An automatic refractory brick laying device for a cement rotary kiln

Abstract

The present invention relates to the field of automatic laying of refractory bricks, and specifically to an automatic laying device for refractory bricks of a cement rotary kiln, comprising: a curved surface walking device, which is arranged on the curved surface of the lower part of the cement rotary kiln, and the circumferential angle between the driving wheels and the vehicle body is adjustable, so that the wheels can walk along tracks on curved surfaces of different radians; a refractory brick supporting device, which is arranged on the curved surface walking device and is used to change the installation quantity according to the different radii of the kiln body, and drive the curved surface walking device to walk and provide support to adapt to the shape of the kiln body; a refractory brick feeding device, which is arranged on the refractory brick supporting device; a refractory brick stacking device, which is arranged on the curved surface walking device and cooperates with the refractory brick feeding device, quantifies the laying detection process through a visual recognition camera and a servo camera, effectively improves the laying effect of the refractory bricks, eliminates gaps through a wide-surface knocking device and a narrow-surface knocking device, and reduces the influence of human factors on the laying quality of the refractory bricks.

Description

Technical Field

[0001] The invention relates to the field of automatic laying of refractory bricks, in particular to an automatic laying device for refractory bricks of a cement rotary kiln. Background Art

[0002] Traditionally, the laying of refractory bricks in cement rotary kilns is done manually, which is labor-intensive and cannot effectively guarantee the quality of the kiln's construction. Furthermore, workers work in a closed environment filled with toxic and harmful cement clinker dust for long periods of time, which is extremely harmful to their health. Manual brick laying typically involves a team of 8-10 people, with forklifts moving in and out to transport refractory bricks. If a safety hazard were to occur in the kiln during construction, especially in the upper arch, the consequences would be disastrous. The automated laying device of the present invention can replace manual labor to complete most of the heavy work, effectively freeing workers from this environment and improving production safety.

[0003] The existing refractory brick laying process relies on manual line-laying and calibration, gaps are eliminated by manual tapping with a rubber hammer, and the concentricity of the refractory bricks is visually inspected by workers. The operation method is very rough and the laying quality of the kiln body is difficult to effectively control. Summary of the Invention

[0004] In order to solve the above problems, the present invention proposes an automatic refractory brick laying device for a cement rotary kiln.

[0005] An automatic refractory brick laying device for a cement rotary kiln, comprising:

[0006] The curved surface walking device is installed on the curved surface at the bottom of the cement rotary kiln. The circumferential angle between the driving wheel and the vehicle body can be adjusted, so that the wheels can move along the curved surface with different curvatures.

[0007] The refractory brick support device is installed on the curved surface walking device, which is used to change the installation quantity according to the different radii of the kiln body, and drive the curved surface walking device to adapt to the shape of the kiln body to provide support;

[0008] The refractory brick loading device is installed on the refractory brick supporting device, and moves through the cambered walking device to determine the selected refractory brick model and position;

[0009] The refractory brick stacking device is arranged on the curved walking device and cooperates with the refractory brick loading device. It is used to grab the specified refractory bricks and place them in the specified position, accurately identify and correct the stacking position and detect the stacking quality of the refractory bricks to ensure that the gaps between the refractory bricks and the concentricity between the refractory bricks and the kiln body meet the kiln construction process requirements.

[0010] The refractory brick supporting device comprises a supporting frame arranged on the cambered walking device, a contour-matching supporting mechanism arranged on the supporting frame, and a supporting cylinder arranged on the contour-matching supporting mechanism.

[0011] The refractory brick loading device includes a support platform arranged on a support frame for placing a pile of refractory bricks of specified models, a visual detection bracket arranged on the support platform, and a visual recognition camera arranged at the top end of the visual detection bracket for identifying the model and position of the pile of refractory bricks of specified models in the area.

[0012] The refractory brick stacking device includes an operating platform, a six-degree-of-freedom robotic arm arranged on the operating platform, a special refractory brick clamp arranged on the six-degree-of-freedom robotic arm for grabbing refractory bricks, a clamp mounting plate arranged on the six-degree-of-freedom robotic arm for installing the special refractory brick clamp, and a seam closing platform arranged on the operating platform for adjusting the height and supporting workers to perform hydraulic tensioning of refractory bricks and complete the seam closing work.

