Forming equipment for ceramic guide rail production and forming method thereof

Abstract

The invention discloses forming equipment for ceramic guide rail production and a forming method thereof, and relates to the technical field of ceramic guide rail forming, the forming equipment comprises a conveyor, a forming processing box and a raw material box, and the top of the conveyor is provided with the forming processing box. The ultrasonic disperser arranged in the raw material box is combined with the constant-temperature heating sleeve and the viscosity sensor of the conveying pipe, uniform flowing and accurate metering injection of slurry are guaranteed, in the forming stage, the vacuum pump actively pumps out bubbles in a cavity through the micropore array, pores are further eliminated in cooperation with the high-frequency micro-vibration device, the compactness and surface smoothness of the guide rail are greatly improved, and the production efficiency is improved. The cooling runner realizes gradient cooling and curing through closed-loop control of a temperature sensor and a temperature regulator, ceramic cracking deformation is effectively inhibited, the rotary mold assembly supports multi-angle adjustment, nondestructive demolding of a complex structure is facilitated, the production period is shortened, the process stability, energy consumption control and equipment adaptation flexibility are further enhanced, and the production efficiency is improved. And the targets of high precision, low defect and batch production are achieved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of ceramic guide rail forming, in particular to a forming equipment for ceramic guide rail production and a forming method thereof. BACKGROUND

[0002] As a core component of high-precision mechanical transmission systems, ceramic guide rails need to have ultra-high hardness, sub-micron surface roughness and complex special-shaped structures. Currently, the mainstream is to use alumina ceramic slurry injection molding process. However, in the forming process, the alumina ceramic slurry injection molding process is prone to incomplete bubble cleaning.

[0003] The existing ceramic guide rail forming equipment has the following defects:

[0004] 1. Patent document US5671878A discloses a ceramic-made rolling guide rail, but the device in the above document has the technical problems of rough slurry flow control, incomplete bubble removal, low product density, and many surface defects;

[0005] 2. Patent document US4688527A discloses a ceramic valve guide rail and seat, but the device in the above document has the technical problems of rough demolding process, leading to surface scratching and edge cracking of the workpiece;

[0006] 3. Patent document US4533968A discloses a ceramic guide rail for strip material and a manufacturing method thereof, but the device in the above document has the technical problems of low bubble removal and demolding efficiency;

[0007] 4. Patent document CN113829466B discloses a ceramic guide rail forming process, but the device in the above document has the technical problems of slurry viscosity regulation lag, leading to flow defects and particle sedimentation. SUMMARY

[0008] The present application aims to provide a forming equipment for ceramic guide rail production and a forming method thereof to solve the technical problems raised in the background.

[0009] To achieve the above-mentioned purpose, the present application provides the following technical scheme: a forming equipment for ceramic guide rail production, comprising a conveyor, a forming processing box and a raw material box, the top of the conveyor is provided with the forming processing box, and the top of the forming processing box is provided with the raw material box;

[0010] The inside of the forming processing box is provided with a rotating mold assembly, which is used to adjust the angle of the mold. The mold comprises a base and symmetrically arranged left and right molds, and the left and right molds are combined to form a mold cavity suitable for ceramic guide rails. The output end of the base seals the bottom of the mold cavity.

[0011] The outer wall of the left mold and the right mold is provided with a high-frequency micro-vibrator and a vacuum pump, one end of the vacuum pump is connected with a filter, the outer wall of the filter is respectively mounted on the outer wall of the left mold and the right mold, the other end of the filter is connected with a micropore array through a pipeline, and the micropore array is respectively embedded on the inner wall of the left mold and the right mold;

[0012] The inside of the left mold and the right mold is embedded with a cooling flow channel, the inlet of the cooling flow channel is connected with a cooling liquid supply tank through an extension hose, and the cooling liquid supply tank is arranged on the outer wall of the molding processing box, the outlet of the cooling flow channel is connected to the cooling liquid supply tank through a temperature regulator and an extension hose to form a closed loop circuit;

[0013] The inside of the left mold, the right mold and the base is respectively embedded with a temperature sensor, and the temperature sensor is electrically connected with the temperature regulator;

[0014] The inner wall of the raw material box is embedded with an ultrasonic disperser, the bottom of the raw material box is provided with a conveying pipe, the outer wall of the conveying pipe is covered with a constant temperature heating jacket, the inlet of the conveying pipe is provided with a viscosity sensor, and the outlet of the conveying pipe is provided with an electromagnetic valve.

[0015] Preferably, the rotating mold assembly comprises a transmission bin arranged on both sides of the molding processing box, one side of the transmission bin is provided with a servo motor, the output end of the servo motor is installed with a rotating disc penetrating through one side of the transmission bin, the middle of one side of the rotating disc is installed with a rotating shaft, one end of the rotating shaft penetrates through the outer wall of the molding processing box and is installed with a limiting block, a limiting groove is opened at the top of the limiting block, and the inner wall of the limiting groove is arranged at the bottom of the outer wall of the base.

