BORSATO, Alberto (Rogerio & Borsato AlbertoVicolo Pier Sante Mattarell, 6 Quinto Di Treviso, I-31055, IT)
BORSATO, Rogerio (Rogerio & Borsato AlbertoVicolo Pier Sante Mattarell, 6 Quinto Di Treviso, I-31055, IT)
BORSATO, Alberto (Rogerio & Borsato AlbertoVicolo Pier Sante Mattarell, 6 Quinto Di Treviso, I-31055, IT)
| CLAIMS 1. Plant for the continuous inline production of products, comprising a plurality of machines (20, 22, 24, 26, 28, 30, 32) which are adapted to work in line and are installed inside parallelepiped transportable containers, characterized in that each of said machines is installed and contained inside a single container (12) to form an autonomous unit, and that all the containers of the plant are aligned in a single row, matingly engaged on the short side, so as to reconstruct the production line. 2. Plant according to claim 1, destined for the continuous production of panels and comprising the series of at least (i) one profiling machine (20) adapted to unwind, from rollers, two metal sheets and impart a desired profile for the panel thereon; (ii) a foaming machine (24) adapted to form insulating foam and inject it between the two facing metal sheets; (iii) a continuous press (26) adapted to maintain a constant distance between the two metal sheets during the foam expansion, (iv) a cutting machine (28) for cutting the metal sheets and obtaining a panel of the desired length, wherein at least each of said machines from (ii) to (iv) is installed and contained inside a single container (12) to form an autonomous unit, and that all the containers of the plant are aligned in a single row, matingly engaged on the short side. 3. Plant according to claim 2, wherein the profiling machine (20) is divided into two profiling sections, each being installed and contained inside a single container (12) to form an autonomous unit, and in a manner such that by placing the relative containers in a row, an uninterrupted profiling line is obtained. 4. Plant according to claim 3, wherein each profiling section comprises a base (70) which extends for the entire length of the container; removable modules (72), which comprise a series of rollers (74), adapted for the profiling of the metal sheets, and mechanical adapters or connections for drawing mechanical power from motor means present in the base (70) and adapted to actuate the rollers (74). 5. Plant according to any one of the preceding claims, wherein the continuous press (26) is formed by two superimposed, parallel belts of plates, between which the two sheets filled with foam can slide, and comprises lateral plates or strickles , directly connected to the continuous press, which have size such to remain inside the width of the container and have the function of lateral containment for the expanded foam. 6. Plant according to one of the preceding claims, wherein each container (12) has, on its short sides, two doors (40) hinged to a fixed structure which comprises a roof (44), a floor (48) and four corner pillars (42), in a manner such that by opening all the doors (40) of each container (12) and by attaching the containers to each other, a continuous tunnel is obtained. 7. Plant according to one of the preceding claims, wherein the containers (12) comprise, on the long sides, large doors or lateral walls that can be removed or hinged in order to be opened, said walls (50) being as long as the container and half the height thereof, and are hinged to the upper and lower edge of the container, with folding opening. 8. Plant according to one of the preceding claims, wherein the containers (12) comprise an empty rectangular frame (60) hinged to the upper edge and adjustable with regard to slope, a plane (62) being centrally hinged to the frame, such plane supporting or integrating photovoltaic panels (64). 9. Method for configuring a plant for the continuous inline production of products, the plant comprising a plurality of machines (20, 22, 24, 26, 28, 30, 32) that are adapted to work in line and are installed inside transportable containers, characterized by installing each of said machines inside a single container, forming an autonomous unit, and aligning all the containers in a single row by making them matingly engage on the short side, so as to reconstruct the production line. 10. Method according to claim 9, wherein the plant is for the continuous production of panels and comprises the series of at least (i) one profiling machine (20) adapted to unwind, from rollers, two metal sheets and imparting a desired profile for the panel thereon; (ii) a foaming machine (24) adapted to form foam insulation and inject it between two facing metal sheets; (iii) a continuous press (26) adapted to maintain constant distance between the two metal sheets during foam expansion, (iv) a cutting machine (28) for cutting the metal sheets and obtaining a panel of the desired length, characterized by installing at least each of said machines from (ii) to (iv) inside a single container, forming an autonomous unit, and aligning all the containers of the plant in a single row, making them matingly engage on the short side. 11. Method according to claim 9 or 10, wherein the row of all the containers is installed inside a ship and the resulting plant is made to work on the ship. 12. Method according to claim 11, wherein the plant is power-supplied by means of solar panels arranged on the ship. 13. Ship comprising a plant on board according to claims 1 - 8. |
TECHNICAL FIELD OF THE INVENTION
The present invention refers to inline production plants, particularly of insulating panels.
