high load on the mixer.

[0068] By applying such a mixer 50, the mixing performance for ordinary concrete is 3 to 4 m 3 It can achieve approximately / h, and in terms of mixing performance for special concrete, it is 2 to 3 m 3 It can achieve approximately / h.

[0069] Furthermore, since the concrete plant unit 20 is mounted on the cargo bed 11 of a single transport vehicle 10, there is no concern that multiple vehicles or plant units will occupy a large area at the site. For example, in the repair of road bridge decks, repair work can be carried out while the road remains in use. Therefore, the vehicle-mounted concrete plant 100 is suitable for narrow construction sites, construction sites where the concrete manufacturing location changes frequently, and construction sites where concrete pouring is performed in a relatively short time.

[0070] [Concrete plant according to the second embodiment] Next, an example of a concrete plant according to the second embodiment will be described with reference to Figures 10 to 12. Here, Figure 10 is a perspective view showing a stationary concrete plant, an example of a concrete plant according to the second embodiment, in a self-supporting state with its outriggers extended. Figure 11 is a perspective view showing the state in which the transport vehicles have been moved aside and the stationary concrete plant has been formed, and Figure 12 is a perspective view showing the state in which an external fiber storage device and an external fiber conveying device have been installed in the stationary concrete plant. Here, the stationary concrete plant shown is equipped with an external aggregate storage device and an external powder storage device as components, and the concrete plant according to the third embodiment described below is similarly equipped, so the explanation referring to the block diagram schematically showing the components of the stationary concrete plant will be given in the concrete plant according to the third embodiment described below.

[0071] The stationary concrete plant 200 shown in Figures 11 and 12 is a stationary concrete plant in which the plant unit 20, which is mounted on the loading platform 11 of a transport vehicle 10 and transported to the construction site, stands upright on the road surface R, and the transport vehicle 10 moves out of the way to form the posture for concrete production.

[0072] As shown in Figure 10, after the transport vehicle 10 arrives at the construction site with the plant unit 20 loaded on its platform 11, multiple outriggers 15 are extended from the sides of the frame structure 21 of the plant unit 20, and the plant unit 20 is jacked up using jacks 16 such as hydraulic jacks provided on the outriggers 15. Here, the extension of the outriggers 15 from the frame structure 21 can be done either by an automatic mechanism (not shown) equipped on the frame structure 21 that extends the outriggers 15 to the sides, or by a worker manually attaching the outriggers 15.

[0073] Multiple jacks 16 lift the plant unit 20, allowing the plant unit 20 to stand independently on the road surface R.

[0074] In the self-contained plant unit 20, the mixer stand 25 is already in a state where the mixer can be installed, and the mixer 50 is installed on the mixer stand 25 in the manner described above.

[0075] Subsequently, as shown in Figures 10 and 11, the transport vehicle 10 moves back in the X5 direction, thereby forming a stationary concrete plant 200 in which the configuration of the plant unit 20 during transport is maintained.

[0076] In a stationary concrete plant 200, concrete may be manufactured while maintaining the configuration of the plant unit 20 during transport. However, in the illustrated example, as shown in Figure 12, an external mixing material supply device 80 is installed on the plant unit 20 during transport, resulting in a concrete plant that includes a plant unit 20A that enables the manufacture of ultra-high-strength fiber-reinforced concrete such as UFC and UHPFRC.

[0077] The configuration of the kneading material supply device 80 will be described in detail below, but the kneading material supply device 80 has a lifting platform 83 (an example of a kneading material transport device) which is erected on the road surface R near the mixer 50 and has an elevator above it and guide rails 85, and a container 81 (an example of a kneading material storage device) in which the kneading material is contained.

[0078] The elevator pulls the housing 81 along the guide rail 85 to above the input opening of the mixer 50, and the housing 81 rotates so that the mixing material is supplied to the mixer 50.

[0079] With the stationary concrete plant 200, the transport vehicles 10 are not occupied at the construction site, and therefore, during the concrete pouring period, the transport vehicles 10 that have been moved can be used for other purposes.

[0080] Furthermore, as shown in Figures 10 and 11, in the configuration in which the plant unit 20 is maintained during transport, the area occupied by the plant unit 20 can be made as small as that of a vehicle-mounted concrete plant 100. Therefore, it is suitable for construction sites with limited space, similar to the vehicle-mounted concrete plant 100, or for construction sites where the concrete pouring time is longer than that of the vehicle-mounted concrete plant 100.

[0081] Then, as shown in Figure 12, the plant unit 20A equipped with an external mixing material supply device 80 is formed, making it possible to manufacture ultra-high-strength fiber-reinforced concrete and the like.

