An apparatus and method for roll forming

Abstract

This invention discloses a roll forming apparatus and method. The apparatus includes a conveying component, a pressing component, and a limiting plate. The conveying component conveys powder along a conveying direction. The pressing component includes a first forming roller and a second forming roller, which are spaced apart in the vertical direction and together form a compaction space. The compaction space receives the powder from the conveying component and compacts the powder to form a brick blank. The limiting plate is arranged sequentially with the first forming roller in the conveying direction and abuts against the brick blank to restrict the expansion of the upper surface of the brick blank. The roll forming apparatus and method of this invention, by using the first forming roller, the second forming roller, and the limiting plate to form a compaction space, prevents the upper surface of the brick blank from expanding and gradually releases the internal stress of the brick blank, thereby reducing the occurrence of cracks in the brick blank and ensuring the quality of the brick blank.

Description

Technical Field

[0001] This invention relates to the field of brick blank forming machinery, and more particularly to a roll forming apparatus and method thereof. Background Technology

[0002] Roll forming is a process that relies on the plastic movement characteristics of materials to form various complex parts using the principle of rolling extrusion. In existing technology, a roll press mainly consists of several parts, including a feeding device, a material level control device, a pair of rollers, a transmission device, a hydraulic system, and a lateral leak-proof device.

[0003] When a roller press is working, the movable rollers are driven by a motor to rotate, and loose material is conveyed to the gap between the two rollers, where it is crushed and compressed to form a dense material bed. Under the condition of material layer crushing, pure pressure crushing consumes much less energy than pure shearing and impact crushing. The roller press utilizes pure pressure in the material layer crushing process to achieve the purpose of improving efficiency and saving energy. However, in the existing roller press technology, extrusion molding is only performed through the gap between the upper and lower forming rollers. This may lead to the expansion of the brick blank after extrusion molding, resulting in cracks or reduced quality in the brick blank. Summary of the Invention

[0004] In order to overcome the shortcomings of the prior art, one of the objectives of the present invention is to provide a roll forming device, which forms a pressing mechanism by means of a first forming roller, a limiting plate and a second forming roller, to ensure that the occurrence of cracks in the brick blank is reduced.

[0005] The second objective of this invention is to provide a method for roll forming, in which the powder passes through the compaction space between the first forming roller and the second forming roller and is extruded and formed, and is then restricted by the limiting plate to ensure that the brick blank has fewer cracks.

[0006] One of the objectives of this invention is achieved through the following technical solution:

[0007] An apparatus for roll forming, comprising:

[0008] A conveying assembly for conveying powder along a conveying direction;

[0009] The pressing assembly includes a first forming roller and a second forming roller, which are spaced apart in the vertical direction and together form a compaction space. The compaction space is used to receive powder from the conveying assembly and compact the powder to form a brick blank.

[0010] The limiting plate, the first forming roller and the limiting plate are arranged in sequence in the conveying direction. The limiting plate is used to abut against the brick blank to limit the expansion of the upper surface of the brick blank.

[0011] Furthermore, the pressing assembly also includes a first driving roller, a first driven roller, and a compaction belt. A first forming roller is disposed between the first driving roller and the first driven roller. The first driven roller, the first forming roller, the limiting plate, and the first driving roller are arranged sequentially in the conveying direction. The first driving roller and the first driven roller cooperate with each other to tension the compaction belt.

[0012] Furthermore, the compaction belt between the first driven roller and the first forming roller forms a compaction section, and the compaction section forms an angle A with the conveying end face of the conveying assembly, where 0° < A < 10°.

[0013] Furthermore, the compaction belt between the first drive roller and the first forming roller forms the blanking section, and the blanking section forms an angle B with the conveying end face of the conveying assembly, where 0°≤B<10°.

[0014] Furthermore, the conveying assembly is provided with a side guard strip assembly, a side guard strip adjustment assembly, and a powder suction assembly on both sides of the conveying direction; the two side guard strip assemblies are spaced apart to form a conveying interval, which is connected to the compaction space; the side guard strip adjustment assembly can be used to adjust the two side guard strip assemblies to move closer to each other or further away from each other; the two powder suction assemblies are respectively located at the ends of the two side guard strip assemblies away from the compaction space, and the powder suction assemblies are used to suck up excess powder that exceeds the width of the conveying interval.

