Method of manufacturing wood concrete products

Abstract

FIELD: wood processing.SUBSTANCE: method for producing wood concrete products includes preparing the main raw material being wood chips in a chipper, then separating it with a cyclone into two fractions, dust and the larger fraction, which is sent to a drum sieve, where it is divided into two subsequent fractions, the larger fraction is sent to a storage bin, then to a skip-dosing machine, with its moisture content checked and poured into the main mixer, in parallel, a solution of porous cement-activated mixture is prepared in a mixer-activator with the supply of technical foam and the prepared porous mixture is mixed with wood chips in the main mixer, regulating its mobility, after which the product is formed.EFFECT: increase in the efficiency, quality and speed of production of wood concrete products.4 cl, 8 dwg

Description

[0001] Field of technology to which the invention relates

[0002] The invention relates to methods for manufacturing products, including wall material for prefabricated house kits made of porous arbolite.

[0003] Technology Level

[0004] A technological line for the production of arbolite wall blocks is known from the prior art (SU 1216001 A1, 07.03.1986), including equipment for a molding mixture preparation station, installed in a technological sequence on trailer vehicles, equipment for molding and storage stations, and for the purpose of utilizing wood waste directly at the sites of its formation, the molding mixture preparation station is equipped with an installation for preparing arbolite mixture, containing a hopper with a container installed underneath for soaking wood pulp and a wood chip bin with a transport pipeline installed on trailer vehicles.

[0005] This line and the method for producing arbolite products using it are low-efficiency, have high energy losses, the production process and equipment do not have the necessary technological efficiency and reliability to allow for the quick and high-quality production of arbolite products.

[0006] The claimed invention eliminates the above-mentioned disadvantages.

[0007] Disclosure of invention

[0008] The problem solved by the invention is the creation of an effective method that allows for the rapid and high-quality production of arbolite products with low energy losses.

[0009] The technical result consists in increasing the efficiency, quality and speed of production of arbolite products.

[0010] The technical result is achieved due to the fact that the method for producing products from arbolite includes the following stages:

[0011] - prepare the main raw material - wood chips:

[0012] - place the required amount of raw material into the chipper for grinding, and then separate the ground raw material using a cyclone into two fractions - dust and larger,

[0013] - from the cyclone, the first dust fraction is sent to a settling chamber with water, and the second, larger fraction is sent to a drum sieve,

[0014] - in the drum sieve, the larger fraction is separated into two subsequent fractions, where the fraction of the sifted material from under the drum sieve is loaded into a separate container, and the main fraction - wood chips - is fed into the storage bin for further production;

[0015] - after preparing the wood chips, they are loaded from the storage bin into the skip-dispenser, where they are checked for moisture;

[0016] - then wood chips are poured from the skip-dispenser into the main mixer;

[0017] - after or in parallel, prepare the working solution of porous cement-activated mixture in a mixer-activator:

[0018] - fill the activator mixer with water,

[0019] - fill the weigh batcher container with the cement-mineral composition, from which it is discharged into the activator mixer,

[0020] - feed the technical foam solution into the mixer-activator,

[0021] - mix all the components added to it in the activator mixer;

[0022] - then the activator mixer is filled with air and the prepared mixture is pumped into the main mixer to the prepared wood chips, where they are mixed at a certain time interval;

[0023] - simultaneously monitor the preparation of the mixture and, if necessary, control its mobility using a water dispenser connected to the main mixer;

[0024] - the prepared mixture from the main mixer is loaded into the side-mounted equipment installed on the pallet, which is then sent for curing with subsequent stripping.

[0025] In addition, the chipper contains a disk with windows, on which blades with a sectoral overlap and knives are installed at an angle.

[0026] In addition, the mixer-activator contains a rotor with blades mounted at an angle on the shaft in a spiral.

[0027] In addition, the main mixer is made single-shaft with a multi-directional cut screw auger, the blades of which are directed from the edges to the center towards each other.

[0028] In addition, the side equipment is a metal assortment of the necessary parts, pre-cut using laser cutting and welded together into the required shape configuration, in the sides of which magnetic blocks are installed.

