concrete machinery brochure english
TRANSCRIPT
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YOUR RELIABLE pARtnER
KVM IntERnAtIOnAL A/S
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KVM wORLd-wIdEKVM International A/S is the largest manufacturer
of machines, equipment and turnkey plants for the
concrete industry in Northern Europe. With over
50 years of experience KVM is among the leading
manufacturers globally. KVM has had a great in-uence on the way concrete products are manufac-
tured today.
The KVM head ofce is situated in the city of Kjel-
lerup in Denmark. Besides the head ofce KVM
consists of subsidiary companies operating in the
USA, Poland, the UK and Germany. Furthermore
KVM has local sales staff and agents all over the
world.
KVM - A RELIABLEpARtnER
RESEARCH, dEVELOpMEnt And
tECHnOLOGY ARE HIGHLY VALUEdKVM is world known as a reliable producer and
a loyal partner through the entire project process:
Pre-phase, production, commissioning, service,
training of operators and continued support.
Moreover KVM values points as product develop-
ment, technology, security and quality as important
factors.
These points are achieved in co-operation with
existing customers and through feedback. There-
fore KVM is familiar with the market demands and
solutions, creating increasingly efcient plants and
continual developments.
SERVICE ESSEntIAL FOR EARnInGKVMs team of experts is at your disposal 24 hours
7 days a week. With our service line we guarantee
quick respond and help if a problem occurs in pro-
duction.
KVMs world-famous operator academy ensures
machine and concrete understanding. We educate,
talk, listen and gather interesting information and
develop these into useful production support.
VERSAtILItY tOdAYS KEYwORd
The trends among designers and architects are touse a large variety of different concrete products
in the Landscaping process. This gives the produ-
cers an extra challenge as they have to develop the
mould and the production process to suit.
To make this process protable it is necessary to
have a very versatile production machine. This
scenario has been a fact for the Danish concrete
producers for several years due to the fact that their
consumer volume is in the low end.
For this reason a KVM block machine is con-
structed to operate protably, making high class
output, with a large variety of products even pro-ducts not normally seen made on a block machine.
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BLOCK MAKInGMACHInEThe heart of all block and paving producing facto-
ries is the blockmachine. KVM blockmachines can
produce all shapes and sizes from large slabs 1m by1,2m to kerbstones, blocks and pavers. The smallest
28mm thick pool slabs to the largest 600 kg retai-
ning wall blocks - all on the same machine and all
with exactly the same high quality.
MACHInE pROGRAMMEKVM International manufactures three different
series of Block Making Machines. Depending on
the customers needs and demands large or small
production capacities KVM will guide the custo-
mer in the direction of the most suitable blockma-
chine.
Series I: Type 62/80, pallet size 750 x 900mm
Series II: Types 62/105, 90/105 and 62/125,
pallet size up to 750 x 1400mm
Series III: Types 80/125, 105/125 and 125/125,
pallet size up to 1300 x 1450mm
All types of blockmachines use the well known
KVM controlled concrete handling system ensu-
ring that every kilo of concrete delivered into the
mould is handled in exactly the same way.
The controlled concrete handling is based on the
following features:
Transport of concrete to the silo on the
blockmachine is done with a slow moving belt
conveyor that delivers concrete in the same rate
as it is being used. This gives the same weight
and density of the concrete all the time
A cone shaped rubber sock in the silo guaran-
tees against segregation of the concrete The silo is lowered into the lling box each
cycle to ensure that only the needed amount of
concrete is delivered
The lling box has no internally moving parts
making it possible to empty it after each cycle
The tuning vibrator allows for adjustment of
both amplitude and frequency during both the
lling and the compaction part of the produc-
tion cycle
All movements are controlled by the advanced pro-
portionally controlled hydraulic system. The easy-
to-operate control system enables the operator to
quickly implement changes and to adjust to chan-
ges in materials and products.
KVM blockmachines are delivered with the follo-
wing standard features:
The blockmachine is placed on rubber dampers
under the machine frame which minimises the
need for foundation work and reduces the
vibrations transmitted to the surroundings
High efciency motors and a special energy
saving hydraulic system reduces the environ-mental impact.