[0016] Preferably, the inner wall of the molding processing box is provided with an arc-shaped sliding groove on both sides, the inner wall of the arc-shaped sliding groove is movably connected with a sliding block, one end of the sliding block is fixedly connected to the outer periphery of one side of the rotating disc, the other end of the sliding block is fixedly connected with an electric telescopic cylinder, the output end of the electric telescopic cylinder is installed with a connecting block, and the connecting block is respectively installed on the outer wall of the left mold and the right mold.

[0017] Preferably, the middle of the top of the base is embedded with a hydraulic ejector rod, and the output end of the hydraulic ejector rod is arranged at the bottom of the mold cavity, the surface of the output end of the hydraulic ejector rod is coated with a high-temperature-resistant ceramic coating.

[0018] Preferably, the vibration frequency of the high-frequency micro-vibrator is 80-150Hz, which is used to realize resonance defoaming in the early stage of alumina ceramic slurry solidification and vibration demolding in the later stage of solidification.

[0019] Preferably, the temperature control range of the constant temperature heating jacket is 40-80℃, and the temperature value of the constant temperature heating jacket is dynamically related to the slurry viscosity value detected by the viscosity sensor, when the slurry viscosity is greater than 1800cP, the constant temperature heating jacket is started.

[0020] Preferably, the micro-hole array is composed of conical micro-holes with a hole diameter of 0.1-0.5 mm and a cone angle of 15-30°, for inhibiting slurry backflow.

[0021] Preferably, the ultrasonic disperser has a working frequency of 25-40 kHz and is electrically connected to the viscosity sensor, and when the viscosity of the slurry is detected to be >1800 cP, the ultrasonic disperser is started and continues until the viscosity is reduced to <1200 cP.

[0022] Preferably, the cooling medium circulating in the cooling channel is an aqueous ethylene glycol solution, and when the temperature sensor detects that the mold temperature is ≥80℃, the temperature regulator automatically starts the cooling program to reduce the mold temperature to 60±2℃ at a rate of 2-5℃ / min, and the high-frequency vibrator is synchronously turned off when the cooling program is started.

[0023] Preferably, the forming step of the forming equipment for producing ceramic guide rails is as follows:

[0024] S1. Start the equipment to make the left mold, the right mold and the base close in the rotating mold assembly to form a closed mold cavity, monitor the mold temperature through the temperature sensor embedded in the mold, and if the mold temperature is lower than the process requirement, preheat the mold to the set initial temperature by reversing the cooling channel to pass in the heating medium;

[0025] S2. The ceramic slurry in the raw material box is continuously dispersed by the built-in ultrasonic disperser to prevent particle sedimentation and agglomeration, maintain the uniformity of the slurry, and the slurry is transported through the feed pipe, the constant temperature heating jacket maintains the temperature stability of the slurry during transportation, and the viscosity sensor monitors the viscosity of the slurry in real time to ensure that it is within the appropriate range for injection molding;

[0026] S3. Open the electromagnetic valve of the feed pipe discharge port, and the ceramic slurry is slowly injected into the bottom of the mold cavity under the action of gravity, and the high-frequency micro-vibrator and vacuum pump on the left mold and right mold are started at the same time, and the vacuum pump generates negative pressure on the inner wall of the mold cavity through the filter and pipeline, and the micro-hole array;

[0027] S4. After the injection molding is completed, the electromagnetic valve is closed, and the vacuum negative pressure and high-frequency vibration are maintained for a period of time in the horizontal position to ensure that the slurry is further degassed and densified;

[0028] S5, turn off the high frequency vibrator and vacuum pump, start the cooling program, the temperature sensor real-time monitoring mold temperature, detected mold temperature >= 80 DEG C, temperature regulator automatically starts, the ethylene glycol aqueous solution in the cooling liquid supply tank is pumped into the cooling flow channel inside the mold through the telescopic hose, the temperature regulator precisely controls the flow and temperature of the cooling liquid, the mold temperature is uniformly decreased at a rate of 2~5 DEG C / min, the cooling target temperature is reduced to 60±2 DEG C, and after reaching this temperature and stabilizing, the cooling program stops or enters the holding state.

