Method and device for manufacturing a canal component
10195763 · 2019-02-05
Assignee
Inventors
Cpc classification
B28B1/0873
PERFORMING OPERATIONS; TRANSPORTING
B28B21/94
PERFORMING OPERATIONS; TRANSPORTING
B28B1/30
PERFORMING OPERATIONS; TRANSPORTING
International classification
B28B11/04
PERFORMING OPERATIONS; TRANSPORTING
E03F5/02
FIXED CONSTRUCTIONS
B28B21/94
PERFORMING OPERATIONS; TRANSPORTING
B28B1/30
PERFORMING OPERATIONS; TRANSPORTING
B28B1/087
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The present invention relates to a method for manufacturing a canal component which comprises a connection portion 104, 106 designed to come into contact with a component 100, in particular an adjacent canal component, which is to be connected to the canal component 100, the method comprising the following steps: providing a concrete base body, coating the base body with a plasticized plastics material 110 in the region of the connection portion 104, 106 and in the region of an internal wall (108) of the base body facing the canal inner space 106, and curing the plastics material (110).
Claims
1. A method for manufacturing a concrete canal component, comprising the following steps: providing an inner mould which forms an internal contour of the concrete canal component facing a canal inner space; coating the inner mould with a plasticised plastics material; curing the plasticised plastics material to form a solid plastics material layer; arranging the inner mould, along with the solid plastics material layer, and a mould shell which forms an external contour of the concrete canal component in such a way that the mould shell encloses the inner mould; pouring concrete in between the inner mould and the mould shell; at least partially curing or compacting the concrete; and, demoulding the concrete canal component including the cured plasticised plastics material on the concrete canal component.
2. The method of claim 1, wherein the concrete canal component is a lower shaft part comprising a conduit and wherein the inner mould comprises a conduit moulding body of a foamed plastics material, which forms the conduit.
3. The method of claim 2, wherein the foamed plastics material is expanded polystyrene.
4. The method of claim 1, wherein the concrete canal component comprises a connection portion designed to come into contact with another component, which is to be connected to the concrete canal component, wherein a portion of the inner mould, which forms the connection portion, or a mould sleeve, which forms the connection portion, is also coated with plasticised plastics material.
5. The method of claim 4, wherein a seal is placed the portion of the inner mould forming the connection portion (80) or on the mould sleeve, the plasticised plastics material being applied in such a way that it overlaps or covers the seal.
6. The method of claim 4, wherein the component, which is to be connected to the concrete canal component, is an adjacent canal component.
7. The method of claim 1, wherein bonding courses in the form of grit, sand, granulate, anchoring projections or in the form of a lattice are either applied to the solid plastics material layer or introduced into the plasticised plastics material.
8. The method of claim 1, wherein, prior to coating the inner mould with the plasticised plastics material, the inner mould is coated with a separating medium.
9. A method for manufacturing a concrete canal component, comprising the following steps: providing an inner mould which forms an internal contour of the concrete canal component which faces a canal inner space; coating the inner mould with a plasticised plastics material; coating the inner mould with a separating medium prior to coating the inner mould with the plasticised plastics material; curing the plasticised plastics material to form a solid plastics material layer, providing a mould shell which forms an external contour of the concrete canal component; pouring concrete in between the inner mould and the mould shell; at least partially curing or compacting the concrete; and, demoulding the concrete canal component including the cured plasticised plastics material on the concrete canal component, wherein the concrete canal component comprises at least one of a shaft ring, a shaft cone, or a pipe.
Description
(1) In the following, the invention is described in greater detail by way of preferred embodiments with reference to the accompanying drawings, in which:
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(13) At an upper peripheral edge of the shaft wall 14, which wall extends around the duct 12, the lower shaft part 12 is formed as a first connection portion 32 which is designed to couple to a component positioned thereabove in a fitting manner, in most cases a shaft ring positioned thereabove. In the embodiment, an annular projection 34 is provided on the first connection portion 32 and can engage in a fitting manner in a corresponding annular recess of a component positioned thereabove. Further connection portions are provided on the pipe connections 22, 24, 26 and designed to receive pipes or the like, which are to be connected thereto, in a fitting manner.