PRIOR ART
Many industrial plants are inline plants, i.e. a series of sequentially placed machines which operate on the product by means of a specific operation. One machine modifies the product and forwards it to the next machine. This principle is applied in panel production plants, which are discussed herein as an example.
These plants are made and tested in factory, and then dismantled for remounting at the working site. It is clear that the sending and reassembly of the single components are costly processes, rather long, delicate and requiring the use of specialized labor and supervisors.
Naturally, the above does not assist the transfer of the industrial production, for example in underdeveloped countries with low labor cost or to sites of a natural disaster where it would be possible to prepare temporary shelters with the produced panels. WO 2006/123373 proposes as a solution the preparation of a plant that is completely transportable inside containers. Taken a conventional plant, it is divided up having as measurement unit the dimensions of the usual containers. In practice, it is as if one superimposed a grid having the dimensions of the containers on the plan of a known plant. The resulting subdivision of the grid is transferred to the machines of the plant.
It follows that not only are the machines subdivided over several containers in an arbitrary manner, without adaptation (e.g. the press 10), but also that some containers are inserted in the series with different orientation, e.g. the saw cutter 12 with the long side.
Perfectly aligning the machine segments thus obtained is very difficult and requires precisions, albeit obtainable, that are disproportionate with respect to the mounting simplicity that is desired for these applications. The drawback becomes even more serious for containers arranged one time in one direction, other times rotated 90° in another direction.
In addition, the system of WO 2006/123373 provides for two rows of empty containers next to the main line with auxiliary functions, considerably weighing down the structure of the plant and the mounting procedure.
OBJECTS OF THE INVENTION
The main object of the invention is to improve the state of the art with a plant that is more easily transportable.
Another object is to make a plant that can be assembled onsite in less time and in a simpler manner.
Such objects are obtained with a method and plant defined in the attached claims. The invention proposes a plant for the continuous inline production of products, comprising a plurality of machines which are adapted to work inline and installed inside parallelepiped transportable containers. Each of said machines is installed and contained inside a single container to form an autonomous unit, and all the containers of the plant are aligned in a single row, matingly engaged on the short side so as to reconstruct the production line.
Hence, the plant is formed on a single container row, and the row is only one container "wide".
This has the advantages of:
- limiting the bulk area of the plant;
- rationalizing and simplifying the assembly step of the containers (all are in a single row);
- simplifying the structure of the connections between containers, since only the two short sides and not four must comprise connection means between containers;
- simplifying the maintenance and access to the machines (they are accessible from the two major sides of the containers).
The same advantages are offered by a method for configuring a plant, whereby each machine is installed within a single container to form an autonomous unit, and then all the containers are aligned in a single row, making them matingly engage on the short side so as to reconstruct the production line.
BRIEF DESCRIPTION OF THE DRAWINGS
The characteristics and advantages of the invention will be more evident from the exemplifying description of a plant for producing panels, together with the attached drawings in which:
Figure 1 shows a plan schematic view of a plant according to the invention;
Figure 2 shows a partial three-dimensional view of a container according to the invention; Figure 3 shows a partial three-dimensional view of another container according to the invention;
Figure 4 shows a schematic view of a forming machine;
Figure 5 shows a partial three-dimensional view of the short side of a container. EMBODIMENTS OF THE INVENTION
Fig. 1 shows a plan view of a plant 10 for the continuous production of panels composed of the succession of seven containers 12 (with standard parallelepiped dimensions and weight within that prescribed by law) in which each comprises a different and functionally autonomous machine or a part thereof which is functionally autonomous.