[0029] Compared with the prior art, the beneficial effects of the present application are:

[0030] 1. The present application guarantees uniform flow and accurate metering injection of slurry by built-in ultrasonic disperser in raw material box combined with constant temperature heating jacket of feeding pipe and viscosity sensor, actively removes bubbles from the cavity by vacuum pump through micropore array in the forming stage, further eliminates pores with high frequency vibrator, greatly improves the density of guide rail and surface finish, realizes gradient cooling solidification through closed loop control of cooling flow channel by temperature sensor and temperature regulator, effectively inhibits ceramic cracking and deformation, the rotary mold assembly supports multi-angle adjustment, facilitates non-destructive demolding of complex structure, shortens the production cycle, and further strengthens the process stability, energy consumption control and equipment adaptation flexibility, achieves the goal of high precision, low defect and batch production;

[0031] 2. The present application realizes multi-angle accurate positioning of the mold base by servo motor driving rotating disc and rotary shaft linkage, cooperates with limit block and limit groove, meets the demolding needs of complex ceramic guide rail, the arc-shaped sliding groove on the inner wall of the forming processing box guides the sliding block to move along the predetermined track, the opening and closing actions of the left mold and the right mold are synchronously controlled by the electric telescopic cylinder, avoiding the surface scratching caused by traditional linear mold opening, the finished product is vertically ejected from the bottom of the mold cavity by the hydraulic ejector rod in the demolding stage, the high-temperature-resistant ceramic coating on its surface effectively prevents metal adhesion, ensures non-destructive separation of brittle ceramic guide rail, and further significantly reduces the risk of edge collapse and cracking, improves the yield rate and production efficiency of special-shaped structure guide rail;

[0032] 3. The present application uses 80~150Hz vibration frequency to regulate and control in stages through high frequency vibrator, which can trigger resonance effect to efficiently break bubbles in the initial stage of alumina ceramic slurry solidification, improve the green body density, and reduce the adhesion between the green body and the mold interface through the same frequency vibration in the later stage of solidification, realizing zero-damage vibration assisted demolding, the micropore array is designed as 0.1~0.5mm conical micropore with a taper angle of 15~30°, the small pore structure ensures high capture efficiency of micron-sized bubbles by vacuum suction, and the conical pore channel actively inhibits slurry backflow by using fluid reverse resistance, solving the problem of micropore blockage, and further achieving the goals of prolonging the continuous operation life of micropore assembly and improving product yield and production continuity;

[0033] 4. The present application detects the slurry viscosity >1800 cP by a viscosity sensor, immediately raises the temperature in the range of 40-80℃ by a constant temperature heating jacket to reduce the viscous resistance, and simultaneously starts the ultrasonic disperser at a high frequency of 25-40 kHz to break the particle agglomerates, and the two systems work together until the viscosity is reduced to below 1200 cP to automatically stop the machine, thereby achieving the real-time maintenance of the injection flowability, eliminating the filling defects, inhibiting the particle sedimentation, and reducing the energy consumption and prolonging the service life of the equipment according to the demand start-stop mechanism. BRIEF DESCRIPTION OF DRAWINGS

[0034] Figure 1 It is a three-dimensional schematic diagram of the overall structure of the present application;

[0035] Figure 2 It is a three-dimensional schematic diagram of the arc-shaped sliding groove structure of the present application;

[0036] Figure 3 It is a three-dimensional schematic diagram of the rotating mold assembly structure of the present application;

[0037] Figure 4 It is a three-dimensional schematic diagram of the base structure of the present application;

[0038] Figure 5 It is a front cross-sectional schematic diagram of the overall structure of the present application;

[0039] Figure 6 It is a schematic diagram of the structure at A in the present application; Figure 5

[0040] It is a schematic diagram of the structure at B in the present application; Figure 7 Figure 5

[0041] Figure 8 It is a cross-sectional schematic diagram of the cooling flow channel structure of the present application;

[0042] Figure 9 It is a schematic diagram of the working process of the present application.

[0043] In the figure: 1, conveyor; 2, forming processing box; 3, raw material box; 4, base; 5, left mold; 6, right mold; 7, mold cavity; 8, high-frequency micro-vibrator; 9, vacuum pump; 10, filter; 11, micropore array; 12, ultrasonic disperser; 13, material conveying pipe; 14, constant temperature heating jacket; 15, viscosity sensor; 16, electromagnetic valve; 17, transmission bin; 18, servo motor; 19, rotating disc; 20, rotating shaft; 21, limit block; 22, limit groove; 23, arc-shaped sliding groove; 24, sliding block; 25, electric telescopic rod; 26, connecting block; 27, hydraulic ejecting cylinder; 28, high-temperature-resistant ceramic coating; 29, cooling flow channel; 30, cooling liquid supply tank; 31, temperature regulator; 33, temperature sensor. DETAILED DESCRIPTION​​

[0044] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments of the present application. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative work fall within the scope of the present application.

[0045] In the description of the present application, it should be noted that the terms "upper", "lower", "inner", "outer", "front end", "rear end", "two ends", "one end", "the other end" and the like indicate the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application. In addition, the terms "first" and "second" are only for descriptive purposes and cannot be understood as indicating or implying relative importance.

