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Title:
AN APPARATUS FOR SAND WASHING AND STONE CRUSHING WITH PREDETERMINED GRANULATION AND GRINDING LEVEL AND PROCESS THEREOF
Document Type and Number:
WIPO Patent Application WO/2023/209534
Kind Code:
A1
Abstract:
An apparatus and a process thereof for sand washing and stone crushing, comprising a mechanical feeding mechanism (100), an elevator (105); and at least one belt conveyor (106). a first rotary washing and sieving tunnel (102) for washing the raw material fed to the said apparatus and separating the containing sands in the raw material, with a plurality meshes installed on a truncated cone (154); and a first stone crushing part (103), which the said first stone crushing part (103), comprising: a fixed part (122), and a vibrating part (123); and a second stone crushing part (104), which the second stone crushing part (104) comprising: a central cylinder (132), a plurality of peripheral cylinders (136) wherein the said peripheral cylinders are installed around the said central cylinder (132); and a second sieving tunnel (107); and at least one washing basin (108).

Inventors:
SADEGHI AGHDAM RENDI VALI (IR)
Application Number:
PCT/IB2023/054179
Publication Date:
November 02, 2023
Filing Date:
April 24, 2023
Export Citation:
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Assignee:
SADEGHI AGHDAM RENDI VALI (IR)
International Classes:
B02C21/00; B02C23/02
Foreign References:
CN107511241A2017-12-26
Download PDF:
Claims:
Claims

[Claim 1] An apparatus for sand washing and stone crushing, comprising: a mechanical feeding mechanism (100), an elevator (105); and at least one belt conveyor (106); characterized in that the apparatus further comprising: a first rotary washing and sieving tunnel (102) for washing the raw material fed to the said apparatus and separating the containing sands in the raw material, with a plurality meshes installed on a truncated cone (154); a first stone crushing part (103), wherein the said first stone crushing part (103), comprising: a fixed part (122), and a vibrating part (123); a second stone crushing part (104), wherein the second stone crushing part (104) comprising: a central cylinder (132), a plurality of peripheral cylinders (136) wherein the said peripheral cylinders are installed around the said central cylinder (132); a second sieving tunnel (107); and at least one washing basin (108).

[Claim 2] The apparatus according to Claim 1 , wherein the said first rotary washing and sieving tunnel (102) further comprising: a first cylinder shape part equipped with a plurality of diagonal blades (117), for directing the material forward through the said truncated cone.

[Claim 3] The apparatus according to Claim 2, wherein the said first rotary washing and sieving tunnel (102) rotates within the said water washing basin (108), and cause the containing materials rotation inside the water.

[Claim 4] The apparatus according to Claim 1 , wherein the said washing basin (108), have a sloping floor for directing the sands toward a plurality of drainage buckets (118), wherein the said buckets (118) are installed around the first tunnel (102). [Claim 5] The apparatus according to Claim 4, wherein the said drainage buckets (118), equipped with a mesh (121 ) to dewatering and discharge the sands out of the system.

[Claim 6] The apparatus according to Claim 2, wherein the said first rotary washing and sieving tunnel (102) is horizontally mounted on a plurality of roller bases (113), and is further equipped with an electric motor with a gearbox (114).

[Claim 7] The apparatus according to Claim 2, wherein the said first rotary washing and sieving tunnel (102) is further equipped with a 12 mm or 19 mm round hole diameter mesh (119), followed by the said truncated cone mesh (154).

[Claim 8] The apparatus according to Claim 7, wherein the said first rotary washing and sieving tunnel (102) is further equipped with an another 19 mm round hole diameter mesh (120), followed by the first said the 12 mm or 19 mm round hole diameter mesh (119).

[Claim 9] The apparatus according to Claim 1 , wherein the surfaces of both the fixed part (122), and the vibrating part (123) of the said first stone crushing part (103), are covered with a plurality of triangular profiles (125).

[Claim 10] The apparatus according to Claim 1 , wherein the said first stone crushing part (103), further comprising: at least two semi-circular weights (126), rotating around an axis (127) by an electric motor (128), and a plurality of springs (124), wherein the said springs release the stored energy generated by the said electric motor, in order to vibrate the said vibrating part (123) back and forth, and crush the aggregates between the said triangular profiles (125).

