Pottery kiln firing pushing system and method
By using heat insulation and sensing units during the firing process of ceramic pots into the kiln, the problem of collision force in the kiln workshop was solved, achieving intelligent pushing of kiln cars and energy-saving effects.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Patents(China)
- Current Assignee / Owner
- CHONGQING ANDU CERAMICS CO LTD
- Filing Date
- 2022-06-30
- Publication Date
- 2026-07-24
AI Technical Summary
Under the high temperature conditions inside the kiln, during the process of pushing the pottery jars into the kiln for firing, the kiln cars in front are subjected to excessive collision forces caused by the inertia of the kiln cars behind, which affects the service life of the kiln cars and the quality of the products.
The system employs a combination of heat insulation units and sensing units. The heat insulation units include heat insulation bricks, sand sealing plates, and sand sealing grooves. The sensing units include distance sensors and brakes. The sensors detect the distance to the kiln workshop and control the brakes to decelerate, thus preventing kiln car collisions.
It effectively reduces collision forces in the kiln workshop, extends the service life of kiln cars, ensures product quality, and saves energy consumption.
Smart Images
Figure CN115143773B_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of kiln technology, specifically to a system and method for feeding ceramic jars into a kiln. Background Technology
[0002] With the advent of the industrial age, kilns have developed rapidly. Tunnel kilns are used for firing ceramic products and refractory materials for kiln furniture. Kiln cars are used to load the fired blanks into the kiln, where they are then propelled by a top-mounted conveyor to the firing position. Especially for large kiln cars, which bear a heavy load after loading, sufficient pushing force is required to move them to their designated positions. The top of the kiln car is usually located inside the tunnel kiln, where the temperature is high. The sides of the kiln car are typically insulated to keep the temperature of its lower surface within a reasonable range. Actual measurements show that, depending on the insulation effect of the materials, the temperature of the lower surface of the kiln car is usually between 70-200℃.
[0003] For example, in the Chinese patent publication CN213873819U, a car-topping machine includes a car-topping frame, with rollers installed at the bottom of the car-topping frame and a car-topping device installed at the top of the car-topping frame. The car-topping device includes a motor, which is connected to a reducer via a belt. The reducer is connected to a gear via a transmission shaft, and the gear is connected to a rack. The car-topping frame has multiple mounting seats on the underside of the rack, and rollers that contact the rack are mounted on the mounting seats. A push plate is mounted on one end of the rack, and a shock-absorbing layer is mounted on the push plate. A support frame is mounted on the lower side of the rack near the push plate, and a support wheel is mounted on the bottom of the support frame.
[0004] Undoubtedly, this patent changes the previous practice of using hydraulic power for kiln car toppers, replacing it with an electric motor and reducer input. Compared to hydraulic toppers, this allows for more precise control of the rack extension length and speed. However, in practical applications, this patent still has the following problems: the topper sequentially pushes multiple kiln cars into the kiln, with each push distance generally exceeding the length of the kiln car (usually around 5-6 meters). The pushing process is as follows: after the first car is positioned on the track (at this time, the second and third cars are inside the tunnel kiln), the pusher plate of the topper moves towards the first car under the action of the motor or hydraulic power. The pusher plate then contacts the first car, pushing it to move at a constant speed on the track. The first car then contacts the second car, and continues to move under the action of the pusher plate. The second car then contacts the third car (subsequent adjacent kiln cars all contact each other), forming a kiln car queue that moves simultaneously until the last car exits the tunnel kiln. At this point, the first car also enters the tunnel kiln, and finally the insulated door at the tunnel kiln entrance is closed.
[0005] During the aforementioned process, when the pusher plate contacts the first kiln car, and when the first kiln car contacts the second, or even the second and third kiln cars, the kiln cars being contacted (whose speed before contact is 0) are propelled forward by the top-mounted machine. Due to inertia, the kiln cars in front are subjected to excessive impact forces, affecting their service life. Furthermore, severe impacts (if the speed is too high) can easily deform the products to be fired on the kiln cars. However, if the impact at contact is reduced by decreasing the speed (to a constant speed), the insulation door will be open for too long, affecting the preheating effect of the preheating zone inside the tunnel kiln. If the insulation door is kept open for a long time, it may even lead to excessive temperature differences during preheating, reducing the success rate of product firing.
