REIT RT15A Completely AutomaticConcreteBlock Production Line
| Pallet size | 1400 ×1150 ×16 mm（Steel） |
|---|---|
| Capacity/per Pallet | 15 hollow blocks 400×200×200mm |
| Dimensions of machine | 7800×2800×3600(4000)mm |
| Operation Cycl | 15-30s (depend on the products) |
1.Product Specifications
The block machine contains three main parts, including base concrete feeding device, face concrete feeding device and compacting system. For the fourth version of REIT QFT15, base concrete feeding device and face concrete feeding device can be moved independently, in order to adjust and fix machines easier. The improvement provides more space for workers to operate, maintain and adjust machines. It can be universally used for the manufacturing of pavers with and without face mix, kerbstones, hollow blocks and similar elements.
Pos.1 Green Block Conveyor
It is used for transporting the pallets with green blocks to the chain elevator orderly. It includes transferring device inside and crawl conveyor.
The transferring device inside is parallel four rod structure and is driven by cylinder, so it works more stable.
The crawl conveyor is combined with stationary bucket and movable frame. The moveable frame can move the pallet horizontally for one pitch in one cycle. The movement of frame with gear and rack mechanism is driven by electric motor controlled by frequency controller. The beginning and stopping position are controlled by a highly sensitive switch. In the end of the movement, there are a forced machinery limitation and protecting device for ensuring the quality of products.
Main parameter:
Distance transferring device moves: 120mm
Driven motor: 4kw
Transport speed: 0.20—0.48m/s
Pos.2 Rotate Brush for Green Block
It is for clean of the fresh products. The body of brush is the high strengthened whirling nylon brush, and is supported by steel frame. The height of brush can be adjusted according to the height of products. It is driven by a speed reducing motor and chain.
Main parameter:
- Driven motor: 0.75kw
- Dimension of thread: 0.4-0.5mm
- Speed of whirling: 137r/min
Pos.3 Chain Elevator with 12 Layers
It is for lifting the pallet with green blocks to certain position and stores them as designed distance and layers. When it is full, pallets with green blocks are transferred to the curing kiln by finger car. Its frame is sectional steel design with two lateral safety grids. Supporting angles are fixed on bush roller chains.
The lifting and storage device is formed by the steel hooks. The chains are working inverted synchronous which make the pallets horizontally when being lifted or stopped. The chains in the two sides work steadily.
The synchronous speed transmission for which REIT has patent driven by an electric motor is equipped for ensuring the chain’s lifting synchronously. The synchronous speed transmission is equipped with auto-lock to protect from danger when the electricity is broken off.
The high-quality proximity sensor controllers lifting height, and the combination of beam sensor with proximity sensor controllers the equipment working and safety protection with double protecting device.
Main parameter:
Driven Motor: 11kw Travel speed: 0.1m/s
Stages no.: 12 Pallets per stage: 2
Stage distance :400mm
Pos.4 Finger Car with 12 Layers
It is used for the transport of the pallets with green blocks from the chain elevator to the curing racks or chambers and for returning the cured products to the chain lowerator. The finger car assembly consists of finger car, platform car and control system.
Finger car
The finger car consists of base frame, stationary support, finger lift, hydraulic station, driven device and thread device. The function is lifting and transporting the pallets with blocks.
The steel base frame is fixed two shifts with wheels (one is driving and another is driven) which is driven by frequency-controlled motor. The stationary support is made of rectangle steel and fixed on the base frame for supporting and guiding the movements of finger lift. There are 12 pares of finger forks in the finger lift. The finger lift is guided by 4 groups of wheels fixed on the stationary support and driven by hydraulic cylinder. For conformed the length of cables, it is used the synchronous whirling roller device (including elements of roller, the station of roller, shrinking and extending device, and cable-nipped device, etc.) for ensuring the cable extension and shrinking with the finger car synchronously. This mechanism makes power supply and controlling signal to be input and output steadily.
Main Parameter:
Driven Power: 11kw
Travel Speed: 0.1-1.2m/s
The distance of layers: 400mm
Layers: 12
Pallet per stage: 2
Hydraulic pump power: 4kw
Working pressure of hydraulic system: 8mpa
Platform car:
Platform car is a steel transported platform, used for carrying finger car moving among the locations of elevator, curing kiln and lowerator.
