JPH0654014B2 - Machine installation method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION a) Field of Industrial Application The present invention relates to a machine installation method. More specifically, the purpose is to install the machine quickly and effectively based on an idea completely different from the conventional machine installation method, and its application range is wide-ranging.

B) Conventional technology Conventionally, when installing a machine, simply place it on the floor.

Anchor bolts are embedded in the floor in advance, and when installing the machine, fix the machine with the anchor bolts.

Install a concrete foundation higher than the floor and fix the machine with anchor bolts embedded in the concrete foundation.

The three methods are common.

However, whether a machine that is placed directly on the floor like the one that does not vibrate, does not get out of order even if it is used for a long time, or is an inexpensive one that can withstand short-term use. It is either. Therefore, a machine having such a simple installation method is out of the scope of the present invention.

Many machines need to be installed on a horizontal surface, and the first condition for installation is to secure them securely with pre-embedded anchor bolts. Furthermore, since it is technically extremely difficult to keep the floor or the surface of the concrete foundation horizontal with high accuracy as described above, not only in the past but also in the present, the following operations are required to keep the machine horizontal. is necessary.

a. Place a steel base plate on hard-mixed cement mortar or resin mortar that does not cause flow, adjust the height of the base plate surface with a mallet, etc., and then install the machine. Drive the machine horizontally with a single-sided steel spacer called a taper liner.

b. Use a push bolt installed on the machine body to level out, or use a steel base plate with a push bolt to level out and then mount the machine on it.

There are two ways.

After that, mortar with hard kneading (hereinafter called pad),
It is common to fill the gap created by a taper liner or push bolt with a filling called grout.

The conventional installation method of a concrete machine is performed by the following method and sequence.

(1) Basic concrete hardening and curing (2) Removal of brittle parts on the surface of basic concrete (3) Pad making (4) Pad hardening and curing (5) Mechanical equipment installation (6) Mechanical equipment horizontal temporary adjustment (a. Tapered liner, b.
(Or push bolt method) (7) Fill the grout into the hole of the anchor bolt (hereinafter the grout filled in the hole of the anchor bolt is referred to as the anchor grout) (8) Anchor grout hardening curing (9) Machine horizontal adjustment (10) Form seal (11) Grouting filling (12) Grouting hardening curing (13) Anchor bolt tightening The machine is installed through the extremely complicated process and sequence described above, but the surface on which the machine is installed is horizontal in advance. If so, it is possible to drastically shorten the process since the pad preparation and its curing and curing, the horizontal temporary adjustment, and the main adjustment are completed in one process. At the same time, as a recent trend,
It is also a big problem that the number of workers skilled in leveling the machine is decreasing year by year, but such a problem can be solved as long as the method of the present invention is adopted.

And in the conventional method, a pad for receiving these, whether it is a taper liner or a push bolt, is required in advance. The pad is complicated because it must be molded and hardened with hard-mixed cement or resin mortar, and after adjusting the level, the grout must be poured and the hardening and curing must be awaited.

C) Problems to be Solved by the Invention As described above, it is of course possible to keep the surface of the floor or the surface of the concrete foundation smooth due to hardening shrinkage which is an inherent defect of concrete. ， Making the concrete foundation with high dimensional accuracy
It is still difficult to use today's technology.

On the other hand, the machining accuracy of the machine is so high that it cannot be compared with that of concrete. Therefore, when the machine is installed directly on the concrete foundation, there is always a gap. For this reason, at the time of installation, after the machine was lifted up and leveled, a filling material called grout was poured into the gap. As described above, in the conventional method, it is necessary to prepare the pad, cure and cure the pad, and then perform horizontal adjustment after installing the machine, wait for the grout to be poured and the cure and cure, and it takes a lot of time from loading the machine to operation. Needed.

If this is a precise, horizontal, and tough molded product on the basic concrete before the machine is carried in, the great advantage is that it can be installed at the same time as the machine is carried in. For example, when installing, replacing, or repairing a machine such as a generator, engine, or compressor at a large petroleum complex or a power plant, which is the same as the heart of human beings, it is a vague amount of money because the operation of the machine is delayed for only one day. Will be lost. In the conventional method, not only it took time to form and harden the pad, but there was a big drawback that horizontal adjustment or grout placement could not be performed after the machine was loaded.