[0006] Therefore, there is an urgent need for a device that can solve the problem of excessive collision force caused by the inertia of the kiln car in front of the pottery jar during the firing and pushing process in the kiln under high temperature conditions. Summary of the Invention
[0007] This invention provides a system and method for pushing ceramic jars into a kiln during firing, aiming to solve the problem of excessive collision force caused by the inertia of the kiln car behind it during the process of pushing ceramic jars into the kiln under high temperature conditions inside the kiln.
[0008] To achieve the above objectives, this solution provides the following technical solution:
[0009] A ceramic pot firing and kiln feeding system includes a kiln body and a top car machine, and also includes:
[0010] The heat insulation unit includes heat insulation bricks, sand sealing plates and sand sealing grooves. The heat insulation bricks are placed on the surface of the kiln car, the sand sealing grooves are fixed to the lower end of the side wall of the kiln body and are filled with sand. The sand sealing plates are fixed to the side of the kiln car and are inserted into the sand in the sand sealing grooves.
[0011] The sensing unit includes a first distance sensor, a second distance sensor, a brake, and a controller. The first distance sensor transmits a first distance signal detected in the kiln workshop to the controller. The second distance sensor transmits a second distance signal detected between the kiln car and the top car machine to the controller. The controller receives the first and second distance signals and generates a brake activation signal when the first distance signal is within a preset range and a brake deactivation signal when the second distance signal exceeds the preset range. The brake starts and decelerates the kiln car upon receiving the brake activation signal and releases the deceleration of the kiln car upon receiving the brake deactivation signal.
[0012] The principle and beneficial technical effects of this technical solution:
[0013] Because it includes insulating bricks, sand sealing plates, and sand sealing grooves, and the insulating bricks are placed on the surface of the kiln car, the surface of the kiln car is well insulated, so that not all the heat in the kiln is directly conducted to the kiln car, thus reducing energy consumption.
[0014] Because the sand sealing groove is fixed to the lower end of the side wall of the kiln body, and the sand sealing groove is filled with sand particles, and the sand sealing plate is fixed to the side of the kiln car, and the sand sealing plate is inserted into the sand particles in the sand sealing groove, the kiln car can maintain a sealing effect during the movement of the kiln car. The heat insulation effect is excellent, which reduces the heat exchange between the hot air on the upper surface of the kiln car and the air on the lower surface of the kiln car, and effectively protects the lower surface of the kiln car from damage caused by high temperature.
[0015] Because it includes a first distance sensor, a second distance sensor, a brake, and a controller, the first distance sensor is used to sense and transmit the distance between itself and the rear end of the kiln car in front; the controller is used to receive the distance signal from the first distance sensor, and activate the brake when the distance signal is within a preset range; the brake is used to decelerate the kiln car after receiving the activation signal, so when the top car machine pushes the rear kiln car into the kiln, when the distance between the rear kiln car and the front kiln car enters the preset range, the control unit controls the activation of the brake, so that the speed of the rear kiln car gradually decreases and slowly moves forward, avoiding the phenomenon of the rear kiln car violently colliding with the front kiln car, and improving the service life of the kiln car.
[0016] Because the second distance sensor transmits the distance signal between the kiln car and the top car machine to the controller, the controller closes the brake when the distance signal received by the controller deviates from the preset range. Therefore, when the top car machine returns, the brake is closed, and the kiln car is no longer constrained. When another kiln car enters the kiln from behind, it will not obstruct the kiln car's movement, thus realizing intelligent kiln car pushing control.
[0017] This solution addresses the problem of excessive impact force from rear kiln cars on the front kiln cars during the firing and pushing of ceramic jars into the kiln.
[0018] Furthermore, the brake includes a mechanical claw, a brake disc, and brake pads. The mechanical claw is fixed to the lower surface of the kiln car, the brake pads are fixed to the inside of the mechanical claw, and the brake disc is coaxially fixed to the wheels of the kiln car.