Platform welded heavy duty steel frame is equipped with two shifts under and large flanged wheels and is driven by frequency-controlled motor. On the platform there are rails and safety device. Except the electronic positioning there are mechanical positioning and locking device (for which REIT has patent) which make platform position at certain location and locked for finger car travelling smoothly and exactly without bounce.
The main parameter:
Driven motor: 15kw
Travel speed: 0.1-1.1m/s
Motor of mechanical positioning and locking device: 2.2kw
Pos.5 Chain Lowerator with 12 Layers
The chain lowerator is used for fetching and storing the pallets with cured blocks, and loaded on the conveyor for cubing and pallets returning and recycle.
Its technical data is same as chain elevator, which lowerates the pallet with the cured products.
Pos.6 Atomizing Device (water spray device)
This device is designed mainly for the purposes:
1. Prevent the dusting when packing the dry blocks and cleaning the empty pallet.
2. Keep the moisture inside of final blocks for more curing to reach certain hardness.
Pos.7 Dry Block Conveyor
It is used for fetching the pallets with the cured products, and separating the two pallets moreover transferring them to the cubing device and pallets brushes, then conveying the cleaned pallets to the pallet turning device.
Combined with stationary bucket and movable frame, the moveable frame can move the pallet horizontally for one pitch in one cycle. The movement of frame is driven by motor through rack and pinion device. The beginning and stopping position are controlled by a highly sensitive switch. There is separated device for pallets in the beginning of dry block conveyor.
The main parameter:
Driven motor: 5.5kw
Transport speed: 0.42m/s
Pos.8 Automatic Cubing Plant
The function of automatic cuber is used for stacking the cured products from the pallets to product pallets which are on the slat conveyor. According to the different blocks, the layers, height and cubing style can be adjusted. The cuber can move, lift and circumrotate automatically at the same time.
The cuber consists of frame, moving cart, lifting device, whirling device and clamps. The frame of cuber is bridge type and there are rails of moving cart on the top. The moving cart is driven by SERVO motor through crank and rocker mechanism and moving along rails, which could meet the production need. The lifting device on which the clamps are fixed is 2 strong steel columns with 4 V-type guiding rails and is driven up and down by hydraulic cylinder. The whirling device is driven by motor and makes clamps turning 90 degree to left and right separately. The clamps are two pares cross arranged, one is main another is assistant. They are driven by cylinders with synchronous mechanism. On the top of the cuber there is the maintenance platform with safety grids.
Hydraulic Drive Unit
The independent of hydraulic station is consists of oil tank, valves, cylinders, cooling and heating device, filter and pipelines. The elements and cylinder are high quality products from world-famous company such as American Uranus and Yuken brand etc.so that the station is working reliably.
Electronic control system
The horizontal move position, whirling angle and the height of lifting is controlled by digital encode. There are protecting device in the system.
Main parameter:
Effective height of cubing 50-1200mm
The scope of main clamps; 840-1400mm
The scope of assistant clamps: 940-1400mm
Tangle of clamps head: ±90°
Lifting capacity: 650kg
Driven power of horizontal movement: 5kw （SERVO）
Driven power of revolution: 0.75kw
Motor of hydraulic pump: 22kw
Pressure of hydraulic system: 16mpa
Pos.9 Pallet Cleaning Brush
It is rotating brush to clean pallets. The brush is the high strengthened nylon brush, and is supported by steel frame. The height of brush can be adjusted. It is driven by motor through chains.
Main parameter:
Driven power: 0.75kw
Pos.10 Pallet Turning Device
It is used for turning the empty and cleaned pallets driven by low rotate speed motor. The device is controlled by limited switches, proximity sensor, and equipped the beam sensor as safety protection.
Main parameter:
Driven power: 0.75kw
Pos.11 Pallet Cross Transfer Device
It is for conveying the empty pallet to the turning device and transferring the turned pallets to the pallets hopper. Combined with stationary bucket and movable frame, the moveable frame can move the pallet horizontally for one pitch in one cycle. The movement of frame is driven by motor through rack and pinion device. The beginning and stopping position are controlled by a high sensitive switch.
Main parameter:
Driven power: 7.5kw
Travel Speed: 0.47m/s
Pos.12 Pallet Hopper
It is used for storing the pallets. Using the high-sensitive electrical switch controls the position and quantity of pallets.
The main parameter:
Storage Quantity: 4 pieces/pallet (steel)
Pos.13 Pallet-collecting Hopper
The pallet-collecting hopper is used to supply the pallet for block making machine in the beginning of the production, when the lowerator is not operating to supply the empty pallets for block making machine. Another purpose for it is that in the process of production, it is used to stack the empty pallet for the forklift to take it away.