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HAndLInG SYStEMAll KVM handling systems are designed to be fa-
ster than the blockmachine at all times and have
built in buffers to enable the system to avoid small
stops giving delays for the blockmachine.
tRAnSpORt wEt SIdETransport from the blockmachine to the elevator
is done by roller or v-belt conveyors that ensure a
gentle transport of the wet products. The wet side
conveyor is divided into several individual sections
that allow the conveyor to work as a buffer zone.
OptIOnS FOR wEt SIdEThe wet side can be equipped with additional optio-
nal equipment:
QUALItY COntROL
Weight, height and density can be controlled and
the information can be presented to the operator
and it can be used to either manually or automati-
cally adjust the settings on the blockmachine;
A laser based height measurement unit controlsthe height of the product
A weight measuring unit weighs the products
An ofine control position allows for detailed
measurements while the production continues
SCRAp EjECtOR
To scrap the waste from cleaning or reject bad prod-
ucts the control position can include a function to
tilt the materials into a skip. Afterwards the empty
pallet will automatically return to the wet side con-
veyor system.
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HAndLInG SYStEMThe size and shape of the handling system is de-
cided by and adapted to the needs and demands
from the customer based on product portfolio, site
layout, climate, capacity, existing buildings etc.
ELEVAtOR And LOwERAtORKVM elevators and lowerators are as a standard of a
double pallet conguration ensuring that the hand-
ling system always works faster than the blockma-
chine and cubing units, whether it is working with
28mm slabs on every shelf or 500mm high chimney
elements on every third.
The elevators and lowerators can be tted with ac-
tive or passive buffers that reduce the risk of delays
caused by different cycle time on wet and dry sides.The elevators can be equipped with service plat-
form and automatic lubrication of the chains.
RACK SYStEMThe racks are designed according to the demands of
the customers product programme regarding shelf
distance, load bearing capability, steel type etc.
Racks can be made in Zinc-coated or stainless steel
materials or a combination of both.
The racks can be left open or insulated in indivi-
dual sections with automatic roller doors or as one
closed big chamber solution that also includes the
elevator, the nger car and the lowerator. The cu-
ring climate can be controlled and improved by air
circulating and ventilation systems adapted to the
demands of the customer. Advanced climate con-
trol units can enhance the curing climate by adding
active gasses or preheated moisturised air to the
curing area.
FInGERCARA heavy duty ngercar transports the products from
the elevator to the racks and back to the lowerator.
The ngercar is controlled by lasers and is driven
by servo units for fast and precise movements. The
ngercar can be equipped with turn table and with
displaceable forks for high and low products.
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tRAnSpORt dRY SIdERoller conveyors handle the transport of cured
concrete products from the lowerator to the cubing
position. The dry side conveyor is divided into in-
dividual sections that allow the conveyor to work as
a buffer zone.
OptIOnS FOR dRY SIdEThe dry side can be equipped with additional optio-
nal equipment:
Quality control zone where the operator can
remove rejects safely while the rest of the dry
side conveyor system continues without delays
In-line splitting unit
Prepress unit for loosening products
Doubling unit for delivering 2 layers at the
time to the cuber Scrap ejector for removing rejects
Production board de-doubling unit
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HAndLInG OF EMptY
pROdUCtIOn BOARdSAt the end of the dry side conveyor the pallet return
system cleans, oils, turns, stacks and accumulates
the production pallets before sending them back to
the blockmachine.
The pallet return system comes in several variations
depending on the need to accumulate empty pallets:
Single pallet return on roller conveyors with up
to 10 pallets between cuber and blockmachine
A transfer car system that accumulates
approx. 100 pallets and allows for easy fork lift
access to the area between the blockmachine
and cuber
An additional transfer car buffer with up to1000 pallets
A traditional crane unit stacking up to 4000
pallets in a buffer
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CUBInGKVM cubers are constructed for maximum versati-
lity and can handle all the products produced on a
blockmachine with high speed and precision. The
clamp is encoder controlled and driven by a high
power hydraulic unit. The drive unit is by a toot-hed belt drive and the cuber has an elevated service
platform and ladder for safe and easy service.
Product formatting units are used to reshape the
product format to t special types of transport pal-
lets or to build void packs with holes for forklift
ngers.