[0046] In the description of the present application, it should be noted that unless otherwise explicitly specified and limited, the terms "mounting", "provided with", "connection" and the like should be understood broadly, for example, "connection" can be fixed connection, can also be detachable connection, or integral connection; can be mechanical connection, can also be electrical connection; can be directly connected, can also be indirectly connected through an intermediate medium, can be the communication inside two elements. For those of ordinary skill in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0047] Embodiment 1: Please refer to Figure 1 , Figure 3 , Figure 4 , Figure 5 and Figure 7The application provides a ceramic guide rail production forming equipment, which comprises a conveyor 1, a forming processing box 2 and a raw material box 3. The top of the conveyor 1 is provided with the forming processing box 2, the top of the forming processing box 2 is provided with the raw material box 3, the inside of the forming processing box 2 is provided with a rotary die assembly, the rotary die assembly is used for adjusting the angle of a die, the die comprises a base 4 and symmetrically arranged left and right dies 5 and 6, the left and right dies 5 and 6 are combined to form a die cavity 7 suitable for ceramic guide rails, the output end of the base 4 seals the bottom of the die cavity 7, the outer walls of the left and right dies 5 and 6 are provided with high-frequency micro-vibrators 8 and vacuum pumps 9, one end of each vacuum pump 9 is connected with a filter 10, the outer wall of the filter 10 is mounted on the outer wall of the left or right die 5 or 6, the other end of the filter 10 is connected with a micropore array 11 through a pipeline, and the micropore array 11 is embedded in the inner wall of the left or right die 5 or 6, a cooling flow channel 29 is embedded in the inside of each of the left and right dies 5 and 6, the inlet of the cooling flow channel 29 is connected with a cooling liquid supply tank 30 through an extension hose, the cooling liquid supply tank 30 is arranged on the outer wall of the forming processing box 2, the outlet of the cooling flow channel 29 is connected to the cooling liquid supply tank 30 through a temperature regulator 31 and an extension hose to form a closed loop, a temperature sensor 33 is embedded in the inside of each of the left and right dies 5 and 6 and the base 4, the temperature sensor 33 is electrically connected with the temperature regulator 31, an ultrasonic disperser 12 is embedded in the inner wall of the raw material box 3, a material conveying pipe 13 is arranged at the bottom of the raw material box 3, a constant-temperature heating jacket 14 is arranged on the outer wall of the material conveying pipe 13, a viscosity sensor 15 is arranged at the inlet of the material conveying pipe 13, and an electromagnetic valve 16 is arranged at the outlet of the material conveying pipe 13.

[0048] Further, the ultrasonic disperser 12 in the raw material box 3, the constant-temperature heating jacket 14 and the viscosity sensor 15 of the material conveying pipe 13 guarantee uniform flow and accurate metering injection of the slurry, the vacuum pump 9 actively extracts the cavity bubbles through the micropore array 11 in the forming stage, and the high-frequency micro-vibrator 8 further eliminates the pores, greatly improves the density and surface finish of the guide rail, the cooling flow channel 29 realizes gradient cooling and solidification through the closed loop control of the temperature sensor 33 and the temperature regulator 31, effectively inhibits the cracking and deformation of the ceramic, the rotary die assembly supports multi-angle adjustment, facilitates non-destructive demolding of complex structures, shortens the production cycle, and further strengthens the process stability, energy consumption control and equipment adaptation flexibility, and achieves the goal of high-precision, low-defect and batch production.

[0049] Embodiment 2: see Figure 1 , Figure 2 , Figure 3 and Figure 5In one embodiment provided by the application, the rotary die assembly comprises a transmission bin 17 arranged on both sides of the forming processing box 2, a servo motor 18 arranged on one side of the transmission bin 17, a rotating disc 19 installed at the output end of the servo motor 18 and penetrating through one side of the transmission bin 17, a rotating shaft 20 installed at the middle of one side of the rotating disc 19, a limiting block 21 installed at one end of the rotating shaft 20 and penetrating through the outer wall of the forming processing box 2, a limiting groove 22 formed in the top of the limiting block 21 and arranged on the bottom of the outer wall of the base 4, an arc-shaped sliding groove 23 formed in the inner wall of the forming processing box 2 and arranged on both sides of the base 4, a sliding block 24 movably connected to the inner wall of the arc-shaped sliding groove 23 and fixedly connected to the outer periphery of one side of the rotating disc 19, an electric telescopic cylinder 25 fixedly connected to the other end of the sliding block 24, a connecting block 26 installed at the output end of the electric telescopic cylinder 25 and arranged on the outer wall of the left die 5 and the right die 6, and a hydraulic ejection rod 27 embeddedly arranged at the middle of the top of the base 4 and arranged at the bottom of the die cavity 7, wherein the surface of the output end of the hydraulic ejection rod 27 is coated with a high-temperature-resistant ceramic coating 28.