[0082] Regarding the occupied area, if the vehicle-mounted concrete plant 100 is designed to fit within a single lane 2.5m wide, when its functionality is expanded to a self-supporting, stationary concrete plant 200, the outriggers 15 will extend, for example, to occupy two lanes 5m wide. In a configuration where an external mixing material supply device 80 is installed, the roadside will be utilized, for example, to occupy an area of ​​about 6m width.

[0083] [Concrete plant according to the third embodiment] Next, an example of a concrete plant according to the third embodiment will be described with reference to Figures 13 and 14. Here, Figure 13 is a perspective view showing a stationary concrete plant, which is an example of a concrete plant according to the third embodiment, and Figure 14 is a block diagram schematically showing each component of the plant unit that constitutes the stationary concrete plant.

[0084] The stationary concrete plant 300 shown in Figure 13 is a stationary concrete plant in which external aggregate storage devices 71A, 71B and an external powder storage device 75 are installed in addition to the plant unit 20A of the concrete plant 200, thereby increasing the aggregate storage capacity and powder storage capacity.

[0085] As aggregate and powder storage capacities are increased, for example, while a vehicle-mounted concrete plant 100 and a stationary concrete plant 200 are semi-automatic concrete plants that produce one batch of concrete, the stationary concrete plant 300 becomes an automated concrete plant that continuously produces, for example, two or three batches of concrete. However, the stationary concrete plant 300 allows for selection between automated and semi-automatic manufacturing, and semi-automatic manufacturing may be selected.

[0086] An external coarse aggregate storage device 71A (an example of an external aggregate storage device) and the coarse aggregate input port 32A are connected by an external coarse aggregate transport device 74A, which is a belt conveyor; an external fine aggregate storage device 71B (an example of an external aggregate storage device) and the fine aggregate input port 32B are connected by an external fine aggregate transport device 74B, which is a belt conveyor; and an external powder storage device 75 and the powder input port 36 are connected by an external powder transport device 78, which is a screw conveyor. In addition, the receiving port 52d of the mixer 50 (see Figure 14) is positioned below the mixing material input position of the fiber storage device 81, which constitutes the mixing material supply device 80.

[0087] The external coarse aggregate conveying device 74A and the external fine aggregate conveying device 74B shown in the figure are both surrounded by a cover around the belt conveyor to prevent scattering of coarse and fine aggregate during conveyance. Similarly, the external powder conveying device 78 is also surrounded by a cover around the screw conveyor to prevent scattering of cement during conveyance. In Figure 13, the inclination gradients of the external coarse aggregate conveying device 74A, the external fine aggregate conveying device 74B, and the external powder conveying device 78 are all different, but the inclination gradient of each conveying device is appropriately changed according to the installation position of the corresponding external storage device and the installation position of the corresponding input port on the work stage 22. Furthermore, by using an inclination gradient for each conveying device in this way, the total occupied area of ​​the concrete plant can be made as small as possible, making it possible to apply a stationary concrete plant 300 with expanded functionality in a planar manner to narrow construction sites.

[0088] As shown in Figure 14, the external coarse aggregate storage device 71A has a storage hopper whose cross-section decreases in diameter as it goes downwards. This storage hopper serves as a weighing tank and weighs and stores, for example, one or two batches of coarse aggregate. Below the external coarse aggregate storage device 71A, an external coarse aggregate conveying device 74A is connected. The coarse aggregate conveyed in the Y11 direction by the external coarse aggregate conveying device 74A falls downward in the Y12 direction at the downstream end of the external coarse aggregate conveying device 74A and is supplied to the coarse aggregate storage device 31A via the coarse aggregate input port 32A of the work stage 22.

[0089] The external aggregate storage device 71B has a storage hopper whose cross-section decreases in diameter as it goes downwards. This storage hopper serves as a weighing tank and weighs and stores, for example, one or two batches of aggregate. Below the external aggregate storage device 71B, an external aggregate conveying device 74B is connected. The aggregate conveyed in the Y13 direction by the external aggregate conveying device 74B falls downward in the Y14 direction at the downstream end of the external aggregate conveying device 74B and is supplied to the aggregate storage device 31B via the aggregate input port 32B of the work stage 22.

[0090] The external powder storage device 75 has a storage hopper whose cross-section narrows as it goes downwards. This storage hopper serves as a weighing tank and weighs and stores, for example, one or two batches of powder (cement). An external powder conveying device 78 is connected below the external powder storage device 75. The cement conveyed in the Y15 direction by the external powder conveying device 78 falls downward in the Y16 direction at the downstream end of the external powder conveying device 78 and is supplied to the powder storage device 35 through the powder inlet 36 of the work stage 22.