[0019] Furthermore, the first distance sensor includes a slide rail fixed to the side of the kiln car head and a limiting plate fixed to the side of the kiln car tail. A slide rod is slidably connected inside the slide rail. One end of the slide rod is fixed with a spring that allows the slide rod to extend from the kiln car head. The other end of the slide rod is at the same height as the limiting plate of the adjacent kiln car. A first hydraulic cylinder is fixed inside the spring. One end of the first hydraulic cylinder is fixed to the end of the slide rail, and the other end of the first hydraulic cylinder is fixedly connected to the end of the slide rod. A gear and a Hall sensor are provided on the slide rail. The slide rail is rotatably connected to the gear. The Hall sensor includes a rotating part and a fixed part. The fixed part is fixedly connected to the side of the kiln car, and the gear is coaxially fixedly connected to the rotating part. A rack that meshes with the gear is fixed on the slide rod. The Hall sensor is signal-connected to the controller. The mechanical gripper includes a body, The system comprises two claw arms, each consisting of a vertical section and an inclined section. The vertical section is located on both sides of the brake disc, with brake pads fixedly connected to the vertical section. Both vertical sections are fixedly connected to the inclined sections. The two inclined sections are rotatably connected to the machine body at the same point. Each inclined section has a tail section extending beyond its connection point with the machine body. The two ends of the second hydraulic cylinder are hinged to the two tail sections respectively. A high-temperature resistant hydraulic pipeline is provided between the second hydraulic cylinder and the first hydraulic cylinder. A sliding frame is provided between the machine body and the lower surface of the kiln car, with the sliding frame fixedly connected to the lower surface of the kiln car and the machine body slidably connected to the sliding frame. A third cylinder is fixedly mounted on the sliding frame, with its bottom fixed to the sliding frame and its top fixed to the machine body. The third cylinder is filled with a liquid with a boiling point of 70-200℃.
[0020] Beneficial effects: The first sensor is used to detect the distance between adjacent kiln cars. As one kiln car approaches another, the sliding rod extends from the head of the kiln car. As the distance between the two kiln cars gradually decreases, the sliding rod on one kiln car will contact the limiting plate on the other kiln car. Then, as the distance further decreases, the sliding rod will compress the spring and the first hydraulic cylinder, and the spring will cause the first hydraulic cylinder to return to its original position. Furthermore, the movement of the sliding rod will cause the gear to rotate, which in turn will cause the rotating part of the Hall sensor to rotate, thereby generating a signal feedback to the controller.
[0021] Then, after the first hydraulic cylinder compresses, the hydraulic oil is transmitted through the hydraulic lines to the second hydraulic cylinder, causing it to extend. Since the two ends of the second hydraulic cylinder are hinged to the tail section of the inclined section, it's similar to a pair of scissors where one end opens and the other closes, bringing the two vertical sections closer together and clamping the brake disc to achieve braking. In other words, it reduces the speed of the two vehicles during approach, minimizing the risk of impact.
[0022] Because the machine body and the sliding frame are slidably connected (sliding up and down, and in the same direction as the extension of the third cylinder), as the ambient temperature of the third cylinder rises, the length of the third cylinder will extend, causing the machine body to move upwards as well, thus disengaging the vertical section from the brake disc. This prevents the kiln cars inside the tunnel kiln from locking up with the brakes, reducing pushing resistance. This solution primarily addresses the issue of some kiln cars locking up with each other after entering the tunnel kiln. Therefore, this solution mainly optimizes this situation.
[0023] Furthermore, it also includes thermal insulation asbestos felt laid on the outer surface of the kiln.
[0024] Beneficial effects: Reduces the temperature of the outer surface of the kiln, resulting in excellent energy-saving effects.
[0025] Furthermore, the thickness of the thermal insulation asbestos felt is 60mm.
[0026] Beneficial effects: Achieve optimal insulation performance while saving costs.
[0027] An operating method for a ceramic jar firing and kiln feeding system includes:
[0028] Step S10: Place the pottery jar to be fired on the brick support;
[0029] Beneficial effect: It allows the bottom of the pottery jar to be baked and shaped at high temperatures in the kiln.
[0030] Step S20: The top car machine proceeds, driving the kiln car into the kiln;
[0031] Step S30: The first distance sensor detects the distance between the front end of the rear kiln car and the rear end of the front kiln car, and transmits the distance signal to the controller;
[0032] Step S40: The controller determines whether the distance between the kiln workshop and the brake is within the preset range. When the distance is within the preset range, the controller transmits a signal to the brake to activate the brake.
[0033] Beneficial effect: Reduces the speed of kiln cars behind, avoiding excessive collisions in the kiln workshop.
