JP2019188825A - Concrete field mixing production unit - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a concrete on-site kneading production unit suitable for small-scale placing work such as repair work. SOLUTION: A mixer 20, a main hopper 30, a sub hopper 31, a belt conveyor 40, a screw feeder 50, a water supply device 60, and a control device 70 are mounted on a truck bed to be transported and can be loaded and unloaded on a unit platform 10. It is incorporated as one. The belt conveyor 40 and the screw feeder 50 are arranged below the main hopper 30 and the sub hopper 31 arranged on the short side of the unit base 10 and above the mixer 20 arranged on the other short side of the unit base 10. It is installed so as to extend substantially parallel to. [Selection diagram] Fig. 4

Description

  The present invention can produce concrete by mixing concrete materials such as cement, aggregate, and water at the construction site when performing a placement operation (work for pouring concrete into a formwork) at the construction site. The present invention relates to an on-site kneading unit, and more particularly to an on-site kneading manufacturing unit suitable for repairing or repairing an existing structure.

  At present, ready-mixed concrete (so-called ready-mixed concrete) is used in many constructions. Since ready-mixed concrete is manufactured in large quantities based on certain standards in a factory that has been maintained, stable quality concrete is obtained, and the quality is also guaranteed at the time of shipment.

  Since the quality of the ready-mixed rice changes with the passage of time, according to the standard, the carrying time of the ready-mixed food is limited to a certain time. Therefore, in order to stably obtain high-quality concrete using raw concrete, there is a disadvantage that the process from manufacture to transportation and placement must be performed in a limited time.

  In that regard, the on-site kneading, which mixes concrete material and water at the construction site, has the advantage of not being restricted by the transportation time.

  For example, in Patent Document 1, concrete materials such as cement, sand, gravel, and water packed in a predetermined amount are transported to a construction site by a truck separately from the mixer truck, and each concrete material transported at the construction site is transported. A method for producing concrete by kneading with a mixer truck is disclosed.

  There has also been proposed a truck-integrated weighing device capable of weighing and mixing each concrete material with a predetermined composition (Patent Document 2).

  The weighing device is composed of a weighing hopper for cement, a weighing hopper using sand, a weighing hopper for sand, a belt conveyor, and the like, and is assembled integrally with a truck bed. Each concrete material is weighed by a weighing hopper, then sequentially transferred by a belt conveyor, and stored in a container bag.

  Then, the container bag is transported to a construction site, and concrete materials are manufactured by putting each concrete material stored in the container bag into the mixer and kneading it together with the measured water.

JP 2006-123285 A JP 2014-151577 A

  When repairing or renovating existing structures such as office buildings in the city, work hours are often limited to nighttime, and there are some sites where mixer trucks cannot be installed. In addition, there are many sites where it is difficult to use ready-mixed concrete, such as indoors and rooftops, and the amount of concrete required is small compared to new construction, so the site is well-kneaded.

  In such a field, an operator often repeats an operation of manually weighing each concrete material and water and kneading using a small mixer. Therefore, the work burden on the operator is large and the quality of the concrete is likely to vary.

  Moreover, in the case of repair work, unlike the new construction work, it is necessary to adjust the type of concrete material used and the amount of water added to the existing structure, making it difficult to manage manufacturing conditions and measuring errors. There is also a drawback that the risk of occurring is high.

  Accordingly, an object of the present invention is to provide a concrete on-site kneading production unit suitable for small-scale placement work such as repair work.

  In the concrete on-site kneading production unit according to the present invention, a plurality of related devices are integrally incorporated on a unit table that can be loaded on a truck bed and transported and unloaded.

  The related apparatus includes a main hopper and a sub hopper that each receive concrete material, a belt conveyor that conveys the concrete material received by the main hopper and puts it into the mixer, and the concrete material received by the sub hopper. A screw feeder that transports and feeds into the mixer; a water supply device that supplies water to the mixer; and a control device that controls the mixer, the belt conveyor, the screw feeder, and the water supply device.

  The unit table has a shape with a long side when viewed from above, and is configured to be carried on a truck bed. The mixer, the main hopper, the sub hopper, the belt conveyor, the screw feeder, the water supply device, and the control device are integrated into the unit base.

