Porous concrete massifs on the automated contour bend machine with electro-programming control “ÐÈÔ-1»
The main aim of production porous concrete items is production of quality products with maximally possible level of specified sizes. Concerning physical-mechanical characteristics of products, made of porous-concrete, it’s obvious that they’ve reached rather high level. But if to speak about geometry – dimensions accuracy and surface quality of wall blocks of majority of producers are usually lacking. Geometry and quality of blocks surface are determined by using technology of formation.
There are many different kind of mechanisms for getting foam concrete and gas concrete mixtures, but only four techniques of wall blocks forming are known at the time.
1. Pouring of foam concrete into bar moulds – the simplest and widespread technique. Working under this technique it’s possible to get blocks with accurate geometrical size using only expensive heavy-gage sheets metal moulds. At seeming simplicity of this technique it’s necessary to have great stock of difference size moulds, that unreasonably increases steel consumption and, consequently, equipment cost. While forming a foam concrete block a peelable cement film with hydrophobic properties is generated on the sides, contacting with metal mould walls. This film makes difficulties while plastering. That’s why it’s desirable to make cutting of side surfaces. Besides pouring of foam concrete into metal mould does not give to blocks accurate edges and right angles. This causes their worse positioning while laying and, consequently, degrades its quality.
2. At the present time the structural cutting on a certain stage of getting the plastic strength by cellular-concrete raw-massifs becomes widespread, but this technique possesses a number of considerable shortages.
Firstly, the dimensions accuracy of blocks is not enough because of string walking, especially in cases of its sliding on the side faces of blocks (so-called «barrel» defect), that prevents laying such blocks on clue and lowers the quality of laying on the mortar.
Secondly, short cutting of the middle bottom block part, which is caused by considerable length of the string and impossibility to provide its enough tension, by horizontal position of strings and rounding by string high-density inclusions – leads to breaking off of the corner pieces.
Thirdly, blocks cutting at a certain moment of technological cycle needs thoroughly technology observance and does not allow to accumulate massifs before cutting, that lowers technology flexibility.
Wavy sides surface after cutting can be estimated as advantage of string cutting technique. The products surface after cutting has small tracery, which promotes better adhesion between masonry mortar and mortar for plastering. Packed surface layer has variotrop structure, its peeling wasn’t observed.
3. Cutting with circular blade saw also has a number of considerable shortages:
– to cut 600 mm height monoblock it needs one disk with large diameter or two disks precisely matched in the cutting line. Either the first, or the second decisions are rather expensive. Disks wobbling leads to low-quality cutting.
– disk (disks) sharpening requires special equipment and is expensive procedure;
– coming in and out of the spinning disk into massif body results in extraction of foam concrete pieces – chippings on blocks are formed. To solve this problem the monoblock needs to harden more, but in this case much dust will be generated during gutting process and cutting saw teeth are abraded faster.
4. Cutting of massifs with closed chain and belt saws has recently acquired more and more adherents. Different Russian manufacturers developed several types of cutting lines and machines. The specific feature of cutting technology on such lines is the necessity to separate massif from the pallet and further multiple tipping of sawn half-finished blocks on several sequentially set contour bend saws during cutting process. The massif should have enough mechanical strength (1.0 MPa and higher up to final strength of the type). This implies the necessity the prolongation of the process of porous concrete mixture curing in metal mould, that reduces to lowering of their turnover, increasing of metal moulds stocks, increasing of volume and area of heat-humidity treatment chambers. Besides, tipping process need additional equipment installation and because of heightened strength of cutting massifs it’s necessary to use expensive belt saws with special carbide teeth, which abraded too fast and this causes abrupt increase of the prime cost of the cutting process.
Besides heightened energy consumption this technique has one more disadvantage – dusting.
In spite of shown disadvantages, in existing value system, when the quality of the product is the first importance fact and becomes the main competitive advantage, producing wall blocks made of porous concrete using mechanical technique comes to the foreground.
On the basis of analysis of the wall blocks production on various famous Russian equipment using belt saw, OOO “IIC” specialists came to the conclusion that majority of abovementioned disadvantages can be eliminated if massifs are sawn after stage of gaining plastic strength within the stage of hardening beginning, when the string cutting technique can not be used by this time.
Firstly, massifs can be cut on the bottom part of the ôîðìîîñíîñòêè, thereby exclude operations of separating and tipping of monoblock and semiblocks.
Secondly, the necessity to use expensive imported carbine saw falls away, cutting process is carried out by cheap Russian belt metal saw in standard model, without carbine teeth.
Thirdly, only one saw is used for cutting.
Fourthly, there is no dusting, because cellular-concrete mixture has certain humidity at cutting moment.