Pos.14 Slat Conveyor
It is for transporting and storing cubed blocks. The blocks are take out by forklift from this device and transferred outside. The carrier of conveyor is metallic battens which are made of steel. The conveyor system is driven by motor and move according to the fixed pitch. Controlled by high-sensitive grating device, it can convey
the pallet and blocks to the
designed position exactly.
The main parameter:
Driven power: 7.5kw
Length: 11m
Speed of movement: 0.18m/s
Pos.15 Product Pallet Magazine
It is used for store the pallets and supply it for slat conveyor to meet the auto cuber need. The extended slats in three directions make the new pallet position exactly. The synchronically linked haulm makes sure the pallet lay up and down vertically in the magazine. The hydraulic and pneumatic control system is used.
Pos.16 Overpass
Pos.17 Mixing and Batching plant (for base)
Pos.17.1 Aggregate hoppers (for base)
The three (3) aggregate hoppers with the capacity of 20m3 for each are used for store the sand and stone. It consists of stationery frame and store hopper.
The stationery frame is used for supporting hoppers and fixing the weighing system and concrete belts conveyors.
The hopper is a net-like steel frame so its strength and rigidity are raised. There are two exits for loading down the aggregate in each hopper. The outlet of hopper is driven by pneumatic cylinder it can realize the batching rapid or slow, raise the precision and speed. There is vibrating device in the hopper which is used for store fine aggregate, for the smooth of unloading the aggregate.
Pos.17.2 Weighing Belt
The weigh belts measures and batches the aggregates with load cell sensors. The Belts conveyor consists of frame, support rollers, side rollers, driving and driven drums, clearing device, rubber conveyor belts.
Main parameter:
The maximum capacity of weigh: 3000kg
Precision of dynamic weigh: ±2%
Motor: 4.5kw
Effective conveyor quantity: 300ton/h
Pos.17.3 Aggregate Skip Hoister (for base concrete)
It is used for transporting the batched aggregate to the mixer. It consists of windlass, lifting hopper, the rails for lifting hopper. The limited switches can control the beginning and stopping at any position.
Main parameter:
Hopper: 3480L
Driven motor: 18.5kw
Pos.17.4 JN2000 Mixer (for base concrete)
It is advanced planetary mixer. The characters are two arms which can not only revolute along the main axes but also rotate along its axes. The mixing is uniformly and fast.
Main parameter:
Model: JN2000
Power: 75kw
Loading capacity: 3000L
Compacted concrete per batch: 2000L
Pos.17.5 Cement Weighing Scale (for base)
The cement weighing scale is used for batching the cement. It is fixed over top of mixer, and made up by batching hopper and 3 load cells. The main parts are the products of SVA Series and RAP Series of Italy Mix Company. The batching hopper is controlled by the program controlling device for screws. It can supply the material exactly.
Main parameter:
Maximum weighing ability: 1000kg (for base)
The precision for weighing: ±2%
Pos.17.6 Mixer Platform
Supporting for the mixers.
Pos.17.7 Base concrete conveyor belt
For the transport of the base mixed concrete from the mixer to the storage hoppers of block machine.
Main parameter:
Driven motor: 5.5kw
Effective conveyor quantity: 360t/h
Pos.17.8 Water Metering and Moisture Measurement
Hydronix moisture measurement by microwave is equipped for the base mixer, one microwave sensor inside of base mixer. One micro-water-pump is used to metering the water into mixer. Control computer controls water dosing and moisture for base mixer for the fully automatically.
Pos.17.9 Two Cement silos (customer makes locally)
The cements silos with collecting ash device are equipped with level indicator and gas breaking device. There are two silos, the capacity of them will be 80-100 tons. Among the two silos, there is at least one with a thunder-avoiding device on its top.
Pos.17.10 two cements screws (for base mixer)
The screws transport the cements from the silos to the cement weighing hopper. The length is about 8 meters.
Main parameter:
Conveying ability: 20-25tons/hour
Motor: 7.5kw
Pos.17.11 water supply system
Provide the water source for the mixing system, is built by customer.
Pos.18 Mixing and Batching plant (for face) (optional)
Pos.18.1 Aggregate hoppers (for face)
One aggregate hopper with the capacity of 12m3, mainly used for storing fine sand. The steel plate welding structure has two independent discharge ports, and the door opening and closing is driven by the cylinder. It can achieve fast and slow batching when batching and weighing, and improve the batching precision and speed. The hopper for storing fine aggregate is equipped with a vibrating device to ensure the smooth flow of materials during mixing.