[0015] Furthermore, the powder suction component includes a distribution bin, which is connected to the end of the side guard strip assembly away from the compaction space. The distribution bin is provided with a distribution port, and a first scraper and a second scraper are provided on both sides of the distribution port. The first scraper is flush with the side guard strip, and the second scraper is spaced apart from the first scraper. The first scraper is used to guide excess powder exceeding the width of the conveying interval into the distribution bin through the distribution port.

[0016] Furthermore, the edge strip assembly includes a first edge strip and a second edge strip, which are arranged sequentially and sealed against each other in the conveying direction; the second edge strip is provided with an inclined surface that slopes from top to bottom in the conveying direction, and the inclined surface abuts against and fits against the compaction section.

[0017] Furthermore, the lower surface of the limiting plate is provided with at least one airbag or hydraulic capsule.

[0018] Furthermore, the roll forming apparatus also includes a drive mechanism, which is used to drive the limiting plate to move up and down relative to the second forming roller.

[0019] The second objective of this invention is achieved by the following technical solution:

[0020] A roll forming method includes the following steps:

[0021] Step 1: Fill the hopper with powder. Adjust the height of the hopper, the first forming roller and the limiting plate according to the thickness of the brick blank. The hopper controls the powder to fall onto the conveying assembly.

[0022] Step 2: The powder is conveyed to the conveying interval along the conveying direction. The powder suction component picks up the excess powder that exceeds the width of the conveying interval. The powder with its edges trimmed passes through the conveying interval and is gradually transported to the compaction space along the compaction section.

[0023] Step 3: In the compaction space, the first forming roller and the second forming roller work together to compact the powder into a brick blank, and the blank is shaped under the action of the limiting plate.

[0024] Step four: The brick blanks are output through the conveying assembly along with the blank output section.

[0025] In summary, the present invention has the following technical effects:

[0026] 1. The roller pressing apparatus of this application forms a compaction space through a first forming roller, a second forming roller, and a limiting plate. When the powder passes through the gap between the first forming roller and the second forming roller and is squeezed and formed by the first forming roller and the second forming roller, the limiting plate restricts the upper surface of the brick blank to prevent the upper surface of the brick blank from expanding and gradually releases the internal stress of the brick blank, thereby reducing the occurrence of cracks in the brick blank and ensuring the quality of the brick blank.

[0027] 2. The roll forming method of this application forms a compaction space through the first forming roller, the second forming roller and the limiting plate. When the powder passes through the gap between the first forming roller and the second forming roller and is squeezed and formed by the first forming roller and the second forming roller, the limiting plate restricts the upper surface of the brick blank to prevent the upper surface of the brick blank from expanding and gradually releases the internal stress of the brick blank, which can reduce the occurrence of cracks in the brick blank and thus ensure the quality of the brick blank. Attached Figure Description

[0028] Figure 1 This is a front view of the roll forming apparatus of the present invention;

[0029] Figure 2 This is a top view of the roll forming apparatus of the present invention;

[0030] Figure 3 This is a schematic diagram of an embodiment of the lower surface of the limiting plate of the present invention;

[0031] Figure 4 This is a schematic diagram of the edge guard strip of the present invention.

[0032] The meanings of the reference numerals in the attached drawings are as follows: 10, compaction belt; 11, first driving roller; 12, first driven roller; 13, compaction section; 14, billet discharge section; 20, conveyor belt; 21, second driving roller; 22, second driven roller; 30, first forming roller; 31, limiting plate; 40, second forming roller; 50, hopper; 60, side guard assembly; 61, first side guard; 62, second side guard; 63, side guard adjustment device; 64, side guard pushing device; 70, drive mechanism; 80, material distribution bin; 81, material distribution port; 82, powder collection port; 90, compaction space; 91, conveying interval; 92, stabilization space. Detailed Implementation

[0033] The present invention will now be further described with reference to the accompanying drawings and specific embodiments:

[0034] In the description of this invention, it should be noted that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0035] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention.

[0036] The present invention will now be described in further detail with reference to the accompanying drawings.