The plant 10 starts with a profiling machine 20, which unwinds two metal sheets (not shown) from rollers and impart a desired profile for the panel thereon (e.g. fretted, corrugated or smooth if the sheets are simply facing each other without processing). There follows an insertion machine 22 (optional) which inserts fiberglass splines between the metal sheets with reinforcement function.
In series with the machine 22, there is a foaming machine 24 in which a foam is produced from elementary components, e.g. polyurethane or generally insulating foam is produced, and it is injected between the two facing metal sheets. At the exit of the machine 24, a continuous press 26 is provided, in which the two metal sheets are forced between two parallel planes during the foam expansion. Optionally, the press 26 comprises heating means for heating from the outside the sheets/foam sandwich. Such sandwich reaches a cutting machine 28, which cuts the metal sheets, now separated by expanded foam, in order to obtain a panel with the desired length.
The cut panels are transported to a cooling machine 30 (optional) where the panels give away the heat chemically generated during the foam expansion to the environment.
Finally, the panels reach an ordering machine 32 (optional), which draws the panels from the line and stacks them and/or releases them in packs of pre-established format.
According to the invention, each of the described machines 22, 24, 26, 28, 30, 32 is installed, fixed and contained within a single container 12, and is designed for constituting an autonomous unit that is ready to cooperate with the others. During operation, the containers 12 are aligned in a single row, abutting against each other and being coupled to each other along the short side with coupling and fixing means. Other lateral containers are not necessary, and no machine 22, 24, 26, 28, 30, 32 extends over two or more containers due to a precise scale design.
The profiling machine 20 is preferably subdivided into two or more containers, but the following design criterion is always valid: each machine or each part thereof is designed, sized and scaled so that it stays within a single container 12 (even the two or more sections of the profiling machine 20) and so that it can be interfaced and operate with the preceding or subsequent machine only with the connection between the containers 12.
Some of the solutions which allowed this adaptation include the following. The press 26 is about 11m long, in order to stay within a standard 12m container. The press 26 is formed by two superimposed, parallel belts of plates, between which the two foam- filled sheets slide. In order to block the outflow of foam from the sides, bulky containment tools are usually used that are mounted on the side of the press (in WO 2006/123373, in the lateral containers). In place of such additional tools, it is preferred to use lateral plugs, strickles or plates, directly connected to the press and with reduced encumbrance, such to remain inside the width of the container. These plugs are like rods or wedges adapted to be fixed to the sides of the belts, with containment function.
The profiling machine 20 is schematically shown in fig. 4.
The total length of the machine 20 is such to take up at least two containers, as in WO2006/123373, but with a substantial difference that avoids all the disadvantages described above. Whereas in WO 2006/123373 the machine is a known machine and trivially partitioned in order to be contained in various containers, without redesigning, the invention adapts the sections composing the machine to a container, and in a manner such that by placing the containers in a row, the machine 20 is "reconstructed".
For example, in every container 12, there is a sole base 70, with size smaller than those known, which lies within a single container. Depending on the type of panels to be produced, the base 70 is prepared with the suitable modules. On the base 70, removable modules or drawers 72 can be mounted and substituted, comprising a series of rollers 74, adapted for the profiling of the sliding metal sheets; and mechanical adapters or connections (gears, belts and kinematic chains in general, not shown) for drawing mechanical power from motor means present in the base 70 and thus actuating the rollers 74. In another container, which is arranged upstream those of the machine 20, a machine can be situated for setting a protective film on the metal sheets, and there can be a shearing machine for cutting the sheets and changing production type.
In order to have different profiling in the panels, it will suffice to mount different modules 72. The substitution of the modules 72 occurs with the containers 12 already positioned in a row, for example by accessing the sides with a fork-lift truck, with the advantage that time is saved in the machine-change and there is a reduction of the number of different transported containers (the different modules 72 will suffice). Preferably, the plant 10 comprises a service container 14, equipped with generator means for generating electrical power supply and compressed air. The container 14, by means of cables or ducts or similar energy or fluid transmission means 15, supplies power to the machines in the containers 12.