[0013] The special clamp for refractory bricks includes a clamp mounting plate, two groups of sponge suction cups arranged on the clamp mounting plate, two groups of wide-side knocking devices and narrow-side knocking devices arranged on the clamp mounting plate and cooperating with the sponge suction cups, a servo camera arranged on the clamp mounting plate facing the narrow side of the refractory bricks for monitoring the gap size of the refractory bricks after stacking, and a laser ranging sensor arranged in the middle of the clamp mounting plate for measuring the distance between the refractory bricks and the center of the kiln body and judging the centripetal degree of the refractory bricks.

[0014] The wide surface knocking device includes a cylinder 1, a connecting rod mechanism connected to the cylinder 1, and a knocking block 1 installed on the connecting rod mechanism; the narrow surface knocking device includes a cylinder 2, a connecting rod connected to the cylinder 2, and a knocking block 2 installed on the connecting rod.

[0015] The arc walking device includes a laser tracking navigation system located at the front end for correcting the walking trajectory in real time and determining the position of the equipment, a heavy-loaded arc walking AGV arranged on the laser tracking navigation system, a platform stabilizing support rod arranged on the inner wall of the rotary kiln and cooperating with the heavy-loaded arc walking AGV, and a walking positioning support rod arranged at the bottom of the laser tracking navigation system.

[0016] The beneficial effects of the present invention are: through the quantification of the laying inspection process by visual recognition cameras and servo cameras, from the selection of refractory bricks to the laying and then to the inspection, all operations are digital, the process is controllable, the results are reliable, and the laying effect of refractory bricks can be effectively improved. The gaps are eliminated by the wide-surface knocking device and the narrow-surface knocking device. The operating procedures and standards are completely consistent, which greatly reduces the influence of human factors on the laying quality of refractory bricks. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The present invention will be further described below with reference to the accompanying drawings and examples.

[0018] Figure 1 It is the front view of the present invention;

[0019] Figure 2 A perspective view of the present invention;

[0020] Figure 3 A three-dimensional diagram of the special clamping jaws for refractory bricks of the present invention;

[0021] Figure 4 It is a schematic diagram of the wide-surface knocking device of the present invention;

[0022] Figure 5 It is a schematic diagram of the narrow surface striking device of the present invention. DETAILED DESCRIPTION

[0023] In order to make the technical means, creative features, objectives and effects achieved by the present invention easier to understand, the present invention is further described below.

[0024] like Figures 1 to 5 As shown, an automatic refractory brick laying device for a cement rotary kiln includes:

[0025] The curved surface walking device is installed on the curved surface at the bottom of the cement rotary kiln. The circumferential angle between the driving wheel and the vehicle body can be adjusted, so that the wheels can move along the curved surface with different curvatures.

[0026] The refractory brick support device is provided on the cambered walking device, and is used to change the number of installations according to the radius of the kiln body 101, and drive the cambered walking device to adapt to the shape of the kiln body 101 and provide support;

[0027] The refractory brick loading device is installed on the refractory brick supporting device, and moves through the cambered walking device to determine the selected refractory brick model and position;

[0028] The refractory brick stacking device is arranged on the curved walking device and cooperates with the refractory brick loading device. It is used to grab the specified refractory bricks and place them in the specified position, accurately identify and correct the stacking position and detect the stacking quality of the refractory bricks to ensure that the gaps between the refractory bricks and the concentricity between the refractory bricks and the kiln body meet the kiln construction process requirements.

[0029] The kiln body 101 is scanned by a 3D recognition camera, and the refractory bricks required for the curved surface and the stacking positions are calculated by a stacking algorithm.

[0030] The refractory brick supporting device includes a supporting frame 501 arranged on the cambered walking device, a contoured supporting mechanism 503 arranged on the supporting frame 501 , and a supporting cylinder 502 arranged on the contoured supporting mechanism 503 .

[0031] The number of the contoured support mechanisms 503 can be changed according to the radius of the kiln body 101 to adapt to the shape of the kiln body 101 .

[0032] After the refractory bricks in the lower half of the arch are stacked, the corresponding upper half of the arch is stacked. The stacking and inspection process is the same as that of the lower half of the arch. When a refractory brick is stacked, the support cylinder in the contour support mechanism 503 is pushed out to complete the support and fixation of the refractory bricks in the corresponding position. After all the refractory bricks in an arch are laid, the equipment is paused and the hydraulic push rod is used manually to tighten the refractory bricks in the arch and complete the seam closing work.

[0033] When the equipment is initially working, it first drives to the set starting position, performs 3D scanning and modeling of the kiln body 101, and performs digital modeling based on the selected refractory brick parameters to determine the position and model of the refractory bricks in the kiln body 101. The refractory brick stacking device takes out the refractory bricks of the corresponding model and stacks them at the designated position under the visual servo of the refractory brick loading device.