Besides this, it’s important that time period for cutting fulfilment is considerably longer if to compare with string cutting and it’s possible to accumulate dismantled massifs before cutting.
Starting developing of a new contour band machine OOO “IIC” specialist used their own long experience of developing and manufacturing string cutting machines (“ÓÐÊ-2”, “ÓÐÊ-2ì”, “ÓÐÊ-3”). There were produced more then 70 such machines since 2002 up to 2007. At the same time permanent experimental-designing works and researches of new in essence technique of porous concrete raw-massifs cutting using different types of belt saws took place. After prolonged and numerous tests they were managed to find the optimal parameters of cutting mode and choose the most multipurpose type of belt saw. At the end of 2006 as the result of done work the unique cutting equipment of a new generation was created – automated bandsaw cutting machine with electronic-programmed control «Ðèô-1» for cutting large, 1240?12400?610 mm sized, cellular-concrete massifs.
The machine set includes unit for cutting the top side of the massif, one horizontal contour band module and è coordinating-transporting unit. All the mechanisms variable-frequency electric drive. «Ðèô-1» is equipped with convenient and easy-to-work control panel. Necessary dimensions of cut (block dimensions) are set on electric panel of operator. None of additional operations for machine changeover for new sizes are necessary. Besides, the display on the operator panel shows the analysis of machine work in real-time mode. Manual control is provided for adjustment the machine or for working in semiautomatic mode. Positioning and transporting of the cutting massif takes place on the coordinating table of the machine.
The machine works like that: pallet-trolley with massif, hardened enough, is taken by special positioning transporter and goes to cutting machine «ÐÈÔ-1». At the first stage the top side of the massive is cut off by screw cutter (up to 30 mm) and block length is formed (600 mm). The bottom side of the massif has strictly horizontal surface due to usage of rigid thick-walled bakelized veneer sheet in the pallet. At the second stage cross and length cutting of the massif by horizontal saw with sequential number of cycles of cutting module lifting and lowering takes place; cutting step and width and height dimensions are fixed by the coordinating table operation. After this parted into blocks massif is rolled on the overpassing trolley to the pushing transporter to be places into tunnel thermos chambers for heat and humidity treatment.
Besides this, «Ðèô-1» can be equipped with a belt knife for calibration of top and bottom sides of massif under special order.
Machine can operate with saws of two types:
– cutting massifs with gained plastic strength;
– cutting massifs with gained designed strength.
Specification for «ÐÈÔ-1»
Capacity (regarding final products), ì3/÷ ………………………………………………………… up to 5
Design capacity, kWt…………………………………………………………………………………………… 4,5
Floor-level space of the machine with coordinating-transporting unit, mm………4,6? 4,5
Weight, kg …………………………………………………………………………………………………………… 3500
Cutting accuracy, mm……………………………………………………………………………………………±1
Cutting elements…………………………………………………………………………screw cutting and belt saw (horizontally located)
Quantity of saws……………………………………………………………………………………………………1
Width of kerf, mm …………………………………………………………………………………………………from 1,1 till 1,5
Maximum height of cut, mm …………………………………………………………………………………600
Dimensions of mould for producing foam concrete massifs, mm…………………………1240 ? 1240 ? 600
Block dimensions, main standard size, mm ……………………………………………………………198 ? 300 ? 598
Finished products outcome from one massif, m3 …………………………………………………0,86
Quantity of cut sides in block ……………………………………………………………………………… 5 (6)
Time for one massif cutting in automatic mode, min ……………………………………………9,5.
Time for machine changeover for a new size, min ………………………………………………… 1
Time for belt saw exchange, min …………………………………………………………………………… 5
Lifting mechanism drive ……………………………………………………………………………………… electromechanical
Operating modes ………………………………………………………………………………………………… automatic, semiautomatic, manual
Permissible strength, kg/sm3 ……………………………………………………………………………… from 2 till 45
One operator is enough to operate the machine. The control can be handled manually or in automatic mode.
The main advantage of the present cutting technology can be named the possibility of the short equipment changeover to produce blocks of any size. Among other advantages are: accuracy and quality of wall blocks surface. Such blocks allow to make masonwork using special thin-layer mortar clue.
More then 10 production samples of “ÐÈÔ-1”were installed to the beginning of the 2008 we are planning to produce at our enterprise not less the 30 such machineries in 2008.
All the experience of machineries usage in production conditions showed the high reliability of all actuating mechanisms, extremely low level of expenses for raw materials (for 1 m3 ãof final products from 10 till 15 rubles, dependently on the filler used).
Regarding purchasing of equipment contact marketing department
ÎÎÎ «Incorporated Industrial Company»
Russia, city Kaluga, Svetlaya St., 37
Tel. +7 4842 70 02 52,
+7 4842 70-04-92