[0034] Step S50: The top car machine returns, the second distance sensor detects the distance between the kiln car behind and the top car machine, and transmits the distance signal to the controller;
[0035] Step S60: The controller determines whether the distance between the rear kiln car and the top car machine has deviated from the preset range. When the distance deviates from the preset range, the controller transmits a signal to the brake to close the brake.
[0036] Beneficial effect: It facilitates pushing the kiln car in front when the kiln car enters the kiln.
[0037] Step S70: Close the kiln door;
[0038] Beneficial effects: It isolates the temperature exchange between the inside and outside of the kiln, reduces heat loss during the heating process, and facilitates subsequent high-temperature firing.
[0039] Step S80: Start the control system and turn on the flame gun;
[0040] Beneficial effect: Allows the pottery jars on the kiln car to enter the firing process.
[0041] Step S90: After the kiln car passes through the preheating section and enters the firing section, the smoke extraction fan is turned on;
[0042] Beneficial effects: Removes flue gas and prevents large amounts of harmful flue gas from escaping from the kiln.
[0043] Step S100: After the kiln car passes through the firing section and enters the cooling section, the flame torch is turned off and the quench fan is turned on.
[0044] Beneficial effects: Gradually cooling the pottery jar facilitates its shaping and reduces the chance of it breaking.
[0045] Step S110: Open the kiln door and send the kiln car out of the kiln;
[0046] Step S120: Remove the pottery jar;
[0047] Step S130: Clean up the debris under the insulation bricks.
[0048] Beneficial effects: Prevents debris from clogging the gaps between insulation bricks, reduces the chance of unevenness in insulation bricks, increases the service life of insulation bricks, and maintains the insulation effect of insulation bricks. Attached Figure Description
[0049] Figure 1 This is a logic block diagram of the sensing unit of the present invention;
[0050] Figure 2 This is a front view of the kiln car portion of the present invention;
[0051] Figure 3 This is a three-dimensional view of the mechanical gripper of the present invention. Detailed Implementation
[0052] The following detailed explanation illustrates the specific implementation methods:
[0053] The reference numerals in the accompanying drawings of the instruction manual include: 1. kiln body; 2. track; 3. sand seal trough; 4. support frame; 5. kiln car; 6. heat insulation brick; 7. fixing plate; 8. pad brick; 9. sand seal plate; 10. mechanical claw; 11. brake pad.
[0054] Example 1
[0055] like Figure 1-3 As shown:
[0056] A ceramic pot firing and kiln feeding system includes a kiln body 1, a top car mechanism, a flame gun for spraying flames into the kiln, and a control system for controlling the temperature of the flames sprayed from the flame gun. It also includes:
[0057] The heat insulation unit includes heat insulation bricks 6, sand sealing plates 9, and sand sealing grooves 3. The sand sealing grooves 3 are bolted to the lower end of the side wall of the kiln body 1. The support frame 4, which supports the sand sealing grooves 3, is bolted to the side wall of the kiln body 1 and placed at the lower end of the sand sealing grooves 3 to provide good support for the sand sealing grooves 3. The sand sealing grooves 3 are filled with sand. The side of the sand sealing plate 9 is bolted to the side of the kiln car 5. The sand sealing plate 9 is inserted into the sand in the sand sealing grooves 3. The sand can pass through a 0.3*0.3cm filter screen. The sand used in the sand sealing grooves 3 cannot be too large. If the sand is too large, it will be plowed up by the sand sealing plate 9 when the kiln car 5 passes by. At this time, there will be gaps between the sand grains. If there are gaps, it will not be able to play a sealing role and will not be able to prevent cold air from the bottom of the car from entering the kiln chamber or high-temperature gas from the kiln chamber from being squeezed into the bottom of the car. The sand sealing plate is inserted 6cm deep into the sand. When the kiln car 5 is running, the sand sealing plate 9 moves in the sand sealing groove 3 and forms a good heat insulation layer with the sand, ensuring the sealing effect of the upper and lower surfaces of the kiln car 5. The heat insulation effect is excellent, reducing the heat exchange between the hot air on the upper surface of the kiln car 5 and the air on the lower surface of the kiln car 5, and effectively protecting the lower surface of the kiln car 5 from damage caused by high temperature.