[0037] Example 1,

[0038] like Figure 1 and Figure 2 As shown, this embodiment provides a roll forming apparatus, including a conveying assembly and a pressing assembly. The conveying assembly is used to convey powder along a conveying direction. In this embodiment, specifically, the conveying assembly includes a second driving roller 21, a second driven roller 22, and a conveyor belt 20. The second driving roller 21 and the second driven roller 22 cooperate to tension the conveyor belt 20. When the roll forming apparatus is working, the second driving roller 21 is driven to rotate, thereby driving the conveyor belt 20 to drive.

[0039] The pressing assembly includes a first forming roller 30 and a second forming roller 40, which are distributed at intervals in the vertical direction. In this embodiment, the second forming roller 40 is specifically disposed between the second driving roller 21 and the second driven roller 22, and the first forming roller 30 and the second forming roller 40 together form a compaction space 90. The compaction space 90 is used to receive powder on the conveying assembly and compact the powder to form a brick blank.

[0040] The roll forming device also includes a limiting plate 31. The first forming roller 30 and the limiting plate 31 are arranged sequentially in the conveying direction, and the limiting plate 31 can abut against the formed brick blank. The limiting plate 31 and the conveying end face of the conveyor belt 20 form a stable space 92, which restricts the surface of the brick blank from expanding.

[0041] Based on the above structure, when using the roll forming device of this embodiment, powder is added to the hopper 50, and the height of the discharge port is automatically adjusted according to the thickness of the formed brick blank. Then, the hopper 50 controls the powder to fall onto the conveying assembly, and the conveyor belt 20 drives in the conveying direction. The powder also moves in the conveying direction and enters the compaction space 90. When the powder enters the compaction space 90, it is gradually compacted under the combined action of the first forming roller 30 and the second forming roller 40. Most of the gas between the powder is discharged, and then it is formed into a brick blank. After being formed, the brick blank enters the stabilization space 92. Due to the restriction of the lower surface of the limiting plate 31 and the conveying end face of the conveyor belt 20, it will not expand. In this process, the internal stress of the brick blank is gradually released, thereby forming a stable brick blank.

[0042] In the existing technology, when the powder passes through the compaction space 90, it is only squeezed and crushed by the first forming roller 30 and the second forming roller 40. After the powder is squeezed and formed into a brick blank by the first forming roller 30 and the second forming roller 40, the brick blank may still have internal stress and gas that wants to be released. If it is not subjected to other pressure, the surface of the brick blank may expand during the release process, which may cause cracks in the brick blank or even cause it to break again.

[0043] Therefore, in this embodiment, by arranging the first forming roller 30 and the limiting plate 31 sequentially in the conveying direction, after the powder is crushed and squeezed by the first forming roller 30 and the second forming roller 40 to form a brick blank, it still moves forward a certain distance under the restriction of the limiting plate 31. During this distance, the internal stress and gas of the brick blank are gradually released, but the surface expansion will not occur due to the pressing effect of the limiting plate 31. After passing this distance, the internal stress and gas of the brick blank have been partially released, thereby forming a stable brick blank without cracking, thus ensuring the quality of the brick blank.

[0044] It should be noted that, in addition to the second driving roller 21 and the second driven roller 22 working together to tension the conveyor belt 20, the conveyor assembly can also be implemented using other solutions in the prior art, such as using multiple drive rollers to tension the conveyor belt 20, or other methods that can drive the conveyor belt 20 in the conveying direction. The selection and setting can be made according to the actual needs.

[0045] Furthermore, such as Figure 1 As shown, the pressing assembly also includes a first driving roller 11, a first driven roller 12, and a compaction belt 10. A first forming roller 30 is disposed between the first driving roller 11 and the first driven roller 12. The first driven roller 12, the first forming roller 30, the limiting plate 31, and the first driving roller 11 are arranged sequentially in the conveying direction. The first driving roller 11 and the first driven roller 12 cooperate with each other to tension the compaction belt 10.

[0046] Based on the above structure, when the roll forming device of this embodiment is started, the first drive roller 11 rotates, driving the compaction belt 10 for transmission; and the second drive roller 21 rotates, thereby driving the conveyor belt 20 for transmission. In the conveying direction, the powder first contacts the compaction belt 10 on the conveying end face, and under the action of the compaction belt 10, some of the gas between the powder is gradually discharged, and then it is extruded and formed into a brick blank under the action of the first forming roller 30 and the second forming roller 40.

