Note: Descriptions are shown in the official language in which they were submitted.
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Method and apparatus for the artificial aging of blocks
The invention relates to an apparatus for the
artificial aging of blocks, in particular concrete
blocks, clinker bricks and natural stone blocks,
according to the preamble of claim 1. The present
invention also relates to a method for the artificial
aging of blocks according to the preamble of claim 43.
An apparatus of the generic type for aging has been
disclosed by DE 20 2004 020 206.9.
Blocks, for example surfacing elements, facade
elements, sand-lime blocks, concrete blocks, bricks or
clinker bricks, natural stone blocks and the like,
irrespective of their material condition, are often
subjected to a subsequent treatment in order to lose
their artificial appearance.
Freshly produced, set concrete blocks, in particular
concrete paving blocks, are subjected to such a
subsequent treatment especially frequently, in the
course of which the surfaces and/or the edges are
struck or broken in order to adapt the appearance to
natural stone in this way. To this end, a relatively
large number of concrete blocks are put into a rotary
drum and "rumbled" there, the surfaces and edges of the
blocks striking one another and the blocks thus treated
leaving the drum in an "aged" state. Such an apparatus
has been disclosed by DE-A 29 22 393.
During the treatment of the concrete blocks in a rotary
drum, surfaces and edges which, for example. when using
the aged blocks, are not visible at all in a paving are
also treated. To this extent, energy and time are
needlessly wasted. Furthermore, it is necessary to put
the treated concrete blocks leaving the rotary drum
onto a pallet for dispatching in a regular arrangement,
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the amount of work and time which this involves being
disproportionately high.
Sorting installations for sorting the blocks are known
from the prior art, these sorting installations
accordingly orienting the blocks and arranging them in
a pallet form. Such sorting installations involve high
procurement and operating costs and also take up a
corresponding amount of space.
DE 36 21 276 C2 discloses a method in which concrete
blocks are put onto a platelike base in a single layer
in a regular arrangement. The exposed surfaces and the
adjoining exposed edges or essentially only the edges
of the concrete blocks are then struck irregularly by
means of a vibrating knocking or striking device.
Due to this method, a subsequent sorting device can be
dispensed with, since the production layer is not
changed. Before the treatment by the knocking or
striking devices, the blocks are pushed together and
oriented on the platelike base, so that the blocks fit
closely against one another and there is no longer any
intermediate spaces between them. The striking tools of
the striking device are arranged on a movable carriage
which guides said striking tools across the surfaces of
the blocks, so that the free surfaces of the blocks and
those edges of the blocks lying at the top are struck
by the striking tools.
A disadvantage with this method, however, is that the
blocks aged in this way look artificially treated and
not naturally aged. The use of the method of the
generic publication does not result in ideal breaking
of the edges of the blocks as is obtained by the
rumbling of the blocks in a rotary drum.
Disclosed by EP 0 860 258 B2 is an apparatus and a
method in which the blocks are arranged in one or two
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layers, preferably in their production layer, between
two elements, preferably plates. In this case, the
bottom plate, on which the concrete blocks rest, is in
interaction with a vibrating device. The blocks are set
in motion by the vibrating device, so that they move
back and forth between the plates. In the process, the
blocks strike one another and also strike the top and
the bottom plate, as a result of which the edges on the
top side and the underside are broken. In addition, the
top sides and the undersides of the blocks are struck
by the respectively assigned plates. The vertical side
edges of the concrete blocks and the side faces are
broken or struck by the respectively adjoining concrete
blocks.
It has been found in tests that the breaking of the
edges is all the poorer, the larger the block to be
aged is. This results from the fact that the striking
angle becomes all the smaller, the larger the block put
between the plates is. The small striking angle results
in unfavorable breaking of the edges.
As with the aging method by means of the rotary drum,
there is the disadvantage in this case that surfaces
and edges of the blocks are treated which are possibly
not visible at all, as a result of which energy and
time are needlessly wasted. In addition, the requisite
treatment time, in particular in the case of set
concrete blocks, is long and the breaking of the edges
is not ideal.
The generic publication DE 20 2004 020 206.9 discloses
an apparatus for the artificial aging of blocks in
which the blocks - preferably in their production layer
- are placed on a base, so that the surfaces to be
treated and the adjoining edges of the blocks are
exposed. By means of a magnet, freely movable striking
bodies (of metal) are then applied to the surface to be
treated. The base on which the blocks rest is set in
CA 02612884 2010-05-17
WH-13287CA
SN 2,612,884
-4-
vibration by means of a vibrating device. The blocks
and the striking bodies are therefore set in motion
relative to one another in such a way that the striking
bodies act on the surfaces and the exposed edges of the
blocks.
The apparatus disclosed by DE 20 2004 020 206.9 enables
rapid and effective aging of the top side of the blocks
and the adjoining, exposed edges. The striking bodies
randomly hit the surface of the blocks and therefore
strike the latter irregularly, so that an optical
effect is produced which corresponds to that of a
naturally aged block.
According to the aging process, the metallic striking
bodies are lifted from the surface of the blocks again
by the magnet - by the latter being brought close to
the blocks. The block layer can be removed and a new
block layer can be fed. It is a disadvantage that the
magnet to be used involves high costs. A further
disadvantage is that downtimes occur due to the
striking bodies being put down and picked up again by
the magnet, and these downtimes lead to longer cycle
times.