[0029] Brief description of drawings

[0030] Fig. 1 shows the production line diagram;

[0031] Fig. 2 shows the body of the chipper (a - with windows for air intake, b - with counter knives, c - with windows and knives, d - with the motor part, side view).

[0032] Fig. 3 shows the main mixer (a - general view, b - top view, c - side view).

[0033] The following elements are indicated by numbers on the figure:

[0034] 1. Chipper (wood shredder);

[0035] 2. Dust fan;

[0036] 3. Cyclone with wet filter;

[0037] 4. Belt conveyor from under the drum sieve;

[0038] 5. Drum sieve;

[0039] 6. Scraper conveyor to the wood chip storage bin;

[0040] 7. Wood chip storage bin with feed conveyor;

[0041] 8. Belt conveyor;

[0042] 9. Main mixer skip;

[0043] 10. Main mixer;

[0044] 11. Self-propelled vibratory platform;

[0045] 12. Mixer-activator;

[0046] 13. Dry component dispenser;

[0047] 14. Dry component de-aging agents;

[0048] 15. Cement silo;

[0049] 16. Control panels;

[0050] 17. The body of the chipping machine is made like a radial fan;

[0051] 18. Chipper frame;

[0052] 19. Windows in the body for air intake;

[0053] 20. Receiving loading neck for processed raw materials;

[0054] 21. Cutter shaft bearing housing;

[0055] 22. Counter knives;

[0056] 23. Chipper cutter;

[0057] 24. Calibration sieve;

[0058] 25. Windows in the cutter for the passage of crushed material;

[0059] 26. Chopping knife;

[0060] 27. Limiting ring - nozzle installed on the blades;

[0061] 28. Cutter blades;

[0062] 29. Internal combustion engine;

[0063] 30. Manual transmission;

[0064] 31. Cardan shaft;

[0065] 32. Shaft with bearing assemblies of small pulley;

[0066] 33. Cutter shaft;

[0067] 34. Small pulley;

[0068] 35. Large pulley;

[0069] 36. Cutter-shaft mounting coupling;

[0070] 37. Mixing chamber of main mixer;

[0071] 38. Mixer shaft;

[0072] 39. Mixer reducer;

[0073] 40. Gearbox coupling with shaft;

[0074] 41. Mixer motor;

[0075] 42. Bearing block;

[0076] 43. Wood chip loading hopper;

[0077] 44. Loading hopper lifting gear motor;

[0078] 45. Ready mix unloading window;

[0079] 46. Loading hopper lifting mechanism block;

[0080] 47. Loading hopper lifting mechanism cable winding reel;

[0081] 48. Cable.

[0082] Implementation of the invention

[0083] The proposed production method can be carried out on a production line consisting of separate interconnected production sections, representing a conveyor method for the production of products from organic concrete of various nomenclatures.

[0084] The method includes the following main steps:

[0085] - prepare the main raw material - wood chips:

[0086] - place the required amount of raw material into the chipper for grinding, and then separate the ground raw material using a cyclone into two fractions - dust and larger,

[0087] - from the cyclone, the first dust fraction is sent to a settling chamber with water, and the second, larger fraction is sent to a drum sieve,

[0088] - in the drum sieve, the larger fraction is separated into two subsequent fractions, where the fraction of the sifted material from under the drum sieve is loaded into a separate container, and the main fraction - wood chips - is fed into the storage bin for further production;

[0089] - after preparing the wood chips, they are loaded from the storage bin into the skip-dispenser, where they are checked for moisture;

[0090] - then wood chips are poured from the skip-dispenser into the main mixer;

[0091] - after or in parallel, prepare the working solution of porous cement-activated mixture in a mixer-activator:

[0092] - fill the activator mixer with water,

[0093] - fill the weigh batcher container with the cement-mineral composition, from which it is discharged into the activator mixer,

[0094] - feed the technical foam solution into the mixer-activator,

[0095] - mix all the components added to it in the activator mixer;

[0096] - then the mixer-activator is filled with air and the prepared mixture is pumped into the main mixer to the prepared wood chips, where they are mixed at a certain time interval;

[0097] - simultaneously monitor the preparation of the mixture and, if necessary, control its mobility using a water dispenser connected to the main mixer;

[0098] - the prepared mixture from the main mixer is loaded into the side-mounted equipment installed on the pallet, which is then sent for curing with subsequent stripping.