Pos.18.2 Weighing Belt (for face)
The weigh belts measures and batches the aggregates with load cell sensors. The Belts conveyor consists of frame, support rollers, side rollers, driving and driven drums, clearing device, rubber conveyor belts.
Main parameter:
The maximum capacity of weigh: 1000kg
Precision of dynamic weigh: ±2%
Motor:3kw
Effective conveyor quantity: 300ton/h
Pos.18.3 Aggregate Skip Hoister (for face concrete)
It is used for transporting the batched aggregate to the mixer. It consists of windlass, lifting hopper, the rails for lifting hopper. The limited switches can control the beginning and stopping at any position.
Main parameter:
Hopper:580L
Driven motor: 5.5kw
Pos.18.4 Planetary Mixer (JN330 for face)
It is advanced planetary mixer. The characters are two arms which can not only revolute along the main axes but also rotate along its axes. The mixing is uniformly and fast.
Main parameter:
Model: JN330
Power: 7.5kw
Loading capacity: 500L
Compacted concrete per batch: 330L
Pos.18.5 Wet concrete conveyor belt
The belt is used for transporting the mixed aggregate to hopper of block machine. Including the supporting frame.
Main parameter:
Driven motor: 5.5kw
Effective conveyor quantity: 300t/h
Pos.18.6 Cement Weighing Scale (for face)
The cement weighing scale is used for batching the cement. It is fixed over top of mixer, and made up by batching hopper and 3 load cells. The main parts are the products of SVA Series and RAP Series of Italy Mix Company. The batching hopper is controlled by the program controlling device for screws. It can supply the material exactly.
Main parameter:
Maximum weighing ability: 300kg (for face)
The precision for weighing: ±2%
Pos.18.7 Water Metering and Moisture Measurement
Hydronix moisture measurement by microwave is equipped for the face mixer, one microwave sensor inside of face mixer. One micro-water-pump is used to metering the water into face mixer. Control computer controls water dosing and moisture for face mixer for the fully automatically.
Pos.18.8 Cement silos (customer makes locally)
One 60ton’s silos with collecting ash device are equipped with level indicator and gas breaking. There is a thunder-avoiding device on its top.
Pos.18.9 One cements screws
The screws transport the cements from the silos to the cement weighing hopper. The length is about 8 meters.
The main parameter:
Conveying ability: 20-25tons/hour
Motor: 7.5kw
Pos.19 Intelligent Control and Management System（ICMS）
The electric control group includes hardware part and software part.
Hardware part contains electric control cabinet, console, PC, PLC, remote communication module, sensors and etc. Components are mainly from international famous brand, such as: the central controller PLC from Siemens, inverters from Toshiba, operation buttons and joy-sticks from Schneider, limit switches from German Bedook, moisture measure meter (provide material humidity accurately measuring precision technology guarantee) from British Hydronix, encoders from Japanese Omron. The PC is using the control configuration software. Host system has a friend interface, data input and output, graphic display function. Operators can be easily and quickly to set the parameters and grasp the running state of the whole production line at any time. English operation interface is also available in this system.
The software part includes the following functions:
1) Intelligent computing function module
This module mainly realizes the implementation of the logic function of judgment and action. For example: the action of electromagnet, formula processing of raw material and the moisture of the material guarantee, etc. Through intelligent operation function module can be precisely and efficiently coordination of the execute device action, according to the demand of the technological process, to achieve the objective of the preserved operation. The whole system has more wisdom ultra-energy effect.
2) Cloud network communication function module
This module mainly coordinates distributed I/O problems of communication, and remote screen and debugging capabilities. Production of equipment used in the various functional areas can ensure the safe operation of equipment and high efficiency. Real-time record the material ratio of mixing plant, dry wet degree and the running state; It can also real-time record the trajectories and status and innovation product maintenance status of the finger car; Assist the remote processing problems, reduce downtime, improve equipment utilization; For the standard project, the engineer can install the machine at home by remote debugging, shorten the scene in the cycle and into production in advance.
3) Fault diagnosis and fault tolerance/correction function module
This control system includes program operation, running of fault tolerance and error correction function. Through this function effectively avoid the equipment damage caused by the wrong operation and the damage caused injuries which can timely to remind operator to do necessary adjustment, to reach “fool” of the operating system. Greatly reduced requirements for the knowledge level of operators, saving the artificial cost.