The apparatus and method of the present invention
provides a cost-effective and a rapid aging of blocks.
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Owing to the fact that the striking bodies are movably
fastened, but this fastening allows a movement of the
striking bodies within a defined region of the
surface of the blocks, this achieves the effect that,
firstly, surfaces or the adjoining edges of the blocks
continue to be struck irregularly and thus an optical
effect is produced which corresponds to that of a
naturally aged block, and, secondly, a magnet for
putting down the striking bodies and picking them up
again from the surface can be dispensed with. By the
initiation of vibrations, for example caused by a
vibrating table which is arranged under the blocks, the
blocks and the striking bodies are set in motion
relative to one another in the manner as described in
the generic publication, so that the striking bodies
act on the surfaces and the adjoining edges of the
blocks.
The solution according to the invention permits a
plurality of variants for setting down the striking
bodies and for removing them from the surfaces of the
blocks and thus makes it possible to dispense with a
hitherto required magnet in several ways. For example,
in one embodiment, provision may be made for the
retaining device on which the striking bodies are
movably fastened to perform a lifting movement in order
thus to be able to lift the striking bodies from the
surface of the blocks or to feed them to said surface.
The lifting of the striking bodies from an aged layer
of blocks and the placing of the striking bodies again
on a new layer of blocks to be aged can be carried out
very quickly in this manner, so that short cycle times
can be maintained. The downtimes are markedly reduced
compared with the prior art.
As the inventor has recognized, a special advantage of
the solution according to the invention consists in the
fact that lifting the striking bodies and setting them
down again can be completely dispensed with. This is
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because the movable fastening or suspension of the
striking bodies enables the apparatus according to the
invention to be designed with a conveying device, for
example in the form of a push rod or a conveying band,
which pushes the blocks to be aged continuously or
discontinuously through below the movably fastened
striking bodies. The expression "continuous aging" also
refers to an interval during which the blocks are
pushed through below the striking bodies with brief
interruptions of, for example, 5 seconds. In the
process, the striking bodies - excited in a
conventional manner by the initiated vibrations - act
on, so as to age, the blocks. As already described, the
movable and flexible fastening ensures that firstly the
blocks are struck unevenly and that secondly the
striking bodies can be prevented from traveling along
with the blocks. The striking bodies in each case age
the blocks which are located within the defined region
available to them.
The defined region may be selected, for example, as a
function of the number of striking bodies, the number
of blocks and the speed of passage.
It has been found in this case that just a relatively
small region within which the striking bodies are
movable on the surface of the blocks is sufficient.
This avoids a situation in which the striking bodies
(on account of excessive mobility) can penetrate into
the intermediate space between two blocks and possibly
jam there.
According to the invention, provision may be made for
the striking bodies to be arranged unevenly or
irregularly on a retaining device, arranged
transversely to the feed direction, both in the feed
direction and transversely thereto, so that the blocks
are not aged evenly.
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Furthermore, according to the invention, provision may
be made for the striking bodies to be arranged in a
plurality of rows transversely to the feed direction of
the blocks in such way that the rows of striking bodies
in each case span the blocks conveyed through. The
aging effect may in this case be varied by the number
of rows of striking bodies below which the blocks have
to pass through under the striking action of the
striking bodies. Furthermore, the intensity of the
aging is determined by the speed of passage and by the
initiated vibrations.
Due to the selection of a suitable number of rows with
striking bodies, the apparatus according to the
invention can be integrated in the continuous process
for producing blocks in a simple manner without this
leading to a reduction in the cycle time. The blocks
can pass through the apparatus of the generic type at
the desired speed, the desired aging effect being
achieved by the number of rows of striking bodies. The
striking bodies of a row may in each case preferably be
arranged offset from an upstream or downstream row of
striking bodies, so that the surfaces of the blocks are
uniformly treated. In principle, a non-uniformly aged
appearance should certainly be produced, but this is
obtained automatically by the movable fastening of the
striking bodies. The offset arrangement reliably avoids
a situation in which the blocks are increasingly struck
(in a lasting manner) within a certain region due to
the system. Provision may also be made in this respect
for the distance between the rows to vary.
In a configuration of the solution according to the
invention with a continuously working conveying device,
it is sufficient if at least the striking bodies of a
row are arranged in such a way that their defined
regions cover the entire width of the blocks passing
through under the striking bodies.
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In principle, just one row of striking bodies or a few
rows of striking bodies may be sufficient in order to
age the blocks. However, as has been found in practice,
this does not produce an optimum aging appearance and
also results in the speed of passage being relatively
low.
In a configuration of the solution according to the
invention in which no continuously working conveying
device is provided, provision may be made for the
striking bodies to be fastened in such a way that the
defined regions of the individual striking bodies
together cover at least the entire surface of the
blocks - preferably fed in layers.
During the discontinuous aging, provision is made for
the blocks to be fed in layers or as a unit to the
region in which they are aged and for them to be aged
in one operation, i.e. the blocks are not transported
further until the aging has been completed.