[0058] The sensing unit includes a first distance sensor, a second distance sensor, a brake, and a controller. The controller uses an STM32F103ZET6 microcontroller, which is inexpensive, highly reliable, and low-noise. The kiln's insulation unit allows the microcontroller to operate well at a lower temperature on the lower surface of the kiln car 5. The first distance sensor transmits distance signals between kiln cars 5 to the controller, and the second distance sensor transmits distance signals between the kiln car 5 and the top car machine. The controller receives the distance signals from the first and second distance sensors. When the distance signal from the first distance sensor is within a preset range, the brake is activated; when the distance signal from the second distance sensor deviates from the preset range, the brake is deactivated. The brake is used to decelerate the kiln car 5. The brake includes a brake disc, a mechanical claw 10, and two brake pads 11. The mechanical arm of the mechanical claw 10 is bolted to the lower surface of the kiln car 5 above the track 2. The brake disc is coaxially welded and fixed to the wheel of the kiln car 5. One side of the brake pad 11 is bolted to the inside of the mechanical claw 10. The structure is simple, the deceleration effect is good, and replacement is convenient.
[0059] A 60mm thick insulating asbestos felt is laid on the outer surface of the kiln body 1 to reduce the temperature of the outer surface of the kiln body 1 and achieve a good insulation effect.
[0060] Insulating bricks 6 are placed on the kiln car 5. The two sides, the top of the kiln, and the surface of the kiln car 5 form the four heated surfaces of the kiln. Except for the surface of the kiln car 5, the temperature of the other three surfaces remains constant during the firing process in the kiln. Their heat consumption is limited to the heat loss conducted outward. The kiln car 5 is pushed into the tunnel kiln at room temperature. As the kiln car 5 moves forward in the kiln, in addition to the heat conducted downward, it also absorbs and stores heat to make the temperature of its surface and the kiln passage consistent. The pottery jars on the kiln car 5 pass through the preheating section, firing section, and cooling section in the kiln in sequence, and finally form and exit the kiln. When the kiln car 5 comes out of the tunnel kiln, the temperature of the kiln car 5 will drop to room temperature again. Therefore, the use of insulating bricks 6 can reduce the heat storage and heat loss of the kiln car 5.
[0061] A fixing plate 7 is placed on the heat-insulating brick 6. The fixing plate 7 facilitates the placement of the pottery jar and improves the stability of the pottery jar during the movement of the kiln car 5. A gap of 0.25cm to 0.5cm is left between the heat-insulating bricks 6 to prevent the bricks from cracking due to thermal expansion in high-temperature environments. However, the gap should not be too large to avoid reducing the heat insulation effect. This would allow the kiln car 5 to be directly exposed to high temperatures, causing it to absorb too much heat, wasting energy, and damaging the structure of the kiln car 5.
[0062] The bricks 8 are stacked on the fixing plate 7, and then the pottery jar is placed on the bricks 8. This allows the bottom of the pottery jar to be baked and shaped at high temperatures in the kiln, resulting in more even heating.
[0063] After the top car machine pushes the kiln car 5 into the kiln, the top car machine returns and exits the kiln, and the kiln door is closed.
[0064] After the pottery jars have undergone the firing process, the kiln door is opened, and the top car machine pushes the rear kiln car 5, which is waiting to enter the kiln, into the kiln. The first distance sensor sends the distance signal between the rear kiln car 5 and the front kiln car 5 to the controller. When the controller determines that the distance is within the preset range, it determines that the two cars are too close and controls the mechanical claw 10 to tighten. When the mechanical claw 10 tightens, the brake pad 11 contacts the track 2, decelerating the kiln car 5 and causing it to slowly move forward, gently colliding with the front kiln car 5 and pushing the front kiln car 5 into the preset temperature range. This solves the problem of the front kiln car 5 being subjected to excessive collision force from the rear kiln car 5 during the pottery jar firing and kiln entry process.
[0065] After the top car machine pushes the kiln car 5 to the designated position, the top car machine starts to return. The second distance sensor sends the distance signal between the kiln car 5 and the working end of the top car machine to the controller. When the controller determines that the distance is not within the preset range, it determines that the top car machine has moved away from the kiln car 5 and controls the mechanical claw 10 to relax, so that the kiln car 5 is no longer constrained. When the heating is completed, the top car machine will not hinder the normal operation of the kiln car 5 when pushing the subsequent kiln car 5 into the kiln.