[0091] The external kneading material supply device 80 is erected on the road near the mixer 50 and has a lifting platform 83 equipped with an elevator 84 above it and a guide rail 85, and a container 81 in which the kneading material is contained. The elevator 84 pulls the container 81 along the guide rail 85 in the Y17 direction above the input opening of the mixer 50, and as the container 81 rotates, the kneading material falls in the Y18 direction and is received into the receiving opening 52d of the mixer 50. An on-off valve 53d is provided between the receiving opening 52d and the mixer body 51, and when fiber material is supplied to the mixer body 51, the on-off valve 53d opens and the kneading material is supplied.

[0092] The stationary concrete plant 300 has a plant unit 20B with expanded functionality compared to the stationary concrete plant 200, which maintains the configuration of the plant unit 20 during transport, making it a concrete plant capable of automatically producing more concrete. This increased concrete production volume and the ability to automatically produce concrete in a stationary concrete plant reduce the number of workers required for concrete mixing, making it suitable for construction sites with relatively long concrete placement periods. The mixing performance of the stationary concrete plant 300 for ordinary concrete is 10 m 3 It can achieve approximately / h, and in terms of mixing performance for special concrete, 3m 3 It is possible to achieve more than / h.

[0093] Here, the mixing materials include fibrous materials and admixtures (coarse aggregate, fine aggregate, powder). Fibrous materials include all materials that can be mixed into concrete, such as metallic fibers (steel fibers, stainless steel fibers) and non-metallic fibers (aramid fibers, nylon fibers, vinylon fibers, polyethylene fibers, polypropylene fibers, carbon fibers, basalt fibers). Admixtures also include all materials that can be mixed into concrete, such as special aggregates, slag, recycled aggregates, limestone, calcium carbonate, etc.

[0094] [Control method for a concrete plant according to this embodiment] Next, with reference to Figures 15 to 19, the specific configuration of the control device provided in each embodiment of the concrete plant and an example of a control method for the concrete plant according to the embodiment will be described. Here, Figure 15 is a diagram showing an example of the hardware configuration of the control device, and Figure 16 is a diagram showing an example of the functional configuration of the control device. Figure 17 is a flowchart showing an example of the control flow of a control method for the concrete plant according to the embodiment.

[0095] As shown in Figure 15, the control device 60 is composed of information processing devices such as a personal computer (PC) or a programmable logic controller (PLC), and is installed as a control panel or operation panel inside the frame structure 21 that forms the plant units 20, 20A, and 20B.

[0096] The information processing devices constituting the control device 60 include a CPU (Central Processing Unit) 61, main memory 62, auxiliary storage 63, input / output interface 64, and communication interface 65, all interconnected by a connection bus 66. The main memory 62 and auxiliary storage 63 are recording media readable by a computer. Note that each of the above components may be provided individually, or some components may be omitted.

[0097] The CPU 61, also known as an MPU (Microprocessor) or processor, may be a single processor or a multiprocessor. The CPU 61 is a central processing unit that controls the entire control unit 60, which consists of a computer. For example, the CPU 61 expands a program stored in the auxiliary storage device 63 into an executable format in the working area of ​​the main memory device 62, and controls peripheral devices through the execution of the program, thereby providing a function that matches a predetermined purpose.

[0098] The main memory 62 stores computer programs executed by the CPU 61 and data processed by the CPU 61. The main memory 62 includes, for example, flash memory, RAM (Random Access Memory), and ROM (Read Only Memory). The auxiliary memory 63 stores various programs and various data on a recording medium that can be read and written freely, and is also called an external memory device. The auxiliary memory 63 stores, for example, the OS (Operating System), various programs, various tables, etc. The OS includes, for example, a communication interface program that exchanges data with external devices connected via the communication IF 65. External devices connected to the control device 60 include the measuring tanks in each storage device, the belt conveyors and screw conveyors that constitute each transport device, the supply pump 43a, flow meter 43b, and on-off valve 43c leading to the water tank 41, the supply pump 47a, flow meter 47b, and on-off valve 47c leading to the additive tank 45, and the mixing motor 54 and various on-off valves that constitute the mixer 50.