In a modification of the discontinuous aging, a
plurality of aging stations to which the blocks are fed
in succession may also be provided, the blocks being
aged in the desired manner after they have passed
through all the aging stations.
In contrast to the discontinuous aging, provision is
made during the continuous aging for the blocks to be
transported constantly in the feed direction; that is
to say a layer or unit of blocks is not fed
specifically to the aging station or stations, but
rather the process is a continuous process. This is
also possible by feeding the blocks at intervals. To
this end, the vibrating process need not be
interrupted. In this case, the blocks are left in their
position (no feed) for a relatively short period of
time, e.g. 5 seconds, and are then transported further
by a short distance. In tests, this has resulted in an
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advantageous aging appearance without the blocks being
struck increasingly due to the system.
According to the invention, provision may be made for
the defined regions of the striking bodies to overlap.
The space which is predetermined by the movable
fastening and in which the striking bodies can move is
preferably to be selected in such a way that the
striking bodies cannot penetrate into the intermediate
space possibly forming between two blocks. According to
the invention, provision is made in this case for the
striking bodies to rest on the blocks in the rest
state, that is to say when no vibrations act on the
blocks and the striking bodies.
However, it is also possible for the striking bodies to
be arranged at a distance above the blocks. The blocks
can therefore be transported through below the striking
bodies without being scratched. A distance between the
blocks and the striking bodies is possible without any
problems in particular in the case of thicker blocks,
since the latter can be aged with a high amplitude and
are thus pushed up accordingly. As has been found, a
distance increases the aging of the block edges and
reduces the aging of the block surface, a factor which
may be advantageous depending on the application or the
desired appearance.
However, with regard to especially effective aging, it
is appropriate if the striking bodies rest on the
surface and therefore do not first have to overcome a
distance (loss of striking energy). In particular
during the aging of thin blocks, which are aged only
with a low amplitude on account of the risk of said
blocks being rotated by the vibrations, contact between
the striking bodies and the surface of the blocks is
also appropriate in the rest state.
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Provision may be made for the defined region within
which the striking bodies can move on the surface of
the blocks to correspond to a movement or deflection of
the same of 5 - 40 mm, preferably 10 mm, in all
directions. Under the assumption that the striking
bodies are spherical and have a diameter of 40 mm, this
would result in a circular defined region having a
diameter of preferably 60 mm. The circumference or the
horizontal cross section of the striking bodies is
therefore extended by 10 mm horizontally in all
directions for reproducing the defined region.
It is advantageous if the striking bodies are fastened
in such a way that they can perform a largely
unrestricted lifting movement, resulting from the
initiated vibrations.
In a constructive configuration of the invention,
provision is made in this case for the retaining device
on which the striking bodies are fastened to be
arranged above the blocks. Here, the retaining device
may constitute a plane or a pattern of retaining
elements which extend in a plane-parallel manner to the
surface of the blocks and are formed, for example, by a
plurality of retaining rows running transversely to the
direction of passage of the blocks. The striking bodies
may be fastened to the retaining elements via fastening
members, which may be designed, for example, as chains,
ropes, rods or profile elements of varying form. The
fastening members may be designed in various ways and
should at the same time preferably ensure that the
striking bodies can move as far as possible without
restriction within the defined region and that, on the
other hand, the striking bodies can carry out the
lifting movement without considerable energy loss.
The striking bodies are preferably each fastened
individually to the retaining elements.
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In a configuration of the apparatus according to the
invention with a continuously working conveying device,
provision may be made for means which lift at least a
section of a block to be provided in the region through
which the blocks pass under the striking action of the
striking bodies, so that the lifted section of the
block projects in the direction of the striking bodies
and is subjected to a more intense action of the
striking bodies. The means may be designed, for
example, as prominences, over which the underside of
the blocks are pushed on account of the feed movement
(resulting from the conveying device). The prominences
may preferably be of ramp-shaped design, so that the
block travels up the ramp with at least one section and
then drops down again or travels down said ramp again.
Thus, as viewed in the feed direction, first the front
region of the block is lifted and is thus subjected to
a more intense action of the striking bodies, whereas
subsequently the middle region and finally the rear
region of the block projects in the direction of the
striking bodies.
According to the invention, provision may be made for
the prominences to be arranged in such a way that the
blocks, with their underside, are pushed eccentrically
over the prominences, as a result of which one side of
the block (as viewed in the direction of passage) is in
each case subjected to increased aging. Provision is
made in this case for each block to be lifted at least
once on each side. In order to reduce the friction
between the prominence and the underside of the block,
provision may be made for the prominences to have
rollers or to be designed as rollers. However, owing to
the fact that the blocks are continuously lifted in
this region anyway by the vibrating movement, the
friction between the prominence and the block underside
is not high in any case.
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The means for lifting the blocks may also be designed
in such a way as described in US 2002/0145224 Al.
Advantageous configurations and developments follow
from the further subclaims. Two exemplary embodiments
of the invention are explained in principle below with
reference to the drawing.