[0050] Further, the servo motor 18 drives the rotating disc 19 and the rotating shaft 20 to link with each other, and the limiting block 21 and the limiting groove 22 are used to realize the multi-angle accurate positioning of the die base 4, so as to meet the demolding requirement of the complex ceramic guide rail, the arc-shaped sliding groove 23 of the inner wall of the forming processing box 2 guides the sliding block 24 to move along the predetermined track, the electric telescopic cylinder 25 is used to synchronously control the opening and closing actions of the left die 5 and the right die 6, so as to avoid the surface scratch of the workpiece caused by the traditional linear die opening, the hydraulic ejection rod 27 is used to vertically eject the finished product from the bottom of the die cavity 7 in the demolding stage, the high-temperature-resistant ceramic coating 28 on the surface of the finished product can effectively prevent the metal adhesion, so as to ensure the lossless separation of the brittle ceramic guide rail, and further significantly reduce the risk of edge collapse and cracking, and improve the yield rate and production efficiency of the special-shaped structure guide rail.

[0051] Embodiment 3: please refer to Figure 3 、 Figure 4 and Figure 5 In one embodiment provided by the application, the vibration frequency of the high-frequency micro-vibrator 8 is 80-150 Hz, which is used to realize the resonance defoaming in the initial stage of the alumina ceramic slurry solidification and realize the vibration demolding in the later stage of the solidification, the micro-pore array 11 is composed of tapered micro-pores with a pore diameter of 0.1-0.5 mm and a taper angle of 15-30°, which is used to inhibit the slurry backflow;

[0052] Further, by using 80-150 Hz vibration frequency to control in stages through the high-frequency micro-vibrator 8, the resonance effect can be triggered to break bubbles efficiently at the initial stage of alumina ceramic slurry solidification, so as to improve the green body density, and the adhesion between the green body and the mold can be reduced through the same frequency vibration at the later stage of solidification, so as to realize zero-damage vibration-assisted demolding. The micropore array 11 is designed as a 0.1-0.5 mm tapered micropore with a taper angle of 15-30°. The small pore diameter structure ensures high capture efficiency of micron-sized bubbles through vacuum suction, and the tapered pore channel actively inhibits slurry backflow by using fluid reverse resistance, so as to solve the problem of micropore blockage, and further to extend the continuous operation life of the micropore assembly and improve product yield and production continuity.

[0053] Embodiment 4: please refer to Figure 5 and Figure 6 An embodiment provided by the present application: the temperature control range of the constant-temperature heating jacket 14 is 40-80℃, and the temperature value of the constant-temperature heating jacket 14 is dynamically associated with the slurry viscosity value detected by the viscosity sensor 15. When the slurry viscosity is greater than 1800 cP, the constant-temperature heating jacket 14 is started, and the working frequency of the ultrasonic disperser 12 is 25-40 kHz, and is electrically linked with the viscosity sensor 15. When the slurry viscosity is detected to be greater than 1800 cP, the ultrasonic disperser 12 is started and continues until the viscosity is reduced to below 1200 cP;

[0054] Further, when the slurry viscosity detected by the viscosity sensor 15 is greater than 1800 cP, the constant-temperature heating jacket 14 immediately intelligently heats up in the range of 40-80℃ to reduce the viscous resistance, and the ultrasonic disperser 12 is simultaneously started to vibrate at a high frequency of 25-40 kHz to break the particle agglomerates, and the two systems are cooperated until the viscosity is reduced to below 1200 cP to automatically stop, so as to realize real-time maintenance of the injection flowability, elimination of filling defects, inhibition of particle sedimentation, and reduction of energy consumption and extension of equipment life through the on-demand start-stop mechanism.

[0055] Embodiment 5: please refer to Figure 5 and Figure 8 An embodiment provided by the present application: the cooling medium circulating in the cooling flow channel 29 is an ethylene glycol aqueous solution. When the temperature sensor 33 detects that the mold temperature is greater than or equal to 80℃, the temperature regulator 31 automatically starts the cooling program to reduce the mold temperature to 60±2℃ at a rate of 2-5℃ / min, and the high-frequency micro-vibrator 8 is synchronously turned off when the cooling program is started;

[0056] Further, when the mold temperature is detected by the temperature sensor 33 to be greater than or equal to 80°C, the temperature regulator 31 immediately starts a cooling program, drives the glycol water solution to flow through the cooling flow channel 29 at a precise gradient rate of 2-5°C / min, synchronously closes the high-frequency micro vibrator 8 to eliminate vibration interference, until the mold temperature is stabilized to 60±2°C, and further enables the gradient cooling to orderly rearrange the aluminum oxide molecules, reduce internal stress, eliminate cracking and deformation, and prolong the service life of the equipment.