  The mixer is disposed at a central portion on one short side of the unit base, and each of the main hopper and the sub hopper is disposed side by side over substantially the entire other short side of the unit base. Yes. And the said belt conveyor and the said screw feeder are installed so that it may extend substantially in parallel toward the upper part of the said mixer from the downward direction of each of the said main hopper and the said sub hopper.

  Therefore, according to this on-site kneading production unit, the related equipment for producing concrete, such as a mixer, is integrated on the unit base, so it is only necessary to carry the on-site kneading production unit to the construction site and install it. It is easy to work on site.

  In addition, a mixer is installed in the on-site kneading production unit, and a belt conveyor and a screw feeder are provided side by side as means for measuring and feeding the concrete material into the mixer.

  Therefore, a crushed stone having a large particle size can be fed into a mixer using a belt conveyor, and a material having a small particle size can be fed into a mixer using a screw feeder.

  The mixer is preferably a pan-type mixer. That is, it has a bottomed cylindrical kneading container, a driving unit connected to the kneading container, and a stirring blade that is attached to the rotating shaft of the driving unit that protrudes from the center of the kneading container and rotates. It is good as well.

  In addition, for example, the unit table has a rectangular floor surface composed of a short side of 1.5 m or less and a long side of 3 m or less, and the related device is installed so as to fit on the floor surface. The total weight is preferably set to 2000 kg or less.

  Then, it can be easily transported by being loaded on the platform of a small truck, and can be easily loaded and unloaded, which is suitable for small-scale placement work such as repair work.

  According to the on-site kneading production unit of the present invention, even on a small-scale construction site such as repair work, on-site kneading can be easily performed, high-quality concrete can be produced, and quality assurance can also be performed.

It is a flowchart which shows the main processes of the manufacturing method of on-site kneaded concrete. It is a flowchart which shows each process in a material preparation process. (A), (b) is the schematic which shows the bagging form of concrete material. It is a schematic side view which shows an on-site kneading manufacturing unit. It is a schematic plan view which shows an on-site kneading manufacturing unit. It is a schematic side view which shows one form of an on-site kneading manufacturing unit. It is a block diagram which shows the main structures of a control apparatus.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. However, the following description is merely illustrative in nature and does not limit the present invention, its application, or its use.

<Production method of on-site kneaded concrete>
The manufacturing method shown in this embodiment is mainly established for construction sites where work time and work space are limited, such as repair work, repair work, and reinforcement work for existing structures. This is a so-called on-site kneaded concrete manufacturing method in which water is mixed and manufactured at a construction site. This production method is devised so that high-quality can be stably produced on-site kneaded concrete (also simply referred to as concrete) and the quality can be guaranteed.

  FIG. 1 is a flowchart showing the main steps. The manufacturing method includes a material production process S1, a manufacturing unit installation process S2, a material transport process S3, an on-site kneading process S4, a manufacturing condition storage process S5, and the like.

(Material preparation process)
The material production process S1 is a preparation stage process. In material preparation process S1, the concrete material used for preparation of concrete is packaged in a dry state.

  FIG. 2 shows details of the material manufacturing step S1. The concrete material here refers to a solid material other than water used in the production of concrete, and specifically, cement, admixture, sand (fine aggregate), crushed stone (coarse aggregate), and the like. Examples of the admixture include fly ash, silica fume, and blast furnace slag powder. The material of the concrete material itself is common in this industry and can be appropriately selected according to the situation of the construction site.

  In this production method, the moisture of the concrete material used is thoroughly eliminated in order to ensure a high quality of the concrete stably and to ensure the quality.

  Since the moisture content of commonly used cement and admixture is at an error level relative to the amount of water supply, the cement and admixture can usually be used as they are.

  However, aggregates such as sand and crushed stone are generally in a state of containing moisture (surface dry state) even if the surface is dry, and the amount thereof is not small. Therefore, when it is used as it is, the quality of the concrete may become unstable due to the variation in the amount of water. In particular, it is easily affected when a small amount of concrete is produced in a batch system.

  Therefore, the aggregate used in this manufacturing method is dried by using a rotary kiln or the like until it is in an absolutely dry state (a state in which the water evaporates at a temperature of 100 ° C. or higher does not exist) (aggregate). Drying step S6).

