An efficient production line of dry method ecological stone material with the whole body imitating natural stone

Abstract

The application discloses a kind of high-efficiency production lines of ecological stone dry method material of whole body imitating natural stone, including powder scattering equipment, batching equipment, material distribution equipment, ferry belt, excess material real-time recycling device, ferry belt, vacuum extraction vibration pressing device and mould turnover demoulding device;Powder scattering equipment, batching equipment and material distribution equipment are sequentially linked, and excess material real-time recycling device is set around material distribution equipment, and ferry belt is used to link material distribution equipment, vacuum extraction vibration pressing device and mould turnover demoulding device;Each batching line is equipped with 1 transfer hopper, and the batching line has at least one loading station and a plurality of unloading stations;The discharge end of a powder scattering assembly is located above a loading station;Transfer hopper receives the powder transported out by the discharge end of a powder scattering assembly at a loading station, and transfers the powder to a specified unloading station.The production efficiency of the ecological stone dry method material of the application is high, and the ecological stone of whole body imitating natural stone is obtained.

Description

Technical Field

[0001] This invention relates to the field of eco-stone production equipment technology, and in particular to a high-efficiency production line for dry-process eco-stone fabric that mimics natural stone throughout. Background Technology

[0002] With the continuous development of society and the economy, people have increasingly higher requirements for the natural-looking effects and textures of eco-stone products. Currently, the preparation of eco-stone typically involves material preparation and a material distribution process. For dry material distribution, in order to give the eco-stone a certain texture, multiple colors of powder need to be prepared. These powders are then loaded into different hoppers, and the order of feeding and the arrangement on the material distribution belt allow the powder to be spread into the mold to form textures. Therefore, the dry material distribution method for eco-stone requires feeding into a large number of hoppers. However, current technology involves feeding each hopper individually, resulting in a relatively large structure for the material distribution equipment.

[0003] In the production process of eco-stone, a material feeding device is typically used to feed powder into a mold. The mold moves below the feeding device, driven by a mold conveyor belt. During this process, powder inevitably spills onto the conveyor belt surface and falls to the ground, resulting in waste and environmental pollution. Currently, a traditional offline recycling method is used, where spilled powder is directly transported to a recycling bin. Once the bin is full, the powder is then transported to the raw material workshop for secondary processing. This results in a low recovery rate and a long recycling cycle for the entire powder recovery process.

[0004] Furthermore, in existing technologies, the dry-laying process is used to achieve the patterned texture decorative effect of eco-stone. For example, current dry-laying methods involve dropping various colored powders onto a conveyor belt, which then transfers the powders into a mold, forming a multi-colored layer, which is then pressed into shape. While the resulting eco-stone has a uniform color and texture, it cannot achieve the multi-colored block decorative effect of natural stone. Currently, there are also dry-laying processes that involve inkjet printing on the material layer before pressing, but these also fail to achieve the uniform multi-colored block decorative effect of natural stone.

[0005] In view of this, it is necessary to provide a high-efficiency production line for eco-stone that imitates natural stone throughout. Summary of the Invention

[0006] The purpose of this invention is to propose a high-efficiency production line for dry-process fabrication of eco-stone that imitates natural stone throughout, which can effectively improve the production efficiency of dry-process fabrication of eco-stone and obtain eco-stone that imitates natural stone throughout.

[0007] To achieve this objective, the present invention adopts the following technical solution:

[0008] A high-efficiency production line for dry-process fabrication of eco-friendly stone that mimics natural stone throughout includes a powder dispersing device, a feeding device, a fabrication device, a mold conveyor belt, a waste material recycling device, a transfer belt, a vacuum vibration pressing device, and a mold flipping and demolding device.

[0009] The powder dispersing device, the feeding device, and the cloth spreading device are connected in sequence. The mold conveyor belt is located below the cloth spreading device. The residual material recycling device is arranged around the cloth spreading device. The shuttle belt is used to connect the cloth spreading device, the vacuum vibration pressing device, and the mold flipping and demolding device. The shuttle belt is used to transfer the mold from the cloth spreading device to the vacuum vibration pressing device and from the vacuum vibration pressing device to the mold flipping and demolding device.