(14) According to the method of the first embodiment, to manufacture a lower shaft part 10 according to
(15) The conduit moulding body 36 is preferably made of a plastics material, in particular a foamed plastics material (for example expanded polystyrene), such that it is easy to process, is simple to handle, and additionally, because of the low costs thereof, can also effectively be designed as a disposable moulding body for single use and subsequent destruction. To provide a desired shape of the conduit moulding body 36 corresponding to a conduit 18 to be formed, the conduit moulding body 36 may preferably be adapted to the desired shape using a milling tool 42. The milling tool 42 may be controlled in an automated manner, for example by a robot on the basis of three-dimensional measurement data regarding the desired conduit 18. In particular, it is possible to use a method for manufacturing a moulding body 36, as described in EP 2 318 625, the relevant content of which is to be incorporated into the present disclosure by reference.
(16) In a subsequent method step, a separating medium known per se, for example an oil-based or wax-based separating medium, may be applied to the conduit moulding body 36.
(17) Subsequently, the surface of the conduit moulding body 36 which will subsequently face the concrete is coated with a layer 44 made of plasticised plastics material. In particular polyurea, an epoxy resin, polyethylene, polypropylene or other thermosets are conceivable as the material. Particularly preferably, a polyurea is used. The plastics material 44 may be applied in a liquid or spreadable form, and, prior to or directly during the application, can be mixed with a curing agent which can accelerate curing of the plastics material after application. A spraying method may be used in which the plastics material is thrown out through a nozzle using pressurised air. Alternatively, the plastics material can be applied to the surface of the conduit moulding body using a paintbrush or a roller.
(18) Advantageously, the tool for applying the plastics material layer 44 may be guided along on the surface of the conduit moulding body 36 in an automated manner, or a blast direction of a spray tool may be controlled in an automated manner in accordance with the contour of the conduit moulding body 36. The automated tool guidance may in particular be carried out by a robot. The robot may operate analogously to the robot which is optionally used for milling the conduit moulding body 36, and with a particular synergistic effect may even be the same robot.
(19) The plastics material layer 44 may be provided with bonding courses 45. For this purpose, grit, sand, granulate or the like may be attached to (for example sprayed onto) the plastics material layer 44 or integrated into the plastics material layer. Optionally, these materials may also already be contained in the plasticised plastics material during the application of the plastics material layer 44, or the bonding courses may be introduced into the plastics material when it has not yet completely cured. Alternatively or in addition, anchoring projections may be placed on and attached to the plastics material layer 44 as bonding courses, or the plastics material layer 44 is covered with a lattice or mesh. The bonding courses 45 serve to improve the adhesion between the plastics material layer 44 and the concrete.
(20) After the plastics material layer 44 has been applied, it cures on the conduit moulding body 36.
(21) In a subsequent method step of the method of the first embodiment, the conduit moulding body 36, including the plastics material layer 44 cured thereon, is guided to a mould 46 in which a lower shaft part 10 is to be produced. In a manner known per se, the mould 46 comprises a cylindrical mould shell 48 which is designed to form an external wall of the lower shaft part 10, a mould core 50 which is arranged coaxially in the mould shell 48 and is of a substantially cylindrical shape, for forming an internal wall of the lower shaft part 10, and a mould sleeve 52, which is arranged annularly in a gap between the mould shell 48 and the mould core 50, for forming the peripheral edge comprising the first connection portion 32, optionally including the annular projection 34, of the lower shaft part 10.
(22) The conduit moulding body 36 is placed on the mould core 50, where it is preferably fixed against slipping or floating by means of fastening means 54, for example screws. Subsequently, recess cores 56, which are intended to form the pipe connections 22, 24, 26 and are preferably likewise manufactured from a foamed plastics material in a milling process, are placed on and likewise attached to the conduit moulding body 36.
(23) Alternatively, the recess cores 56 may already be attached to the conduit moulding body 36 before the plastics material layer is applied, or may even be formed in one piece with the conduit moulding body 36. In a variant of the invention of this type, the recess cores 56 (which can in this case be considered part of the conduit moulding body 36) are subsequently also likewise covered with the plastics material layer 44 before being introduced into the mould 46, in other words prepared in the same manner described above for the conduit moulding body 36 (optionally including separating medium application and/or bonding course attachment). It is also possible for the conduit moulding body 36 and the recess cores 54 to be provided as an integral moulding body (for example manufactured from a foamed plastics material by the above-described milling method) and for this moulding body to be coated with a plastics material layer in an upstream method step in the above-described manner. If the recess cores 54 are attached to or formed on the conduit moulding body 36 before the application of the plastics material layer in the above-described variants, and if the plastics material layer is subsequently applied over the conduit mould 36 and the recess cores 54 in a continuous and joint-free manner, it can be provided that substantially the entire conduit 18, including the pipe connections 22, 24, 26, can be provided with a plastics material cladding both continuously and homogeneously.