[0034] By using the visual recognition camera 403 and the servo camera 307 to quantify the laying inspection process, from the selection of refractory bricks to the laying and then to the inspection, all operations are digitalized, the process is controllable, the results are reliable, and the laying effect of refractory bricks can be effectively improved. The wide-surface knocking device 305 and the narrow-surface knocking device 306 are used to eliminate gaps. The operating procedures and standards are completely consistent, which greatly reduces the impact of human factors on the quality of refractory brick laying.

[0035] The refractory brick loading device includes a support platform 401 arranged on a support frame 501 for placing a pile of refractory bricks 402 of specified models, a visual inspection bracket 404 arranged on the support platform 401, and a visual recognition camera 403 arranged at the top end of the visual inspection bracket 404 for identifying the model and position of the pile of refractory bricks 402 of specified models in the area.

[0036] The refractory brick stacking device includes an operating platform 301, a six-degree-of-freedom robotic arm 302 arranged on the operating platform 301, a special refractory brick clamp arranged on the six-degree-of-freedom robotic arm 302 for grabbing refractory bricks 303, a clamp mounting plate 309 arranged on the six-degree-of-freedom robotic arm 302 for installing the special refractory brick clamp, and a seam closing platform 310 arranged on the operating platform 301 for adjusting the height and supporting workers to perform hydraulic tensioning of refractory bricks and complete the seam closing work.

[0037] The refractory brick stacking device establishes a digital model of the stacked refractory bricks in advance based on the scanning results of the cement rotary kiln body 101 and the parameters of the selected refractory bricks. The refractory brick loading device then determines the model and position of the selected refractory bricks and communicates with the six-degree-of-freedom robotic arm 302. After the six-degree-of-freedom robotic arm 302 grabs the specified refractory bricks and places them in the specified position, the wide-surface knocking device 305 and the narrow-surface knocking device 306 work to eliminate the stacking gaps. Finally, the servo camera 307 detects the gaps between the refractory bricks, and the laser ranging sensor 308 detects the concentricity between the refractory bricks and the center of the kiln body. After passing the test, the stacking operation is completed.

[0038] The special clamp for refractory bricks includes a clamp mounting plate 309, two groups of sponge suction cups 304 arranged on the clamp mounting plate 309, two groups of wide-surface knocking devices 305 and narrow-surface knocking devices 306 arranged on the clamp mounting plate 309 and cooperating with the sponge suction cups 304, a servo camera 307 arranged on the clamp mounting plate 309 facing the narrow surface of the refractory bricks and used to monitor the gap size of the refractory bricks after stacking, and a laser ranging sensor 308 arranged in the middle of the clamp mounting plate 309 for measuring the distance between the refractory bricks and the center of the kiln body 101 and judging the centripetal degree of the refractory bricks.

[0039] The visual servo camera 307 and the laser ranging sensor 308 can accurately identify and correct the stacking position and detect the stacking quality of the refractory bricks, ensuring that the gaps between the refractory bricks and the concentricity between the refractory bricks and the kiln body meet the kiln construction process requirements.

[0040] The wide-surface knocking device 305 includes a cylinder 1 3051, a connecting rod mechanism 3052 connected to the cylinder 1 3051, and a knocking block 1 3053 installed on the connecting rod mechanism 3052; the narrow-surface knocking device 306 includes a cylinder 2 3061, a connecting rod 3062 connected to the cylinder 2 3061, and a knocking block 2 3063 installed on the connecting rod 3062.

[0041] After the refractory bricks reach the designated position, they are struck on both sides by the wide-side striking device 305 and the narrow-side striking device 306 to eliminate the gaps between the refractory bricks. The visual servo camera 307 detects the gaps and shows that they meet the set standards. The laser ranging sensor 308 then performs a centring detection on the refractory bricks to determine whether the centring degree of the refractory bricks meets the standards. If they meet the standards, they are shown as qualified. If the above process shows that something is unqualified, after the gap elimination operation and adjustment, if it is still unqualified, the equipment will alarm and call for manual intervention.

[0042] The extension and contraction of cylinder 1 3051 and cylinder 2 3061 drive knocking blocks 1 3053 and 2 3063 installed at the ends of connecting rod mechanism 3052 and connecting rod 3062 to knock the refractory bricks, thereby eliminating the gaps between the refractory bricks.