[0099] The production line for the manufacture of wood concrete products includes a chipping machine, a pneumatic-mechanical sorting station, a storage bin for organic raw materials, a set of automatic dosing equipment with containers for storing dry and liquid components, a mixer-activator with blades, a main mixer, and additionally metal side equipment on magnetic blocks.

[0100] Chipper 1 is a disc-blade unit, where the disc is a flywheel consisting of a stack of torsion-shaped discs with windows. The blades have a specific angle and sector-shaped overlap to maximize the flow during the destruction and transport of the processed material, with minimal energy loss throughout the unit. The angle of the chipping knives additionally ensures maximum efficiency in the crushing of the incoming raw material, while significantly reducing wear on the chipping knives. The chipper is equipped with a calibrating (drum) screen. The calibrating screen is installed along the entire plane of the flywheel, thus describing a circle, which in turn maximizes high-quality separation and ensures a rapid and complete discharge of finished chips. A specially designed snail-shaped housing 17 further enhances the efficiency of the entire unit.

[0101] The disc chipper cutter has several ports. These ports are designed to transfer the wood cut during processing into the interior of the drum. The size of the ports is calculated based on the volume of raw material being processed and to prevent clogging with processed wood. The ports are teardrop-shaped and angled at 25 degrees relative to the horizontal plane. This ensures efficient transfer of the workpiece cut by the knives. The same number of knives are angled to the same angle as the ports. This creates a non-impact cutting effect, as they do not cut the workpiece at a right angle, but rather a sliding, saber-like action. This maximizes the knife's working area, reducing the load on the knife by more than half, and correspondingly increasing the service life of the knives.

[0102] The chipper cutter has several teardrop-shaped blades (the number of blades equals the number of windows), limited at the upper side by a ring-shaped disk (a sector overlap), and serve as a blower fan. The blades (vanes) are attached perpendicular to the cutter and are positioned at an angle of 25 degrees (relative to the horizontal plane). The rotation of the milling cutter with blades is designed in such a way that the incoming material cut by the knives, passing through the windows, enters the internal space of the drum, where it is collected by the blades. At the same time, the blades, taking the processed material, easily transfer it to the mesh of the fractional grid located around the disc cutter, without loss of power of the unit, since at an angle of 25 degrees and the centrifugal effect, the processed material is unhindered torn off from the blades, which affects the rapid release of the internal space of the drum and reduces the load on the unit as a whole.The disk, which is shaped like a ring and limits the upper part of the blades, serves to stabilize the blades themselves from bending loads, and also sets the direction of movement when the blades eject the processed material, and also serves as a guide nozzle for the air coming from the outside of the housing.

[0103] The chipper cutter has several knives (the number of knives is equal to the number of windows / blades) made of alloy tool steel (e.g., 9ХС, hardened to 55 units). The knives are installed in special grooves on the cutter along the edges of the windows, the angle of the grooves having the same angle as the windows. The knives have through longitudinal elliptical windows for bolting to the cutter. The bolts have machined heads, so loosening the nuts and turning the heads 90 degrees allows for quick removal of the knives without disassembling or unscrewing all the bolts. To maintain tension on the bolts during removal, they are spring-loaded by springs installed in the wells of the elliptical channels of the cutter. The knives at the ends of the opposite cutting side have a pair of bolts for adjusting the knife extension in relation to two counter knives, fixedly attached to the receiver body of the input throat of the chipping machine.The knives, also having a 25-degree angle, perform a saber-shaped cut when cutting the workpiece. This increases the cutting efficiency many times over, since with different sizes of input raw material, the working area of ​​the knife during cutting will always be maximum, and the load on the knife will be reduced. As a result, the dynamic loads on all components will also decrease, while the cutting efficiency will increase.

[0104] The disc chipper housing can be designed similarly to a dust fan, a type of medium- and high-pressure radial fan specifically designed to efficiently move solids of varying sizes, dust-laden air, and gas-air mixtures, with an efficiency of 80 percent or more. This housing design results in higher wood removal efficiency than other similar disc chipper housings.

