EP0035010A1 - Apparatus for the manufacture of profiled plate-like moulded articles of concrete or the like, preferably roof tiles - Google Patents

Abstract

1. Apparatus for the manufacture of profiled, platelike moulded articles (6), preferably roof tiles, of concrete or a similar abrasive material by means of a rotatably mounted compression roller (3) and a shaping and stationary smoothing device (7) arranged directly adjacent the roller (3) in the direction of manufacture, moulds (5) filled with concrete or the like being arranged below the roller (3) and the smoothing device (7) and passing through in the direction of manufacture, the moulded articles (6) disposed therein being compressed and shaped, the compression roller (3) and/or the smoothing device (7) comprising a coating (13 or 23) consisting of a hard metal coating adjacent regions subject to wear, characterised in that the hard metal coating (13 or 23) is connected by way of an intermediate layer (12 or 25) consisting of a metal-plastics-mixture, preferably a steel-plastics-mixture, to a base (11 or 16), preferably consisting of steel, possibly in a positive manner, for example -as is known per se- by means of interlocking undercut springs (14) and grooves (15).

Description

The invention relates to a device for producing profiled, plate-shaped moldings, preferably roof tiles, made of concrete or the like. abrasive material by means of a rotatably mounted compacting roller and a shaping and fixed smoother directly adjoining it in the production direction, below which or the like with the concrete. filled formwork forms in the production direction and the moldings contained therein are compacted and profiled.

The above-mentioned cooperating components of such a device have hitherto usually been drop-forged or cast, but they are subject to very high wear when processing a comparatively abrasive material, such as concrete, particularly when quartz sand is used as an additive the consequence of this is that the distance between these components, that is to say the distance between the edge of the smoothing device and the circumference of the compacting roller, has to be readjusted again and again during the operation of such a device in order to prevent the quality of those formed by means of these components from changing Products deteriorate = tert. The manipulations required for such re-adjustments result in uneconomical business interruptions and unnecessary expenditure of time and personnel as well as losses in the material to be processed. That being said the service life of these comparatively expensive device components is short, because with increasing wear and tear the target dimensions of the products can no longer be guaranteed; the products become increasingly thicker with increasing wear in those areas that are more subject to wear, so that when a certain tolerance limit is exceeded, an exchange of the components is necessary, especially with roof tiles due to the exact fitting laying in association with a roof covering to maintain exact target dimensions special value must be placed.

The object of the invention is to remedy this situation and to increase the life of the above-mentioned device = components and to ensure dimensional accuracy of the products manufactured in the long term. However, there are certain problems in so far as it hardly seems possible to simply use higher quality steel for these components according to the current state of technology. Even if the conditions were met, it would be too costly to process such high quality material and too difficult due to the brittleness of this material. In the present case, this brittleness would already result in an excessively high reject rate in the manufacture of the components and an excessive risk of breakage in operation. The breakage of an entire expensive component would be too great an economic risk, also because of the resulting business interruption.

The above-mentioned object is now achieved according to the present invention in that the compacting roller and / or the smoothing have in their surface areas subject to wear a pad made of hard metal.

This measure is due to the fact that the above-mentioned components subject to wear by the abrasive material to be processed may indeed be made in their massive, wear = the part from conventional steel as before, but their work surfaces may be made of a higher quality, more wear-resistant material are formed that guarantees a significantly longer service life for these components. This higher quality, but more brittle, material is in turn - as a mere edition - so easy to design that it can be processed without difficulty and applied to the base, i.e. the steel core of the components, in order to be intimately connected to this base.

From AT-PS 313 230 it has already become known to provide rolling mill rollers with hard metal supports, but this known measure is not about producing molded parts with exact target dimensions from an abrasive material, but rather the hard metal supports are only intended to be used enable and improve high profiling pressure. For the teaching according to the invention, this known measure does not provide any useful suggestion.

A certain problem arises with the application of the hard metal pads according to the invention in that the materials of the base on the one hand and the pad on the other hand show different physical behavior, with the additional factor that the material of the pad has considerable brittleness. In order to result, e.g. Difficulties and dangers arising from temperature differences are excluded, according to a further feature of the invention, that the hard metal layer is connected to the base, which preferably consists of steel, via an intermediate layer consisting of a metal-plastic mixture, preferably a steel-plastic mixture.

It was recognized that such an intermediate layer with high adhesive strength and good elastic properties can perfectly compensate for the different changes in shape of the support on the one hand and the base on the other hand, but nevertheless brings about an extremely reliable, tough connection of these different materials.