[0043] The arc walking device includes a laser tracking navigation system 201 located at the front end position for correcting the walking trajectory in real time and determining the position of the equipment, a heavy-loaded arc walking AGV 202 arranged on the laser tracking navigation system 201, a platform stabilizing support rod 203 arranged on the inner wall of the rotary kiln and cooperating with the heavy-loaded arc walking AGV 202, and a walking positioning support rod 204 arranged at the bottom of the laser tracking navigation system 201.

[0044] When the equipment stops at a specified position, the platform stabilization support rod 203 and the travel positioning support rod 204 will rigidly position the travel unit, improving the operating accuracy and repeatability of the entire system. The entire positioning process will coordinate with the laser tracking navigation system 201 to ensure that the position of the travel mechanism does not change during this process.

[0045] After the seam is closed, the equipment starts and begins laying refractory bricks for the next arch. The refractory bricks are laid within the working range of the six-degree-of-freedom robotic arm 302, and the platform stabilizing support rod 203 is retracted. The equipment moves to the next working section, stops after the position is calibrated by the laser tracking navigation system 201, and then the positioning support rod 204 fixes the position of the equipment. 3D scanning and modeling of the kiln body to be laid is carried out, and laying work at the next position is carried out.

[0046] The method of using the present invention is as follows: the data of the refractory bricks required for the masonry of the kiln body 101 is input into the laying database for use in data modeling, the refractory bricks are delivered to the material tray of the refractory brick loading device by a forklift, and the position and type of the refractory bricks are determined by the visual recognition camera 403 above the material tray. Each time the six-degree-of-freedom robotic arm 302 grabs a refractory brick, the six-degree-of-freedom robotic arm 302 communicates with the six-degree-of-freedom robotic arm 302 in a timely manner to ensure that the six-degree-of-freedom robotic arm 302 accurately grabs the refractory bricks of the required type;

[0047] After the refractory bricks are loaded, the cambered walking device transports the entire equipment to the designated starting point and then stops. The platform stabilizing support rod 203 and the positioning support rod 204 work in sequence to complete the positioning and support of the entire system, ensuring the accuracy and fixation of the working position of the refractory bricks.

[0048] After the working position is confirmed, the kiln body 101 is scanned and modeled in three dimensions by a 3D scanning device. Based on the input refractory brick parameters, digital calculation and modeling of the overall stacking work are performed to determine the location and type of refractory bricks to be stacked in the kiln body 101. The refractory brick feeding device communicates with the six-degree-of-freedom robotic arm 302, and the visual recognition camera 403 of the refractory brick feeding device takes out the refractory bricks of the corresponding type and stacks them in the designated position.

[0049] After the refractory bricks arrive at the designated position, the gap size detection servo camera 307 and the laser distance sensor 308 begin to identify the stacking position and detect the stacking quality of the refractory bricks to ensure that the gaps between the refractory bricks meet the requirements and the concentricity of the refractory bricks and the kiln body 101 meet the process requirements of the project. If the stacking quality does not meet the set data, the wide-surface knocking device 305 and the narrow-surface knocking device 306 perform double-sided knocking to eliminate the gaps between the refractory bricks and improve the concentricity. After the servo camera 307 detects that the gap meets the set standard, it will be displayed as qualified; then the laser distance sensor 308 will perform the concentricity detection of the refractory bricks to determine whether the concentricity of the refractory bricks meets the standard, and display it as qualified if it meets the standard; if the above process displays unqualified, and it is still unqualified after adjustment in this operation, the equipment will alarm and call for manual intervention;

[0050] The operation is repeated in this way until the stacking work of the lower half of the ring by the six-degree-of-freedom robot 302 is completed, and the stacking operation of the upper half of the ring begins. The operation logic of the upper half of the ring is the same as that of the lower half of the ring, except that when a refractory brick is stacked, the support cylinder in the contour support mechanism 503 is ejected to complete the support and fixation of the refractory brick at the corresponding position. When all the refractory bricks in a circular arch are laid, the equipment is paused, and the refractory bricks of the arch are manually tightened using a hydraulic push rod to complete the seam closing work. After the worker completes the operation and exits the work area, the support cylinder in the contour support device is retracted to complete the masonry work of one arch.

[0051] If the masonry work is correct, the equipment starts and begins to lay the refractory bricks of the next arch. The work cycle continues until the refractory bricks are laid within the working range of the six-degree-of-freedom robot arm 302. The platform stabilizing support rod 203 is retracted, and the equipment moves to the next working section. After the position is calibrated by the laser tracking navigation system 201, it stops. The equipment position is then fixed by the travel positioning support rod 204. The kiln body to be laid is 3D scanned and modeled, and the laying work at the next position is carried out until the work is completed. If there is a shortage of refractory bricks during this period, the equipment will pause and alarm, waiting for the forklift to replenish the refractory bricks before continuing to work.