  Aggregates dried in an absolutely dry state are each classified into a predetermined particle size, weighed to a certain amount, and then packaged with a packaging material having excellent moisture resistance to prevent water absorption.

  The form of packaging can be appropriately selected according to the specifications. For example, each concrete material may be packaged, or a plurality of concrete materials may be mixed and packaged. All of the concrete material may be mixed and packaged.

  In particular, a mixture of cement, admixture, and sand mixed at a predetermined blending ratio is weighed and packed in a fixed amount to make a mortar pack. It is preferable to prepare a coarse aggregate pack by packing.

  If a plurality of finely divided materials are blended in advance, the burden of blending at the construction site is reduced, so that the quality can be improved. As will be described later, the compact manufacturing unit 1 can be used with a simple operation. Highly accurate blending can be realized.

  As shown in FIG. 3 (a), the form of bagging is preferably a general bagging of several tens of kilograms, but it may be a 1000 kg level container bag as shown in FIG. 3 (b). . In the present embodiment, a mortar pack MP and a coarse aggregate pack KP as shown in FIG.

  In the manufacturing method of the present embodiment, identification data SD such as symbols and barcodes is assigned to each of the mortar pack MP and the coarse aggregate pack KP (identification data providing step S7).

  In the material production process S1, each of the mortar pack MP and the coarse aggregate pack KP has data (material data) related to the quality of the concrete such as the date data produced, the lot of the concrete material used, and the measurement data. To be acquired.

  A manufacturing condition database is mounted on a predetermined computer system 100 (an example of an external terminal, see FIG. 4), and the acquired material data is stored in the manufacturing condition database in a state associated with the identification data SD. It has become so.

  In this embodiment, the identification data SD is given to each outer surface of the mortar pack MP and the coarse aggregate pack KP by printing or sealing. The mortar pack MP and the coarse aggregate pack KP produced in this way are stored in a warehouse or the like until an opportunity for use comes.

(Manufacturing unit installation process)
The manufacturing unit installation process S2 is a preparation stage process. In the production unit installation step S2, a dedicated on-site kneading production unit is used.

  The on-site kneading production unit is easy to transport and can be installed even in small construction sites, and is devised so that high-quality concrete can be stably produced with simple operations. Next, the details of the on-site kneading production unit 1 will be described.

<On-site kneading production unit>
4 and 5 show an example of the on-site kneading production unit (also simply referred to as production unit 1). This production unit 1 is a small batch-type production device with a single concrete production amount of about 50 to 200 L, and a plurality of related devices necessary for on-site kneading are integrated on one compact unit base 10. It is built in and configured.

  Specifically, the unit table 10 includes a rectangular floor surface 11, a support frame 12, and the like. The short side length W of the floor 11 is set to 1.5 m or less, and the long side L is set to 3 m or less. The support frame 12 includes a lower frame installed along the edge of the floor surface 11, a rectangular upper frame arranged to face the upper side of the lower frame, and a plurality of frames installed between the lower frame and the upper frame. It consists of a support frame.

  The related devices are the mixer 20, the main hopper 30, the sub hopper 31, the belt conveyor 40, the screw feeder 50, the water supply device 60, the control device 70, and the like.

  These related devices are installed on the unit base 10 so as to be accommodated on the floor surface 11 and do not protrude outside the floor surface 11, and the height H from the floor surface 11 does not exceed 2 m. It is installed as follows. The total weight of the production unit 1 is set to 2000 kg or less.

  As a result, the production unit 1 can be easily transported by being loaded on the platform of a small truck, and can be easily loaded and unloaded.

  The mixer 20 is a so-called bread-type mixer, and includes a kneading unit 21 and a driving unit 22 connected to the lower part thereof. The kneading part 21 can be opened and closed with a bottomed cylindrical kneading container 23 having a shallow bottom, an upper lid 24 covering the upper part of the kneading container 23, and a stirring blade 25 installed inside the kneading container 23. And a discharge outlet 26. A motor 27 is installed inside the drive unit 22, and a stirring blade 25 is attached to the rotating shaft of the motor 27 protruding into the kneading vessel 23.