[0066] A method for feeding and pushing ceramic jars into a kiln during firing includes:
[0067] Step S10: Place the pottery jar to be fired on the support brick 8 so that the bottom of the pottery jar can also be baked and shaped by the high temperature in the kiln, resulting in more even heating and improved pottery jar shaping quality.
[0068] Step S20: The top car machine proceeds, driving the kiln car 5 into the kiln;
[0069] Step S30: The first distance sensor detects the distance between the front end of the rear kiln car 5 and the rear end of the front kiln car 5, and transmits the distance signal to the controller;
[0070] Step S40: The controller determines whether the distance between the 5 kiln cars is within the preset range. When the distance is within the preset range, the controller transmits a signal to the brake to activate the brake, decelerate the 5 kiln cars, and avoid collisions between the 5 kiln cars.
[0071] Step S50: The top car machine returns, the second distance sensor detects the distance between the kiln car 5 behind and the top car machine, and transmits the distance signal to the controller;
[0072] Step S60: The controller determines whether the distance between the rear kiln car 5 and the top car machine is outside the preset range. When the distance is outside the preset range, the controller transmits a signal to the brake to close the brake. When the top car machine pushes the subsequent kiln car 5 into the kiln again, it will not hinder the normal operation of the kiln car 5.
[0073] Step S70: Close the kiln door to isolate heat exchange between the inside and outside of the kiln and reduce energy consumption;
[0074] Step S80: Start the control system, turn on the flame torch, and fire the ceramic pot;
[0075] Step S90: After the kiln car 5 passes through the preheating section and enters the firing section, the smoke extraction fan is turned on to remove the flue gas;
[0076] Step S100: After the kiln car 5 passes through the firing section and enters the cooling section, the flame torch is turned off and the rapid cooling fan is turned on to gradually cool the pottery jar, which is conducive to the shaping of the pottery jar and reduces the chance of the pottery jar breaking.
[0077] Step S110: Open the kiln door and send the kiln car 5 out of the kiln;
[0078] Step S120: Remove the pottery jar;
[0079] Step S130: Clean up the debris under the heat insulation brick 6 to reduce the chance of unevenness in the heat insulation brick 6, increase the service life of the heat insulation brick 6, and maintain the heat insulation effect of the heat insulation brick 6.
[0080] Compared with the prior art, the present invention solves the problem of excessive collision force between the front kiln car 5 and the rear kiln car 5 during the process of pushing the pottery pot into the kiln, reduces the collision between the kiln cars 5, improves the service life of the kiln cars 5, and saves costs.
[0081] Example 2
[0082] Compared with Embodiment 1, the only difference is that the first distance sensor includes a slide rail (in this embodiment, the slide rail is dovetail-shaped, mainly to prevent the slide rod from falling off) embedded and fixed on the lower side (i.e., bottom surface) of the kiln car head and a limiting plate fixed to the lower side (i.e., bottom surface) of the kiln car tail by bolts. A slide rod is slidably connected inside the slide rail. One end of the slide rod is glued and fixed with a spring that allows the slide rod to extend from the kiln car head. The other end of the slide rod is at the same height as the limiting plate of the adjacent kiln car. A first hydraulic cylinder is provided inside the spring. One end of the first hydraulic cylinder is glued and fixed to the end of the slide rail, and the other end of the first hydraulic cylinder is glued and fixed to the end of the slide rod. A gear and a Hall sensor are provided on the slide rail. The Hall sensor includes a rotating part and a fixed part. The fixed part is fixed to the side of the kiln car by bolts. The gear is coaxially welded and fixed to the rotating part. A rack that meshes with the gear is welded on the slide rod. The Hall sensor is connected to the controller signal.
[0083] The mechanical claw includes a body, claw arms, and a second hydraulic cylinder (essentially equivalent to a motorcycle disc brake; however, in this embodiment, the brake pads of the disc brake are triggered by the spacing between kiln cars to achieve braking function, and will detach from the brake disc when the temperature is high, facilitating the next push). There are two claw arms, each including a vertical section and an inclined section. The vertical section is located on both sides of the brake disc, and the brake pads are fixedly connected to the vertical section. The vertical section is also fixedly connected to the inclined section. The two inclined sections are rotatably connected to the body at the same point. Both inclined sections have a tail section extending beyond the connection point with the body. The two ends of the second hydraulic cylinder are hinged to the two tail sections respectively. A high-temperature resistant hydraulic pipeline is provided between the second hydraulic cylinder and the first hydraulic cylinder. A sliding frame is provided between the body and the lower surface of the kiln car, and the sliding frame is fixedly connected to the lower surface of the kiln car. The body and the sliding frame are slidably connected. A third cylinder is fixed on the sliding frame, with its bottom fixed to the sliding frame and its top fixed to the body. The third cylinder is filled with clean water.