(24) In a subsequent method step of the method according to the first aspect of the invention, concrete 58 is poured into the mould 46 in such a way that it is distributed in the space between the mould shell 48 and the mould core 50 or conduit moulding body 36. In this case, the lower shaft part 10 can actually be manufactured in a production process known per se, in particular in a direct demoulding process or a mould-setting process. In a direct demoulding process, at least one vibration apparatus is arranged on the mould 46, for example integrated in the mould core 50, positioned on the mould shell 48, or the mould 46 is placed on a vibrating table. During or after pouring in the concrete, the vibration apparatus is set in operation in such a way that the poured-in concrete is compacted and gains sufficient stability for the lower shaft part 10 to be able to demould. Subsequently, the concrete is actually cured outside the mould 46, or at least with the mould shell 48 removed. In a mould-setting process, it is not necessary to provide vibration apparatuses. In this case, the poured-in concrete is kept in the mould 46 until it has at least partially cured and demoulding is reliably possible.
(25) In the demoulding process, the mould shell 48 may first be opened, and subsequently the lower shaft part can be moved away from the mould core 50. Preferably, in this context the attachment 54 between the conduit moulding body 36 and the moulding body 50 is released so that when the lower shaft part 10 is lifted off, the conduit moulding body 36 initially remains on the lower shaft part 10. In a subsequent method step, the conduit moulding body 36 can subsequently be released from the plastics material layer 44. Releasing the conduit moulding body 36 from the plastics material layer 44 thereof is facilitated by the optionally applied separating medium. However, in particular if foamed plastics material (expanded polystyrene) is used as the material for the core of the conduit moulding body 36, it should be anticipated that when the foamed plastics material is removed, the material may get damaged or destroyed. Conduit moulding bodies made of foamed plastics material can advantageously be used as disposable conduit moulding bodies.
(26) After demoulding, a lower shaft part 10 is obtained, the conduit of which and preferably also the connection portions of which are cladded with a plastics material to a high surface quality and with effective sealing.
(27) In the following, a second embodiment of the invention is described with reference to
(28) In the embodiment, a device for manufacturing a canal component 60, in this case a concrete pipe, is a mould 62 which comprises: a mould core 64, which forms an inner face 68, of the canal component 60, facing a canal 66, a mould shell 70, which forms an outer face 72 of the canal component 60, a first sleeve 74, which forms a first connection portion 76 at the rim of a first opening of the canal component 60, and a second sleeve 78, which forms a second connection portion 80 of the canal component 60 at the rim of a second opening. The mould core 64, the mould shell 70, the first sleeve 74 and the second sleeve 78 enclose a mould cavity, in which the canal component 60 is manufactured. The mould 62 may be arranged on a table 82.
(29) The connection portions 76 and 80 of the canal component 60 comprise such contours that they are designed to receive an adjacent component in a fitting manner, in particular a canal component connected thereto, so as to form a continuous canal 66. In the embodiment, the first connection portion 76 is formed as an end portion having a portion 84 of tapered diameter (tapering of the external diameter of the canal component 60), and the second connection portion 80 is formed as a receiving portion having a portion 86 of expanded diameter (expanded internal diameter of the canal component 60). As can be seen in
(30) The first and second connection portion 76, 80 of the canal component 60 may in particular be designed in such a way that a first connection portion 76 of a canal component 60 can be inserted into a second connection portion 80 of an adjacent canal component 60, in that in particular the annular projection 76 engages in the recess 88. At the connection portions 76, 80, adjacent canal components 60 touch one another. In a manner known per se, in the region of the connection portions 76, 80 (in the embodiment at the second connection portion 80 in the region of the recess 88), a seal 89 in the form of an annular seal may be inserted, which further improves the seal between the canal components at the transition between the canal components.