  A dust collector 28 is attached to the mixer 20. The dust collector 28 captures dust generated inside the kneading container 23 during kneading and suppresses the diffusion of the dust to the outside.

  The mixer 20 is disposed on one short side of the unit table 10 and is supported by the unit table 10 via a load cell 80. The load cell 80 is a sensor that converts a load into an electric signal, and the load cell 80 can measure a change in the weight of the mixer 20.

  Each of the main hopper 30 and the sub hopper 31 is a box-shaped container having a large input port 33 for receiving a concrete material at the top and a small discharge port 34 at the bottom, and is arranged on the other short side of the unit table 10. It is installed at. In the present embodiment, the main hopper 30 and the sub hopper 31 are formed in the same shape and the same size, and both are configured to be split at an intermediate portion in the height direction.

  Specifically, each of the main hopper 30 and the sub hopper 31 includes a fixed lower portion 35 fixed to the unit base 10 and a detachable upper portion 36 detachably mounted on the upper side of the fixed lower portion 35. By attaching and detaching the detachable upper part 36, it is possible to change to a container back specification that secures a large accommodation amount and a sachet specification that can be easily put in as shown in FIG.

  The belt conveyor 40 is installed between the main hopper 30 and the mixer 20 so as to convey the concrete material received by the main hopper 30 and put it into the mixer 20.

  Specifically, an end portion on the introduction side of the belt conveyor 40 is installed below the discharge port 34 of the main hopper 30, and an end portion on the lead-out side of the belt conveyor 40 is installed above the mixer 20. The intermediate part of the belt conveyor 40 is inclined upward from the end portion on the introduction side toward the end portion on the lead-out side. The end of the lead-out side is inserted into an introduction duct 43 that communicates with the inside of the kneading vessel 23.

  The screw feeder 50 is installed between the sub hopper 31 and the mixer 20 so as to convey the concrete material received by the sub hopper 31 and put it into the mixer 20.

  Specifically, an end portion on the introduction side of the screw feeder 50 is installed below the discharge port 34 of the sub hopper 31, and an end portion on the lead-out side of the screw feeder 50 is installed above the mixer 20. The screw feeder 50 is inclined upward from the end portion on the introduction side toward the end portion on the lead-out side. The end of the lead-out side is connected to an introduction duct 53 that communicates with the inside of the kneading vessel 23.

  The water supply device 60 includes a water supply pipe 61, an electromagnetic on-off valve 62, a flow meter 63, a buffer tank 64, and the like. The downstream end of the water supply pipe 61 enters the kneading vessel 23. Although not shown, the upstream end of the water supply pipe 61 is connected to a water supply source such as a water supply device 60 constituted by a water storage tank, a pump, or a pipe for industrial water.

  A temperature sensor 90 is disposed in the vicinity of the mixer 20 to measure the ambient temperature.

  The control device 70 includes a computer and various software installed on the computer, and executes control for mechanically producing concrete. The control device 70 is also provided with a function of storing manufacturing conditions for each batch and a function of performing data communication with the computer system 100 in order to guarantee the quality of the concrete to be manufactured.

  Further, the control device 70 includes a monitor capable of displaying manufacturing conditions, an input device capable of inputting instruction data and identification data SD, an output device capable of printing manufacturing conditions, and the like.

  FIG. 7 shows a main configuration of the control device 70. The control device 70 includes a manufacturing control unit 71, a manufacturing condition storage unit 72, a measurement control unit 73, a data communication unit 74, and the like. The metering control unit 73 of the manufacturing unit 1 is provided with a water supply amount correction unit 75.

  The production control unit 71 controls the belt conveyor 40, the screw feeder 50, the mixer 20, and the electromagnetic opening / closing valve 62, and executes control related to production such as operation timing, water supply timing, and operation time of the mixer 20.

  The manufacturing condition storage unit 72 stores, for each manufacturing process, the measurement value of the load cell 80 that changes with the operation of the belt conveyor 40, the measurement value of the load cell 80 that changes with the operation of the screw feeder 50, and the amount of water supply. Remember. In the manufacturing condition storage unit 72 of the manufacturing unit 1, the measurement value and the water supply amount of the load cell 80 can be stored in association with the identification data SD.

