WO2007104293A1 - Device and method for the production of molded articles from moist concrete or materials of the same type - Google Patents

Abstract

The invention relates to a device (2) and a method for producing molded articles (K) from moist concrete (7) or materials of the same type by means of a mold (3) comprising at least one mold cavity (4, 5). According to the invention, vibrations can be introduced into the moist concrete (7) located in the mold cavity (4, 5) in a shaking process.

Description

"Apparatus and method for the production of moldings from wet concrete or similar materials"

The invention relates to a device for the production of Forrαkörpern according to claim 1 or 36 and a method for producing molded articles according to claim 29.

Particularly in the concrete industry, in the production of moldings of wet concrete for solidification and to increase the surface quality, vibratory energy and / or pressure is introduced into the mold in which the wet concrete is located. In order to be able to measure, assess and predict the effects of this energy introduction on the end product, it is known from DE 202 19 768 U1, for example, to arrange a sensor in a mold insert of a mold in order to be able to detect a movement quantity of the mold insert. The disadvantage is that with the proposed device, the actual effect of the shaking on the located in the mold cavities of the mold insert wet concrete is not directly measurable. This leaves a considerable uncertainty in the assessment of the measurement data since only motion quantities of the shape and not of the concrete are detected.

The invention has for its object to develop a device or a method which or which makes it possible to measure directly, what influence a Energy introduction in the form of vibrations and / or an introduction of pressure, for example, in a so-called shaking on movement variables such as frequency and / or amplitude of a moist material such as concrete has.

This object is achieved in a device for producing molded articles by the features of claim 1 and of claim 36 and in a method for producing molded articles by the features of claim 29. In the respective subclaims advantageous and expedient developments of the method or the device are given.

The device according to the invention for the production of moldings from moist concrete or similar materials has at least one sensor, by means of which movement data of at least one solid can be detected during the shaking process, which is located in the moist concrete. This makes it possible to directly detect what influence the so-called machine parameters have on the wet concrete in the mold. This direct observation of the movements in the wet concrete allows to derive general optimizations for the machine parameters in the production of moldings from wet concrete. The core of the invention is thus a detection of movement data of the wet concrete so a hitherto impossible detection of the actual movement processes in the mold in the wet concrete in the production of a shaped body.

Within the meaning of the invention, movement data is understood to mean data which is detected by the sensor in the form of measured values, these measurement values having in common that they are suitable for determining quantities which describe a movement. Such sizes are for example Frequency or amplitude or speed or acceleration or deceleration.

Moisture data in the sense of the invention are understood to be data which are detected by the sensor in the form of measured values, these measured values having in common that they are suitable for determining quantities by which the water content of the moist concrete can be determined.

For the purposes of the invention, materials which are related to moist concrete are understood as meaning all flowable materials which harden and contain solids in the flowable state or can absorb them as foreign bodies.

For the purposes of the invention, a shaped body is understood to be any body that can be produced from moist concrete. These can be concrete blocks as well as large concrete parts such as walls and ceilings. Also concrete parts with reinforcement are understood in the context of the invention by the term shaped body.

In the context of the invention, a shaking process is understood to mean the process in which vibrations are introduced into the moist concrete in the mold or vibrations and pressure are introduced.

The invention provides to equip the sensor with a microwave transmitter and a microwave receiver. Appropriate transmitters and receivers are available as standard components and have a small size.

According to the invention, it is provided to operate the microwave transmitter and the microwave receiver of the sensor with microwaves in a range from approximately 20 GHz to 50 GHz. On the one hand, this frequency range allows for the detection of small solids and, on the other hand, is sufficiently above that Frequencies with which the wet concrete is excited. Thus the frequency range is suitable for exact measurements.

Furthermore, the invention provides for equipping the device with evaluation electronics with which at least one movement parameter such as frequency, direction of movement, speed or acceleration can be calculated from the acquired movement data. Such data can then be used for analysis without further processing or forwarded to an electronic machine controller for further processing.

In particular, the invention provides to determine from the motion data vibrations of the solid, which are between 30 Hz and 400 Hz. Experience has shown that this frequency range has the strongest effects on the behavior of the wet concrete.

According to the invention, the sensor is arranged outside the wet concrete located in the mold cavity. As a result, this can be safely accommodated against unwanted loads.