As an option a vacuum lifting device can be instal-
led to handle special products.
ROBOtICS
For special jobs standard industrial robots with
special grippers can be utilized.
CUBEd pROdUCt tRAnSpORtProducts can be delivered with or without transport
pallets. Depending on the demands of the customer
the following types are used;
Chain conveyor
Roller conveyor Slat conveyor
Steel pallet circulation systems
Depending on the local requirements, stacks can
be strapped or wrapped. KVM offers several dif-
ferent types of packing;
Plastic wrapping
Horizontal strapping
Vertical strapping
Stretch hood
Shrink wrapping
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SECOndARYpROCESSInG- REFInEd SURFACES
The demand for special products big/small, round/triangle concrete products etc. products with re-
ned surfaces and with a natural stone appearance,
is steadily increasing.
KVM offers specially developed product after
treatment either as fully automatic integrated in-
line systems in the concrete stone production or as
off-line systems:
Tumbling
Splitting
Washing
Insulation elements ISO Line 2000
KVM tUMBLInG SYStEMSKVM offers complete production lines for tumbled
products, both in-line and off-line systems.
The concrete products are tumbled in heavy duty
rubber lined drums.
KVM tumbling systems are based on a simple or-
ganiser and the patented QS-1 quality sorting unit
that automatically rejects failed products. The sort-
ing unit can also be used for sorting of up to 3 dif-
ferent sizes at the time.
Advantages by in-line systems;
Can handle 24 hour old products
Capacity up to 375 m2 per hour
Can handle products directly from an in-line
Splitting system
Advantages by off-line systems;
High output and exibility
Up to 4 different colours can be mixed
The Tumbling Systems are fully automatically with
minimum manual intervention necessary by opera-
tors.
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KVM SpLIttInG SYStEMKVM manufactures complete splitting systems.
The splitting unit is capable of both I and Y split-
ting of products of up to 1200 mm.
Splitting lines can be installed as in-line units ca-pable of keeping up with the rest of the blockplant
and as stand alone off-line systems.
The splitting line can be joined to a tumbling line
making it possible to tumble the split products gi-
ving a unique nish.
wASHInG SYStEMThe KVM washing unit is integrated into the wet
side line on the blockplant.
The unit washes the surfaces with an adjustable
high pressure water spray. The products are then
cleaned by water owing over the surface and -
nally dried with a high speed air fan.
InSULAtIOn ELEMEntS
- ISO LInE 2000In order to preserve the global climate the insula-
tion standards world wide are sharpening the de -
mands for walls and foundations in houses.
KVM has developed a process where two standard
building blocks are made into a sandwich block
with insulation inside.
This process has several advantages;
Different inner and outer block materials
Different type and dimension of insulation
materials
Different types of adhesives can be used
Easy change in block dimensions
The ready made insulated blocks greatly reducethe workload on the construction site.
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KVM COntROLtECHnOLOGYAll machines in a KVM supplied factory can be
connected to the central PC giving the operator op-
timum survey and easy control.
The central control system is used for easy
communication between the operator and the com-
plete plant by means of screen pictures and ow
diagrams. The operation of the control system is
user friendly and designed by experienced plant
operators.
The control keeps track of plant performance and
allows for easy fault nding and production ana-
lysis.
KVM SUppORt AndSERVICE
All new KVM supplied factories are backed up by
on-line service 24 hours a day 365 days per year.
Multilingual experts are available to solve pro-
blems and to increase plant performance.
Downtime is very expensive for any company and
even the very best plants need regular maintenance
to obtain optimum efciency. Customer service is
a crucial issue for KVM.
OpERAtOR tRAInInGThe KVM plant operator training academy has
been in operation for more than a decade with more
than 1000 block plant operators passing through so
far. Participation in the operator training courses
results in;
Better product quality
Better maintenance
Enhanced plant performance
Less down time
Lower operating costs
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KVM - tHE pERFEC t pARtnER On YOUR wAY tO SUCCESS
KVM IntERnAtIOnAL A/S
IndUStRIVEj 24
dK 8620 KjELLERUp
dEnMARK
pHOnE: +45 87 702 700
FAx. +45 87 702 701
E -MAI L : K V M@ K V M. dK
www. K V M. CO M