[0057] Embodiment 6: please refer to Figure 9 An embodiment provided by the present application: the molding step of the molding equipment for ceramic guide rail production is as follows:

[0058] S1, start the servo motor 18, drive the limit block 21 through the rotating disc 19 and the rotating shaft 20 to drive the base 4 to be in a horizontal position, the electric telescopic cylinder 25 pushes the left mold 5 and the right mold 6 to move along the arc-shaped sliding groove 23 to close the mold, form a sealed mold cavity 7, the hydraulic ejector rod 27 is retracted, the high-temperature-resistant ceramic coating 28 at the top end is flush with the bottom of the cavity to complete the sealing, the temperature sensor 33 monitors the mold temperature, and if preheating is needed, the cooling flow channel 29 is connected to the hot medium;

[0059] S2, the viscosity sensor 15 monitors the viscosity of the alumina ceramic slurry in the raw material box 3 to the feeding pipe 13 in real time, when the viscosity is greater than 1800 cP, the constant temperature heating jacket 14 is triggered to start, the feeding pipe 13 is heated in the range of 40-80°C to reduce the viscosity of the slurry, and the ultrasonic disperser 12 is synchronously triggered to start, the slurry in the raw material box 3 is ultrasonically dispersed, the viscosity is continuously monitored, until the viscosity is reduced to below 1200 cP, the ultrasonic disperser 12 and the constant temperature heating jacket 14 stop heating;

[0060] S3, the servo motor 18 drives the rotating mold assembly, adjusts the mold cavity 7 to a preset angle through the rotating disc 19, the rotating shaft 20 and the sliding block 24 in the arc-shaped sliding groove 23, opens the electromagnetic valve 16, the ceramic slurry is injected into the mold cavity 7 under the action of gravity through the feeding pipe 13, synchronously starts the high-frequency micro vibrator 8: vibrates the mold at a frequency of 80-150 Hz, the vacuum pump 9: establishes a negative pressure in the mold cavity 7, the gas is pumped out through the micropore array 11 and the filter 10, and the bubbles in the slurry are efficiently discharged under the dual action of high-frequency vibration and vacuum;

[0061] S4, after filling, the electromagnetic valve 16 is closed, the rotating mold assembly is slowly reset to the horizontal position, the vacuum negative pressure and high-frequency vibration are maintained for a period of time to ensure that the slurry is dense and the residual gas is discharged;

[0062] S5, the temperature sensor 33 of the vacuum pump 9 is closed continuously to monitor the mold temperature, when the temperature of any mold part is ≥80℃, the high-frequency micro-vibrator 8 is immediately closed, the temperature regulator 31 automatically starts the cooling program, the ethylene glycol aqueous solution is pumped from the cooling liquid supply tank 30 into the mold cooling channel 29 to precisely control the flow and temperature of the cooling liquid, so that the mold temperature uniformly decreases at a rate of 2-5℃ / min, and after cooling to the target temperature 60±2℃ and stabilizing, the cooling liquid circulation is stopped or the heat preservation is entered;

[0063] S6, confirming that the mold temperature is stable at 60±2℃, the electric telescopic cylinder 25 drives the left mold 5 and the right mold 6 to separate, the high-frequency micro-vibrator 8 is started to vibrate demolding, which lasts for about 3 seconds, the auxiliary blank is separated from the cavity, the hydraulic ejector rod 27 rises by 2-3mm, and the ceramic guide rail green body is ejected;

[0064] S7, the mold cavity 7 and the surface of the micro-hole array 11 are cleaned, the mold is recombined and reset, and the hydraulic ejector rod 27 is reset.

[0065] The working principle is that the ultrasonic disperser 12 in the raw material box 3 is combined with the constant temperature heating sleeve 14 of the feeding pipe 13 and the viscosity sensor 15 to ensure uniform flow and accurate metering injection of the slurry. In the forming stage, the vacuum pump 9 actively removes the bubbles in the cavity through the micropore array 11, and the high-frequency microvibrator 8 further eliminates the pores, greatly improving the density and surface finish of the guide rail. The cooling channel 29 realizes gradient cooling and solidification through the closed-loop control of the temperature sensor 33 and the temperature regulator 31, effectively inhibiting the cracking and deformation of the ceramic. The rotary mold assembly supports multi-angle adjustment, facilitating damage-free demolding of complex structures and shortening the production cycle, thereby strengthening the process stability, energy consumption control, and equipment adaptation flexibility, achieving the goal of high-precision, low-defect, and batch production. The rotating disc 19 is driven by the servo motor 18 and linked with the rotating shaft 20, and the multi-angle precise positioning of the mold base 4 is realized by the limiting block 21 and the limiting groove 22, meeting the demolding requirements of complex ceramic guide rails. The arc-shaped sliding groove 23 on the inner wall of the forming processing box 2 guides the sliding block 24 to move along the predetermined track, and the opening and closing actions of the left mold 5 and the right mold 6 are controlled synchronously by the electric telescopic cylinder 25, avoiding the surface scratching caused by traditional linear mold opening. In the demolding stage, the hydraulic ejector rod 27 vertically ejects the finished product from the bottom of the mold cavity 7, and the high-temperature-resistant ceramic coating 28 on the surface effectively prevents metal adhesion, ensuring the damage-free separation of brittle ceramic guide rails, thereby significantly reducing the risk of edge collapse and cracking, improving the yield and production efficiency of special-shaped structure guide rails. The high-frequency microvibrator 8 uses 80-150Hz vibration frequency to control in stages, which can trigger resonance effect to efficiently break bubbles in the early stage of alumina ceramic slurry solidification, improve the density of the body, and reduce the adhesion between the body and the mold interface in the later stage of solidification, realizing zero-damage vibration-assisted demolding. The micropore array 11 is designed to be 0.1-0.5mm conical micropore, cone angle 15-30°, its small hole structure ensures high capture efficiency of micron-sized bubbles by vacuum suction, while the conical channel actively suppresses slurry backflow using fluid reverse resistance, solving the problem of micropore blockage, thereby extending the continuous operation life of the micropore assembly and improving product yield and production continuity. When the slurry viscosity detected by the viscosity sensor 15 is >1800 cP, the constant temperature heating jacket 14 immediately intelligently heats in the range of 40-80℃ to reduce the viscous resistance, while the ultrasonic disperser 12 is simultaneously started with high frequency vibration of 25-40kHz to break up the particle agglomerates, and the double system works together until the viscosity is reduced to below 1200 cP to automatically stop, thereby achieving real-time maintenance of the injection flowability, eliminating filling defects, suppressing particle sedimentation, and enabling on-demand start-stop mechanism to reduce energy consumption and extend equipment life. When the mold temperature detected by the temperature sensor 33 is ≥80℃, the temperature regulator 31 immediately starts the cooling program, driving the ethylene glycol water solution to flow through the cooling flow channel 29 at a precise gradient rate of 2-5℃ / min, synchronously closing the high-frequency micro-vibrator 8 to eliminate vibration interference, until the mold temperature stabilizes to 60±2℃, thereby enabling gradient cooling to allow aluminum oxide molecules to rearrange in order, reducing internal stress and preventing cracking and deformation, and extending equipment life.