Alternatively, the invention provides to arrange the sensor in the wet concrete, which is located in the mold cavity. Such an arrangement is provided in particular when the sensor is used in the production of larger concrete parts whose form is designed as formwork and which is supplied by means of a vibrating probe, a so-called vibrator, vibrating energy. In such a case, it is advantageous to integrate the sensor in the vibrating probe and thus to arrange during the Rüttelvorgangs in wet concrete.

The invention also provides for the sensor in the mold bottom part of the mold and in particular on a wall of the mold cavity to arrange. As a result, the sensor is connected to the component which essentially determines the shaped body and can thus be arranged on the shaped body individually at a position relevant to the specific shaped body.

The invention also provides for arranging the sensor in the upper mold part and in particular in a stamp surface of the stamp. Here is a comparatively large space available for the sensor.

Furthermore, the invention provides to embed the sensor in a body or to arrange behind a body, which consists of a material permeable to microwaves, wherein the body is in particular designed as a ceramic body. As a result, the sensor is optimally protected against stress.

Furthermore, the invention provides to detect a moisture content of the wet concrete with the sensor. A detection of the moisture content of the wet concrete in the mold also allows conclusions about the requirements in the production of a shaped body. In particular, an alternating or parallel detection of moisture content and movement data allows an even more meaningful evaluation of the data obtained.

According to the invention it is also provided to supply the sensor by a self-sufficient energy source with energy. This can be dispensed with the supply of energy through fault-prone lines.

In particular, the invention provides to generate electrical energy from the supplied vibrating energy with the self-sufficient energy source of the sensor. This form of energy is always available when the sensor needs to acquire data. Furthermore, it is provided to equip the sensor with a wireless interface for data exchange. By such a data transmission can also be dispensed with fault-prone lines.

The invention provides that the solid, which is detected by the sensor, is a component of the wet concrete. As a result, any concrete with a solids content, such as sand, gravel or split, is basically suitable for measurements with the sensor.

Alternatively, the invention provides for mixing in the moist concrete at least one foreign body which assumes the function of a solid. In this way, further statements can be derived from the measured data, taking into account, for example, the exact volume, the exact geometry or the exact weight of the foreign body working as a solid.

The invention also provides for the solid to provide a geometry and / or a material which is well detectable by the sensor. This allows more accurate measurements.

Furthermore, the invention provides to detect a solid with the sensor whose diameter is between about 0.1 mm and 10 mm. This is a solids size typical for concrete.

The inventive method for the production of moldings from wet concrete or related materials provides to capture movement data of at least one present in the wet concrete solid from a sensor during the Rüttelvorgangs. Such a method allows a hitherto impossible detection of the actual Processes in wet concrete in the production of a shaped body.

According to the invention, it is provided to transmit the movement data wirelessly to an evaluation electronics during the shaking process. As a result, can be dispensed with faulty lines.

Furthermore, it is provided to calculate by the evaluation electronics during the shaking operation control and / or control signals for a control unit of the machine and to pass to this and implement them in the machine, in particular during the shaking. By this immediate reaction to the behavior of the wet concrete a consistently high quality of the moldings can be achieved.

The method according to the invention also provides for mixing in the evaluation electronics a transmission signal of the microwave transmitter and a reception signal of the microwave receiver and for deriving a modulation from the mixed signal, from which at least one of the motion characteristics can be calculated with which the solid moves or moves in the moist concrete swinging. Such determination of one or more motion characteristics is done with little computational effort and thus in the shortest possible time.

The method also provides, by the sensor during the shaking process, also to acquire moisture data, which in particular is transmitted and processed in parallel to the movement data. This makes it possible to increase the meaningfulness of the data obtained.

Finally, the invention provides, with the sensor during the Rüttelvorgangs successively capture movement data of different solids. This reduces the likelihood of erroneous measurements. A further device according to the invention for monitoring the movement behavior of a material during an energy introduction phase in which an introduction of energy into the material provides the device with at least one sensor through which movement data of at least part of the volume of the material and / or during the energy introduction phase at least one solid contained in the material can be detected. Such immediate observation and detection of movements of at least one solid and / or solid in the material allows optimization of parameters in the production of moldings from the material. The core of the invention is thus a collection of movement data of at least one solid and / or solid. The term material is to be understood in the sense of claim 36 moist material such as concrete or adhesive or pourable and compressible material such as sand or gravel. As a shaped body in the sense of claim 36, for example, a bonding point to understand, which is formed, for example, teardrop-shaped or strip-shaped. For the purposes of the invention, production is to be understood as meaning the compacting and / or curing of the material to form a shaped body.