[0084] In other embodiments, a pressure relief valve is actually fixed to the end of the slide rail. When the slide rod is compressed to its limit, it abuts against the pressure relief valve, triggering it and causing the hydraulic oil pressure in the first and second hydraulic cylinders to disappear. This requires an oil reservoir on the hydraulic lines, with its bottom connected to the inlet pipe of the first hydraulic cylinder. The reservoir is higher than the first hydraulic cylinder, and a one-way valve (allowing only one-way oil inflow) is installed on the inlet pipe of the first hydraulic cylinder. One end of the pressure relief line is connected to the hydraulic lines, and the other end is connected to the inlet port at the top of the oil reservoir. The pressure relief valve is located on the pressure relief line. After the pressure relief valve is triggered, it opens, allowing the hydraulic oil in the hydraulic lines to flow from the pressure relief line into the oil reservoir. Then, under the action of gravity and spring force, it flows back into the first hydraulic cylinder for future use. This achieves gradual braking before contact between the two vehicles, and releases the brakes after reaching the limit position. Furthermore, under high temperatures, the brake pads are separated from each other, which means they are in contact with the brakes, and also avoids the reduction in service life caused by the different thermal expansion coefficients of the two different materials.
[0085] In practical use: As one kiln car approaches another, the sliding rod extends from the front of the kiln car. As the distance between the two kiln cars gradually decreases, the sliding rod on one kiln car will contact the limiting plate on the other kiln car. Then, as the distance further decreases, the sliding rod will compress the spring and the first hydraulic cylinder, and the spring will cause the first hydraulic cylinder to return to its original position. Furthermore, the movement of the sliding rod will cause the gear to rotate, which in turn will cause the rotating part of the Hall sensor to rotate, thereby generating a signal feedback to the controller.
[0086] Then, after the first hydraulic cylinder compresses, the hydraulic oil is transmitted through the hydraulic lines to the second hydraulic cylinder, causing it to extend. Since the two ends of the second hydraulic cylinder are hinged to the tail section of the inclined section, it's similar to a pair of scissors where one end opens and the other closes, bringing the two vertical sections closer together and clamping the brake disc to achieve braking. In other words, it reduces the speed of the two vehicles during approach, minimizing the risk of impact.
[0087] Because the machine body and the sliding frame are slidably connected (sliding up and down, and in the same direction as the extension of the third cylinder), when the ambient temperature of the third cylinder rises, the length of the third cylinder will extend, causing the machine body to move upward as well, thereby disengaging the vertical section from the brake disc. This ensures that the kiln car inside the tunnel kiln will not be locked by the brake, reducing pushing resistance.
[0088] The above descriptions are merely embodiments of the present invention, and common knowledge regarding specific structures and characteristics is not elaborated upon here. It should be noted that those skilled in the art can make various modifications and improvements without departing from the structure of the present invention, and these should also be considered within the scope of protection of the present invention. These modifications and improvements will not affect the effectiveness of the present invention or the practicality of the patent. The scope of protection claimed in this application should be determined by the content of its claims, and the specific embodiments described in the specification can be used to interpret the content of the claims.