D) Means for solving the problem The present invention has been invented to solve the above-mentioned drawbacks of the conventional method, and the resin used in the present invention is
A thermosetting resin such as epoxy, acrylic, polyester, urethane, or furan that is liquid at room temperature and becomes a tough material by using a curing agent. It is a resin grout with aggregate (hereinafter referred to as one-stage grout). In the case, or when filling in a place with a large gap, an aggregate mainly composed of silica sand is mixed. These resins have extremely high mechanical strength as compared with cement-based materials, and rapid curing is an essential reason for use in the present invention. The aggregate not only suppresses the curing shrinkage of the resin, but also increases the elastic modulus of the material and at the same time suppresses creep. However, since the fluidity is poor in the compounding system with a lot of aggregates, when pouring into a narrow gap,
Not suitable. Furthermore, if the resin itself does not have a low viscosity at room temperature, it is not suitable for flowing into a narrow gap, for obtaining a horizontal surface for flowing, or for mixing aggregates, because the fluidity is extremely poor. It can be used only for.

The thickness of the one-step grout is preferably 20 to 100 mm, 20
If it is less than mm, it is weak when a bending load is applied from the machine,
On the other hand, if it is 100 mm or more, the material price increases and it is uneconomical. The viscosity of the resin not containing the aggregate is 10000 centipoise or less, preferably 50 by a Brookfield viscometer.
A value of 00 centipoise or less is suitable. 1-step grout
It is desirable that the mixing ratio of the aggregate is 2 or more, preferably 5 or more when the resin is 1 by weight, in order to minimize creep and curing shrinkage and to reduce the compounding unit price of the material. It is desirable that the weight is 8 times or less, preferably 7 times or less of the resin.

Using such a compounding system, a first-stage grout is first cast with a predetermined thickness, and in order to shorten the time, a low-viscosity resin is poured with a thickness of 10 mm or less without waiting for complete curing to obtain a horizontal surface. . The anchor bolt is embedded in advance at the place where the one-step grout is placed, or after the resin is cured in the grout, the anchor bolt is pierced and the anchor bolt is embedded to fill and cure the grout having the same composition as the one-step grout. Using this method, the loaded machine can be directly operated by tightening the anchor bolts. In this case, in the case of a machine that vibrates violently, or a machine that requires strict dimensional accuracy for a long period of time, an adhesive with a thickness of several tens of microns is used to bond the machine and the resin, and It is possible to integrate the vibrations to transmit the vibration generated in the machine to the foundation and to damp the vibration in the foundation concrete. On the other hand, in the case of a production line in which equipment is changed frequently unless an adhesive is used, there is no need to perform a complicated installation method every time the equipment is replaced, unlike the conventional method. Cut the anchor bolt of
There is also the benefit that the installation cost will be extremely huge because the machine will be installed simply by burying new anchor bolts.

(E) Action There are two types of grouts called inorganic grouts and organic grouts. Inorganic grout refers to cement grout and organic grout mainly consists of epoxy resin. At present, cement grout is overwhelmingly large in terms of price, but it lacks oil resistance, causes neutralization and rusts the machine, has poor adhesion to steel, has low mechanical strength, and has a curing time. Due to its long length, the amount of organic grout used has increased significantly.

The present invention cannot exist without a resin grout that does not have these drawbacks. Resin grout has no drawbacks such as oil resistance and neutralization, and it has not only 10 times or more the adhesiveness to steel material as cement grout, but also about twice the compressive strength and several times the bending strength. The curing time is about half at the same time. The drawback of such a resin was that its creep was larger than that of cement, but it could be avoided by mixing a large amount of aggregate mainly composed of silica sand. If such a resin grout can be used to obtain a precise and tough casting product in both height and horizontal position or a horizontal steel base plate using the casting product on a concrete foundation by a simple method, It is possible to make a big change in the installation that can be called a stationary revolution. Of the various machines, those that perform reciprocating motion and rotary motion often break due to eccentric force applied to the shaft at the same time when the horizontal of the machine is deviated by several hundreds of microns or tens of microns. Such a reciprocating machine with a severe impact requires a strong foundation. Alternatively, for example, in the case of a diesel engine, not only reciprocating motion but also lubricating oil often deteriorates the basic concrete and the cement grout and causes horizontal deviation, so a grout with high precision and oil resistance is required. .

In the past, due to such strict performance requirements for installation,
The complicated and long-term installation method as described above has been adopted. Also, when the production line is changed frequently, not only is it necessary to adjust the level of the machine every time the equipment is replaced, but also the grout is replaced each time.

The construction method of the present invention makes it possible to solve such problems all at once.