[Claim 11] The apparatus according to Claim 1 , wherein the vibrating part's surface (123), of the said first stone crushing part (103), is inclined and its distance from the fixed part (122) is adjustable with a plurality of adjustment screws (131 ).

[Claim 12] The apparatus according to Claim 1 , wherein the said second stone crushing part (104), further comprising: a gear (135) is connected to the central cylinder axis (132) and an electric motor and gearbox (133) rotate the said gear (135).

[Claim 13] The apparatus according to Claim 1 , wherein the peripheral cylinders (136) of the said second stone crushing part (104), are equipped with a plurality of spring bases (138), and the said spring bases (138) are also equipped with a plurality of adjustment screws (139), to adjust the distance and the amount of applied pressure between them and the central cylinder (132), and hence to adjust the amount of applied pressure on stones and the size of output aggregates.

[Claim 14] The apparatus according to Claim 1 , wherein a mesh (140) is installed next to the central cylinder (132) and the second roller of the said peripheral cylinders (136), to separate the sands from the crushing cycle in the second stone crushing part (104).

[Claim 15] The apparatus according to Claim 1 , wherein the belt conveyor (106), transports the crushed stone materials to the elevator (105), and the said elevator directs the crushed materials to the second sieving tunnel (107).

[Claim 16] The apparatus according to Claim 1 , wherein the elevator (105) is equipped with a plurality of buckets (141 ) and a conveyor belt (143).

[Claim 17] The apparatus according to Claim 1 , wherein the second sieving tunnel (107), comprising: a part of a 0-6 mm hole diameter mesh (146), and a two-layer part (147), wherein the said two-layer part further comprising from two round hole diameter meshes (148 & 149).

[Claim 18] The apparatus according to Claim 17, wherein the two-layer parts meshes (148 & 149), have different hole sizes.

[Claim 19] The apparatus according to Claim 17, wherein a first, a second and a third inclining plates (151 , 152 & 153) directs the output crushed stones of the second sieving tunnel (107), to different parts of the apparatus such as the first and the second stone crushing parts (103 &104).

[Claim 20] The apparatus according to Claim 1 , wherein the feeding mechanism (100), comprising: a plurality of rods (100), a tray with an inclined floor and walls (112) installed next to the said rods, at least two arms (110) connecting the said feeding mechanism to a plurality of supports (111 ), wherein the whole feeding mechanism directing the raw materials and water to the first washing tunnel (102).

[Claim 21] A process of sand washing and stone crushing, the process comprising the following steps: the raw materials are fed to a feeding mechanism (100) wherein the feeding mechanism is equipped with a plurality of rods, and a tray with an inclined floor and walls (112) installed next to the said rods; the raw materials are mixed with water in the feeding mechanism (100), and are directed to a first washing and sieving tunnel (102) which is rotating in a washing basin (108), for washing the raw material and separating the containing sands in the raw material, with a plurality meshes installed on a truncated cone (154); the sands in the washing basin (108), are separated from water and other stone materials with a plurality of drainage buckets (118), wherein the said buckets (118) are installed around the first tunnel (102), and equipped with a mesh (121 ); the stone materials are then directed forward through the said truncated cone with a plurality of diagonal blades (117); a first stone crushing part (103), with a fixed part (122) and a vibrating part (123), covered with a plurality of triangular profiles (125), crushes the stone materials; a second stone crushing part (104), with a central cylinder (132), and a plurality of peripheral cylinders (136) installed around the said central cylinder (132), crushes the stone materials as well; a belt conveyor (106) transports the crushed stone materials to an elevator (105), and the said elevator directs the crushed materials to a second sieving tunnel (107); and in the second sieving tunnel (107), the crushed stone materials are separated to different sizes with a part of a 0-6 mm hole diameter mesh (146), and a two-layer part (147), wherein the said two-layer part has two round hole diameter meshes (148 & 149), each of which has different hole sizes.

Description:
Description

Title of Invention

An apparatus for sand washing and stone crushing with predetermined granulation and grinding level and process thereof

Technical Field

[0001] The technical field of this invention is generally related to industries in which aggregates are used in different sizes, and more specifically, it is related to aggregate production industries for the production of ready-mixed concrete, asphalt and prefabricated concrete parts.