[0099] The auxiliary storage device 63 is used, for example, as a storage area that assists the main memory 62, and stores computer programs executed by the CPU 61, data processed by the CPU 61, etc. The auxiliary storage device 63 is a silicon disk containing non-volatile semiconductor memory (flash memory, EPROM (Erasable Programmable ROM)), a hard disk drive (HDD), a solid-state drive, etc. Examples of auxiliary storage devices 63 include drives for removable recording media such as CD drives, DVD drives, and BD drives, and examples of removable recording media include CDs, DVDs, BDs, USB (Universal Serial Bus) memory, SD (Secure Digital) memory cards, etc.

[0100] The input / output IF64 is an interface for inputting and outputting data between the control device 60 and the connected devices. For example, keyboards, pointing devices such as touch panels and mice, and input devices such as microphones can be connected to the input / output IF64. The control device 60 receives operation instructions from the operator operating the input device via the input / output IF64.

[0101] Furthermore, the input / output IF64 can be connected to display devices such as liquid crystal displays (LCDs) and electroluminescent (EL) panels, as well as output devices such as printers and speakers.

[0102] Communication IF65 is the interface between the control device 60 and the network to which it is connected. Communication IF65 receives measurement data from each weighing tank and weighing meter via various networks, including public networks such as the Internet, wireless networks such as mobile phone networks, dedicated networks such as VPNs (Virtual Private Networks), LANs (Local Area Networks), Bluetooth (registered trademark), infrared communication, etc. Alternatively, the data may be transmitted to communication IF65 via a wired connection.

[0103] As shown in Figure 16, the control device 60 provides various functions, at least the communication unit 67, the control unit 67A, the determination unit 67B, the display unit 68, and the storage unit 69, through the execution of a program by the CPU 61. Here, at least a portion of the above processing functions may be provided by a DSP (Digital Signal Processor), a GPU (Graphics Processing Unit), etc. Similarly, at least a portion of the above processing functions may be provided by a dedicated LSI (large scale integration) such as an FPGA (Field-Programmable Gate Array), a numerical processing processor, an image processing processor, or other digital circuits.

[0104] The communication unit 67 receives weighing data for, for example, one batch of coarse aggregate, fine aggregate, cement, water, and additives weighed in each weighing tank, as well as weighing data from the load cell 51b regarding the total weight of the various materials finally fed into the mixer body 51, and stores it in the storage unit 69.

[0105] The storage unit 69 stores, for example, specified data for one batch of various materials. The determination unit 67B determines that the weighing data for the various materials is the specified data and notifies the control unit 67A that the various materials are ready to be mixed.

[0106] The storage unit 69 further stores control standard values ​​for mixer load values ​​and flow test values ​​during mixing by the mixer 50. Regarding these control standard values, in the production of ordinary concrete, the control standard values ​​for the primary mixing stage, where aggregate, cement, and water (and additives) are mixed, are stored. On the other hand, in the production of ultra-high-strength fiber-reinforced concrete such as UFC and UHPFRC, since both primary mixing (mixing aggregate, cement, and water (and additives)) and secondary mixing (mixing the primary mix material produced in the primary mixing stage with the mixing material) are performed, the control standard values ​​for both primary and secondary mixing are stored.

[0107] Upon receiving notification from the determination unit 67B that the mixture is ready for mixing, the control unit 67A sequentially drives the conveying devices and supply pumps to supply coarse aggregate, fine aggregate, cement, water, and additives to the mixer body 51 in a predetermined order, drives the mixing motor 54 to perform primary mixing, and produces primary mixed material.

[0108] When the primary paste is manufactured, the determination unit 67B compares the primary paste with the management standard value of the primary paste stored in the storage unit 69. If the primary paste does not meet the management standard value, the control unit 67A causes the mixer 50 to perform additional mixing, and additional primary mixing is carried out.

[0109] If the concrete being manufactured is ordinary concrete, the manufacturing of the ordinary concrete is completed when the judgment unit 67B determines that the primary mixer and any additional primary mixer meet the management standards.

[0110] On the other hand, if the concrete to be manufactured is ultra-high-strength fiber-reinforced concrete, after the determination unit 67B determines that the primary mixer and additional primary mixer meet the management standard values, the control unit 67A drives the mixing motor 54 to perform secondary mixing, which involves mixing the primary mixer (or additional primary mixer) with the mixing material, and manufactures the secondary mixer.

[0111] When the secondary paste is produced, the determination unit 67B compares the secondary paste with the management standard value of the secondary paste stored in the storage unit 69. If the secondary paste does not meet the management standard value, the control unit 67A causes the mixer 50 to perform additional mixing, and additional secondary mixing is carried out.

[0112] The manufacturing of ultra-high-strength fiber-reinforced concrete, etc., is completed when the judgment unit 67B determines that the secondary mixer and any additional secondary mixers meet the management standards.