F) Examples Next, the method of the present invention will be described with reference to specific examples.

The main component of the resin is bisphenol A diglycidyl ether,
Bisphenol F diglycidyl ether, alicyclic diglycidyl ether, polyglycol-based diglycidyl ether, etc., such as butyl glycidyl ether, glycol-based di- or monoglycidyl ether, neopentyl diglycidyl ether, etc. It is obtained by adding 5 to 40% of a reactive diluent or a combination of these reactive diluents and a non-reactive diluent such as xylol, furfuryl alcohol, benzyl alcohol or phthalic acid ester. Add 5
% Or less, the viscosity is high and the self-leveling property is low.
If it is 0% or more, the mechanical strength of the cured product is low, so 5-40%
Is preferred. The curing agent can be obtained by adding 0.5 to 10% of tertiary amine to an aliphatic amine, an alicyclic amine, an aromatic amine, or a derivative thereof and a mixture thereof. Tertiary amines are catalysts that improve the physical properties of the cured product. If the amount is 0.5% or less, the effect is low, and if it is 10% or more, the physical properties are deteriorated.

Further, as the bone agent, a mixture of silica sand of various sizes is used, and a silane coupling agent, an organic titanate, a pigment or the like is added to this.

The performance of the resin containing no aggregate and the resin grout containing aggregate (one-stage grout) used in the examples is shown in Table 1 below.

In the example, a horizontal surface was obtained on the foundation concrete by the following process and prepared for the installation of the machine.

Excavate the basic concrete in an area that fits the pedestal of the machine and to a depth of 50 mm, and remove the concrete excavated by the dust collector.

Position the anchor bolt and drill a hole.

Pour the resin grout with aggregate into a concrete foundation that is dug to a thickness of 47 mm, and press the surface down with a trowel etc. so that it is horizontal.

After a few hours, when the resin grout surface gradually hardens and completely loses fluidity, the resin without aggregate is poured into the first-step grout surface at a thickness of about 3 mm.

Approximately 2 days after the resin has been poured, a casting of the above physical properties is obtained in the base concrete.

Therefore, the machine can be operated simply by tightening the anchor bolts immediately after the machine is loaded.

Next, a conventional installation process will be described as a comparative example.

(Comparative example) Remove the leitance on the concrete surface with a chipper and remove the concrete dug with a dust collector.

Position the anchor bolt and drill.

Install anchor bolts.

A pad is made with a ratio of resin to aggregate of 1 to 9 by weight, a steel base plate is placed, and the height is adjusted with a hammer.

Pad curing curing machine installation Temporary leveling is performed using push bolts.

Fill the anchor grout.

Anchor grout hardening curing Horizontal book adjustment Build a wooden formwork around the machine.

Seal the corners of the formwork with a sealant.

Hardening and curing the sealant Fill the resin grout with aggregate into the mold.

Hardening and curing the grout in the form Remove the form and tighten the anchor bolts.

Hereinafter, the required time and process of the example and the comparative example will be compared.

G) Effects of the Invention The present invention has the following unique effects when the machine is installed by the above method and as seen in Examples and Comparative Examples.

(a) It is possible to obtain a cast product that has a toughness, oil resistance, and high-precision horizontal surface on the basic concrete, and then you can directly operate the machine simply by tightening the anchor bolts after loading the machine. Is.

(b) Compared with the conventional installation method, the process is shortened to about 3
It takes only a fraction of the time required.

(c) If an adhesive is used on the surface of the finishing resin, the machine and the basic concrete can be integrated even in the case of a machine that undergoes severe reciprocating and rotating motions, and all vibrations are transmitted to concrete with excellent damping effect. be able to.

On the other hand, if the adhesive is not used, the installation of the machine is completed simply by cutting the original anchor bolt and then burying the new anchor bolt in the machine equipment that is frequently replaced.

As described above, the present invention has many advantages that cannot be achieved by the conventional installation method, and provides a great benefit.

Claims (3)

[Claims] 1. When the machine is installed on a concrete foundation, a resin grout containing aggregate is first placed, and then a low-viscosity resin is poured into the machine to make the machine horizontal, and then the machine is installed. Machine installation method. 2. The resin grout with aggregate has a thickness of 20.
The method for installing a machine according to claim 1, wherein the installation method is about 100 mm. 3. The method of installing a machine according to claim 1, wherein the low-viscosity resin that is poured to make the surface horizontal has a thickness of 10 mm or less.