[0052] During the entire refractory brick stacking process, workers only need to enter when the refractory bricks are capped, which fully guarantees the workers' operational safety; the refractory brick stacking operations have all been changed to mechanical operations, effectively reducing labor intensity; the refractory brick stacking standards have also been digitized, and the project quality is under real-time monitoring and control. The consistency and pass rate of the process have been greatly improved by eliminating human influence.

[0053] The basic principles, main features, and advantages of the present invention are shown and described above. Those skilled in the art should understand that the present invention is not limited to the foregoing embodiments. The foregoing embodiments and description merely illustrate the principles of the present invention. Various changes and modifications may be made to the present invention without departing from the spirit and scope of the present invention. Such changes and modifications are intended to fall within the scope of the present invention. The scope of protection claimed in the present invention is defined by the appended claims and their equivalents.

Claims

1. An automatic refractory brick laying device for a cement rotary kiln, characterized by: include: The curved surface walking device is installed on the curved surface at the bottom of the cement rotary kiln. The circumferential angle between the driving wheel and the vehicle body can be adjusted, so that the wheels can move along the curved surface with different curvatures. The refractory brick support device is installed on the curved surface walking device, which is used to change the installation quantity according to the different radii of the kiln body, and drive the curved surface walking device to adapt to the shape of the kiln body to provide support; The refractory brick loading device is installed on the refractory brick supporting device, and moves through the cambered walking device to determine the selected refractory brick model and position; The refractory brick stacking device is installed on the curved walking device and cooperates with the refractory brick loading device. It is used to grab and place the specified refractory bricks in the specified position, accurately identify and correct the stacking position, and detect the stacking quality of the refractory bricks to ensure that the gaps between the refractory bricks and the concentricity between the refractory bricks and the kiln body meet the kiln construction process requirements; The refractory brick supporting device includes a supporting frame arranged on the cambered walking device, a contour supporting mechanism arranged on the supporting frame, and a supporting cylinder arranged on the contour supporting mechanism; The refractory brick stacking device includes a six-degree-of-freedom robotic arm, a special refractory brick clamp provided on the six-degree-of-freedom robotic arm for grabbing refractory bricks, and a clamp mounting plate provided on the six-degree-of-freedom robotic arm for mounting the special refractory brick clamp; The special clamping jaws for refractory bricks include two groups of sponge suction cups arranged on the clamping jaw mounting plate, two groups of wide-side knocking devices and narrow-side knocking devices arranged on the clamping jaw mounting plate and cooperating with the sponge suction cups, a servo camera arranged on the clamping jaw mounting plate facing the narrow side of the refractory bricks for monitoring the gap size detection after the refractory bricks are stacked, and a laser ranging sensor arranged in the middle of the clamping jaw mounting plate for measuring the distance between the refractory bricks and the center of the kiln body and judging the centripetal degree of the refractory bricks.

2. The automatic refractory brick laying device for a cement rotary kiln according to claim 1, characterized in that: The refractory brick loading device includes a support platform arranged on a support frame for placing a pile of refractory bricks of specified models, a visual detection bracket arranged on the support platform, and a visual recognition camera arranged at the top end of the visual detection bracket for identifying the model and position of the pile of refractory bricks of specified models in the area.

3. The automatic refractory brick laying device for a cement rotary kiln according to claim 1, characterized in that: The refractory brick stacking device also includes an operating platform, a seam closing platform provided on the operating platform for adjusting the height and supporting workers to hydraulically tighten the refractory bricks and complete the seam closing work, and the six-degree-of-freedom robotic arm is provided on the operating platform.

4. The automatic refractory brick laying device for a cement rotary kiln according to claim 1, characterized in that: The wide surface knocking device includes a cylinder 1, a connecting rod mechanism connected to the cylinder 1, and a knocking block 1 installed on the connecting rod mechanism; the narrow surface knocking device includes a cylinder 2, a connecting rod connected to the cylinder 2, and a knocking block 2 installed on the connecting rod.

5. The automatic refractory brick laying device for a cement rotary kiln according to claim 1, characterized in that: The arc walking device includes a laser tracking navigation system located at the front end for correcting the walking trajectory in real time and determining the position of the equipment, a heavy-loaded arc walking AGV arranged on the laser tracking navigation system, a platform stabilizing support rod arranged on the inner wall of the rotary kiln and cooperating with the heavy-loaded arc walking AGV, and a walking positioning support rod arranged at the bottom of the laser tracking navigation system.

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