[0047] Due to the action of the compaction belt 10, the powder material is pre-compressed by the compaction belt 10 before entering the compaction space 90, which removes some of the gas between the powder particles. Then, the powder material enters the compaction space 90 and is further crushed and squeezed by the first forming roller 30 and the second forming roller 40 to form a brick blank. This arrangement ensures that the overall strength and thickness of the brick blank are as consistent as possible, thus improving the quality of the brick blank.

[0048] It should be noted that, in addition to using the first driving roller 11 and the first driven roller 12 to drive the compaction belt 10 as described above, other methods can also be used to drive the compaction belt 10, such as using multiple drive rollers to cooperate with each other to tension the compaction belt 10, or using multiple compaction belts 10, such as providing a first compaction belt 10 between the first driving roller 11 and the first forming roller 30, and providing another second compaction belt 10 between the first driven roller 12 and the first forming roller 30, which can also achieve the above effect. The selection and setting can be made according to the actual needs.

[0049] In addition, the compaction belt 10 or conveyor belt 20 mentioned in this article can be made of leather belt or steel belt. Leather belt is cheaper and has elasticity and good tension, making it easy to transmit power, but it is more prone to wear. Steel belt is more expensive, but it is not easy to wear and does not easily deform. The choice and setting can be made according to the actual needs.

[0050] Furthermore, such as Figure 1 As shown, a compaction section 13 is formed in the compaction belt 10 between the first driven roller 12 and the first forming roller 30. The compaction section 13 forms an angle A with the conveying end face of the conveying assembly, where 0° < A < 10°.

[0051] Based on the above structure, when the powder is conveyed to the compaction space 90 on the conveying component, it comes into contact with the compaction section 13. The compaction section 13 gradually removes some of the gas between the powder particles, and then the powder enters the compaction space 90 to be compacted and formed into a brick blank.

[0052] Because the compaction section 13 has an inclined surface that forms an angle with the conveying end face of the conveyor belt 20, the gap between the compaction section 13 and the conveying end face gradually tightens and the height gradually decreases. When the powder enters the gap between the compaction section 13 and the conveying end face, it is squeezed by the compaction section 13. The upper layer of powder is gradually squeezed into the lower layer of powder, and some of the gas between the powder is discharged. Then, the powder is squeezed a longer distance while the drop is smaller. Then it enters the compaction space 90 and is further squeezed and crushed by the first forming roller 30 and the second forming roller 40 to form a brick blank.

[0053] During this distance, the angle A between the compaction section 13 and the conveying end face of the conveying component should not be too large, nor should it be 0°.

[0054] If the included angle A is too large, the gap between the compaction section 13 and the conveying end face will decrease rapidly from a high height during this distance of the powder in the compaction section 13. That is, the effective compression distance will be shortened. The larger the included angle A is, the greater the initial gap height and the shorter the effective compression distance. When the powder is pre-compressed by the compaction section 13, the drop will be large. When the powder in the upper layer falls, it may cause the powder in the lower layer to disperse due to the effect of gravitational potential energy, resulting in uneven powder layer texture. Furthermore, the shortened effective compression distance also makes it impossible to effectively expel the gas between the powders.

[0055] If the included angle A is 0°, the compaction end face of the compaction section 13 is parallel to the conveying end face. When the powder passes through the compaction section 13, the upper layer of powder is blocked by the compaction section 13 and falls directly to the rear section. Since there is no gap between the compaction section 13 and the conveying end face at this time, the upper layer of powder cannot be gradually pressed into the bottom, so the gas between the powder cannot be effectively discharged.

[0056] Therefore, in this embodiment, when the compaction section 13 forms an angle A with the conveying end face of the conveying assembly, 0° < A < 10°.

[0057] Furthermore, such as Figure 1 As shown, the compaction belt 10 between the first active roller 11 and the first forming roller 30 forms the blanking section 14, and the blanking section 14 forms an angle B with the conveying end face of the conveying assembly, where 0°≤B<10°.