  The measurement control unit 73 executes control related to the measurement of the concrete material and water. Specifically, the input amount of concrete material and the amount of water supply to the mixer 20 are controlled based on the instruction data. The instruction data is data for instructing the control device 70 to manufacture concrete including manufacturing conditions such as a blending ratio.

  In particular, the manufacturing unit 1 can control the input amount of concrete material and the amount of water supplied to the mixer 20 based on the identification data SD input for each manufacturing process.

  The data communication unit 74 has a function of transmitting / receiving data to / from the computer system 100. The water supply amount correction unit 75 executes control for correcting the water supply amount based on the measurement value of the temperature sensor 90. Details of these controls will be described later.

  In the manufacturing unit installation step S2, the manufacturing unit 1 having such a structure is installed on the construction site.

(Material transport process)
The material transporting step S3 is a step of transporting the packed concrete material to the construction site. The material carrying step S3 is not limited to after the manufacturing unit installation step S2, but may be before or at the same time. In short, the amount of concrete material required for the construction may be transported to the construction site during the construction period.

(On-site kneading process)
The on-site kneading step S4 is a step of operating the manufacturing unit 1 to mechanically produce concrete. Specifically, the operator operates the production unit 1 to introduce a certain amount of concrete material and water into the mixer 20 and mix them for a certain period of time to produce concrete. Since there are a plurality of manufacturing patterns, an example is shown below.

  The operator takes out the crushed stone from the coarse aggregate pack KP and puts it into the main hopper 30, takes out the mixed material from the mortar pack MP, and puts it into the sub hopper 31. By operating the control device 70, the instruction data is manually input and the manufacturing unit 1 is operated.

  Then, the production control unit 71 drives the belt conveyor 40 and crushed stone is thrown into the mixer 20. Based on the measured value of the load cell 80, the weighing control unit 73 measures the crushed stone, and when one batch of crushed stone is loaded, the production control unit 71 stops the belt conveyor 40.

  Subsequently, the production control unit 71 drives the screw feeder 50, and the mixed material is charged into the mixer 20. The mixed control material 73 is weighed based on the measurement value of the load cell 80, and when one batch of the mixed material is charged, the production control unit 71 stops the screw feeder 50. Note that the order of adding the crushed stone and the mixed material may be reversed.

  Subsequently, the production control unit 71 opens the electromagnetic on-off valve 62 to supply water to the mixer 20. The metering control unit 73 measures the amount of water supply based on the flow meter 63, and closes the electromagnetic on-off valve 62 when the amount corresponding to the concrete material charged into the mixer 20 is supplied.

  Thereafter, the production control unit 71 operates the mixer 20 to produce concrete. The manufactured concrete is discharged from the discharge outlet 26. A required amount of concrete is manufactured by repeatedly performing such on-site kneading process S4.

  Since the concrete material used contains almost no moisture, moisture management can be easily performed, and concrete with a constant moisture ratio can be stably produced. Apart from the crushed stone having a large particle size, fine-grained materials are collectively weighed by the screw feeder 50 with high measurement accuracy, so that the blending ratio is stable and a higher quality concrete can be produced.

  Moreover, since it is mechanically manufactured while being measured by the manufacturing unit 1, an artificial error is eliminated, and even a small amount of on-site kneading can be stably manufactured.

(Manufacturing condition storage process)
In the manufacturing condition storage step S5, the manufacturing conditions are stored in batch units. Specifically, every time the on-site kneading step S4 is performed, from the mixed material, crushed stone, and water measurement data, date data on which batch processing was performed, manufacturing data such as the operation time of the mixer 20 and the ambient temperature, etc. The manufacturing condition data is stored in the manufacturing condition storage unit 72.

  Therefore, since data affecting the quality of the concrete is stored for each batch, the quality of the concrete can be guaranteed.

  At the construction site, the identification data SD of the mortar pack MP and coarse aggregate pack KP to be input is read by using a reader or the like and input to the control device 70, and the manufacturing condition data is stored in association with the identification data SD. Also good. By doing so, the corresponding material data can be specified, so that higher quality assurance can be performed.