[0113] In the stationary concrete plant 300, for example, two or three batches of concrete are automatically produced. By setting continuous production in the control panel, the above flow for the production of each batch is executed continuously.

[0114] The display unit 68 displays a settings screen for setting various initial settings when manufacturing concrete.

[0115] The display unit 68 further displays the time history waveform of the mixer load value during the mixing of various materials by the mixer 50. The same screen of the display unit 68 plots the control standard values ​​(ranges) related to the mixer load value (mixing power value, mixing current value, etc.) set at the completion of the primary and secondary mixing processes.

[0116] The administrator can use the display unit 68 to confirm whether the primary and secondary mixed materials fall within their respective ranges of specific control standards at the completion of each stage of primary and secondary mixing. Here, the illustrated example shows a configuration in which a comparison with the specific control standards is performed at the completion of each stage of primary and secondary mixing. However, other configurations may be applied, such as a configuration in which a comparison with the control standards is performed only at the completion of primary mixing, or a configuration in which a comparison with the control standards is performed only at the completion of secondary mixing. For example, the system may be configured so that the desired option can be selected from options such as a configuration in which a comparison with the control standards is performed at the completion of either primary or secondary mixing, or a configuration in which a comparison with the control standards is performed at the completion of both primary and secondary mixing.

[0117] Next, an example of a control method for a concrete plant according to an embodiment will be described with reference to Figures 17 and 18A to 18D.

[0118] As shown in Figure 18A, the display screen of the control device 60 shows a screen selection screen, which is an example of a setting operation screen 68A. This screen is a touch panel that allows selection of various screens such as the main screen, mixing screen, timer screen, specifications screen, and weighing screen. In addition, the display screen may also show the mixing status inside the mixer 50, which has been captured by a camera or video camera.

[0119] First, initial setup is performed before manufacturing the concrete. This initial setup involves, for example, one batch or 1 m 3 Set the proportions for the minutes, set timers for when each ingredient is added, set a timer for the mixing time, set the proportion number, and set the mixing volume and number of times.

[0120] Figure 18B shows an example of the selected mixing screen. For volume settings, for example, set the mixing volume for one batch, and set the number of batches for the number of mixes. In S Surface Water Setting, set the surface water content of the sand, and in G Surface Water Setting, set the surface water content of the gravel. Selecting Write switches to the weighing screen, and selecting Screen Selection switches to the screen selection screen.

[0121] By selecting the timer screen on the screen selection screen, the screen switches to the mixing timer setting screen shown in Figure 18C. Note that the timer screen also includes other settings, such as a release timer setting screen for setting the timer for waiting for material release to the mixer 50, but these are not shown in the illustration.

[0122] As shown in Figure 18C, when manufacturing ultra-high-strength fiber-reinforced concrete, etc., and both primary and secondary mixing are required, the primary mixing time, additional primary mixing time, secondary mixing time, and additional secondary mixing time are set. When manufacturing ordinary concrete, the secondary mixing time, etc., are set to zero.

[0123] The mixer gate opening time sets how many seconds after the mixer gate fully open limit switch is detected the gate will close. The mixer gate half-open time 1 sets the time the mixer gate is held in the half-open 1 position, and sets the opening degree from fully closed to half-open 1, half-open 2, and fully open in terms of time. Furthermore, the mixer gate half-open hold time 1 sets how many seconds the mixer gate is held in the half-open 1 position, and automatically switches to the half-open 2 operation when the time is up.

[0124] Figure 18D shows an example of the operation screen in the setting operation screen 68A. This operation screen displays the setting and elapsed time (countdown) for each mixing time. Touching the mixing time section switches to the mixing timer, which displays whether or not there is a second mixing (secondary mixing) and whether or not there are additional mixing 1 and 2 (additional primary mixing and additional secondary mixing).

[0125] Touching "Stop All" will stop all weighing equipment except the mixer. With the mixer gate set to automatic / manual, the mixer gate will open and close automatically after mixing is complete in the automatic setting. If you do not want the mixer gate to open after mixing is complete, set it to the "off" (manual) setting. After checking the slump of the primary and secondary mixers, the mixer gate will open and close automatically in the automatic setting.

[0126] Starting with "Additional Mixing 1" initiates additional mixing after the initial mixing is complete, and the mixer is activated. Starting with "Secondary Mixing" initiates secondary mixing after the initial additional mixing is complete, and the mixer is activated after the mixing materials are added.