[0058] Based on the above structure, after the brick blank is formed, it continues to be transported outward through the conveying assembly, passing through the gap between the blank exit section 14 and the conveying end face, and then being transported outward.

[0059] In the conveying direction, the gap between the billet section 14 and the conveying end face gradually increases, and the height gradually increases. When the brick blank is formed and conveyed outward from the compaction space 90, it passes through the gap between the billet section 14 and the conveying end face. In order to prevent the formed brick blank from wearing down the billet section 14, an angle B is formed between the billet section 14 and the conveying end face of the conveying assembly, thereby gradually increasing the gap between the billet section 14 and the conveying end face.

[0060] To prevent the surface of the brick blank from expanding after molding, which could lead to cracks and reduce the quality of the brick blank, the included angle B should not be too large. That is, the gap between the blank exit section 14 and the conveying end face should not become too large all at once. The blank exit section 14 is still needed to restrict the brick blank, and the distance of this restriction should be lengthened. The larger the included angle B, the shorter the effective restriction distance of the brick blank.

[0061] Therefore, when the billet discharge section 14 forms an angle B with the conveying end face of the conveying assembly, 0°

[0062] ≤B<10°.

[0063] Furthermore, such as Figure 2 As shown, the conveying assembly is provided with a baffle strip assembly 60, a baffle strip adjustment assembly, and a powder suction assembly on both sides of the conveying direction; a conveying interval 91 is formed between the two baffle strip assemblies 60, and the conveying interval 91 is in communication with the compaction space 90; the baffle strip adjustment assembly can be used to adjust the two baffle strip assemblies 60 to be closer to each other or further apart; the two powder suction assemblies are respectively located at the ends of the two baffle strip assemblies 60 away from the compaction space 90, and the powder suction assemblies are used to suck up excess powder that exceeds the width of the conveying interval 91.

[0064] Based on the above structure, in order to achieve the width required by the manufacturer after the brick blank is formed, the gap width between the two edge strip assemblies 60 needs to be adjusted before entering the compaction space 90, so that this gap forms a conveying gap 91. When the powder passes through this conveying gap 91, the excess powder exceeding the width of this conveying gap 91 will be sucked away by the powder suction assembly. Then the trimmed powder is transported to the conveying gap 91. The edge strip assemblies 60 on both sides of the conveying gap 91 constrain the two sides of the powder to prevent the powder at the edge from spreading again. Finally, it is transported to the compaction space 90, where the pressing assembly compacts the powder to form a brick blank. The brick blank is then transported to the stabilization space 92, where it is restricted by the limiting plate 31 and the conveying end face, gradually releasing the internal stress and forming a stable brick blank.

[0065] The aforementioned side edge strip assemblies 60 and pressing assembly together form a system with the same function as the mold. The side edge strip assemblies 60 define the width of the brick blank, and the first forming roller 30 and the second forming roller 40 together define the thickness of the brick blank, so that the powder can be made into brick blanks of corresponding specifications according to the needs of the manufacturer.

[0066] Furthermore, such as Figure 2 As shown, the powder suction assembly includes a distribution bin 80, which is connected to the end of the side guard strip assembly 60 away from the compaction space 90. The distribution bin 80 is provided with a distribution port 81, and a first scraper and a second scraper are provided on both sides of the distribution port 81. The first scraper is flush with the side guard strip assembly, and the second scraper is spaced apart from the first scraper. The first scraper is used to guide excess powder exceeding the width of the conveying interval 91 into the distribution bin 80 through the distribution port 81. In addition, in this embodiment, the powder suction assembly also includes a powder collection port 82, which is connected to the distribution bin 80. The powder collection port 82 is used to remove and recycle the powder in the powder suction assembly.

[0067] Based on the above structure, in this embodiment, the material distribution port 81 is specifically composed of a first scraper and a second scraper. The first scraper is disposed on the side guard strip assembly and forms a plane with the inner side of the side guard strip assembly. That is, the spacing width between the first scrapers on both sides of the conveying direction is equal to the spacing width between the side guard strip assemblies on both sides. The second scraper is disposed on the other side of the material distribution port 81. The second scraper and the first scraper are spaced apart to form the material distribution port 81 together, and the material distribution port 81 is in communication with the material distribution bin 80.