(31) For providing the plastics material cladding of the canal component 60, the mould core 64 carries a plastics material layer 90. In a first method step of the method according to the second embodiment, the plastics material layer 90 may be applied to the mould core 64 in a plasticised form. A face, of the first and/or second mould sleeve 74, 78, facing the canal component 60 may also be covered with the plastics material layer 90 so as also to provide the first connection portion 76 or the second connection portion 80 with a plastics material layer. For the description of the preferred plastics materials and the techniques for applying the plastics material in a plasticised form, reference is made to the description of the first embodiment. Particularly preferably, in the second embodiment too liquid polyurea is applied by a spray method from a nozzle which is automatically controlled.
(32) The first sleeve 74 and/or the second sleeve 78 may be formed integrally on the mould core 64. When the plastics material layer 90 is applied, the sleeve 74 or 78 and the mould core 64 are preferably coated continuously, ensuring a reliable, continuous plastics material layer. However, it may be advantageous to form the first sleeve 74 and/or the second sleeve 78 as a separate moulding which can be released from the mould core 64 or can be mounted on the mould core 64. The first or second sleeve 74, 78 can subsequently be suitably positioned so as to be able to apply the plastics material layer 90 reliably and accurately without the mould core 64 obstructing the positioning of an application tool. If a separate first and/or second sleeve 74, 78 is/are used, a tight connection between the plastics material layer of the sleeve 74, 78 and the plastics material layer 90 of the mould core 64 should be established after the sleeve 74, 78 is mounted on the mould core 64. This can be provided by way of an adhesive connection or by subsequently applying plasticised plastics material to the joint.
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(36) At the rim 94, of the plastics material layer 90, protruding outwards from the mould core 64, the plastics material layer may overlap the seal 89 optionally provided at this point. For example, a particularly reliable and sealed connection is established in that the seal 89 is initially placed on the sleeve 78 and optionally temporarily fixed there, and in a subsequent step plastics material in a plasticised form is applied to the sleeve 78 and to part of the seal 89 as a continuous coating. As a result of the overlap, effective fixing and good sealing between the plastics material layer 90 and the seal 89 are ensured.
(37) Alternatively, direct integration of a seal 89 into the concrete of the connection portion 80 can be omitted, and instead the plastics material layer 90 may substantially cover the entire recess 88 of the second connection portion 80 as a continuous layer, in other words the plastics material layer 90 may extend as far as an outermost axial end of the canal component 60, in other words as far as an axial end face 95 of the second connection portion 80. A seal may subsequently be placed for example on the first connection portion 76 before the adjacent components are joined together such that the seal is subsequently arranged between the first and second connection portions of two canal components which have been joined together, but the entire region which the seal abuts on both sides is completely and generously covered with a plastics material cladding layer.
(38) In a further method step of the method according to the second embodiment, bonding courses are arranged on the plastics material layer 90. For the description of possible bonding courses and variants for providing such bonding courses, reference is made to the description of the first embodiment, which is completely transferable to the second embodiment.
(39) In a further method step of the method according to the second embodiment, the mould core 64 is arranged in the mould shell 70. For example, if a pipe is being manufactured, the mould shell 70 can be drawn coaxially over the mould core 64 along the axial central axis M. Alternatively, the mould shell 70 may be configured in such a way that it can be opened and closed so as to insert the mould core 64. The first and second sleeves 74, 78 may be mounted on the mould core 64 or on the mould shell 70 at the appropriate time as long as they are not formed as a solid unit together with the mould core or mould shell. For example, a variant is conceivable in which the second sleeve 78 is rigidly connected to the mould shell 70 and/or the table 82 and the first sleeve 74 is rigidly connected to the mould core 64 in such a way that, to close the mould 62, the assembly of the mould core 64 and the first sleeve 74 merely has to be introduced concentrically into the mould shell 70 and into the second sleeve 78.
(40) Once the mould 62 has been closed, concrete is introduced into the mould cavity and processed in a manner known per se in a direct demoulding process or in a mould-setting process to form the canal component 60. For a direct demoulding process, a vibration apparatus may be provided on or in the mould core 64 or on the mould shell 70 or else on the table 82, and transfers a vibrational or wobbling movement to the concrete so as to compact the concrete after it is poured in such that demoulding is possible immediately afterwards. In the mould-setting process, vibration apparatuses are not necessary, and the concrete is left at least until it has partially set in the mould pipe cavity in such a way as to make demoulding possible.