Regardless of this, the hard metal support can also be connected to the base in a form-fitting manner, for example by means of interlocking, undercut profiled tongues and grooves.

Another problem is that hard metal is relatively difficult to process into more complicated shapes.

This problem can, if necessary, be taken into account in the context of the invention in that the hard metal layer of the compacting roller or of the smoothing device, the profiling of which is correspondingly divided over its entire width from parts.

In this respect, the subject of the invention is therefore also the design of the components of a device according to the invention, which is specifically intended for the production of roof tiles with a plurality of regions that extend over the entire width, partly domed and partly flat, in particular for the production of so-called Roman products filen. In this regard, the aim of the invention is to develop a design of the device components in which a desirably simple, robust and hard-wearing form of the hard metal pads can be used.

According to the invention, the hard metal support of the smoothing device - according to the profile of the roof tiles to be produced, which have partly curved and partly flat areas over their width - can be divided into as many flat and curved sections, which are joined together with their longitudinal edges to the base.

Equally, however, the base of the compaction roller can advantageously also be subdivided according to the profile of the roof tiles into those sections which are then mounted on a common drive shaft. This results in a further advantage that such sections can be replaced or renewed individually in the event of a break, without the need to replace the entire stock. Accordingly, according to the invention, separate sections of the base of the compacting roller are assigned to the curved areas, the flat areas and the area of the profiling of the roof tile provided with folds.

It is advisable to have only the heavily used areas, namely only the flat areas and the area with folds Edge area of the compaction roller is a hard metal pad that is attached to the base by means of the intermediate layer. Experience has shown that no such requirement is required in the domed areas, which are less stressed and worn from the outset. The sections of the curved areas can therefore consist entirely of a material that is softer in comparison to the hard metal of the supports, especially since the sections are compact and comparatively small and are not subject to any risk of breakage from the outset.

Instead of a positive connection of the hard metal supports to the base or also in addition to such a connection, a hard metal support, preferably in one piece, can have depressions in the context of the invention on its side facing the base or in the edge portion of the smoother profiled with folds , are screwed into the threaded bushings, and the hard metal support can then be connected to the base by means of screws screwed into these threaded bushings which penetrate the base, preferably Allen screws.

In order to absorb the high shear forces acting on the hard metal support of the smoothing device, this smoothing device can also be connected at its end facing away from the compacting roller to a strip overlapping the edge of the hard metal support, e.g. by means of screws.

Finally, according to a further advantageous feature of the invention, the hard metal coating of the smoothing device in the edge area immediately adjacent to the compacting roller can be made of a softer material than in the rest of the area that is more subject to abrasion, these areas of different hardness continuously in a boundary zone merge.

• Figur 1 die schematische Seitenansicht des an sich bekannten grundsätzlichen Aufbaues der Vorrichtung,
• Figur 2 die zugehörige Draufsicht in Richtung des Pfeiles II der Figur 1 und die
• Figur 3 eine Stirnansicht in Richtung des Pfeiles III der Figur 1, wobei der Deutlichkeit wegen nur der Formling im Schnitt dargestellt ist.
• Figur 4 und 5 zeigen einen Querschnitt bzw. einen Längsschnitt des Glätters und die
• Figur 6 ist ein Längsschnitt durch eine Verdichtungs= walze. Die
• Figur 7 zeigt einen Querschnitt durch eine andere AusführungsforM eines Glätters und die
• Figur 8 ist ein Schnitt in der Ebene VIII der Figur 7.

The invention is explained in more detail below with reference to the embodiments of the device components shown in the drawings, for example. It show in these drawings

• FIG. 1 shows the schematic side view of the basic structure of the device known per se,
• Figure 2 shows the associated top view in the direction of arrow II of Figure 1 and
• Figure 3 is an end view in the direction of arrow III of Figure 1, only the molding is shown in section for clarity.
• Figures 4 and 5 show a cross section and a longitudinal section of the smoothing device and
• Figure 6 is a longitudinal section through a compacting roller. The
• FIG. 7 shows a cross section through another embodiment of a smoothing device and the
• Figure 8 is a section on the plane VIII of Figure 7.

Figures 1 to 3 first represent the storage container 1, into which the concrete to be processed with a grain size of the aggregate of about 0 to 3 mm is fed from a mixer and in which it is separated from the rotating distributor, e.g. a spiked roller 2, the task of which is to evenly distribute the material, is conveyed under the compression roller 3, the so-called "roller". The underside of this compressor roller 3 are also fed on a machine = bed 4 (FIG. 3) formwork molds 5 for the moldings 6 to be molded.