[0010] The powder dispersing equipment includes several powder dispersing components, and the feeding equipment includes multiple feeding lines, each feeding line having a transfer hopper. The transfer hopper moves along the feeding line, and the feeding line has at least one loading station and several unloading stations. The unloading station is equipped with a receiving hopper. The discharge end of one of the powder dispersing components is located above one of the loading stations. The transfer hopper receives a single-color powder from the discharge end of one of the powder dispersing components at one of the loading stations and transfers the single-color powder to one of the unloading stations.

[0011] The fabric feeding equipment includes a mold conveyor belt, a main material feeding mechanism, a large texture pressing and breaking mechanism, and a fabric feeding mechanism. The mold conveyor belt carries the mold through the main material feeding mechanism, the large texture pressing and breaking mechanism, and the fabric feeding mechanism in sequence. The mold conveyor belt carries the mold back and forth multiple times in the main material feeding mechanism. Both the main material feeding mechanism and the fabric feeding mechanism include a frame with several feeding units. The feeding units are arranged side by side and installed at intervals on the frame.

[0012] Each fabric unit includes several fabric hoppers, each fabric hopper in the fabric unit corresponds to one of the feeding lines, and the positions of the fabric hopper and the receiving hopper are opposite to each other;

[0013] The real-time recycling device for surplus materials includes a bottom recovery belt, a side conveyor belt, an inclined belt, a material recycling and dispersing mechanism, a lifting belt, and a material replenishment device.

[0014] The bottom recovery belt is located directly below the output end of the mold conveyor belt, and the side conveyor belt is located on the side of the mold conveyor belt and is connected to the bottom recovery belt. The side conveyor belt is used to transport the residual material collected by the bottom recovery belt to the inclined belt. The discharge end of the inclined belt is located above the feed end of the return material dispersing mechanism.

[0015] The discharge end of the material return and dispersing mechanism is connected to the lifting belt, and the lifting belt transports the dispersed residual material to the feeding hopper of the feeding device;

[0016] The material recycling and dispersing mechanism is used to disperse the recycled surplus material, and the material replenishing device is used to replenish the dispersed surplus material into the mold of the mold conveyor belt.

[0017] Furthermore, the bottom of the transfer hopper is connected to an opening and closing assembly, which slides at the bottom of the transfer hopper to block and open the discharge port of the transfer hopper.

[0018] Each of the unloading stations is equipped with a liftable gate opening device, and the gate opening device is installed on the side of the receiving hopper away from the loading station. When the gate opening device is raised, it blocks the moving opening and closing components, thereby opening the discharge port of the transfer hopper.

[0019] The loading station is equipped with a liftable gate device. When the gate device is raised, it blocks both sides of the opening and closing assembly. The transfer hopper moves on the feeding line, thus blocking the discharge port of the transfer hopper.

[0020] Furthermore, the opening and closing assembly includes a sliding frame and a gate, the gate is fixedly installed in the middle of the sliding frame, and a discharge space is formed between the end of the gate and the end of the sliding frame. Both ends of the sliding frame have the discharge space.

[0021] The sliding frame is slidably installed at the bottom of the transfer hopper. The sliding frame slides so that the gate and the discharge slot correspond to the discharge port of the transfer hopper. The receiving hopper is located below the travel path of the sliding frame.

[0022] Furthermore, the gate opening device includes a first tilting seat, a first tilting arm, a first lifting cylinder, and a first angle limiting frame. The first tilting seat is connected to the feeding line. One end of the first tilting arm is hinged to the first tilting seat, and a first blocking block is fixedly installed on the other end of the first tilting arm. The first lifting cylinder is located below the first tilting arm, and the telescopic end of the first lifting cylinder corresponds to the position of the first tilting arm.