[0127] The "Additional Mixing 2 Start" command initiates additional mixing after the completion of the second mixing cycle, activating the mixer. The "Automatic Discharge Start" command initiates automatic discharge from the mixer gate after the completion of additional mixing 2, simultaneously activating the mixer.

[0128] Using the various setting operation screens 68A described above, various settings in the control device 60 and drive control of the mixer 50 are performed.

[0129] Returning to Figure 17, after performing various initial settings as described above (step S10), the control device 60 instructs the mixer 50 to perform a predetermined amount of primary mixing (step S12).

[0130] Once the predetermined time for the primary mixing is completed and the primary mixed material is produced, the display screen 68 of the control device 60 displays the time-series data of the mixer load value during the primary mixing and the control standard value, as shown in Figure 19. Here, Figure 19 shows the time-series data up to the point of completion of the secondary mixing, but in reality, at the point of completion of the primary mixing, only the time-series data up to that point and the control standard value during the primary mixing are displayed.

[0131] In Figure 19, the mixer is started at time t0 to begin dry mixing, and water is added at time t1. After the mixing power value, which is the mixer load value, rises sharply by time t2 and reaches a primary peak, it is visually confirmed whether the convergence value of the mixing power value falls within the set primary control reference range by time t3, which is set as the primary mixing time. In the illustrated example, it is shown that the convergence value falls within the primary control reference range.

[0132] Returning to Figure 17, at the completion of the first mixing, it is determined whether the first mixed material meets the primary control standard value (step S14). If it does not meet the primary control standard value, the control device 60 instructs the mixer 50 to perform additional first mixing (step S16).

[0133] Once the additional primary mixing for a predetermined time is completed and the additional primary mixing material has been produced, it is determined again whether the additional primary mixing material meets the primary control standard value (step S18). If it does not meet the primary control standard value, the control device 60 instructs the mixer 50 to perform another additional primary mixing (step S20).

[0134] On the other hand, if the additional primary mixer meets the primary control standard value for mixer load, or if the primary mixer already meets the primary control standard value for mixer load at the primary mixer stage, a predetermined amount is taken from the primary mixer or additional primary mixer to form a test specimen, and a flow test is performed on the test specimen.

[0135] If the flow test results show that the test specimen meets the primary control standard for flow values, then the primary mixer and any additional primary mixers are considered to meet all of the primary control standards, and the process can proceed to secondary mixing.

[0136] As shown in Figure 19, after adding the mixing material to the primary mixer or additional primary mixer that has been confirmed to meet the primary control standard value at time t5, the control device 60 causes the mixer 50 to perform secondary mixing for a predetermined time (step S22 in Figure 17).

[0137] Once the secondary mixing process for a predetermined time is complete and the secondary mixed material is produced, the display screen 68 of the control device 60 displays the time-series data of the mixer load value during secondary mixing and the control standard value, as shown in Figure 19. In the illustrated example, after the mixing material is added at time t5, the mixing power value, which is the mixer load value, rises sharply by time t6 to reach a secondary peak, and then the convergence value of the mixing power value by time t7, which is set as the secondary mixing time, is shown to be within the secondary control standard value range.

[0138] Returning to Figure 17, at the completion of the secondary mixing, it is determined whether the secondary mixed material meets the secondary control standard value (step S24). If it does not meet the secondary control standard value, the control device 60 instructs the mixer 50 to perform additional secondary mixing (step S26).

[0139] Once the additional secondary mixing for a predetermined time is completed and the additional secondary mixing material has been produced, it is determined again whether the additional secondary mixing material meets the secondary control standard value (step S28). If it does not meet the secondary control standard value, the control device 60 instructs the mixer 50 to perform another additional secondary mixing (step S30).

[0140] On the other hand, if the additional secondary mixer meets the secondary control standard value for mixer load, or if the secondary mixer already meets the secondary control standard value for mixer load at the secondary mixer stage, a predetermined amount is taken from the secondary mixer or additional secondary mixer to form a test specimen, and a flow test is performed on the test specimen.

[0141] If the flow test results show that the test specimen meets the secondary control standard value for flow, then the secondary mixer and any additional secondary mixer will be considered to meet all of the secondary control standard values, and the production of ultra-high-strength fiber-reinforced concrete, etc., will be completed.

[0142] According to the control flow of the control device 60 shown in the figure, high-quality primary and secondary pastes can be manufactured.

[0143] Furthermore, by monitoring the mixer load value on the display screen 68 during manufacturing, it is possible to prevent mixer shutdowns due to high loads, especially when adding and mixing ingredients, and to prevent malfunctions of related equipment.