From the compacting roller 3, which, like the spiked roller 2, rotates at a certain speed, the concrete penetrating from the storage container 1 into the formwork forms 5 is compacted and at the same time metered correctly.

Now the formwork molds 5 filled with the compacted concrete get under the smoother 7, which is inclined at a certain angle of attack with respect to the machine bed 4 and with its end formed towards a pointed edge facing the compressor roller 3 directly on its side Bottom connects tangentially. This smoother 7, the so-called "slipper", presses, smoothes and profiles the concrete located in the passing formwork forms 5 and is adjustable by means of a pressure plate 8 in relation to the compacting roller 3 in order to be able to regulate the size of the gap existing between these components. This size had to be in the previous Known devices of this type with constant wear and tear of the constituents are repeatedly adjusted at relatively short intervals. The smoother 7 is held by a bridge 9 spanning the machine bed 4 and the conveying path of the formwork 5. The direction of manufacture and the direction of conveyance of the formwork 5 is indicated by the arrow 10.

In this respect, the basic structure of the device is part of the prior art.

According to the invention, the smoother 7 shown in FIGS. 4 and 5 on a larger scale in longitudinal and cross-section now has a base 11 made of cast or forged steel, which has an initially castable, hardenable mixture of about 80% steel and 20% Epoxy resin be = existing intermediate layer 12 is connected to a support 13 consisting of the so-called hard metal.

As is known, hard metal is a sintered hard metal alloy that consists of one or more hard materials, e.g. Tungsten, titanium, tantalum carbide etc. with a binding metal of the iron group, mostly cobalt but also nickel or iron, is made and has a particularly high hardness and wear resistance.

The connection between the base 11 and the support 13 essentially results from the cementing by means of the intermediate layer 12, but - in accordance with the embodiment according to FIGS. 4 and 5 - additionally also undercut profiled springs 14 and grooves 15 can be made be provided for the positive locking of this connection, as shown in Fig.5.

As further shown in FIG. 4, the support consists of parts which correspond to the flat or curved areas of the smoothing element 7 and are joined to the base 11 with their longitudinal edges closely joined together. The pad 13 could - in the context of the invention - also consist of one piece. An edge part 27 of the smoothing device 7 is profiled with folds 26; it can consist entirely of hard metal.

The compressor roller 3 shows the one shown in FIG Construction according to the invention, namely its base 16 consists of the sections 17, 17 ', 18 and 19, which are lined up on the drive shaft 20 and are held in a rotationally fixed manner by means of a wedge 21 and a nut 22.

This compacting roller 3 also includes - in accordance with the profiling of the moldings 6 to be produced - partly flat partly curved areas, namely the sections 17 and 17 'are the less stressed curved areas, the two sections 18, however, the more stressed flat areas and the section 19 assigned to the edge region of the compression roller 3 which forms the lateral folds of the roof tile molding 6.

The small sections 17 and 17 ', because they are less stressed, can be manufactured in one piece from a comparatively softer and easier-to-work hard metal.

On the other hand, the mutually identical sections 18 and section 19 must each have a support 23 made of harder hard metal in order to be sufficiently wear-resistant. The supports 23 of the sections 18 and the support 24 of the section 19 are in turn connected to the base 16 or its sections via an intermediate layer 25 from the above-mentioned suitable metal-plastic mixture.

In the modified embodiment of a smoothing device 7 according to FIGS. 7 and 8, the one-piece hard metal support 13 has depressions 28 on its side facing the base 11, into which threaded bushings 29 are soldered. The edge part 27 of the smoothing device, which is profiled with folds 26, also carries such threaded bushings 29. The hard metal bearing 13 is screwed into these threaded bushings 29 and screws 30 penetrating the base 11, preferably by means of so-called Allen screws, which are used to rotate the head have angular recess, connected to the base 11.

On its end facing away from the compacting roller, the smoothing device is connected by means of screws 32 to a strip 31 overlapping the edge of hard metal support 13.

This bar 31, made of steel, takes over part of the strong shear forces acting on the hard metal support 13 and thereby secures their connection to the base 11 of the smoothing device 7.