Further details of the invention are described in the drawing with reference to schematically illustrated Ausführungsbeisielen.

Hereby shows:

Figure 1 is a schematic view of a molding machine in different positions with a device according to the invention and

Figure 2: a schematic view of a Device according to the invention in three variants.

FIG. 1 shows a schematic view of a molding machine 1 in which a device 2 according to the invention is arranged. The device 2 comprises a sectional shape 3, which has two mold cavities 4 and 5. The mold cavities 4 and 5 are filled with a flowable and hardening mass 6, which is formed in the embodiment of Figure 1 by wet concrete 7. The wet concrete 7 is processed in the molding machine to a molded body K. In each of the two mold cavities 4 and 5, a respective solid body 8 or 9 located in the moist concrete 7 is illustrated by way of example and not to scale. In the following, the embodiment A shown in the left half of the drawing will first be considered in more detail. The mold cavity 4 is rectangular in plan view and is bounded laterally to all four sides by the mold 3. To a bottom, it is further completed by a mold base 10 and to a top, the mold cavity 4 is closed by a punch surface 11 of a punch 12. A belonging to the device 2 sensor 13 is arranged in a pressure piece 14 of the punch 12. The sensor 13 comprises a microwave transmitter 15 and a microwave receiver 16, both of which are embedded in ceramic bodies 17, 18. In this case, the ceramic bodies 17, 18 form part of the stamp surface 11 in order to ensure the unimpeded exit and entry of microwaves M. The sensor 13 furthermore has a wireless interface 19, by means of which this data D is transmitted to an evaluation electronic unit 20. For compaction of the moist concrete 7, oscillations are introduced into the mold 3 and thus into the flowable mass 6 contained in the mold cavity 4 by means of a vibrator 21, which is designed as a vibrating table 22. During this process, the sensor 13 detects movement characteristics of the solid 8 and transmitted corresponding data D to the evaluation electronics: 20. The evaluation electronics 20 is connected to a machine control 23, by means of which machine parameters such as, for example, vibration frequency or vibration duration can be influenced as a function of the determined motion characteristics. The illustrated in the right half of Figure 1

Embodiment B has many similarities with Embodiment A described above. In contrast, a punch 24 is still in a raised position. A sensor 25 is integrated into the mold 3, wherein a microwave transmitter 26 and a microwave receiver 27 are arranged in a wall 28 of the mold cavity 5. From this position, for example, a frequency can be determined with the sensor 25, with which the solid body 9 oscillates, which has a diameter d. In the molding machine 1, the mold 3 consists of a mold base 29 and the stamp 12, 24 form a mold top 30. The sensor 25 is associated with a self-sufficient energy source E, which gains electrical energy from the vibrations introduced into the mold 3 and this in particular with intermediate shuttering an energy storage provides the sensor.

FIG. 2 schematically shows three further variants of a device 2 according to the invention. A mold 3 is designed as a formwork 31, which forms a limited to five of six sides mold cavity 32. This mold cavity 32 is filled with a flowable mass 6, in particular a moist concrete 7. In the wet concrete 7 is a trained as a so-called bottle F vibrator 21, which is designed as a hydraulic vibrator 33. The mold 3 are assigned by way of example three sensors 34, 35, 36, which each have a structure which corresponds to the sensors shown and described in FIG. The sensor 34 is disposed on an open side 37 of the mold cavity 32 and directed to a solid 38. Via a data line DL is the sensor 34 with an electronic evaluation 20 connected. The sensor 35 is arranged in the bottle F and connected via a further data line DL with a further evaluation electronics 39. In this case, it is provided to program the evaluation electronics 39 such that vibrations generated by the hydraulic shaker 33 are mathematically eliminated in order to determine, for example, the actual frequency of a solid 40. The sensor 36 is arranged in a formwork plate 41 of the formwork 31 and monitors a solid 42 which has been mixed with the wet concrete 7 as a foreign body FK. The sensor 26 is connected to the evaluation electronics 20 via a further data line DL.