Background Art

[0002] The following problems are clearly visible in the machines that are currently used for washing and crushing river and mountain materials and their granulation: The sand production line in the existing technology requires a large space for installation and deployment, which sometimes causes challenges in locating the production unit. In most cases, due to the large space required, it makes locating difficult and also creates additional costs due to the unwanted transportation of raw materials and produced materials from the origin to the required place (consumption). Allocation of transportation and loading machines, in addition to additional costs, reduces the speed of project implementation and causes waste of resources.

[0003] Installing the equipment and machines of the sand production unit requires the construction of heavy and expensive foundations. In construction projects, in addition to the cost of construction, demolition, dismantling and cleaning costs are also required after the completion of the project.

[0004] Furthermore, using conventional technologies presents the following challenges:

- Inadequacy of equipment performance in producing sand materials with the desired quality and variety,

- The high cost of purchasing and setting up a sand production unit

- High depreciation and maintenance costs

- Repairs are time-consuming and cause the production unit to shut

- Repairs are time-consuming, which causes the production unit to be closed until the repairs are completed,

- Requirement for many skilled workforces

- Limitation on the granulation size of production materials

- Insufficient equipment safety for production line workers. [0005] The current equipment does not have the ability to convert low-consumption size sands into high-consumption size sands, so part of the material remains unused and is inevitably deposited in the factory area and thus is left out of the production cycle.

[0006] In any of the current sand production units, it is not possible to simultaneously convert low- consumption production materials into other high-consumption and needed materials, for example, in the current technology, it is not possible to grind the size of 6 to 12 mm to size zero to 6 or 4 or even 2 mm, which is one of the most widely used sizes of sand in the production industries of prefabricated concrete parts, asphalt and all kinds of ready-made mortars.

[0007] Currently, there is no portable sand production unit that can completely wash, granulate and crush the incoming raw materials to any required size, all in one machine.

[0008] For instance, published patent application No. US20060021915 discloses a mined ore processing apparatus for processing mined ore, including oil sand ore, into granular materials, in which consecutive axes are rotated to direct the material forward, detach the smaller aggregates from the space between the two axes, and direct the coarse stones towards the crusher. To make it easier to separate coarse stones from fine stones, water solvents can be sprayed while the stones are being processed, if necessary. Eventually, the coarse stones enter the crusher machine, where they are crushed into smaller pieces by the treads of two counter-rotating balls and enter the chamber through which the hot water solvent is circulating. In this machine, there is no size separation and granulation, and it is not possible to grind the produced materials into other small sizes if necessary.

[0009] A jaw crusher device and related method are also disclosed in document US7448564B2, wherein the mentioned device has a base and a jaw assembly fastened to the base, wherein the fixed component of the jaw in the shape of a curve in its height decreases the distance relative to the eccentric crushing roll, and the crushed stones leave the device after several steps of crushing. The central shaft of the crushing roll, has a larger diameter surrounding it and a certain amount of eccentricity. The rotation of crushing roll, generates the necessary force to press on the stones trapped between the two components. This device is designed to crush coarse-grained stones, but it cannot crush stone materials enough to the extents required by consumption units.

[0010] In addition, the US20080203202A1 patent application introduces a portable stone crusher and scarifier for crushing, grinding, and roadbed preparation that can crush all bed components to a restricted depth on-site without transporting them to a processing plant and satisfy the user’s demands. This device may be employed to perform a variety of tasks, such as destroying and restoring road pavements, grinding stone beds, and so on. This machine has a horizontally rotating cylinder that can adjust its angle to the horizon to account for the transverse slope of the roads or other inclined surfaces, on which a predetermined number of fingers with protuberances made of extremely tough components are mounted in a specific configuration. They rotate with a rotational cylinder, hitting objects or materials to crush them. By connecting to other machines through their arms, this apparatus can be moved and used. This device is used for specific objectives and is not intended for sand production, washing, or granulation.

In this invention, a solution to the problems of the current sand production units is presented and with the proposed technology, all kinds of sand with very diverse granulations will be provided to the consumers.