[0066] It will be obvious to a person skilled in the art that the application is not limited to the details of the above-described exemplary embodiments, but that the application can be implemented in other concrete forms without departing from the spirit or essential characteristics of the application. Therefore, the embodiments should be considered in all respects as illustrative and not restrictive, the scope of the application being defined by the appended claims rather than by the above description, and it is therefore intended that all changes that come within the meaning and range of equivalency of the claims are embraced therein. Any reference signs in the claims should not be construed as limiting the claims to the figures in which the reference signs are used.

Claims

1. A molding device for producing ceramic guide rails, comprising a conveyor (1), a molding processing box (2) and a raw material box (3), characterized in that: A forming processing box (2) is provided on the top of the conveyor (1), and a raw material box (3) is provided on the top of the forming processing box (2); A rotating mold assembly is provided inside the molding processing box (2), and the rotating mold assembly is used to adjust the angle of the mold. The mold comprises a base (4) and a left mold (5) and a right mold (6) that are symmetrically arranged. The left mold (5) and the right mold (6) are combined to form a mold cavity (7) adapted to the ceramic guide rail. The output end of the base (4) seals the bottom of the mold cavity (7). The outer walls of the left mold (5) and the right mold (6) are both provided with a high-frequency microvibrator (8) and a vacuum pump (9), one end of each of the vacuum pumps (9) is connected to a filter (10), and the outer walls of the filter (10) are respectively installed on the outer walls of the left mold (5) and the right mold (6), and the other end of the filter (10) is connected to a microporous array (11) through a pipeline, and the microporous array (11) is respectively embedded in the inner walls of the left mold (5) and the right mold (6); The left mold (5) and the right mold (6) are both embedded with cooling channels (29), the inlet of the cooling channel (29) is connected to the coolant supply tank (30) via a telescopic hose, and the coolant supply tank (30) is arranged on the outer wall of the molding processing box (2), and the outlet of the cooling channel (29) is connected to the coolant supply tank (30) via a temperature regulator (31) and a telescopic hose to form a closed loop; Temperature sensors (33) are embedded in the left mold (5), the right mold (6) and the base (4), respectively. The temperature sensors (33) are electrically connected to the temperature regulator (31). An ultrasonic disperser (12) is embedded in the inner wall of the raw material box (3), a feed pipe (13) is provided at the bottom of the raw material box (3), an outer wall of the feed pipe (13) is covered with a constant temperature heating jacket (14), a viscosity sensor (15) is provided at the feed inlet of the feed pipe (13), and a solenoid valve (16) is provided at the feed outlet of the feed pipe (13).

2. The molding equipment for producing ceramic guide rails according to claim 1, characterized in that: The rotary mold assembly includes a transmission bin (17) arranged on both sides of the molding processing box (2), a servo motor (18) is arranged on one side of the transmission bin (17), an output end of the servo motor (18) passes through one side of the transmission bin (17) and is installed with a rotating disk (19), a rotating shaft (20) is installed in the middle of one side of the rotating disk (19), and one end of the rotating shaft (20) passes through the outer wall of the molding processing box (2) and is installed with a limiting block (21), a limiting groove (22) is provided on the top of the limiting block (21), and the inner wall of the limiting groove (22) is arranged at the bottom of the outer wall of the base (4).