The invention is not limited to illustrated or described embodiments. Rather, it includes developments of the invention within the scope of the patent claims.

List of reference numbers:

1 molding machine

2 device

3 form

4 mold nest

5 mold nest

6 flowable mass

7 wet concrete

8 solids

9 solids

10 Forrα underlay

11 stamp surface

12 stamps

13 sensor

14 pressure piece

15 microwave transmitters

16 microwave receivers

17 ceramic body

18 ceramic bodies

19 wireless interface

20 evaluation electronics

21 vibrators

22 vibrating table

23 machine control

24 stamps

25 sensor

26 microwave transmitters

27 microwave receiver

28 wall of the mold cavity

29 mold base

30 form top

31 formwork

32 mold nest

33 hydraulic vibrator

34 sensor 35 sensor

36 sensor

37 open side of 32

38 solids

39 evaluation electronics:

40 solids

41 formwork panel

42 solids

D data d diameter of 9

DL data line

F bottle

E self-sufficient energy source

M microwave

K shaped body

FK foreign body

Claims

Claims: 1. Device (2) for the production of moldings (K) from wet concrete (7) or related materials with a mold (3) having at least one mold cavity (4, 5), wherein in a vibration Vibrations in the wet concrete (7) can be introduced, which is located in the mold cavity (4, 5), characterized in that the device (2) at least one sensor (13, 25, 34, 25, 36), through which movement data of at least one solid state during the Rüttelvorgangs ( 8, 9, 38, 40, 42) are detectable, which is located in the wet concrete. 2. Apparatus according to claim 1, characterized in that the sensor (13, 25, 34, 25, 36) comprises a microwave transmitter (15, 26) and a microwave receiver (16, 27). 3. Device according to one of the preceding claims, characterized in that the microwave transmitter (15, 26) of the sensor (13, 25, 34, 25, 36) emits microwaves (M) in a range of about 20 GHZ to 50 GHZ. 4. Device according to one of the preceding claims, characterized in that the microwave receiver (16, 27) of the sensor (13, 25, 34, 25, 36) receives microwaves (M) in a range of about 20 GHZ to 50 GHZ. 5. The device according to claim 1, characterized in that the device (2) comprises an evaluation electronics (20, 39), by which from the detected movement data at least one motion characteristic such as frequency, direction of movement, speed or acceleration can be calculated. 6. Device according to one of the preceding claims, characterized in that from the movement data Vibrations of the solid (8, 9, 38, 40, 42) can be determined, which are between 30 Hz and 400 Hz. 7. Device according to one of the preceding claims, characterized in that the sensor (13, 25, 34, 25, 36) outside the in the mold cavity (4, 5) located moist concrete (7) is arranged. 8. Device according to one of the preceding claims, characterized in that the sensor (13, 25, 34, 25, 36) in which in the mold cavity (4, 5) located moist concrete (7) is arranged. 9. Device according to one of the preceding claims, characterized in that the mold (3) in a machine (1) is arranged, wherein by the machine (1) vibrations in the in the mold cavity (4, 5) located wet concrete (7 ) can be introduced. 10. Device according to one of the preceding claims, characterized in that the mold (3) has a lower mold part (29) and a upper mold part (30), wherein in the lower mold part (29) the at least one mold cavity (4, 5) is arranged and wherein the upper mold part (30), at least one punch (12, 24). 11. Device according to one of the preceding claims, characterized in that the machine (1) the vibrations via a mold base (10) on which rests the lower mold part (29), and / or via the punch (12, 24) in the wet Concrete (7) initiates. 12. Device according to one of the preceding claims, characterized in that the sensor (13, 25, 34, 25, 36) in the lower mold part (29) is arranged. 13. Device according to one of the preceding claims, characterized in that the sensor (13, 25, 34, 25, 36) in a wall (28) of the mold cavity (4, 5) is arranged. 14. Device according to one of the preceding claims, characterized in that the sensor (13, 25, 34, 25, 36) is arranged in the upper mold part (30). 15. Device according to one of the preceding claims, characterized in that the sensor (13, 25, 34, 25, 36) in a punch surface (11) of the punch (12) is arranged. 16. Device according to one of the preceding claims, characterized in that the sensor (13, 25, 34, 25, 36) in one of a microwaves (M) permeable material body, in particular a ceramic body (17, 18) is embedded , 17. Device according to one of the preceding claims, characterized in that the mold (3) as a formwork (31) is formed. 