[0105] Fig. 2 (a, b, c, d) shows a chipping machine, where the following are visible: the body 17 of the chipping machine, made as a radial fan, the frame 18, the windows 19 in the body for the air inflow, the receiving loading neck 20 for the processed raw material, the body 21 of the milling cutter shaft bearing, the counter. Knives 22, cutter 23 of the chipping machine, calibration sieve 24, windows 25 in the cutter for the passage of the material being crushed, chopping knife 26, limiting ring - nozzle 27 mounted on the blades, blades 28 of the cutter, internal combustion engine 29 (installation of an electric motor of the same power is possible), mechanical gearbox 30, cardan shaft 31, shaft 32 with bearing assemblies of the small pulley, shaft 33 of the cutter, small pulley 34, large pulley 35, coupling 36 for fastening the cutter to the shaft.

[0106] The mixer-activator is designed to activate the cement-mineral base and prepare a porous activated cement-mineral base solution by introducing technical foam at minimum rotor speeds. It features individual blade geometry for high-quality mixing at various speeds, which enables both solution activation and the preparation of the foam-cement-mineral base without foam breakdown during short mixing periods. The mixer-activator features pneumatic unloading and can be operated with a gerotor or other transfer pump. A drain valve is provided for collecting a sample during the preparation of the foam-cement-mineral base while the mixer-activator is operating. Rotor speed is controlled by a frequency converter. The rotor blades are wedge-shaped with a 45-degree pitch angle and a pitch that ensures the blades are installed on the shaft in a spiral pattern.This type of blades and their spiral arrangement ensure the fastest possible activation and homogenization of dry and liquid components, as well as the operation of a single piece of equipment—the mixer-activator for preparing the porous activated cement-mineral base. Using a single unit allows for the fastest possible use of the activated solution without compromising the quality of the resulting mixture, such as stratification or loss of activity. Specifically, the technical foam can be immediately injected when the rotor speed is reduced, without fear of foam breakdown.

[0107] The 12-piece mixer-activator features a sealed design with a loading hatch and the necessary butterfly valves for controlling sample collection, mixture discharge, and technical foam delivery. An air line is connected to the mixer-activator, allowing for the ready-mixed mixture to be pumped through hoses. A gerotor pump with a receiving hopper or interchangeable pumps can be used to ensure the ready-mixed solution is delivered through hoses without adversely affecting the mixture being pumped.

[0108] Fig. 3 (a, b, c, d) shows the main mixer 10, where the following are visible: mixing chamber 37 of the main mixer, mixer shaft 38, mixer gearbox 39, coupling clutch of the gearbox with the shaft 40, mixer electric motor 41, bearing block 42, wood chip loading hopper 43, loading hopper lifting motor-reducer 44, finished mixture unloading window 45, loading hopper lifting mechanism block 46, loading hopper lifting mechanism cable winding reel 47, cable 48.

[0109] The main mixer is a single-shaft type with a multi-directional split screw conveyor, allowing for the most efficient mixing of viscous organic concrete. The mixer shaft speed is selected based on the maximum volume of concrete being mixed, while minimizing the detrimental impact on the porous organic concrete mix. The mixer features an inspection platform for visual monitoring of the mixing process, a discharge hatch with the ability to discharge the finished concrete by volume, and a skip-dispenser 9 with a lift and a safety system to prevent it from tipping over in the event of a power outage. The mixer is equipped with a batcher-receiver mounted on a self-propelled vibrating platform 11 with a rail tread, allowing it to receive the finished concrete and then move the batcher to the molds using a crane or directly pour the finished mix into the mold mounted on this vibrating platform.

[0110] The main mixer features a horizontal mixing shaft. The shaft is designed like a split auger, with blades directed toward each other from the edges. This shaft effectively mixes the viscous, semi-dry organic filler with the foamed cement-mineral mixture. Due to its efficient mixing, the mixer's capacity was increased without increasing the motor-gearbox section. The blade design ensures thorough mixing of the organic filler, even with its acute, jagged shape, without compromising the integrity of the cement-air envelope. The optimally selected mixer shaft speed, thanks to the reduction in speed, also helps reduce the harmful effects of the mixing process on the finished mixture.