[0144] Although not shown in the diagram, a mobile device such as a tablet owned by one or more administrators may also have a screen similar to the display screen 68 and the setting operation screen 68A, allowing administrators located away from the mixer 50 to remotely configure various settings for the mixer 50 during mixing and to check the relationship between the mixer load value and the management standard value.

[0145] The control flow by the control device 60 described above will be executed by a program installed on the control device 60.

[0146] [Mixing Material Supply Device] Next, with reference to Figures 20 to 23, an example of a mixing material supply device provided in a concrete plant according to each embodiment will be described. Here, Figure 20 is a perspective view showing an example of a mixing material supply device consisting of a fiber storage device and a fiber conveying device, and Figure 21 is a diagram showing the state in which the housing, which is the fiber storage device, is housed inside the safety measures that constitute the mixing material supply device. Furthermore, Figure 22 is a diagram following Figure 20 showing the state in which the housing moves upward and rotates above the mixer, and Figure 23 is a diagram following Figure 22 showing the state in which the housing rotates further and the mixing material is fed into the mixer.

[0147] The mixing material supply device 80 is a component of the stationary concrete plants 200 and 300, and is an external device for supplying mixing materials to the mixer 50.

[0148] As shown in Figure 20, the kneading material supply device 80 is erected on the road near the mixer 50 and has a lifting platform 83 equipped with an elevator 84 above it and two guide rails 85, and a container 81 in which the kneading material is stored.

[0149] As shown in Figure 21, a retractable safety barrier 82 is installed on the road in front of the lifting platform 83, and a predetermined amount of mixing material is poured into the container 81 housed inside the safety barrier 82. After the mixing material is poured into the container 81, the safety barrier 82 is closed, and the process then proceeds to towing the container 81 upwards.

[0150] A hoist or other lifting device 84 is installed above the lifting platform 83. Meanwhile, two guide rails 85 are installed parallel to each other on the lifting platform 83, sloping upward from the street.

[0151] As shown in Figure 20, the housing 81 includes a wheel axle 81b with wheels 81d at both ends, a wheel axle 81c similarly with wheels 81e at both ends, and a rotating handle 81f that is rotatably attached to the housing 81.

[0152] The two wheels 81d on wheel axle 81b and the two wheels 81e on the other wheel axle 81c are each movably engaged with the two guide rails 85. The wire W extending from the hoist 84 is attached to the rotating handle 81f.

[0153] Here, the container 81 may have a rotatable opening and closing lid (not shown) above it. The container 81 may also be equipped with a measuring device (not shown) that stores a storage tolerance value for the amount of kneaded material to be stored and is configured to sound an alarm when the amount of kneaded material to be stored reaches the storage tolerance value.

[0154] As shown in Figure 21, for example, after one batch of mixing material has been put into the container 81, the hoist 84 is driven as shown in Figure 20, and the container 81 is pulled in the Z1 direction above the inlet of the mixer 50 along the two guide rails 85 via the wire W. As shown in Figure 20, of the two wheel axles 81b and 81c, wheel axle 81b is located in the forward direction of movement.

[0155] Furthermore, as shown in Figure 20, each guide rail 85 is equipped with two branch rails 86a and 86b that branch off in two directions above it, and the lower guide rail 85 and the two branch rails 86a and 86b form a rail that is Y-shaped when viewed from the front.

[0156] As the housing 81 is towed upward, the two wheels 81d of the wheel axle 81b, which is located in the forward direction of movement, enter in the Z2 direction into the branch rail 86a on the mixer 50 side, which is located above each guide rail 85, as shown in Figure 22. At this stage, the two wheels 81e of the wheel axle 81c, which is located in the rear direction of movement, are in the middle of each guide rail 85.

[0157] The housing 81 is pulled further upward, and as the two wheels 81d reach the end of the branch rail 86a, the wheel axle 81b comes to a stop ahead of the other wheels.

[0158] As the housing 81 is pulled further upward, the housing 81 rotates in the Z3 direction with the wheel axle 81b, which is already stopped, as the pivot point.

[0159] As shown in Figure 23, further rotation of the housing 81 causes the two wheels 81e of the wheel axle 81c, which is located at the rear in the direction of movement, to enter the other branching rail 86b in the Z4 direction.

[0160] Then, as the container 81 is pulled further upward, the container 81 rotates further around the wheel axle 81b as the pivot point, and when the two wheels 81e reach the end of the branch rail 86b, the container 81 rotates further in the Z5 direction, and the entire amount of the kneading material contained in the container 81 is put into the mixer 50.