[0023] The first tilting seat, the first tilting arm, and the first lifting cylinder are respectively located below the travel path of the sliding frame. When the extension end of the first lifting cylinder is in the retracted state, the first tilting arm is tilted downward, causing the first blocking block to descend below the travel path of the sliding frame. When the extension end of the first lifting cylinder is in the extended state, the first lifting cylinder drives the first tilting arm to rise, causing the first blocking block to rise. The position of the first blocking block after it rises corresponds to the position of the sliding frame, so that the first blocking block after it rises blocks the sliding frame.

[0024] The first angle limiting frame is in the shape of an inverted "U". The opening of the first angle limiting frame is fixedly installed on the first flipping base with the opening facing downward. The end of the first flipping arm near the first flipping base is accommodated in the first angle limiting frame.

[0025] The first angle limiting frame is located below the walking trajectory of the sliding frame.

[0026] Furthermore, the feeding line includes a chain drive device for driving the transfer hopper to move along the feeding line. The gate closing device includes two gate closing components arranged in a mirror image, located on both sides of the loading station. The two gate closing components are used to block both sides of the sliding frame, fixing the position of the sliding frame. The chain drive device drives the transfer hopper to move, causing the discharge port of the transfer hopper to move from the discharge space to the gate.

[0027] The gate closing assembly includes a second tilting seat, a second tilting arm, a second lifting cylinder, a second blocking block, and a connecting plate. The second tilting seat is connected to the mounting rod of the feeding line. One end of the second tilting arm is hinged to the second tilting seat, and the other end of the second tilting arm is connected to the connecting plate. The second blocking block is mounted on the connecting plate. The second lifting cylinder is mounted on the mounting rod of the feeding line, and the second lifting cylinder is located below the second tilting arm.

[0028] The blocking end of the second blocking block faces the second flip base, and the blocking end of the second blocking block is equipped with a sensor;

[0029] The second tilting seat, the second tilting arm, and the second lifting cylinder are respectively located below the travel path of the sliding frame. When the extension end of the second lifting cylinder is in the retracted state, the second tilting arm is tilted downward, causing the second blocking block to descend below the travel path of the sliding frame. When the extension end of the second lifting cylinder is in the extended state, the second lifting cylinder drives the second tilting arm to rise, causing the second blocking block to rise. The position of the second blocking block after it rises corresponds to the position of the sliding frame, so that the second blocking block after it rises blocks one side of the sliding frame.

[0030] The distance between the two second blocking blocks of the two mirror-symmetrical gate assemblies after they rise corresponds to the length of the sliding frame, so that the two second blocking blocks after rising are used to block the two sides of the sliding frame respectively.

[0031] Furthermore, the fabric feeding unit includes several fabric feeding hoppers, several discharge belts, a collection belt, a collection hopper, a briquetting belt, a briquetting device, a spiral cutter, and a fabric feeding toothed plate. Several fabric feeding hoppers are arranged side by side on the frame. Each fabric feeding hopper has a discharge belt below its discharge port, and the discharge belts are located above the collection belts. One fabric feeding hopper is located below a receiving hopper, and the position of the discharge port of the receiving hopper corresponds to the position of the inlet of the fabric feeding hopper.

[0032] The collecting hopper is located below the collecting belt, and the feeding port of the collecting hopper corresponds to the end of the collecting belt in the conveying direction. The briquetting belt is located below the collecting hopper, and the briquetting device is installed above the briquetting belt. The briquetting device is used to pre-press the mixed powder on the briquetting belt into blocks.

[0033] A spiral cutter is provided above the end of the conveying direction of the briquetting belt. The spiral cutter is used to cut the blocky mixed powder into strips. A fabric toothed plate is connected to the end of the conveying direction of the briquetting belt. The cut strips of powder fall into the mold through several teeth of the fabric toothed plate.

[0034] The edge of the fabric toothed plate has several teeth connected in sequence, and the size and shape of the teeth are different.