[0111] Metal flange tooling can be designed and manufactured in various configurations for the production of a wide range of products. It consists of a pre-cut metal assembly of the required parts, laser-cut and welded together to form a mold with magnetic blocks installed in the flanges to hold the flange tooling in a precise position on the pallet mold. Precisely manufactured and correctly aligned flanges with magnetic blocks on the pallet allow for a product's geometry to be achieved with a tolerance of no more than 1-2 mm over its entire length.

[0112] The pneumatic-mechanical sorting station is installed after the chipper and is a complex of interconnected equipment consisting of a dust fan 2, a cyclone 3, a drum screen 5, a filter for hydro-settling of the dust fraction with a receiver, a scraper conveyor 6, a conveyor 4 for removing the sorted fraction of raw materials from under the drum screen, a stationary frame with replaceable soft disposable containers (big bags) installed on it.

[0113] Bunker 7 for storing organic raw materials is equipped with a dosing complex, which allows for the accumulation and storage of the required amount of raw materials for a shift, as well as dosing it according to the operator’s instructions, and is a box-shaped storage tank with a built-in elevator scraper conveyor, operating in continuous mode as the raw materials are filled in the bunker, as well as with a belt conveyor 8 for further loading of the skip-dosing unit of the main mixer.

[0114] The automatic dosing equipment system with storage tanks for dry and liquid components is an automatically programmable station for dispensing the required quantities of dry and liquid components based on operator input. It includes silos for binders with a combined auger feed system, storage bins for mineral powders (primarily in big bags) with auger conveyors, tanks for liquid solutions of mineralizers and catalysts with pneumatic aeration mixing and pumping equipment, a storage bin 13 for dry components of the cement-mineral base with electric valves, strain gauges, and a filter, and a control panel with electronic control equipment.

[0115] The line begins with the preparation of the main raw material: wood chips. This raw material is produced from softwood slabs, which are waste wood brought in from forest processing plants. The primary equipment for obtaining this raw material is a chipper, which enables the rapid production of high-quality wood chips in the required volume and in accordance with GOST standards. The operator and assistant load the required amount of slabs into the chipper's receiver, visually monitoring the entire processing process, and also monitor the sorting line, subsequently replacing the filled big bags with sorted small chips for small-piece products. This team also monitors the filling of the chip storage bin for the main types of products, as well as maintenance and repair of this equipment in these areas.The chipper is connected via a ventilation hose to a dust-removing fan, which transfers the chips from the chipper through the ventilation hose into a cyclone. In the cyclone, the chips are separated into two main fractions: one, the dusty one, is discharged through the ventilation hose into a settling chamber filled with water, while the other is directed through the lower discharge hose into a drum screen. The drum screen effectively separates the two fractions. The fraction screened from the drum screen is loaded into a single-use flexible container (FIBC) and used to manufacture partition blocks, while the main fraction, obtained through a thorough, multi-stage, and efficient processing process, is fed into the receiver of an inclined scraper conveyor. The inclined scraper conveyor delivers the required working fraction of aggregate to the storage bin.

[0116] The required volume of finished raw material—wood chips—has arrived in the storage bin, allowing the scheduled production to begin. The porous wood concrete preparation section operator, after checking the availability of all raw materials and performing technical preparation of the equipment, begins mixing the mixture according to a preset recipe programmed into the line's ECU. Monitoring the operation of all units in this section, he or she switches the necessary devices on and off.

[0117] The storage bin has an overhead elevator scraper conveyor that distributes the supplied filler from the inclined scraper conveyor, rising to the upper limit as it accumulates. Filler can be withdrawn from the storage bin at any point during its filling. The overhead elevator scraper conveyor delivers filler on demand to the inclined belt conveyor, which in turn feeds the filler into the mixer's volumetric skip batcher, where the operator controls the fill level of the batcher.

[0118] The mixture preparation process begins with loading the required amount of wood chips from the storage bin via a belt conveyor into the skip-dispenser, where it is checked for moisture. At this time, the activator-mixer is automatically filled with water and the required liquid chemicals, and the storage bin of the skip-dispenser is automatically filled from the dry component storage bins.

[0119] After filling the dispenser skip with wood chips, the operator lifts the skip and pours it into the main mixer. The automatic feed line, including the dispenser and liquid chemical pump, is activated, using containers containing a pre-prepared liquid mineralizer solution for the wood chips. Once the storage-dispenser hopper is filled, the operator dumps the dry cement-mineral base into the activator mixer, monitoring the mixing time and speed.