As said above, at most the plant 10 comprises from seven to nine containers 12, for a maximum length of 60m for the train of container 12.
The inline arrangement and the inline mounting of the container train are facilitated by a preferred container structure. Each container 12 has, on the short sides, two doors 40 hinged around a vertical axis Y to a fixed structure which comprises the roof 44, the floor 48 and four corner pillars 42. It will suffice to open the doors 40 of each container 12 and attach the containers to each other, in a manner so as to create a continuous tunnel. The machines utilize the entire length of the containers 12, in a manner such that, once the doors 40 are open, the approaching of the short sides of the containers 12 places the ends of the machines, or parts thereof, at the correct working distance - the same distance that would be had if the plant was open-pit.
Unlike WO 2006/123373, the separated parts (then put together) of the machine do not have final size corresponding to the entire machine divided into subsections or fixed modules of unchangeable length equal to the size of the container. In such a manner, a subdivision into machine parts is obtained that either makes no sense or is complicated to assemble.
On the contrary, the invention involves a logical and functional subdivision (also very convenient) of the machine, and adapts the parts thus obtained to the size of the container. Hence, by joining the containers via the short side, the functional and mechanical continuity of the plant is restored.
The containers 12, on the long sides, can have large doors or lateral walls that can be removed or hinged in order to be opened.
One possibility is to have two walls 50 as long as the container 12 and half as high which are hinged to the upper or lower edge of the container 12, with folding opening around an axis X. In this manner, the walls 50 can, when opened, constitute a ground walkway on the sides of the containers 12 and a suspended canopy against rain or sun.
One advantageous variant consists of integrating photovoltaic panels outside the lateral walls 50, in a manner so as to generate, in each container 12, the electrical power for its functioning.
In order to avoid damaging the panels, a modified structure like that of Fig. 3 is preferable. The container 12 has an empty rectangular frame 60 hinged to the upper edge and adjustable with regard to its slope (angle a) with known actuators. A plane 62 is centrally hinged to the frame 60, around a horizontal axis H. Such plane 62 supports or integrates photovoltaic panels 64. The plane 62 can be rotated about the axis H inside the frame 60. During the transportation of the container 12, the frame 60 is adherent to the container 12 (angle oc=0) and the plane 62 coplanar thereto, in a manner such that the active surface of the panels 64 is turned towards inside the container 12, so they are protected from damage. Onsite, the frame 60 is exposed (angle a>0) and the plane 62 is turned upside down (see arrow F) in order to bring the panels 64 outside and have them receive solar light.
One important as well as advantageous aspect of the invention is the possibility of carrying out the production on a ship, whether it is docked at the place of need or sailing.
The row of containers, which form a plant when aggregated, is sufficiently short that it could be set fixed to the deck or to the hold of a ship. The containers form a rigid structure together, and it will suffice to fix it to the floor of the ship, e.g. by means of known positioning wedges, so that the production is immune to wave motion or rolling.
There are innumerable advantages associated with the production on a ship, including: - the transport dead time of the plant can be used for production, arriving at destination with panels already made. If the panels served for forming emergency shelters, the importance of having them ready upon arrival is apparent (a Europe-USA oceanic crossing lasts 30 days); - the plant does not have to be unloaded and installed on the ground, since it can be produced on the shore or at mooring. With trucks or transport means, the panels can be brought from the ship to the ground and immediately assembled;
- the deck of the ship or the walls of the hold can be covered with photovoltaic panels and power supply the entire plant, without power supply and charge problems for the circuit of the ship or the need to transport generators. Or, the panels mounted on the container can be used as described above;
- the volume of the raw material about equals the volume of the finished panel, so that the load capacities of the ship are utilized as much as possible.
The described concepts are not limited to a plant for panels, but can be extended to every inline production plant.
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