[0161] After the mixing material is loaded into the mixer 50, the towing by the hoist 84 is released, and the container 81 is gradually lowered along the two guide rails 85 and returned to the inside of the safety barrier 82, thereby preparing it for loading the next batch of mixing material.

[0162] The kneading material supply device 80 has a relatively simple configuration, does not require a large footprint, and enables efficient feeding of kneading materials into the mixer 50.

[0163] Furthermore, other embodiments may be used in which other components are combined with the configurations listed in the above embodiments, and the present invention is not limited in any way to the configurations shown herein. In this regard, modifications can be made without departing from the spirit of the present invention, and can be appropriately determined according to the application form. [Explanation of Symbols]

[0164] 10: Transport vehicles 11: Truck bed 15: Outrigger 16: Jack 18: Generator 20, 20A, 20B: Plant Unit 21: Frame structure 22: Work Stage 23: Handrail 25: Mixer stand 26: Rail 27:Support leg 28:Support leg 29: Wheels 31A: Coarse aggregate storage device (aggregate storage device) 31B: Fine aggregate storage device (aggregate storage device) 32A: Coarse aggregate input port (aggregate input port) 32B: Fine aggregate input port (aggregate input port) 33A: Coarse aggregate storage hopper 34A: Coarse aggregate conveying equipment (aggregate conveying equipment, belt conveyor) 34B: Fine aggregate conveying device (aggregate conveying device, belt conveyor) 35: Powder storage device 36:Powder inlet 38: Powder conveying equipment (screw conveyor) 41: Water tank 42: Supply pipe 43a: Supply pump 43b:Flowmeter 43c: Shut-off valve 45: Additive Tank 46: Supply pipe 47a: Supply pump 47b:Flow meter 47c: Shut-off valve 50: Mixer 51: Mixer unit 51a: Blade 51b: Load cell 52a, 52b, 52c, 52d, 52e, 52f: Receiving ports 53a, 53b, 53c, 53d: Shut-off valves 54: Mixing motor 55: Slide jig (endless roller) 55a: Jig body 55b: Koro 56: Falling prevention means 57: Stopper 58: Splash prevention cover 60: Control device 67: Communications Department 67A: Control Unit 67B: Judgment section 68: Display section (display screen) 68A: Settings operation screen 69: Storage Unit 71A: External coarse aggregate storage device (external aggregate storage device) 71B: External aggregate storage device (external aggregate storage device) 74A: External coarse aggregate conveying device (external aggregate conveying device, belt conveyor) 74B: External aggregate conveying device (external aggregate conveying device, belt conveyor) 75: External powder storage device 78: External powder conveying device (screw conveyor) 80: Mixing material supply device 81: Mixing material storage device (external mixing material storage device, container) 81b, 81c: Wheel axle 81d, 81e: Wheels 81f: Rotating handle 82: Safety measures 83: Mixing material conveying device (external mixing material conveying device, lifting platform) 84: Elevator (hoist) 85: Guide rail 86a, 86b: Branch rail 100: Vehicle-mounted concrete plant 200,300: Stationary concrete plant W: wire L: Lever block C: Chain R: Road surface

Claims

1. A concrete plant control method comprising a concrete plant unit comprising at least a mixer and a control device for performing drive control of the mixer, The control device is A primary mixing control system is used to manufacture a primary mixed material by having the mixer perform a primary mixing process in which aggregate, powder, and water are mixed together. A secondary mixing control system is used to manufacture a secondary mixing material by having the mixer perform a secondary mixing process in which the primary mixing material and the mixing material are mixed together. If, upon completion of either or both of the primary and secondary mixing processes, the set control criteria values ​​for each process are not met, an additional mixing control is executed, causing the mixer to perform either or both of the additional primary and secondary mixing processes. The control device further, As an option for performing a comparison with the aforementioned control standard value, the system offers the option to perform the comparison with the control standard value at the completion of either the primary or secondary mixing stage, or to perform the comparison with the control standard value at the completion of both the primary and secondary mixing stages. A method for controlling a concrete plant, characterized in that an administrator selects one of the options, and the control device performs a comparative determination.

2. The control method for a concrete plant according to claim 1, characterized in that the aforementioned control standard value is at least a control standard value relating to the mixer load value.

3. The concrete plant control method according to claim 1 or 2, characterized in that the aforementioned control standard value is a control standard value relating to the mixer load value and the flow test value.

4. The control device is equipped with a display screen, The display screen shows the time-series data of the mixer load value and the control standard value related to the mixer load value. The concrete plant control method according to claim 2 or 3, characterized in that the display screen confirms whether the set management standard values ​​are met at the completion of either the primary mixing or the secondary mixing, or both.

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