According to a very advantageous feature of the invention, the hard metal layer 13 of the smoothing device 7 in the edge region 13 '(FIG. 8) immediately adjoining the sealing roller 3 consists of a softer material than in the rest of the region which is subject to higher abrasion, these two regions having different hardness continuously merge into each other in the border zone 33.

The intermediate layers 12 and 25 of the components of the device according to the invention serve - as already explained at the beginning - to compensate for the various changes in shape of the different materials from which these components are composed, and in this way prevent the occurrence of internal hazards Tensions; at the same time they ensure reliable binding of the supports 13, 23, 24 to the bases 11 and 16 of these components. The material of these intermediate layers 12 and 25 can be poured between the bases and the supports before hardening and then hardened.

The lifespan of device components designed according to the invention is considerably increased in comparison to previously used, similar components consisting of forged and cast steel: While previously known components had to be exchanged after the production of about 225,000 units, because the local wear and tear had become so large was that the target dimensions of the moldings could no longer be met, components designed according to the invention showed no significant wear even after the production of more than five million units.

Another appreciable advantage of such constituents is that the readjustments of the smoothing device in relation to the compaction roller, which have previously been necessary at short time intervals in the previously known devices, are unnecessary.

Due to the durability of the trained according to the invention Shaping components of the device is an optimal = constant, consistently high quality and extensive dimensional and weight accuracy of the moldings.

Claims (12)

1. Device for producing profiled, plate-shaped moldings (6), preferably roof tiles, made of concrete or the like. abrasive material by means of a rotatably mounted compaction roller (3) and a shaping and stationary smoother (7) directly adjoining it in the production direction, below which the one with the concrete or the like. filled formwork molds (5) carried out in the direction of production and the moldings (6) located therein are compacted and profiled, characterized in that the compacting roller (3) and / or the smoother (7) has a hard metal in their surface areas subject to wear have an existing edition (13 or 23). _2nd Apparatus according to claim 1, characterized in that the hard metal support (13 or 23) has an intermediate layer (12 or 25) with an, preferably made of steel, layer consisting of a metal-plastic mixture, preferably a steel-plastic mixture , Base (11 or 16) is connected. 3. Apparatus according to claim 1 or 2, characterized in that the hard metal support (13) with the base (11) positively, for example - as known per se - by means of interlocking, undercut profilier = ter springs (14) and grooves (15 ), connected is. 4. Device according to one of claims 1 to 3, characterized in that the hard metal pads (13 or 23) the compacting roller (3) or the smoothing device (7), the profiling of which is composed of sections over its entire width. 5. Apparatus according to claim 4 for the production of profiled roof tiles with several over the entire width partially domed, partially flat areas, characterized in that the support (13) of the smoothing device (7) is accordingly divided into the same flat or curved sections with their edges closely connected to the base (11). 6. The device according to claim 4 for the production of profiled roof tiles with several over the entire width partially domed, partially flat areas, characterized in that the roller-shaped base (16) of the compacting roller (3) accordingly in such sections (17, 17 ', 18th and 19) which are lined up and supported on a common drive shaft (20). 7. The device according to claim 6, characterized in that each of the curved regions of the profiling, the flat regions of the profiling and the edge region of the profiling provided with folds are assigned their own parts (17, 17 ', 18, 19). 8. The device according to claim 7, characterized in that only the heavily stressed, the flat areas and the edge area provided with folds. Parts (18, 19) are made of hard metal and are attached to an intermediate layer (25) , 24). 9. The device according to claim 8, characterized in that the sections of the curved areas (17, 17 ') consist entirely of a soft metal compared to the hard metal = the layers (23, 24). 10. Device according to one of claims 1 to 9, characterized in that the, preferably integrally formed from = hard metal support (13) on its base (11) facing side or with folds (26) per = filmed edge part (27th ) of the smoothing device (7) has depressions (28) into which the threaded bushes (29) are soldered, and that the hard metal support (13) is screwed into these threaded bushings (29) and penetrates the base (11) with screws (30), preferably Allen -Screws connected to the base (11). 11. The device according to one of claims 1 to 10, characterized in that the smoother (7) on its ver = sealing roller (3) facing end with an edge of the hard metal overlay (13) overlapping strip (31), e.g. is connected by screws (32). 12. The device according to one of claims 1 to 11, characterized in that the hard metal support (13) of the smoothing device (7) in the on the compacting roller (3) immediately = bar adjoining edge area (13 ') consists of a softer material than in the remaining area which is more subject to abrasion, the areas of different hardness in this boundary zone (33) continuously merging.

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