In the drawing:
fig. 1 shows a plan view of a production layer of
blocks which are put onto a base and are brought
into an aging region by means of a conveying
device, without the striking bodies being shown;
fig. 2 shows a side view of the apparatus according to
the invention, the striking bodies being
arranged in rows transversely to the push-
through direction of the blocks via fastening
elements;
fig. 3 shows a view according to arrow direction III in
fig. 2;
fig. 4 shows a detailed view of the striking bodies,
which are hung in rail-shaped receptacles via
chain-shaped fastening elements;
fig. 5 shows an alternative configuration of the
fastening elements with an interior space which
encloses the retaining element;
fig. 6 shows a detailed illustration of a fastening
element according to fig. 5 with a striking
body;
fig. 7 shows a detailed illustration of a fastening
element loaded eccentrically with a weight;
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fig. 8 shows a perspective illustration of a conveying
device which is especially suitable for
conveying a layer of blocks, the blocks being
pushed over a base by means of a push rod which
is attached to a chain conveyor;
fig. 9 shows a diagrammatic side view of a conveying
device according to fig. 8;
fig. 10 shows a perspective illustration of a conveying
device, a chain conveyor being provided which
has at least one push rod and one limit stop
rod, and a mat being attached between the push
rod and the limit stop rod, the blocks resting
on this mat and being pulled over the base;
fig. 11 shows a diagrammatic side view of a conveying
device according to fig. 10;
fig. 12 shows a diagrammatic side view of a conveying
device having a chain conveyor with at least one
push rod, a band or belt conveyor on which the
blocks rest additionally being provided; and
fig. 13 shows a diagrammatic side view of a conveying
device according to fig. 9, having a
configuration of the push rod and of the limit
stop rod which is especially suitable for the
aging of blocks which are of trapezoidal cross
section or are unstable in their position.
According to the invention, any desired blocks, for
example surfacing elements, facade elements, sand-lime
blocks, concrete blocks, bricks or clinker bricks or
natural stone blocks, can be aged irrespective of their
material condition. The aging of blocks 1 which are
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designed as concrete blocks will be explained below
with reference to the exemplary embodiments. However,
the invention is of course not restricted thereto.
The production of concrete blocks 1, in particular of
concrete paving blocks, is sufficiently well known, for
which reason this will not be dealt with in any more
detail below. The concrete blocks 1 leave the
production plant generally in a production layer, i.e.
in an arrangement in which a multiplicity of concrete
blocks 1 are arranged next to one another in a single
layer. Such a production layer is shown by way of
example in fig. 1.
As can be seen from fig. 1, the concrete blocks 1 are
put onto a base 2 in a single layer in a regular
arrangement. Here, the concrete blocks 1 are arranged
in such a way that in each case that edge lb or that
surface la (= the subsequent visible side as a rule) of
the block 1 which is to be treated lies at the top.
With regard to the general principle of aging with
freely movable striking bodies 3, as can be seen from
figures 2 to 7, reference is made to DE 20 2004 020
206.9.
As can be seen from figures 2 to 6, the surfaces la and
the edges lb adjoining the surfaces la of the blocks 1
are treated by striking bodies 3 which are essentially
freely movable within a defined region 4 of the surface
la of the blocks 1. To this end, the striking bodies 3
are movably fastened and arranged or suspended on a
retaining device 5.
As can be seen in particular from figures 2 and 3, a
vibrating device 6 is provided in order to set the
blocks 1 and the striking bodies 3 in motion relative
to one another in such a way that the striking bodies 3
act on the surfaces la and the exposed edges lb of the
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blocks 1. The vibrating device 6, which may consist,
for example, of a plurality of unbalance generators,
transmits the vibrating movement to the base 2 and acts
from there on the blocks 1 and the striking bodies 3.
In this case, the base 2 may also constitute the top
side of the vibrating device 6, for example a vibrating
table. However, the base 2 may also constitute a
conveyor band, on which the blocks 1 are placed. With
regard to advantageous configurations in this respect
and to the initiation of the vibrating movement,
reference is made to DE 20 2004 020 206.9.
As can be seen from the figures, the striking bodies 3
are freely movable both within the defined region 4
relative to the surface la and relative to one another.
The striking bodies 3 may be made of any desired
material. In the exemplary embodiment, provision is
made for the striking bodies 3 to be made of carbide,
metal or steel. Any desired shape of the striking
bodies 3 may likewise be selected, it having proved to
be advantageous for the striking bodies 3 to be of
spherical, annular, polygonal, cylindrical or disk-
shaped design. In the exemplary embodiment shown, the
striking bodies 3 are essentially spherical, but are
flattened on two opposite sides. This can be seen in
detail in particular from figures 4, 6 and 7.
As can be seen when viewing fig. 2 and fig. 3 together,
the retaining device 5 extends in a plane-parallel
manner relative to the surfaces la of the blocks 1. In
this case, the retaining device 5 has a plurality of
retaining elements 7, which each extend over the entire
width of the blocks 1 to be aged, i.e. transversely to
the feed direction. The striking bodies 3 are arranged
or fastened or suspended on the retaining elements 7
via fastening members 8. According to the embodiment
shown in figures 2 to 4, the fastening members 8 are
shown as chains. The chains in this case are designed
as metal chains. As can be seen in particular from fig.