Summary of Invention

[0011] This invented device's primary function is to wash and separate raw materials from rivers or mountains, into the necessary granulations, and crush the larger sizes into any necessary size and granulation, based on conformance with the standards associated with the manufacture of stone materials as well as publications and project criteria. It can meet the quality expectations of designers, engineers, and consumers, as well as device owners, in terms of quantity and quality, effectiveness, and expense. A mechanical device discharges raw materials to the feeding component of the invented device, and other operations are carried out uninterruptedly. A grid is installed in the raw material discharge area or feeding part, with appropriate dimensions such that stones larger than the machine's washing and crushing capacity do not enter the system and are separated from the initial stages. Because of the appropriate slope of the walls and the water pressure entering the feeding part, the raw materials enter the washing part and are immersed in water while rolling over each other. The surface of the aggregates has been cleaned of all the considered salts. The aggregates that are introduced simultaneously with the washing process are directed by diagonal vanes into the sand separation unit. Due to the slope of the floor in this part, the sands are taken out of the system and directed toward the special bags mounted surrounding the washing tunnel to collect and drain the dewatering sand. In this section, the sands are separated from other aggregates by a round hole perforated mesh. The remainder of the material keeps moving forward during the rotation and is eliminated from the water because of the change in tunnel diameter, and it is guided to the tunnel after washing. In the continuation of the tunnel, pea-sized particles and then almond-sized particles are sieved and separated from the tunnel simultaneously with materials rotation. The final step involves taking stones larger than almonds out of the tunnel and placing them in the coarse vibrating jaw crusher. After being crushed, the stones are then transferred to the lower conveyor belt and then directed into the elevator. The separated pea-sized particles, enter the fine crusher which makes them into finer particles (broken sand) before being discharged to the lower conveyor belt and guided to the elevator. The elevator transports crushed materials to a second tunnel. Similar to first tunnel, the second tunnel while rotating, sorts input materials into the sand, peas, and broken almond sizes. If any of the mentioned generated sizes are not required, they are then be abled to transmitted by the guides (shot) to the fine crusher for re-crushing, and this closed cycle keeps going. Each granulation is accomplished by varying the diameter of the holes in the mounted meshes. Brief Description of Drawings

Fig.1

[0012] [A perspective view of a preferred embodiment of the invention and its components are shown in Figure 1 .

Fig.2

[0013] [fig.2] shows the various components of the raw material feeder (input) in various views.

Fig.2(a)

[0014] [fig.2(a)] Shows the side view of the feeder and connecting arms, as well as primary sieve rods and the support part of the feeder.

Fig.2(b)

[0015] [fig.2(b)] depicts a perspective view of the primary sieve rods, their angle and placement form of the primary sieve rods used to avoid the entrance of stones greater than the device's capacity.

Fig.2(c)

[0016] [fig.2(c)] shows the embedding position of the water inlets to the feeder, which is planned for initial wetting of the materials and directing the materials towards the washing tunnel.

Fig.2(d)

[0017] [fig.2(d)] depicts a perspective view of the sieve rods and feeder body, as well as the locations where water enters the feeder.

Fig.2(e)

[0018] [fig.2(e)] illustrates the slope of the bottom of the feeder where materials discharged to it are guided toward the washing tunnel due to the slope of the floor and the water pressure.

Fig.2(f)

[0019] [fig.2(f)] is the top view of the feeder. Fig.2(g)

[0020] [fig.2(g)] depicts the feeder's outlet section in which the materials enter the washing tunnel through a pipe at the end of the feeder.

Fig.3(a)

[0021] [fig.3(a)] shows a perspective view of tunnel 1 , demonstrating the components for power transmission, washing and rinsing, material separation, and rotation system.

Fig.3(b) and 3(c)

[0022] [fig.3(b) and 3(c)] respectively show the perspective view and how to install the netting on the bottom of the buckets, which concurrently collects sand and discharges it out of the sand dewatering system.

Fig.4

[0023] [fig.4] shows the various coarse crusher components.

Fig.4(a)

[0024] [fig.4(a)] illustrates the side view of the shock absorber springs liberating along the preferred length and how the shoulders of the fixed and movable jaws are positioned.

Fig.4(b)

[0025] [fig.4(b)] illustrates the top view of the position of the electric motor, the vibration generator, the location of the central shaft of the power transmission pulley, and the shoulders of the fixed and movable jaws.

Fig.4(c)

[0026] [fig.4(c)] shows a perspective view of the location of weights mounted within the Pulleys in the shape of a circular sector, it is also demonstrated how to mount the electric motor and the power transmission.