3. The molding equipment for producing ceramic guide rails according to claim 1, characterized in that: Both sides of the inner wall of the molding processing box (2) are provided with arc-shaped slide grooves (23), the inner wall of the arc-shaped slide groove (23) is movably connected to a slider (24), and one end of the slider (24) is fixedly connected to the periphery of one side of the rotating disk (19), and the other end of the slider (24) is fixedly connected to an electric telescopic cylinder (25), and the output end of the electric telescopic cylinder (25) is installed with a connecting block (26), and the connecting blocks (26) are respectively installed on the outer walls of the left mold (5) and the right mold (6).

4. The molding equipment for producing ceramic guide rails according to claim 1, characterized in that: A hydraulic ejector rod (27) is embedded in the middle of the top of the base (4), and the output end of the hydraulic ejector rod (27) is arranged at the bottom of the mold cavity (7), and the surface of the output end of the hydraulic ejector rod (27) is coated with a high-temperature resistant ceramic coating (28).

5. The molding equipment for producing ceramic guide rails according to claim 1, characterized in that: The high-frequency microvibrator (8) has a vibration frequency of 80 to 150 Hz and is used to achieve resonance defoaming in the early stage of solidification of the alumina ceramic slurry and vibration demoulding in the later stage of solidification.

6. The molding equipment for producing ceramic guide rails according to claim 1, characterized in that: The temperature control range of the constant temperature heating jacket (14) is 40-80°C, and the temperature value of the constant temperature heating jacket (14) is dynamically associated with the slurry viscosity value detected by the viscosity sensor (15). When the slurry viscosity is greater than 1800 cP, the constant temperature heating jacket (14) is started.

7. The molding equipment for producing ceramic guide rails according to claim 1, characterized in that: The micropore array (11) is composed of conical micropores with a pore diameter of 0.1 to 0.5 mm and a cone angle of 15 to 30 degrees.

8. The molding equipment for producing ceramic guide rails according to claim 1, characterized in that: The ultrasonic disperser (12) has an operating frequency of 25 to 40 kHz and is electrically linked to the viscosity sensor (15). When the slurry viscosity is detected to be greater than 1800 cP, the ultrasonic disperser (12) is started and continues until the viscosity drops below 1200 cP.

9. The molding equipment for producing ceramic guide rails according to claim 1, characterized in that: The cooling medium circulating in the cooling channel (29) is an ethylene glycol aqueous solution. When the temperature sensor (33) detects that the mold temperature is ≥80°C, the temperature regulator (31) automatically starts the cooling program to reduce the mold temperature to 60±2°C at a rate of 2-5°C / min. The high-frequency micro-vibrator (8) is synchronously turned off when the cooling program is started.

10. The molding method of a molding device for producing ceramic guide rails according to claim 9, characterized in that: The molding steps of the molding equipment for the production of ceramic guide rails are as follows: S1. Start the equipment and close the left mold (5), the right mold (6) and the base (4) on the rotating mold assembly to form a closed mold cavity (7). The mold temperature is monitored by a temperature sensor (33) embedded in the mold. If the mold temperature is lower than the process requirement, a heat medium can be reversely introduced through the cooling channel (29) to preheat the mold to the set initial temperature. The ceramic slurry in the S2 raw material box (3) is continuously dispersed by the built-in ultrasonic disperser (12) to prevent the particles from settling and agglomerating and maintain the uniformity of the slurry. The slurry is transported through the feed pipe (13). The constant temperature heating jacket (14) maintains the temperature of the slurry stable during the transportation process. The viscosity sensor (15) monitors the slurry viscosity in real time to ensure that it is within the range suitable for injection molding. S3, open the electromagnetic valve (16) of the discharge port of the feeding pipe (13), and the ceramic slurry is slowly injected into the bottom of the mold cavity (7) under the action of gravity. At the same time, the high-frequency micro-vibrator (8) and the vacuum pump (9) on the left mold (5) and the right mold (6) are started. The vacuum pump (9) generates negative pressure on the inner wall of the mold cavity (7) through the filter (10) and the pipeline through the microporous array (11); S4. After the injection molding is completed, the solenoid valve (16) is closed, and the vacuum negative pressure and high-frequency vibration are maintained in the horizontal position for a period of time to ensure that the slurry is further exhausted and dense; S5. Turn off the high-frequency micro-vibrator (8) and the vacuum pump (9), start the cooling program, and the temperature sensor (33) monitors the mold temperature in real time. When the mold temperature is detected to be ≥80°C, the temperature regulator (31) automatically starts, and the ethylene glycol aqueous solution in the coolant supply tank (30) is pumped into the cooling channel (29) inside the mold through the telescopic hose. The temperature regulator (31) accurately controls the flow rate and temperature of the coolant, so that the mold temperature drops evenly at a rate of 2 to 5°C / min, and the cooling target temperature drops to 60±2°C. After reaching this temperature and stabilizing, the cooling program stops or switches to the insulation state.

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