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4, the retaining elements 7 have rail-shaped
receptacles 7a, in which the metal chains 8 can be
hung. Each striking body 3 is connected individually to
the retaining element 7 via an individual fastening
member 8. If a striking body 3 has to be exchanged,
this is therefore possible in a simple manner.
In the embodiment, provision is made for the striking
bodies 3 of a row 7 to lie closely adjacent to one
another, for example to be at a distance apart of 2 to
mm, preferably 5 to 10 mm.
Furthermore, provision is made in the exemplary
embodiment for the retaining elements 7 or for the
15 entire retaining device 5 to move during the striking
action of the striking bodies 3 on the blocks 1. This
assists irregular striking of the blocks 1 by the
striking bodies 3. Provision is made in this case for
an oscillating movement of the retaining elements 7,
20 preferably in such a way that the retaining elements 7
are moved axially back and forth. This can be achieved
from the design point of view with known means (e.g. an
eccentric mounting or a randomly controlled pneumatic
cylinder).
An alternative configuration of the fastening members 8
to that in figures 2 to 4 is shown in figures 5, 6 and
7. In this case, the fastening members 8 have a profile
which forms an interior space 8a, which is suitable for
enclosing the retaining element 7 (tubular or rod-
shaped in the exemplary embodiment) in such a way that
the fastening member 8 is movable relative to the
retaining element 7 in such a way that the striking
body 3 arranged on the fastening member 8 or connected
thereto can perform both a lifting movement and a
movement within the defined region 4. According to the
exemplary embodiment shown in figures 5, 6 and 7, the
fastening member 8 is designed as an appropriately bent
rectangular profile. According to the embodiment shown
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in fig. 6, the defined region 4 has an elliptical
shape. This is due to the fact that the fastening
member 8 designed as a rectangular profile mainly
permits a movement of the striking body 3 in the
direction of passage or against the direction of
passage. In contrast thereto, the embodiment according
to figures 2 and 4 enables a defined region 4 which is
round in principle to be formed. In this case, too,
however, on account of the feed direction of the blocks
1, an elliptical shape for the defined region 4 will
essentially appear, even though this shape is less
highly pronounced.
According to the embodiment shown in fig. 6, provision
may be made for it to be possible to deflect the
striking bodies 3 by 30 to 200 mm, preferably by 50 to
150 mm, in the direction of passage. Furthermore,
provision may be made in this case for the next row 7
with striking bodies 3 to be at a distance from the
preceding row 7 with striking bodies 3 which is 10 to
20 mm greater than the maximum deflection of the
striking bodies 3 during operation.
In the exemplary embodiment, the fastening members 8
including the striking bodies 3 have a length of 200
mm. A length of 100 to 400 mm has generally proved to
be advantageous.
As can be seen from fig. 5, the retaining elements 7
have spacers 9 at regular distances apart, these
spacers 9 ensuring a defined arrangement of the
fastening members 8 of a row and preventing jamming
with other adjacently arranged fastening members 8.
As can be seen from fig. 6, the interior space 8a of
the fastening members 8 may be subdivided by an
intermediate bottom 8b, as a result of which
particularly the lifting movement of the striking body
3 is accordingly limited. In this case, provision may
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be made for the intermediate bottom 8b to be capable of
being set in a variable manner, as a result of which
the lifting movement can be varied - if need be in
relation to the blocks 1 to be aged.
Fig. 7 shows an arrangement of the striking bodies 3 in
such a way that the striking bodies 3 are oriented
against the direction of passage in the rest state. By
the movement of the blocks 1 in the conveying direction
(see arrow), the striking bodies 3 or the fastening
members 8 are oriented perpendicularly in the process
(illustrated by broken lines). The orientation of the
striking bodies 3 in the rest state is selected in such
a way that a perpendicular orientation occurs during
operation. In the exemplary embodiment, the fastening
members 8, on their side lying at the front in the
direction of passage of the blocks 1, are loaded with
an additional weight 15 (this may also be integrated in
the fastening member). The additional weight 15 may
also be attached to the striking body 3. The additional
weight 15 achieves the effect that the striking body 3
is inclined against the conveying direction in the rest
state. Such an inclination may also be achieved in
another manner, e.g. by an asymmetrical or
disproportional suspension and/or configuration of the
fastening members 8 or of the striking bodies 3.
According to the invention, provision may likewise be
made for at least the row 7 of striking bodies 3 which
is arranged in the inlet region, i.e. the row of
striking bodies 3 which the blocks pass first when
being introduced into the aging region, to be inclined
in the direction of passage (not shown) . In terms of
design, this may be effected in a similar manner to the
inclination against the direction of passage. The
advantage consists in the fact that jamming of the
blocks 1 with the striking bodies 3 is avoided and the
blocks 1 can therefore easily be fed. In an alternative
embodiment (not shown) , provision may also be made for
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all the striking bodies 3 to be inclined in the
direction of passage in the rest position.
In the exemplary embodiments, provision is made for the
blocks 1 to be conveyed through below the striking
bodies 3, i.e. for said blocks to pass through the
actual aging region, by means of a conveying device 10.
A plurality of different conveying devices 10 are known
from the general prior art. For example, this may
involve a band, belt or chain conveyor or the like. In
the exemplary embodiment, the conveying device is
designed as a chain conveyor 10 having a push rod 11
which pushes the blocks 1 over the base 2, i.e. in the
actual aging region, directly over the vibrating table.