  Further, the stored manufacturing condition data may be transmitted from the manufacturing unit 1 to the computer system 100 (data communication step). Specifically, the manufacturing condition data is transmitted to the computer system 100 through the data communication unit 74, and the transmitted manufacturing condition data is stored in association with the identification data SD together with the corresponding material data.

  Then, advanced quality assurance can be easily performed. This is also advantageous in that an increase in the storage amount of the manufacturing condition storage unit 72 can be suppressed.

  In the case of this production unit 1, concrete can also be produced more easily by using the identification data SD.

  That is, the identification data SD and the instruction data corresponding to the concrete material are associated with each other, and the identification data SD is read and input to the control device 70 before input. By doing so, the instruction data can be mechanically input, so that there is no need for manual input, and the control device 70 can be operated easily and reliably.

  Furthermore, in this manufacturing method, it is devised so that the influence on the quality by temperature can also be suppressed.

  That is, it is known that an appropriate amount of water supply changes depending on the ambient temperature during mixing. Therefore, water supply correction data that can determine the optimal water supply amount according to the temperature is created by experiments and the like, and the water supply correction data is stored in the control device 70 in advance. The water supply amount correction unit 75 automatically corrects the water supply amount based on the water supply correction data and the measured value of the temperature sensor 90.

  Therefore, even if the ambient temperature at the time of kneading changes, appropriate water supply can be performed, so that high-quality concrete can be manufactured stably. Since the corrected measurement data is stored in the manufacturing condition storage unit 72, its quality can be guaranteed.

  In addition, the on-site kneading manufacturing method according to the present invention is not limited to the above-described embodiment, and includes various other configurations.

  In the embodiment, the mortar pack MP and the coarse aggregate pack KP have been described as examples of the concrete material. However, the concrete material is a mixture of cement, an admixture, and sand individually or all of them. It may be packed in a bag.

DESCRIPTION OF SYMBOLS 1 On-site kneading production unit 10 Unit stand 20 Mixer 30 Main hopper 31 Sub hopper 40 Belt conveyor 50 Screw feeder 60 Water supply apparatus 70 Control apparatus 71 Manufacturing control part 72 Manufacturing condition memory | storage part 73 Measurement control part 74 Data communication part 75 Water supply amount correction | amendment part 80 Load cell 100 Computer system S1 Material production process S2 Manufacturing unit installation process S3 Material transport process S4 On-site kneading process S5 Manufacturing condition storage process S6 Aggregate drying process S7 Identification data providing process MP Mortar pack KP Coarse aggregate pack SD Identification data

Claims (3)

A concrete on-site kneading production unit in which a plurality of related devices are integrally incorporated on a unit table that can be loaded onto a truck bed and transported and unloaded,
The related device is:
A mixer,
A main hopper and a sub hopper each receiving concrete material;
A belt conveyor that transports the concrete material received by the main hopper into the mixer;
A screw feeder that transports the concrete material received by the sub-hopper into the mixer;
A water supply device for supplying water to the mixer;
A controller for controlling the mixer, the belt conveyor, the screw feeder, and the water supply device;
Including
The unit table has a shape with a long side when viewed from above, and is configured to be carried on a truck bed,
The mixer, the main hopper, the sub hopper, the belt conveyor, the screw feeder, the water supply device, and the control device are integrated into the unit base,
The mixer is disposed at a central portion on one short side of the unit table, and each of the main hopper and the sub hopper is disposed side by side over substantially the entire other short side of the unit table. And
The belt conveyor and the screw feeder are on-site kneading production units that are installed so as to extend substantially in parallel toward the upper part of the mixer from below the main hopper and the sub hopper. In the on-site kneading production unit according to claim 1,
The mixer is a bread-type mixer,
A bottomed cylindrical kneading container;
A drive unit connected to the kneading container;
A stirring blade that is attached to the rotating shaft of the drive unit that protrudes from the center of the kneading vessel and rotates;
Has an on-site kneading production unit. In the on-site kneading production unit according to claim 1 or claim 2,
The unit base has a rectangular floor surface composed of a short side of 1.5 m or less and a long side of 3 m or less, and the related device is installed so as to fit on the floor surface,
An on-site kneading unit with a total weight of 2000 kg or less.

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