[0068] Before entering the conveying interval 91, the powder moves forward continuously as the conveyor belt 20 drives it. Powder with a width equal to that of the conveying interval 91 will enter the conveying interval 91. Excess powder exceeding the width of the conveying interval 91 will be blocked by the first scraper and guided by the second scraper, and enter the distribution bin 80 from the distribution port 81. The powder in the distribution bin 80 will then be taken out by the manufacturer for recycling through the powder collection port 82.

[0069] Before entering the conveying interval 91, the powder collapses around its edges due to its own characteristics and gravity. Therefore, the discharge width of the powder is greater than its forming width. The side guard assemblies 60 on both sides of the conveying direction, after adjustment, limit the forming width of the powder. That is, the width of the conveying interval 91 equals the forming width. Thus, powder within the forming width enters the conveying interval 91, and under the constraint of the side guard assemblies 60, the edges are prevented from collapsing again. Excess powder outside the forming width is blocked by the first scraper and guided by the second scraper as it passes through the conveying interval 91. As the conveyor belt 20 continues to move, the powder enters the distribution bin 80 through the distribution port 81, and is then retrieved and recycled by the manufacturer through the powder collection port 82.

[0070] Furthermore, such as Figure 4 As shown, the edge strip assembly 60 includes a first edge strip 61 and a second edge strip 62. The first edge strip 61 and the second edge strip 62 are arranged sequentially and sealed against each other in the conveying direction. The second edge strip 62 is provided with an inclined surface that slopes from top to bottom in the conveying direction, and the inclined surface abuts against and fits against the compaction section 13.

[0071] Based on the above structure, in the conveying interval 91, the powder is simultaneously pre-compressed by the compaction section 13. In order to ensure that the powder on both sides is still constrained by the edge strip assembly 60 during the pre-compressing process of the compaction section 13 and does not collapse, a second edge strip 62 is provided in this distance and is sealed and abutted against the first edge strip 61 to form the edge strip assembly 60. The second edge strip 62 is provided with an inclined surface that slopes from top to bottom in the conveying direction and abuts against the compaction section 13, that is, the inclined surface abuts and fits against the end face of the compaction section 13.

[0072] Therefore, when the powder is pre-pressed by the compaction section 13, both sides are also constrained by the second edge strip 62, and will not leak out from the gap to both sides. This effectively allows the powder to enter the compaction space 90 within a limited width, and is compacted into a stable brick blank under the action of the pressing component, ensuring the specifications and quality of the brick blank.

[0073] Furthermore, such as Figure 3 As shown, at least one airbag or hydraulic capsule is provided on the lower surface of the limiting plate 31.

[0074] Based on the above structure, the lower surface of the limiting plate 31 presses the brick blank, restricts the expansion of the upper surface of the brick blank, and allows the internal stress of the brick blank to be gradually released, ensuring that the brick blank will not crack and guaranteeing the quality of the brick blank.

[0075] In this embodiment, in addition to using a steel plate as the lower surface of the limiting plate 31, an airbag or hydraulic capsule can be selected to limit the brick blank according to the specifications and hardness of the formed brick blank.

[0076] Alternatively, if it is desired that the lower surface of the limiting plate 31 exerts different degrees of pressure on the brick blank, multiple different air bladders or hydraulic capsules can be set on the lower surface of the limiting plate 31, and the gas volumes inside these air bladders or hydraulic capsules can be different, thereby generating different degrees of pressure. The selection and setting can be made according to the actual needs.

[0077] Furthermore, such as Figure 1 As shown, the roll forming device also includes a drive mechanism 70, which is used to drive the limiting plate 31 to move up and down relative to the second forming roller 40.

[0078] Based on the above structure, the limiting plate 31 is driven to move up and down relative to the second forming roller 40 by the driving mechanism 70, thereby adjusting the height of the limiting plate 31 and producing forming brick blanks of different thicknesses. Therefore, when using the roll forming apparatus of this embodiment, forming brick blanks of different thicknesses can be manufactured to meet the needs of different customers.

[0079] It should be noted that the drive device can be hydraulically driven, oil-pressure driven, or gear and rack driven, or other existing drive methods can be used to drive the limit plate 31, as long as the up and down movement of the limit plate 31 is achieved.