Furthermore, provision is made in the exemplary
embodiment for the chain conveyor 10 to push the blocks
1 continuously through below the striking bodies 3. In
this case, the speed of passage can be determined in
connection with the overall production rate or the
aging result to be achieved.
Alternatively, provision may also be made for the chain
conveyor 10 to merely push the blocks 1 to be aged, for
example an entire production layer, into the intended
position and for the blocks 1 not to be pushed forward
during the aging process (discontinuous conveying).
After completion of the aging process, i.e. once the
striking bodies 3 have completed their striking action
on the surfaces la and the adjoining edges lb of the
blocks 1 to the desired degree, the chain conveyor 10
can convey the blocks 1 further and introduce a new
layer to the space which has become free.
The chain conveyor 10 is designed as a circulating
conveying device. In the exemplary embodiment, the two
tension chains of the chain conveyor 10 are guided
outside the vibrating device 6 and their operability is
therefore not impaired by vibrations. In principle, a
multiplicity of design measures are conceivable in
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order to ensure that the chain conveyor 10 is not
subjected to vibrations. The push rod 11, which is
arranged between the two circulating chains of the
chain conveyor 10, is at a distance from the vibrating
table or the base 2 that ensures that the vibrating
table or the base 2 does not come into contact with the
push rod 11. The distance between the push rod and the
top side of the base 2 or of the vibrating table must
therefore be greater than the maximum oscillation of
the vibrating table or of the base 2 in the direction
of the push rod 11. As a rule, the vibrating table or
the base 2 oscillates or moves by no more than at most
4 mm in the direction of the push rod 11, so that a
distance of, for example, 10 mm is sufficient in order
to ensure that the vibrating table or the base 2 does
not touch the push rod 11 and the latter can therefore
run smoothly and unimpeded. The distance between the
push rod 11 and the top side of the vibrating table or
the base 2 depends in this case on the peak-to-peak
displacement or the intensity of the vibration.
Fig. 1 shows an especially advantageous development of
the push rod 11, which is especially suitable for use
in the apparatus according to the invention. Provision
is made here for the push rod 11 to be provided with a
plurality of bearings 16 or rotatable elements, such as
rollers for example. In this case, if the blocks 1 come
into contact with the push rod 11 on account of their
vibrations, the bearings 16 ensure that only minimum
rubbing of the blocks 1 on the push rod 11 takes place,
as a result of which only a little kinetic energy is
lost. According to the invention, provision may be made
in this case for the bearings 16 to have a width of 5
to 30 mm, preferably 10 mm, and to be arranged at a
distance apart of 20 to 50 mm, preferably 30 mm.
Firstly, this ensures that the blocks 1 each bear
against at least two bearings 16 or are pushed forward
by the latter. Secondly, there is little likelihood of
two blocks 1 touching one bearing 16 simultaneously
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during the vibration, in particular with an opposed
movement, as a result of which the functioning of the
bearing 16 would be restricted. Independently of the
solution according to the invention, such a push rod 11
may also be used in other apparatuses in which blocks 1
are aged by means of a combination of a vibrating
device and striking bodies which are arranged on the
surface of the blocks 1.
Fig. 1 shows lateral limit stops 12 which are intended
to prevent lateral escape of the blocks 1 during the
vibrating process. In principle, such limit stops 12
may also be provided in front of and behind the blocks
1 in the direction of passage. The lateral limit stops
12 may in this case also serve as dust protection.
Furthermore, provision may also be made for the
retaining device 5 to have a protective hood or the
like which encloses the layer of blocks 1 which is to
be aged in order to reduce an escape of stone dust.
In the exemplary embodiment, provision is made for the
limit stops 12 to be isolated from the vibrating device
6, that is to say they do not vibrate.
Simple design measures can ensure that the chain
conveyor 10 conveys the push rod 11 in the direction of
passage without the lateral limit stops 12 getting in
the way. For example, the push rod 11 can be connected
to the chain conveyor 10 below or above the lateral
limit stops 12.
As shown in figures 2 and 3 (only in principle), the
region through which the blocks 1 pass under the
striking action of the striking bodies 3 can have means
13 which lift at least a section of the blocks 1, so
that the lifted section of the blocks 1 projects in the
direction of the striking bodies 3 and is subjected to
a more intense action of the striking bodies. In the
exemplary embodiment, the means 13 are designed as
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ramp-shaped prominences which accordingly lift the
blocks when the latter, with their underside, pass the
ramp-shaped prominences 13. In the exemplary embodiment
(not shown), provision is made for the prominences 13
to lift the blocks 1 eccentrically and thus laterally,
as viewed in the direction of passage, each block 1
being lifted at least once on each side.
As shown in fig. 2, the prominences 13 may be provided
with rollers 14 or bearings.
In principle, such ramps 13 can also be realized if the
conveying device is designed as a band conveying
device, the band having to run over the prominences 13
in this case. However, a design as a chain conveyor 10
having a push rod 11 has proved to be more advantageous
for this purpose.