(41) During demoulding, the mould core 64 is removed from the plastics material layer 90 which remains to form the plastics material cladding, in particular as a result of the adhesion, reinforced by bonding courses, to the concrete of the canal component 60. For demoulding, the first sleeve 74 and/or the second sleeve 78 are advantageously also removed and the mould shell 70 is removed. The plastics material layer 90 is also separated from the mould 62 (in other words from the first or second sleeve 74, 78) in the region of the first or second sleeve 74, 78 so that the plastics material layer 90 remains on and on top of the concrete of the canal component 60 as a cover layer.
(42) As can be seen in particular in
(43) In the following, a third embodiment of the invention is described with reference to
(44) The canal component 100 comprises at least one connection portion at which it can be coupled to adjacent components of a canal system. In the illustrated embodiment, the canal component 100 comprises a first connection portion 104 at a first opening of a canal 106 defined by the canal component 100, and comprises a second connection portion 106 at a second opening. The shape of the first and second connection portions 104, 106 may be configured according to the example of the canal component 60 of the second embodiment, reference being made in this regard to the description thereof.
(45) In the method or manufacturing device of the third embodiment, too, the canal component 100 is to be provided with a plastics material layer or inliner layer made of plastics material on an inner wall facing the canal 106 and in the region of the connection portions 104, 106. In the third embodiment, this plastics material layer is applied to a new, at least partially cured concrete body of the canal component 100 in a plasticised form. A polyurea, an epoxy resin, a polyethylene (PE), a polypropylene (PP) or another thermoset material may be used as the material for the plastics material layer 110, polyurea being the preferred material for the reasons explained above. The plastics material may be applied together with a curing agent, it being possible for the plastics material and the curing agent to be mixed prior to the application of the plastics material or else directly at the time of the application of the plastics material, for example using a mixing nozzle.
(46) As regards the various techniques for applying the plastics material, reference is made to the description of the first embodiment. In particular, application by spraying methods is conceivable.
(47) In the illustrated embodiment, the canal component 100 is pipe-shaped and comprises a cylindrical internal wall 108, and in a particularly preferred variant of the invention the plastics material for the plastics material layer 110 is applied by rotational spraying, which is described in the following, using a rotational spraying device 112. The rotational spraying device 112 comprises a first movement arrangement 114, on which a first application arrangement 116 is movably held in such a way that the first application arrangement 116 can move along or in parallel with an axial central axis M of the canal component 100 (central canal axis). The first application arrangement 116 and the movement arrangement 114 can be coupled together by a linear guide known per se so as to make possible movement of the first application arrangement 116 as dictated by an electronic control apparatus 118.
(48) The first application arrangement 116 may comprise a spray head which is rotatable about the axial central axis M or an axis parallel thereto so as to throw a plastics material supplied to the spray head (and optionally mixed with a curing agent) radially outwards with respect to the internal wall 108 of the canal component 100 by means of a centrifugal force, in order to form the plastics material layer 110. The plastics material and optionally the curing agent may be matched to one another in such a way that the plastics material layer 110 cures immediately after the jets strike or after only a short time (for example 10 seconds).
(49) Preferably, the rotational spray device 112 further comprises a second application arrangement 117 which is movably held on a second movement arrangement 120. The second application arrangement 117 may be designed to provide the at least one connection portion 104 or 106 with the plastics material layer 110. The movement arrangement 120 may be designed to move the second application arrangement 117 in a circle about the axial central axis M in such a way that the entire connection portion 104 or 106 can be coated continuously. Preferably, a blast direction of the second application arrangement 117 or a radial distance of the second application arrangement 117 from the axial central axis M may also be adjustable so as to ensure that a seamless plastics material layer 110 can be manufactured which extends outwards from the internal wall 108 over the connection portion 104, 106. This means that the operating regions, in which the first application arrangement 116 and the second application arrangement 117 can apply plastics material to the canal component, preferably overlap.
(50) The first and optionally the second application arrangement and the associated movement arrangements 114, 120 are controlled, preferably fully automatically, in accordance with geometric data regarding the canal component 100 by the control/regulating apparatus 118. After the plastics material layer 110 sets, a canal component 100 is obtained which is cladded completely by a continuous plastics material layer 110 on the internal wall 108 thereof and on at least one of the connection portions 104, 106.