4) Cloud management module
This module function combined with today’s industrial4.0, use the internet to realize cloud management factory. The owner can view the factory anytime and anywhere through the network of data report, and according to the report you can manage all the factory and adjust the data to achieve the maximization of utilization of resources and efficiency of optimization.
5) Cloud diagnosis function module
This module function includes local and remote diagnosis function. By controlling the internal alert code with the assistance of the remote network can quickly and accurately diagnosis the specific reasons for the problem, and the corresponding treatment method, which really achieve “zero time” to exclude, to solve the problem.
6) Intelligent manage system
This system provides management functions for users. It can store dozens of products of its production data and formula, so as to shorten the transformation product after debugging time, and to automatically record each shift, month production to facilitate the production plan preparation and production statistics. All these data can be sent to the manager according to the requirement.
When the intelligent control and management system is utilized, less need to operating personnel, can completely in the central control room to complete all the operation of the equipment, in the automatic condition to reach unattended level; With high reliability, high performance sensor ensures the precision of the mixing material moisture and uniformity; By means of the frequency control of motor speed control, to ensure the product appearance, strength and a high degree of consistency; Through strict control program makes the equipment running stably, increase the service life of equipment. The use of Bluetooth technology enables the finger car cable laying more simple, easy to maintain. The use of industrial network makes the control more modern and efficient. Currently this control system has been rated as the upper-class system both in domestic and international.
The electric control group includes following sub-systems:
1. Block machine control sub-system
2. Transport control sub-system
3. Auto cuber control sub-system
4. Finger car control sub-system
5. Mixing and batching control sub-system
These control sub-systems are integrated in one and operated in the central room for not only controlling the whole line by digital logically controlling system but also controlling every system independently. The system can be linked and locked each other for the safety.
Pos.19.1 Block machine control sub-system
Referring to Pos. 1
Pos.19.2 Transport control sub-system
For the control of: Green block belt conveyor, Rotate brush, Chain elevator, Chain lowerator, Dry block conveyor, Pallet cleaning brush, Pallet turning device, Pallet cross transfer device, Pallet hopper and Pallet oiling device，Pallet scraper.
Pos.19.3 Auto cuber control sub-system
The Cuber, including Slat Conveyor and Product Pallet Magazine, is controlled by the Siemens Siematic S7 PLC. The control desk includes joy-sticks for manual machine operation and a Siemens digital display for data in-put and out-put as well as error diagnosis system.
Pos.19.4 Finger car control sub-system
The Siemens Siematic S7 PLC and the power unit is integrated into a control desk which includes joy-sticks for manual machine operation and a Siemens digital display for data in- and output as well as error diagnosis system.
Pos.19.5 Mixing and batching control sub-system
Pos.19.5.1 Control for base concrete mixing and batching
Automatically control base concrete batching and weighing, water metering and moisture measuring, mixing and transporting to block machine. It can input the related parameter to the control unit according to the production frequency of block machine, the batching and mixing system can feed, mix, water meter, moisture measure, and transport the aggregate to the hoppers of block machine. The transport is controlled automatically and manually as well. The statistic and store of data can realized by the computer, it can memorize much formula.
Pos. 19.5.2 Automatic control unit for face concrete mixing(optional)
Same as Pos.20.5.1
Pos. 19.5.3 Special function and advantages
1. “one touch to reset”
Advantage: Firstly, operating conveniently thus reducing the professional knowledge demand of operator. Secondly, new system has fault reason display. Thirdly, fault-tolerant function makes machine can self-checking and starting.
2. Service through Internet
Advantage: Firstly, eliminating impact on machine, thus extending equipment’s service life. Secondly, upgrade can make machine running more smoothly. Thirdly, it will shorten molding cycle and raising the qualified rate. All in all, it can reduce cost of raw material and lower maintenance cost.
Pos.20 Pneumatic Group
The pneumatic group is the acting device of related equipment with batching and mixing plant, block machine, pallet feeder, pallet turning device and pallet oiling device. The group includes Air compressor, pipe or hose, filter, cylinders, valves and so on.
3.Capacity Table
Additional information
| Pallet size | 1400 ×1150 ×16 mm（Steel） |
|---|---|
| Capacity/per Pallet | 15 hollow blocks 400×200×200mm |
| Dimensions of machine | 7800×2800×3600(4000)mm |
| Operation Cycl | 15-30s (depend on the products) |