It is especially advantageous if the edges lb of the
blocks 1 are lifted. The means 13 may be designed in
various ways, for example as projections, as extendable
plungers according to US 2002/0145224 Al or the like.
It is likewise conceivable for the means 13 to be
formed by a corrugated configuration of the base 2 or
of the vibratory table.
The means 13 for lifting the blocks 1 at least in
sections in such a way that the lifted part of the
blocks 1 projects in the direction of the striking
bodies 3 and is subjected to a more intense action of
the striking bodies 3 may also be used independently of
the inventive idea of movably fastening the striking
bodies 3. For example, such a use is also possible in
the apparatus according to DE 20 2004 020 206.9. During
every treatment of blocks from above, owing to the fact
that the blocks are lifted at least in sections, the
treatment of this section can be intensified. A desired
aging result can therefore be achieved in a simple
manner.
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For reasons of clarity, the blocks 1 are shown in the
nonvibrating state in figures 2, 3 and 5, the striking
bodies 3 resting on the surfaces la of the blocks 1.
The blocks 1 and the striking bodies 3 strike one
another due to the vibration.
The distance, shown in figs. 2 and 5, between the
blocks 1 (in the direction of passage), is reduced or
eliminated during a forward movement of the push rod
11.
In an especially advantageous manner, the solution
according to the invention is also suitable for the
aging of split blocks, which generally have an uneven
surface or a surface provided with prominences and
recesses. In this case, the split area of the block 1
is turned with its fracture surface toward the striking
bodies 3.
Figures 8 to 12 show three different advantageous
conveying devices 10 which are not only suitable for
the solution according to the invention but are also
generally suitable for conveying a multiplicity of
blocks which are arranged in a production layer. The
conveying device 10, as follows from the figures
described below, therefore constitutes an independent
solution according to the invention for conveying
blocks if the blocks are to be aged using a vibrating
device 6.
Figs. 8 and 9 show the conveying device 10 in an
especially cost-effective embodiment. In this case, the
two chain strands of the chain conveyor each run in the
marginal region of the base 2 and are arranged in such
a way that said chain strands are not set in vibration
or are not set substantially in vibration by the
vibrating device 6. Arranged between the chain strands
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of the chain conveyor 10 is the push rod 11 already
described, which serves to move the blocks 1 resting on
the base 2 in the conveying direction. In the process,
the push rod 11 pushes the blocks 1 over the base 2.
Such conveying can already be seen from figures 1 to 3
and fig. 5. In addition to this, a limit stop rod 17 is
shown according to the embodiment shown in fig. 8 and
fig. 9, said limit stop rod 17 being arranged in front
of the push rod 11 in the conveying direction. A layer
of blocks 1 that is to be aged is placed between the
limit stop rod 17 and the push rod 11. The limit stop
rod 17, which is arranged between the chain strands of
the chain conveyor 10 or is connected to said chain
strands in a similar manner to the push rod 11, is
intended to prevent the blocks 1 from escaping at the
front, i.e. in the conveying direction.
The limit stop rod 17 could in principle also be
designed as a push rod for a further layer of blocks,
but this has not turned out to be advantageous. If a
distance is left between the limit stop rod 17 and a
push rod 11 for a further layer of blocks 1, the limit
stop rod 17 can be set for different lengths of block
layers without this affecting all the other push and
limit stop rods. The change in the length between a
push rod 11 and an associated limit stop rod 17 for
accommodating a block layer therefore only has an
effect on the distance between the limit stop rod 17
and a further push rod 11 running in front of it. It is
therefore possible to select a separate modular
dimension for each block layer and change it if need be
without this affecting the modular dimension of other
units (push rod/limit stop rod). Provision is therefore
made according to the embodiment shown in figs. 8 and
fig. 9 for a push rod 11 and a limit stop rod 17 to be
used for each block layer.
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In a preferred configuration, both the push rod 11 and
the limit stop rod 17 can be designed as flat steel
bars or the like.
Shown in figures 10 and 11 is a preferred embodiment of
the conveying device 10, which differs from the
embodiment shown in figures 8 and 9 in that a rest 18
is mounted on or fastened to the limit stop rod 17. The
limit stop rod 17 therefore serves as pull rods for the
rest 18. In contrast to the embodiment shown in fig. 8
and fig. 9, the blocks consequently no longer rest on
the base 2 during the aging process but rather on the
rest 18, which is essentially pulled over the base 2 by
the limit stop rod 17 or the chain conveyor 10. In this
case, the rest 18 is in such contact with the base 2 or
the vibrating device 6 that the rest 18 is set in
vibration, such that the blocks 1 arranged on the rest
18 likewise vibrate or jump. The rest 18 is preferably
made of an elastic material. A rubber mat 18 is
especially suitable for this purpose. The rubber mat 18
can likewise be connected to the push rod 11.
Owing to the fact that the rubber mat 18 is connected
to the limit stop rod 17 and possibly the push rod 11,
the rubber mat 18 moves at the same speed as the chain
conveyor 10. In the embodiment shown in fig. 10 and
fig. 11, the rubber mat 18 is arranged essentially
between the limit stop rod 17 and the push rod 11. In
principle, the rubber mat 18 can also be longer or
shorter than the distance between the limit stop rod 17
and the push rod 11.