Claims
1. A ceramic pot firing and kiln feeding system, comprising a kiln body and a top car machine, characterized in that, Also includes: The heat insulation unit includes heat insulation bricks, sand sealing plates and sand sealing grooves. The heat insulation bricks are placed on the surface of the kiln car, the sand sealing grooves are fixed to the lower end of the side wall of the kiln body and are filled with sand. The sand sealing plates are fixed to the side of the kiln car and are inserted into the sand in the sand sealing grooves. The sensing unit includes a first distance sensor, a second distance sensor, a brake, and a controller. The first distance sensor transmits a distance signal of the kiln workshop to the controller, and the second distance sensor transmits a distance signal between the kiln car and the top car machine to the controller. The controller receives the distance signals from the first and second distance sensors. When the distance signal from the first distance sensor is within a preset range, the brake is activated; when the distance signal from the second distance sensor deviates from the preset range, the brake is deactivated. The brake is used to decelerate the kiln car. The first distance sensor includes a slide rail fixed to the side of the kiln car head and a limiting plate fixed to the side of the kiln car tail. A slide rod is slidably connected inside the slide rail. One end of the slide rod is fixed with a spring that allows the slide rod to extend from the kiln car head. The other end of the slide rod is at the same height as the limiting plate of the adjacent kiln car. A first hydraulic cylinder is fixed inside the spring. One end of the first hydraulic cylinder is fixed to the end of the slide rail, and the other end of the first hydraulic cylinder is fixedly connected to the end of the slide rod. A gear and a Hall sensor are provided on the slide rail. The slide rail is rotatably connected to the gear. The Hall sensor includes a rotating part and a fixed part. The fixed part is fixedly connected to the side of the kiln car, and the gear is coaxially fixedly connected to the rotating part. A rack that meshes with the gear is fixed on the slide rod. The Hall sensor is signal-connected to the controller. The mechanical gripper includes a body and a gripper arm. The second hydraulic cylinder has two claw arms, each consisting of a vertical section and an inclined section. The vertical section is located on both sides of the brake disc, and the brake pads are fixedly connected to the vertical section. The vertical section is also fixedly connected to the inclined section. The two inclined sections are rotatably connected to the machine body at the same point. Each inclined section has a tail section that extends beyond the connection point with the machine body. The two ends of the second hydraulic cylinder are respectively hinged to the two tail sections. A high-temperature resistant hydraulic pipeline is provided between the second hydraulic cylinder and the first hydraulic cylinder. A sliding frame is provided between the machine body and the lower surface of the kiln car. The sliding frame is fixedly connected to the lower surface of the kiln car, and the machine body and the sliding frame are slidably connected. A third cylinder is fixed on the sliding frame. The bottom of the third cylinder is fixed to the sliding frame, and the top of the third cylinder is fixed to the machine body. The third cylinder is filled with a liquid with a boiling point of 70-200℃.
2. The pottery jar firing and kiln feeding system according to claim 1, characterized in that: The brake includes a mechanical claw, a brake disc, and brake pads. The mechanical claw is fixed to the lower surface of the kiln car, the brake pads are fixed to the inside of the mechanical claw, and the brake disc is coaxially fixed to the wheels of the kiln car.
3. The pottery jar firing and kiln feeding system according to claim 1, characterized in that: It also includes the thermal insulation asbestos felt laid on the outer surface of the kiln.
4. The pottery jar firing and kiln feeding system according to claim 3, characterized in that: The thickness of the thermal insulation asbestos felt is 60mm.
5. The pottery jar firing and kiln feeding system according to claim 1, characterized in that: The brake includes a mechanical claw and multiple brake pads. The mechanical claw is fixed to the lower surface of the kiln car above the track, and one side of the brake pad is fixed to the inside of the mechanical claw.
6. A method for feeding and pushing ceramic jars into a kiln during firing, characterized in that, include: Step S10: Place the pottery jar to be fired on the brick support; Step S20: The top car machine proceeds, driving the kiln car into the kiln; Step S30: The first distance sensor detects the distance between the front end of the rear kiln car and the rear end of the front kiln car, and transmits the distance signal to the controller; Step S40: The controller determines whether the distance between the kiln workshop and the brake is within the preset range. When the distance is within the preset range, the controller transmits a signal to the brake to activate the brake. Step S50: The top car machine returns, the second distance sensor detects the distance between the kiln car behind and the top car machine, and transmits the distance signal to the controller; Step S60: The controller determines whether the distance between the rear kiln car and the top car machine has deviated from the preset range. When the distance deviates from the preset range, the controller transmits a signal to the brake to close the brake. Step S70: Close the kiln door; Step S80: Start the control system and turn on the flame gun; Step S90: After the kiln car passes through the preheating section and enters the firing section, the smoke extraction fan is turned on; Step S100: After the kiln car passes through the firing section and enters the cooling section, the flame torch is turned off and the quench fan is turned on. Step S110: Open the kiln door and send the kiln car out of the kiln; Step S120: Remove the pottery jar; Step S130: Clean up the debris under the insulation bricks.