Fig.5

[0027] [fig.5] depicts shows various components of the fine crusher; Fig.5(a)

[0028] [fig.5(a)] shows a side view of the fine crusher along with the installation of the central roller and rollers around it, as well as their capacity to rotate during operation, and support springs;

Fig.5(b)

[0029] [fig.5(b)] shows a side view of the location of the fine crusher in relation to tunnels 1 and 2, as well as how materials are transmitted from the tunnels to the fine crusher;

Fig.5(c)

[0030] [fig.5(c)] shows the power transmission to the central plug;

Fig.5(d)

[0031] [fig.5(d)] shows the back view of the fine crusher;

Fig.5(e)

[0032] [fig.5(e)] shows the front view of the fine crusher;

Fig.6

[0033] [fig.6] shows a perspective view of the invention, more particularly the elevator's left side;

Fig.7

[0034] [fig.7] shows a side view of the entire system arrangement and the location of the material transmission plate that was discharged by the elevator to tunnel 2;

Fig.8

[0035] [fig.8] illustrates the perspective view of tunnel 2 sieve meshes and shoots for the material transmission, and bases that allow the tunnel to rotate;

Detailed Description of Invention

[0036] The following is an explanation of the components of this invention:

The device's overall dimensions are arranged and designed in a manner that allows it to be transported on roads without limitations. The length of one embodiment of this machine is 12 meters, its width is 2.5 meters, and its maximum level height is 3.5 meters. The claimed apparatus is made up of eight major components listed below:

Part 101 : Feeder or raw material input box;

Part 102: Tunnel No. 1 (rotary washing and sanding up tunnel);

Part 103: Coarse Stone Crusher;

Part 104: Fine crusher;

Part 106: Belt conveyor;

Part 107: Tunnel No. (2);

Part 108: Washing basin.

[0037] Feeding portion (feeder) (101) or machine inlet, where raw materials are discharged by a mechanical device: Rods (100) are mounted with specific spacing, such as 400 mm, in the upper portion of the feeder (101) to ensure that larger stones do not enter the system. Because of the longitudinal slope of the tray bottom (112) and its walls, as well as the water flow that enters the system through the tray floor and its walls, the raw materials are directed to the first washing tunnel (102). Depending on the amount of input water, the output of raw materials can be adjusted. The feeding box (feeder) (101) could be constructed from a metal sheet and is mounted and settled on the seat on the supports (111) by two or more arms (110). Pins are used in one embodiment of the device to connect the arms to the feeder. During the system transportation process, if the total length of the system is too long for the transport vehicle, the feeder can be detached from the system and placed upright at the end to be reinstalled at the destination. The feeder part (101) of one embodiment of the invention measures 325 cm in length and 240 cm in width, the loader device (105) has 250 cm width, so it is possible to conveniently discharge raw materials to the feeder. In the mentioned configuration of the feeder (101) and the loader device (105), the whole system can be easily transited on the roads.

[0038] The washing and sanding-up tunnel (102) has a unique cylindrical shape and is horizontally mounted on the roller bases (113). The washing and sanding-up tunnel (102) rotates under the torque force of an electric motor with a gearbox (114), as a result of joining the gearbox (114) gears to installed gears surrounding the washing tunnel (115). The washing and sanding-up tunnel (102) rotates within the water basin (108), which is constantly filled with water up to a specific level and its rotational motion rolls raw materials on each other inside the water. The fine and coarse materials rub against each other and are thoroughly washed in this tunnel. Because the materials are immersed in water, the pressure from their weight is reduced and they cause less wear and tear for the machine parts. At the same time as the raw materials are washed, they are directed to the next parts of the machine by diagonal blades (117). The washed materials will then enter a truncated cone shape sand collection mesh (154). In this part, at the same time as the tunnel rotates and the materials are directed forward, the sands, which have a diameter of 0 to 6 mm, pass through the nets at the same time as they are washed. Due to the slope of the basin floor, they are directed towards the drainage buckets (118). The mentioned drainage buckets (118) are installed in a special way around the tunnel. The sands are collected from inside of the basin by those drainage buckets (118) and at the same time as the sands are discharged out of the system by means of a mesh (121) installed on the bottom of the buckets, dewatering of the sands is also done. The tunnel's diameter progressively reduces in the continuation of the washing tunnel and is eliminated from the basin's water level; subsequently, the remainder of the materials are separated from the water and directed forward after dewatering. The materials are then fed into the round hole perforated pea-mesh (119). The pea-mesh (119) hole diameter could be 12 mm, so when the tunnel rotates, pea-sized materials of 6 to 12 mm will come out of the tunnel. Two routes await the pea-sized materials once they emerge from the tunnel. If it is desired, a ramp (155) directs the pea-sized materials out of the system for consumption. If pea-sized materials are not required, and they are desired to be crushed into broken sands, they will enter the fine crusher (104). In the description of the next parts of the system, how to turn the pea-sized materials into broken sand with the desired adjustable diameters, will be mentioned.