[0035] The transition between two adjacent teeth is smooth, and the spacing between the tips of adjacent teeth in a plurality of teeth is different, and the teeth are arc-shaped or corner-shaped.

[0036] Furthermore, a powder-spreading mechanism is also provided between the fabric-spreading mechanisms. The powder-spreading mechanism includes a screen, a screen fixing frame, and a vibrator. The screen and the vibrator are both installed on the screen fixing frame.

[0037] A spraying mechanism is provided corresponding to the powder spreading mechanism. The spraying mechanism is used to spray water or colored slurry.

[0038] Furthermore, the real-time recycling device for surplus materials includes a bottom recycling belt, a side conveyor belt, a recycling and dispersing mechanism, and a replenishment device;

[0039] The bottom recovery belt is located below the output end of the mold conveyor belt, and the side conveyor belt is located on the side of the mold conveyor belt;

[0040] The side conveyor belt is connected to the bottom recovery belt. The side conveyor belt is used to transport the residual material collected by the bottom recovery belt to the inclined belt. A water replenishment mechanism is provided above the inclined belt. The discharge end of the inclined belt is located above the feed end of the return material dispersing mechanism.

[0041] The discharge end of the material return and dispersing mechanism is connected to the lifting belt, and the lifting belt transports the dispersed residual material to the feeding hopper of the feeding device;

[0042] The water replenishment mechanism is used to replenish the water in the recovered residual material, the material dispersing mechanism is used to disperse the recovered residual material, and the material replenishing device is used to replenish the dispersed residual material into the mold of the mold conveyor belt.

[0043] Furthermore, the shuttle belt includes a mold transport platform and a transfer track, and the mold transport platform moves along the transfer track;

[0044] The vacuum vibration pressing device includes a vacuum vibration press and a pressing conveyor belt. The pressing conveyor belt is positioned corresponding to the vacuum vibration press and is used to feed the mold into or out of the vacuum vibration press.

[0045] The mold flipping and demolding device includes an arc-shaped track, a sliding ring, and a flipping table. The flipping table is installed inside the sliding ring, which is vertically arranged. The outer wall of the sliding ring slides in conjunction with the arc-shaped track. The flipping table is used to position the mold.

[0046] The mold conveying platform, the mold conveying belt, the pressing and transferring belt, and the tilting platform are arranged in parallel; the mold conveying platform moves along the transfer track and connects with the mold conveying belt, the pressing and transferring belt, and the tilting platform respectively.

[0047] Furthermore, the material recycling and dispersing mechanism and the vacuum vibration pressing device are respectively located on both sides of the fabric feeding equipment.

[0048] The above technical solutions have the following beneficial effects:

[0049] 1. The production line of the present invention integrates powder dispersing equipment, feeding equipment, cloth spreading equipment, waste material recycling device, ferry belt, vacuum vibration pressing device and mold flipping demolding device, realizing the assembly line of feeding, cloth spreading, waste material recycling, pressing and molding and demolding in the dry cloth spreading of ecological stone, so as to achieve the purpose of high-efficiency production.

[0050] 2. The material distribution equipment uses multiple material distribution lines to coordinate the transfer of hoppers, enabling a small number of feeding lines to distribute materials to a large number of cloth hoppers. This achieves the effect of each cloth hopper holding a single color material, and the powder in each cloth unit is of a variety of colors, thus achieving diversified cloth distribution. This greatly reduces the difficulty of material distribution and simplifies the structure of the material distribution equipment.

[0051] 3. The fabric-laying device of this invention uses irregular small pieces of material to lay the main material and the fabric to achieve a full-body imitation of natural stone color blocks. Furthermore, it imitates the crack patterns in the texture of natural stone by creating fracture lines within the material layers, achieving a full-body imitation of natural stone. Because of the irregular small piece laying method, the surface of the material layer inside the mold is uneven, with some small pieces in a tilted state. When the powder-sprinkling mechanism sprinkles powder into the mold, the powder slides on the surface of the material layer and accumulates at the edges of some small pieces, forming a wrapping texture, simulating the color accumulation at the edges of large color spots in natural stone, further enhancing the simulation effect. When the spraying mechanism sprays water or colored slurry, it moistens the surface of the material layer inside the mold, increasing the adhesion between the various layers in the mold. Spraying colored slurry also enhances the decorative effect of the ecological stone surface.