The rest 18 or the rubber mat has turned out to be
especially important for a good aging result. This is
due to the fact that, in the case of a conveying device
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10, as shown in fig. 8 and fig. 9, the pushing pressure
which the push rod 11 exerts on the blocks 1 becomes
increasingly higher the closer the blocks 1 are
arranged to the push rod 11. A situation may occur in
which the blocks 1 are pushed together in such a way
that the blocks 1, in particular in the region of the
push rod 11, jump to a smaller extent or no longer
jump. This effect is all the more noticeable, the
smaller the blocks are, because the block rows on which
a lower pushing pressure is exerted, that is to say the
block rows which lie at the front in the conveying
direction, jump to a markedly higher degree or vibrate
much more intensely and thus their block edges are
struck more intensely. This effect is compensated for
by the rest 18, since the rest 18 and therefore also
the resting blocks 1 are not pushed but rather pulled.
The blocks 1 are therefore no longer pressed together
in the region of the push rod 11, as is the case in the
embodiment shown in fig. 8 and fig. 9. Although the
blocks 1 nonetheless still press against the push rod
11 - since the blocks 1 are moved at a lower speed than
the rest 18 on account of the vibration or the jumping
on the rest 18 - the pushing pressure acting on the
blocks 1 due to the push rod 11 is markedly lower and
no longer occurs in a disturbing manner. If need be,
the entire conveying device 10 can be slightly
inclined, such that the blocks 1 run slightly downward
as viewed in the conveying direction, thereby
countering the effect that said blocks 1 shift rearward
in the conveying direction relative to the rest 18.
The rest 18 offers yet another advantage over the
embodiment shown in fig. 8 and fig. 9. As tests have
shown, the risk of fracture in the case of very thin
blocks or in the case of long blocks or blocks of large
surface area is relatively high. Due to the rest 18, in
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particular if it is made of an elastic material, the
risk of fracture is considerably reduced, since the
blocks 1 no longer strike the base 2, which as a rule
is made of steel, but rather strike an elastic
material, preferably rubber.
Fig. 12 shows a modification of the embodiment of the
conveying device 10 shown in fig. 10 and fig. 11, said
modification having essentially the same advantages.
The embodiment according to fig. 12 likewise has a
chain conveyor 10 and a push rod 11 and an optional
limit stop rod 17, which are arranged in a similar
manner to the embodiments according to fig. 8 and fig.
9 or fig. 10 and fig. 11. Provision is made here for
the blocks 1 to rest on a rest 18 which moves the
blocks 1 in the conveying direction at least
approximately at the speed of the conveying device 10.
The rest 18 is in this case designed as a circulating
conveying band which is preferably made essentially of
an elastic material, for example rubber. The conveying
band 18 runs in such a way that it is set in vibration
by the vibrating device 6, as a result of which the
resting blocks 1 jump or vibrate. The conveying device
10 is preferably arranged in such a way that neither
the chain strands nor the push rod 11 or the limit stop
rod 17 vibrate. Provision may optionally be made for
the conveying band 18 to be connected to one or more
limit stop rods 17 or push rods 11. The actual feed
with which the blocks 1 are transported through the
aging region in the conveying direction is based on the
feed movement of the conveying band 18. However, the
blocks 1 shift rearward (at a low speed) relative to
the conveying band 18 on account of their vibration.
This rearward movement is correspondingly limited by
the push rod 11. However, the pushing pressure which
the push rod 11 exerts on the blocks 1 is in this case
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so low that it does not disturb the vibration or the
jumping movement of the blocks 1. The limit stop rod 17
prevents the blocks 1 from being able to leave the
intended region at the front.
Instead of a chain conveyor 10, another conveying
device which is preferably designed to circulate can
also be used in the embodiment according to figures 8
to 12.
Fig. 13 shows a configuration of the push rod 11 and of
the limit stop rod 17 which is especially suitable for
the aging of blocks 1 which are of trapezoidal cross
section or are generally unstable in their position.
Such blocks 1 may be, for example, split blocks, which
generally have an uneven surface or a surface provided
with prominences and recesses. The inventor has found
that, irrespective of the embodiment of the conveying
device (not shown in fig. 13) and irrespective of the
way in which the blocks are transported through the
aging region (figures 8 to 12), the aging result of
blocks 1 which rest on the base 2 in an unstable manner
can be improved by the push rod 11 and the limit stop
rod 17 being designed in such a way that they support
the blocks 1. In the embodiment shown in fig. 13, both
the push rod 11 and the limit stop rod 17 have an
additional supporting element lla and 17a,
respectively. Alternatively, a plurality of supporting
elements may also be provided, or the push rod 11 and
the limit stop rod 17 as such may have a shape which is
suitable for supporting the blocks 1 and for avoiding
their tilting. The supporting elements lla, 17a ensure
that the surfaces la of the blocks 1 form as horizontal
a plane as possible, such that the block surfaces la
can be advantageously aged by the striking bodies 3.
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Alternatively, provision may also be made for only the
push rod 11 or the limit stop rod 17 to have supporting
elements.
The described embodiment of the push rod 11 and of the
limit stop rod 17 shown in fig. 13 can be applied to
all the embodiments described above.