[0039] The washed materials, which are separated up to 12 mm in size, are still guided forward due to the rotary movement of the tunnel until they enter the 19 mm(almond-size) net (120). In this part, the aggregates with a diameter of 12 to 19 mm pass through the net (120) and exit the system through the ramp (155). If almond-size materials are not required, and it is also desired to crush them into broken sands, a 19 mm net will be replaced with 12 mm round hole perforated mesh in the previous step. So that pea-sized and almond-sized materials can enter the fine crusher simultaneously. Following this stage, the remaining aggregates with diameters ranging from 19 to 400 mm are extracted from the tunnel and fed into the coarse crusher (103).

[0040] Tunnel number 1 can be 840 cm long in one embodiment of the invention. In general, in this part, the main operation of washing and separating the sand, dewatering the materials, discharging the sand out of the machine, separating the sizes of peas and almonds, and transferring the coarse stones to the coarse crusher are performed.

[0041] In the coarse stone crusher (103), large stones that cannot be used are broken into smaller pieces by the impact and pressure of the walls with the mechanism that is explained. Coarse stone crusher (103) consists of two main parts, one part is fixed (122) and the second part (123) is mobile by being placed on spring bases (124). Surfaces of both fixed and mobile parts that are in contact with the aggregates are covered by triangular profiles (125) with a base height of 5 cm whose triangular apex is towards the aggregates, so that they are in contact with the stones at a lower surface and as a result, put more shear pressure on the rocks. Due to the vibration force produced by two semi-circular weights (126) rotating around the axis (127) by the electric motor (128), the moving part generates the necessary force to crush the stones. The rotation of the electric motor is transferred to the axis by 2 or more belt pulleys (130) or by similar transmission devices. The number of revolutions is reduced in the same proportion (for example, up to 108 rpm) because of the variation in the diameter of the pulley connected to the electric motor (129) with a sample diameter of 12 cm and pulley (130) with a sample diameter of 100 cm, which supplies the force needed for torqueDuring the rotation, the semi-circular weights produce forward and backward hits due to the centrifugal force, and the backward pressure and shock is stored as kinetic energy by the back springs or shock absorber springs (124). Simultaneously with the forward impact of hammers or triangular profiles (125), the said springs (124) release the stored energy. The sum of these two forward and backward hits, produces the necessary force to break the stones in a fraction of a second.

