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New
Cubing Line Helps Set Production Record
Chicago
Block and Brick
At Chicago Block and
Brick the Dynapac® concrete products machine has been a workhorse,
producing over 70 million concrete masonry units since it was installed
in 1993. John McNicholas, plant superintendent, realized  that the plant’s
production was being compromised by the inefficiency of the cubing line.
John knew that productivity would increase with the installation of a
new Besser cubing line. The difficulty he had was finding the right time
to stop production for the installation.
The decision to bite
the bullet and shut down for a few days to install the new cuber and
strapper came in August 2000. Over a long weekend, with the assistance
of Besser service technician John Campau, the new equipment was put
in-line. The improvement in the productivity of the plant was evident
immediately. "We had a 16% increase in plant productivity the very
next day," stated John.
The plant operates
non-stop 24 hours a day, 6 days per week. Production primarily consists
of 4", 6", 8", 10" and 12" (100 mm,  150 mm, 200
mm, 250 mm and 300 mm) light and medium weight concrete masonry units.
John is pleased that the new cuber continues to run flawlessly and
easily keeps pace with the Dynapac.
The dual lift
cylinders utilize a hydraulic proportional valve to very the lift
speeds. One of the two dual lift cylinders incorporates an LVDT feedback
sensor that provides a percise position of the tier lift for the control
system.
Many new features
contribute to the efficient operation of the cuber and increased plant
productivity. Hydraulic proportional valves precisely control the speed
of many cuber functions. These valves are used on the patternmaker bar,
tier lift, tier pusher, carriage and overhead side feed. The speed
set-ups for all these features are accessed and recalled on the
Allen-Bradley PanelView™ 1000 graphics display unit.
The overhead sidefeed
incorporates a single, solid piece design for the pusher arms and one
large cylinder for moving the pusher up and down. This provides
increased stability and smooth handling. The dual tier lift cylinders on
the tier lift utilize variable speeds to gently and precisely stage
product. One of the dual lift cylinders incorporates a Linear Variable
Displacement Transducer (LVDT) feedback sensor that provides a precise
position of the tier lift for the control system. The LVDT cylinder
locates the carriage (slider plate) above the previous layer with
incredible precision. This accuracy prevents the chipping of product
that cannot be clamped.
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"We
had a 16% increase in plant productivity the very next
day."
- John McNicholas
plant superintendent,
Chicago Block and Brick |
Once the cube is
complete, a short powered cube conveyor quickly moves the cube to the
strapper where it is readied for the yard. A powered 90-degree transfer
at the discharge end of the strapper utilizes rugged, solid steel
rollers to transfer cubes.
The various screens
on the graphics display unit provide all the information that an
operator needs. Production information, diagnostics and cube patterns
are accessible and simple to read. In addition, programming cube
patterns is easy. When a change in products occurs, the simple touch of
a button on the PanelView 1000 recalls the appropriate cube pattern.
Both the overhead
sidefeed and tier pusher are driven by dual chains to provide straight
product tracking while reducing chain stretch and wear. Proportional
valves control speed. Speed set-us are accessed and recalled on the
graphics display unit. The overhead sidefeed also utilizes an encoder
for precise positioning at multiple locations.
John likes the fact
that service and wear parts are readily available from the Holland,
Michigan warehouse. "I know they are going to be there when I need
them and I don’t have to worry about maintaining stock here," he
commented.
Individual components
of the cuber are easy to locate and service, allowing routine
maintenance to be done in spare moments. John has been in the concrete
industry for 29 years and was impressed to see firsthand that Besser
engineers listened to customer ideas when designing the new cubers.
A single, solid piece
design for pusher arms and a large cylinder for moving the pusher up and
down are new features which enhance the strength and smoothness of the
cuber.
The cuber has been a
profitable addition to Chicago Block. According to John, "The cuber
runs great and I am more than happy with it."
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