[0120] At this time, the working solution of the porous cement-activated mixture is being prepared. Preparation begins with filling the activator mixer with water using an automatic batcher. At this point, the automatic batcher also fills the weigh batcher with the cement-mineral mixture. Mineral additives are fed via screw conveyors from the receivers of the installed ageing units, where the large-capacity containers with the necessary mineral additives are stored, into the weigh batcher's common tank. Cement from the silos is also fed via screw conveyors into the common tank of the weigh batcher.

[0121] After filling the weigh batcher's common tank, the operator discharges the dry components through a connected flexible hose into the mixer-activator. As the solution is prepared, the technical foam solution is fed from another tank via an automatic dispenser and a dynamic foam generator. This allows for rapid activation of the solution and high-quality preparation of the foam-cement-mineral base. The activator mixer is filled with air, and the prepared mixture is pumped through a flexible hose connecting the activator mixer to the main mixer, where the prepared mineralized chips are mixed at a predetermined time interval. The operator monitors the solution preparation and, if necessary, controls its flow using a water dispenser connected to the main mixer.The prepared mixture is discharged from the main mixer through a lower hatch into pre-prepared and lubricated forms mounted on a self-propelled rail trolley (vibrating platform) with vibrators attached to assist in placing the mixture. The prepared forms are then removed from under the mixer and lifted by crane for curing and subsequent stripping. The process is repeated.

[0122] Drying freshly stripped molds in winter can be done in a dedicated drying chamber. Due to the large size and weight of the molds and finished products, they are moved using a crane.

[0123] As the finished product matures, it is released to the customer. The finished products are loaded into trailers using a grab and stacked in rows according to the scheme: large panels at the bottom, small ones at the top.

[0124] The method described above, due to the structured chain of production stages and the availability of appropriate equipment, ensures highly efficient, fast and high-quality production of arbolite products.

Claims

1. A method for producing arbolite products, characterized by the fact that it includes the following stages: - prepare the main raw material – wood chips: - the required amount of feedstock is placed in a chipping machine with a flywheel-shaped disk, on which blades with a sectoral overlap and knives are mounted at an angle, consisting of a pack of torsion disks with teardrop-shaped windows for transferring wood cut during processing into the interior of the drum, and a calibration sieve installed along the entire plane of the flywheel, while the crushed raw material is separated by a cyclone into two fractions - dust and larger, the first of which is sent to a settling chamber with water, and the second - to the drum sieve, in which the larger fraction is separated into two subsequent fractions, where the fraction of the material sifted out from under the drum sieve is loaded into a separate container, and the main fraction - wood chips - is sent to a storage bin for further production; - after preparing the wood chips, they are loaded from the storage bin into the skip metering unit, where their moisture content is measured; - then wood chips are poured from the skip-dispenser into the main mixer; - after or in parallel, the working solution of the porous cement-activated mixture is prepared in a mixer-activator: - fill the activator mixer with water; - fill the weigh batcher container with the cement-mineral composition, from which it is discharged into the mixer-activator; - a solution of technical foam is fed into the mixer-activator; - mix all the components added to it in the mixer-activator; - then the mixer-activator is filled with air and the prepared mixture is pumped into the main mixer to the prepared wood chips, where they are mixed; - during the process of preparing the mixture, its mobility is controlled by regulating it using a water dispenser connected to the main mixer; - the prepared mixture from the main mixer is loaded into the side-mounted equipment installed on the pallet, which is then sent for curing with subsequent stripping.

2. A method for producing arbolite products according to paragraph 1, characterized by the fact that a mixer-activator is used, containing a rotor with blades mounted on a shaft at an angle in a spiral.

3. A method for producing arbolite products according to paragraph 1, characterized by the fact that a main mixer is used, made single-shaft with a multi-directional cut screw auger, the blades of which are directed from the edges to the center towards each other.

4. A method for producing arbolite products according to paragraph 1, characterized by the fact that a side-tooling is used, which is an assortment of metal parts pre-cut using laser cutting, welded together into a given shape configuration, in the sides of which magnetic blocks are installed.

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