18. Device according to one of the preceding claims, characterized in that the damp concrete (7) by means of a moist concrete (7) immersed vibrator (21), the vibrations are supplied. 19. Device according to one of the preceding claims, characterized in that the sensor (13, 25, 34, 25, 36) in the vibrator (21) is arranged. 20. Device according to one of the preceding claims, characterized in that with the sensor (13, 25, 34, 25, 36), a moisture content of the wet concrete (7) can be detected. 21. Device according to one of the preceding claims, characterized in that the sensor (13, 25, 34, 25, 36) by a self-sufficient energy source (E) can be supplied with energy. 22. Device according to one of the preceding claims, characterized in that the self-sufficient energy source (E) of the sensor (13, 25, 34, 25, 36) converts the vibrations generated by the machine (1) into electrical energy. 23. Device according to one of the preceding claims, characterized in that the sensor (13, 25, 34, 25, 36) is equipped with a wireless interface (19) for data exchange. 24. Device according to one of the preceding claims, characterized in that the solid body (8, 9, 38, 40, 42) is a component of the wet concrete (7). 25. Device according to one of the preceding claims, characterized in that the solid body (8, 9, 38, 40, 42) is a wet concrete (7) admixed foreign body (FK). 26. Device according to one of the preceding claims, characterized in that the solid body (8, 9, 38, 40, 42) has a geometry which is well detectable by the sensor (13, 25, 34, 25, 36). 27. Device according to one of the preceding claims, characterized in that the solid body (8, 9, 38, 40, 42) consists of a material which is well detectable by the sensor (13, 25, 34, 25, 36). 28. Device according to one of the preceding claims, characterized in that the solid state (8, 9, 38, 40, 42) has a diameter (d) between about 0.1 mm and 10 mm. 29. A method for the production of moldings (K) of wet concrete (7) or related materials in molds (3), in which vibrations are introduced in a shaking process, characterized in that movement data at least one existing in the wet concrete (7) Solid body (8, 9, 38, 41, 42) by a sensor (13, 25, 34, 25, 36) are detected during the Rüttelvorgangs. 30. The method according to claim 29, characterized in that the movement data during the Rüttelvorgangs wirelessly to an evaluation electronics (20, 39) are transmitted. 31. The method according to any one of claims 29 or 30, characterized in that by the evaluation electronics (20, 39) during the shaking operation control and / or control signals for a control unit of the machine (1) are calculated and passed to this. 32. The method according to any one of claims 29 to 31, characterized in that the control unit of the machine (1) converts the control and / or control signals of the evaluation electronics (20, 39) during the Rüttelvorgangs. 33. The method according to any one of claims 29 to 32, characterized in that in the evaluation electronics (20) a transmission signal of the microwave transmitter (15, 26) and a received signal of the microwave receiver (16, 27) are mixed and derived from the mixed signal modulation becomes, from which at least one of the motion characteristics is calculated, with which the solid body (8, 9, 38, 40, 42) in the moist concrete (7) moves or oscillates. 34. The method according to any one of claims 29 to 33, characterized in that by the sensor (13, 25, 34, 25, 36) during the shaking and moisture data are detected, which are transmitted and processed in particular parallel to the movement data. 35. The method according to any one of claims 29 to 33, characterized in that by the sensor (13, 25, 34, 25, 36) during the Rüttelvorgangs successive movement data of different solids (8, 9, 38, 41, 42) are detected. 36. Device (2) for monitoring the movement behavior of a moist material during a Energy introduction phase, in which an introduction of energy into the material takes place, wherein the material is compressible and / or mixable and / or solidifiable by the introduction of energy, characterized in that the device (2) comprises at least one sensor (13, 25, 34 , 25, 36), by means of which movement data of at least one partial volume and / or at least one solid (8, 9, 38, 40, 42) of the material can be detected during the energy introduction phase.