[0042] To crush the stones into ever-tinier pieces, the moving or vibrating part's (123) surface is inclined, and its distance from the fixed part (122) gets smaller downward. It is possible to adjust the distance between the moving part's (123) and the fixed part (122) with adjustment screws (131). In this system, the distance between them the moving part's (123) and the fixed part (122) (input) is set based on the maximum size of stone entering the system in the feeder part (101) (for example, 400 mm), and the lower part (output) is set based on the maximum size of the input of the fine crusher (104), (for example 40 mm). The crushed stone material is removed from the crusher and is discharged on the conveyor belt (106) which guides the crushed material to the elevator (105). An appropriate metal platform is used to install the conveyor belt (106) under the coarse crusher and the fine crusher, which then allows the conveyor belt to transport the crushed materials to the elevator. With the exception of the coarse stones entering the course-crusher, the fine crusher (104), which is essentially the central processing unit of this sand-washing and crusher machine, receives all other stone sizes and grinds them to the necessary and high-use sizes sands, particularly sizes zero to six mm or smaller. The pea sizes are entered into fine crusher (104) if they are undesired, so that they can be crushed and employed in any finer size expected. The fine crusher (104) is capable of producing the crushed sand needed by asphalt plants, ready-made mortar plants, and precast concrete parts plants from the least-consumed size of aggregates, i.e. peas. Because in this device, the output size of broken aggregates can be adjusted in much smaller dimensions, and the main consumption of the mentioned factories ranges from zero to 2 or 4 mm. As a result, the efficiency of the fine crusher (104) is very remarkable, and it is regarded as one of the device's most significant characteristics. This fine crusher's (104) mechanism causes a heavy steel (or other appropriate metal) cylinder (132) to rotate at a sample rate of 36 revolutions per minute while having an outer sample diameter of 55 cm, a high wall thickness (for instance, 40 mm), and a sample length of 120 cm. This rotation is caused by a powerful torque force generated by an electric motor and gearbox (133). In order to reduce the number of revolutions of the electric motor, a reducer gearbox (for example, in the ratio of 1 to 5) has been used, which in addition to reducing the number of revolutions of the electric motor (for example, from 900 rpm) will also increase the torque arm. To create a very high torque, the difference in the diameter of the gear (135) connected to the output shaft of the gearbox (134) with a sample diameter of 20 cm, and the gear (135) connected to the central cylinder axis (132) with a sample diameter of 100 cm is used, which provides the main force of crushing the stones. Around this central cylinder (132), a number of peripheral metal cylinders (136), each of which has a sample length of 120 cm, a diameter of 30 cm, and a wall thickness of 25 mm, are installed at specific distances from each other and the central cylinder. The mentioned cylinders will have rotational movement by the shafts that are connected on both sides on the roller bases with bearings (137). The seating of the roller bases (138) has a spring state so that the cylinders can have a variable distance during the crushing operation based on the diameter of the feeding stones, so that all the feeding stones can be crushed in three stages. The amount of pressure applied to the aggregates and the size of the output broken stones can be adjusted and selected based on the amount of compression of the springs and the increase or decrease of their hardness. The adjustment screw (139) is used to adjust the amount of the springs' compression. Also, the distance of the cylinders (136) from the central cylinder (132) can be adjusted. Because of the rotational torque of the central cylinder (132) and the location of the aggregates in the distance between the central cylinder (132) and the neighboring cylinders (136), as well as the pressure of the springs of the roller supports of the neighboring cylinders, the aggregates are crushed during three or more stages (according to the number of peripheral rollers). After two stages of crushing, the amount of broken sand in the volume of materials inside the machine increases and causes disruption in the third stage, that's why after two stages of crushing, the sands are separated from the crushing cycle by a mesh (140) and the remaining aggregates in other words the coarse ones, enter the third or further following stages for final crushing. Based on the distance between the peripheral cylinders (136) and central cylinder (132) and the defined compression of the springs by the adjustment screw (139), the size of the output broken aggregates can be adjusted. Additionally, the diameter of the mesh holes after the second stage can be set up to 0.5 mm precision. The granulation of the crushed materials can be selected to be as fine as necessary, and this is one of the significant characteristics of this invention.

[0043] All of the broken materials are transferred to the conveyor belt (106) after the third stage, where they will be transported to the elevator (105) alongside the materials that have already been crushed by the coarse jaw crusher (103). The elevator (105) directs the crushed materials to the second tunnel sieve (107).

[0044] The transfer of crushed materials from the fine and coarse crushers is carried out by the conveyor belt towards the elevator (105). The elevator (105) is used to transfer the materials to the necessary height to enter the second sieve tunnel (107). To transfer materials in height, this elevator (105) is equipped with some buckets (141) with sample dimensions of 20x40 cm. Bolts and nuts connect these buckets (141) to the conveyor belt (143) of the elevator. The elevator (105) transports the crushed materials from the exit of the conveyor belt (144), through its buckets to the inclined plate that is installed to transfer the materials to the second sieve tunnel (107). The second tunnel sieve (107) rotates as a cylinder on the roller bases (145), and some nets and meshes that sieve and separate various materials in size as required are installed at defined intervals. In the first part of the second sieve tunnel (107), the broken sand is separated from the imported materials by the 0-6 mm hole diameter mesh (146) and is removed from the system. The next part of the second sieve tunnel (107) is designed in the form of two layers (147) in order to provide the possibility of separating materials of different sizes without adding the length of the device. The almond-sized aggregates are separated by the net (148) of the first sieve layer and remain on the second layer net (149). Then the separated almond-sized aggregates are guided by the inclined plate (152) to be consumed in their size or directed to the fine crusher (104) for re- grinding and turning it into smaller sizes. Larger sizes than almonds are discharged from part (150) on the inclined plate (151) and directed to the fine stone crusher. After passing through the net or mesh of the first layer (148), the pea-size and the almond-size materials enter the round hole perforated mesh of the second layer (149) After the pea-size materials separated from the almond-size materials that is which are kept inside the mesh (148), the pea size materials pass through the mesh (148) and are transferred to the inclined plate (153). If necessary, pea size materials are removed from the system for consumption. If not, they can be sent to the fine crusher (104) with the pea-sized materials that emerged from tunnel 1 (102) to be crushed into broken sand.