[0080] Example 2,

[0081] Based on the above-mentioned roll forming apparatus, a roll forming method is provided, comprising the following steps:

[0082] Step 1: Fill the hopper 50 with powder. Adjust the height of the hopper 50, the first forming roller 30 and the limiting plate 31 according to the thickness of the brick blank. The hopper 50 controls the powder to fall onto the conveying assembly.

[0083] Step 2: The powder is conveyed along the conveying direction to the conveying interval 91. The powder suction component picks up the excess powder that exceeds the width of the conveying interval 91. The powder with its edges trimmed passes through the conveying interval 91 and is gradually transported to the compaction space 90 along with the compaction section 13.

[0084] Step 3: Within the compaction space 90, the first forming roller 30 and the second forming roller 40 work together to compact the powder into a brick blank, which is then shaped under the action of the limiting plate 31.

[0085] Step four: The brick blanks are output through the conveyor assembly.

[0086] In this embodiment, in step one, according to the specifications, thickness and width of the brick blank to be produced, the height of the hopper 50, the first forming roller 30 and the limiting plate 31 are first adjusted, and then the spacing width of the two side edge strip components 60 is adjusted by the above-mentioned side edge strip adjustment component to form the conveying interval 91. Powder is filled into the hopper 50, and then the hopper 50 controls the powder to fall onto the conveyor belt 20, and transports it in the conveying direction with the movement of the conveyor belt 20.

[0087] Step 2: When the powder passes through the conveying interval 91, the powder that meets the width of the conveying interval 91 is conveyed through the conveying interval 91 and is constrained by the side guard strip assemblies 60 on both sides, while the excess powder that exceeds the width of the conveying interval 91 enters the distribution bin 80 through the distribution port 81 and is recycled by the manufacturer; the powder entering the conveying interval 91 is pre-compressed by the compaction section 13 to expel most of the air between the powders, and then enters the compaction space 90.

[0088] Step 3: After the powder enters the compaction space 90, it is first crushed and extruded into a brick blank by the combined force of the first forming roller 30 and the second forming roller 40. Under the restriction of the limiting plate 31, the gas and internal stress inside the brick blank are gradually released and will not cause the upper surface to expand. Then it gradually stabilizes and forms a high-quality brick blank.

[0089] Step four: The formed brick blanks are output through the conveying assembly.

[0090] Example 3,

[0091] The roll forming method provided in this application can also be used when using other roll forming apparatus.

[0092] Step 1: Fill the hopper 50 with powder. Adjust the height of the hopper 50, the first forming roller 30 and the limiting plate 31 according to the thickness of the brick blank. The hopper 50 controls the powder to fall onto the conveying assembly.

[0093] Step 2: The powder is conveyed along the conveying direction to the conveying interval 91. The powder suction component picks up the excess powder that exceeds the width of the conveying interval 91. The powder with its edges trimmed passes through the conveying interval 91 and is gradually transported to the compaction space 90 along with the compaction section 13.

[0094] Step 3: Within the compaction space 90, the first forming roller 30 and the second forming roller 40 work together to compact the powder into a brick blank, which is then shaped under the action of the limiting plate 31.

[0095] Step four: The brick blanks are output through the conveyor assembly.

[0096] In this embodiment, when adjusting the feeding height in step one, the manufacturer can manually adjust the height of the hopper 50 or set an automatically adjustable hopper 50. Alternatively, the thickness of the formed brick blank can be limited by manually or automatically adjusting the height of the first forming roller 30 and the limiting plate 31.

[0097] In step two, when the powder enters the conveying interval 91, the excess powder can be manually swept off and recycled by the manufacturer, or it can be sucked away and recycled using other existing technologies such as suction pipes. Then, the powder entering the conveying interval 91 is pre-compressed under the action of the compaction section 13 and conveyed into the compaction space 90.

[0098] It should be noted that the compaction section 13 can be a complete compaction belt 10, such as a compaction belt 10 that is tensioned by the first driven roller 12 and the first forming roller 30 working together, or it can be a part of the compaction belt 10.