Industrial Applicability

[0045] This system allows for the washing and conversion of all materials to any desired or necessary size in accordance with the standards. Any current system for sand washing and stone crushing lacks this characteristic. The system described above has dimensions that make it portable and movable in various environments.

[0046] In addition to using new methods for washing, separating and crushing stone materials, this invention also has new capabilities. In this invention, in a new way, raw stone materials are rolled on top of each other in a tunnel immersed in water, and they rub and wash each other completely. In this method, the depreciation of the device is very low and it washes and separates the materials without creating dust and noise pollution. Any kind of material can be manufactured using this invention in any size, shape, and concerning grading standards. This invention allows for the production of any required granulation, and if any sizes deemed unnecessary, this machine can crush and produce them into other sizes or granulations. For the first time, coarse stones are crushed using the power of vibration in this invention. This provides the benefit that the device's manufacturing costs are lower than those of similar ones, and it depreciates very slowly. As a consequence, the repair expense is also relatively low. In this invention, the aggregates are crushed and generated to a precision of 0.5 mm after being adjusted to the necessary granulation by the fine-crusher. This invention is designed with all its capabilities in transportable dimensions, requires no operator during operation, and has a very high level of safety in all of its designed components.

[0047] The following are some of the invention's characteristics and benefits: 1. A significant decrease in the amount of space needed to install equipment and the ability to transport it when needed, which solves the problem of location and allows for installation in the least amount of space.

2. It does not require any type of foundation.

3. A wide range of production line equipment for the manufacturing of any category of aggregate and needed granulation, as well as the capacity to alter the variety of output materials of the production line at a higher velocity and a very minimal cost, if not free of charge, for changing the variety of generated aggregates.

4. The ability to develop a production line on a wide range of scales based on the quantity and variety of production materials.

5. Minimal depreciation and lower production costs

6. Elimination of labor and operational workforce, as well as cost reduction in manufacturing

7. Improving the safety of automatic production lines and completely eliminating potential hazards

8. Lower purchase and construction costs than the existing production lines with comparable capacities.

9. However, the acceptance of any type of input raw materials, processing, washing, and granulating of input materials, as well as crushing aggregates larger than necessary levels and granulating them in the required variations, are among the most crucial and primary characteristics of this designed production line. With a half-millimeter precision, it can crush materials as small as 6 to 12 mm, called pea size stones, other sizes ranging from 0 to 2 or 4 or 6 mm, called zero sands, or any other desired sizes. It is important to clarify that the pea-size represents the maximum volume of raw materials and is the least utilized size in the granulation of all types of concrete and that the primary objectives in designing the invention is to crush the pea size to the most utilized size, i.e., sand with granulation of 0 to 6 mm or smaller diameters. The most commonly used size (75%) in the manufacturing of prefabricated concrete parts and types of dry mortars is zero to 2 mm, which can be generated by current production lines with minimal volume and maximal waste, whereas in the design of this invention, the crushing of all raw materials up to 0 to 6 mm size with very quick and easy changes in the equipment is considered and claimed.

[0048] In this invention, after applying the necessary settings to produce the required aggregates and installing the sieving nets to the desired diameters and establishing the flow of water into the device and starting the electrical connection buttons of the electric motors of the device, the system is ready for operation. Then, it is enough to load the raw materials to the feeder part by a mechanical device so that all kinds of desired and needed materials can be produced and delivered by the machine.

Industrial Applicability

[0049] This invention has significant applications in the profession of construction materials and road construction for the manufacturing of standard and necessary aggregates in each granulation. It will enhance the quality of goods generated by factories and construction projects, including the consumption of ready-mixed concrete factories, asphalt factories, factories generating prefabricated concrete sections, factories generating all kinds of dry and ready-made mortars, factories generating all kinds of stone powders, factories providing raw materials for plaster and cement, and other factories that require standard granulated aggregates for the manufacturing of their goods, as well as aggregates and granulations for all kinds of roadway pavements.