[0099] In step three, after the action of the first forming roller 30 and the second forming roller 40, the powder is compacted to form a brick blank. Then, the brick blank can also be restricted by the exit section 14 to prevent the surface of the brick blank from expanding. The exit section 14 can be part of the above-mentioned compaction section, or it can be the compaction belt 10 that is tensioned by the first drive roller 11 and the first forming roller 30 working together.

[0100] Step four: After a stable brick blank is formed, it is produced outward through a conveying assembly.

[0101] For those skilled in the art, various other corresponding changes and modifications can be made based on the technical solutions and concepts described above, and all such changes and modifications should fall within the protection scope of the claims of this invention.

Claims

1. A roll forming apparatus, characterized in that, include: A conveying assembly for conveying powder along a conveying direction; The pressing assembly includes a first forming roller and a second forming roller, which are spaced apart in the vertical direction and together form a compaction space. The compaction space is used to receive powder from the conveying assembly and compact the powder to form a brick blank. The pressing assembly also includes a first driving roller, a first driven roller, and a compaction belt, with the compaction belt between the first driven roller and the first forming roller forming a compaction section. A limiting plate is provided, with the first forming roller and the limiting plate arranged sequentially in the conveying direction. The limiting plate is used to abut against the brick blank to limit the surface expansion of the brick blank. The conveying assembly is provided with a side guard strip assembly, a side guard strip adjustment assembly, and a powder suction assembly on both sides of the conveying direction; a conveying interval is formed between the two side guard strip assemblies, and the conveying interval is in communication with the compaction space; the side guard strip adjustment assembly is used to adjust the two side guard strip assemblies to move closer to each other or further away from each other; the two powder suction assemblies are respectively located at the ends of the two side guard strip assemblies away from the compaction space, and the powder suction assemblies are used to suck away excess powder that exceeds the width of the conveying interval; The edge guard assembly includes a first edge guard and a second edge guard, which are arranged sequentially and sealed against each other in the conveying direction; the second edge guard has an inclined surface that slopes from top to bottom in the conveying direction, and the inclined surface abuts against and fits against the compaction section.

2. The roll forming apparatus according to claim 1, characterized in that, The first forming roller is disposed between the first driving roller and the first driven roller, and the first driven roller, the first forming roller, the limiting plate and the first driving roller are arranged in sequence in the conveying direction; the first driving roller and the first driven roller cooperate with each other to tension the compaction belt.

3. The roll forming apparatus according to claim 2, characterized in that, The compaction section forms an angle A, 0° with the conveying end face of the conveying assembly. <A<10°。 4. The roll forming apparatus according to claim 2, characterized in that, The compaction zone between the first active roller and the first forming roller forms the blank exit section, and the blank exit section forms an angle B with the conveying end face of the conveying assembly, where 0°≤B<10°.

5. The roll forming apparatus according to claim 1, characterized in that, The powder suction component includes a distribution bin, which is connected to the end of the edge strip assembly away from the compaction space. The distribution bin is provided with a distribution port, and a first scraper and a second scraper are provided on both sides of the distribution port. The first scraper is flush with the edge strip assembly, and the second scraper is spaced apart from the first scraper. The first scraper is used to guide excess powder exceeding the width of the conveying interval into the distribution bin through the distribution port.

6. The roll forming apparatus according to claim 1, characterized in that, The lower surface of the limiting plate is provided with at least one airbag or hydraulic capsule.

7. The roll forming apparatus according to claim 1, characterized in that, The roll forming apparatus further includes a drive mechanism, which is used to drive the limiting plate to move up and down relative to the second forming roller.

8. A method for roll forming, using the roll forming apparatus of claim 4, characterized in that, Includes the following steps: Step 1: Fill the hopper with powder. Adjust the height of the hopper, the first forming roller and the limiting plate according to the thickness of the brick blank. The hopper controls the powder to fall onto the conveying assembly. Step 2: The powder is conveyed to the conveying interval along the conveying direction. The powder suction component sucks up the excess powder that exceeds the width of the conveying interval. The powder with its edges trimmed passes through the conveying interval and is gradually transported to the compaction space along the compaction section. Step 3: Within the compaction space, the first forming roller and the second forming roller work together to compact the powder into a brick blank, which gradually stabilizes under the action of the limiting plate. Step four: The brick blank is output outward along with the blank output section via the conveying assembly.

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