[0052] 4. The real-time recycling device for residual materials collects the fallen powder in real time and promptly conveys it to the material recycling and dispersing mechanism for crushing and to the replenishing device for reuse. This achieves real-time collection and reuse of fallen powder, saving labor, ensuring the cleanliness of the recycled powder, and preventing the fallen powder from becoming too dry and difficult to crush. This invention creatively uses the recycled powder in the final powdering step of dry-process fabric application, achieving not only timely use of the recycled powder but also improving the simulation effect of the eco-stone. Attached Figure Description

[0053] Figure 1 This is a schematic diagram of the structure of a high-efficiency production line for dry-process fabrication of eco-friendly stone that mimics natural stone throughout, according to an embodiment of the present invention.

[0054] Figure 2 yes Figure 1A schematic diagram showing the coordination between the material feeding equipment and the powder dispersing equipment in a high-efficiency production line.

[0055] Figure 3 yes Figure 2 A partial top view of the feeding equipment and powder dispersing equipment shown;

[0056] Figure 4 yes Figure 2 A schematic diagram of the feeding equipment and powder dispersing equipment shown from another perspective;

[0057] Figure 5 yes Figure 2 A schematic diagram of the structure of the transfer hopper and the opening / closing assembly in the material delivery equipment shown;

[0058] Figure 6 yes Figure 5 Schematic diagram of the structure of the opening and closing component;

[0059] Figure 7 yes Figure 2 The diagram shows the coordination relationship between the transfer hopper, the gate opening device, and the opening and closing components in the material distribution equipment shown (the discharge port is located at the position of the receiving hopper, at which time the extension end of the first lifting cylinder extends upward, driving the first blocking block to rise and block the opening and closing components).

[0060] Figure 8 yes Figure 2 A schematic diagram showing the coordination relationship between the transfer hopper, the gate closing device, and the opening and closing components in the material distribution equipment shown (a diagram showing the state after the extension end of the second lifting cylinder extends and lifts the second blocking block).

[0061] Figure 9 yes Figure 1 A schematic diagram of the material feeding equipment and the real-time waste material recycling device in the high-efficiency production line shown;

[0062] Figure 10 yes Figure 9 A partial schematic diagram of the fabric-laying unit in the fabric-laying equipment shown;

[0063] Figure 11 yes Figure 9 A schematic diagram of the installation of the fabric-laying unit in the fabric-laying equipment shown;

[0064] Figure 12 yes Figure 6 Side view of the fabric unit shown;

[0065] Figure 13 yes Figure 9 Schematic diagram of the transmission direction of the discharge belt and the collecting belt;

[0066] Figure 14 yes Figure 9Schematic diagram of the large texture pressing mechanism, powder spreading mechanism and spraying mechanism of the medium fabric equipment;

[0067] Figure 15 yes Figure 9 The diagram shows the real-time recycling device for surplus materials working in conjunction with the mold conveyor belt.

[0068] Among them: Fabric feeding equipment A, material feeding equipment B, powder dispersing equipment C, powder dispersing component C1;

[0069] Frame A1, mold conveyor belt A2, material feeding unit A3, material feeding hopper A31, discharge belt A32, collection belt A33, collection hopper A34, briquetting device A35, briquetting belt A36, spiral cutter A37, material feeding toothed plate A38, pressure plate A352, rotating shaft A371, circular blade A372, teeth A381, large texture pressing mechanism A4, lifting frame A41, lifting drive component A42, pressing knife A43, powder spreading mechanism A5, material dropping screen A51, spraying mechanism A6;

[0070] Transfer hopper B1, gate opening device B2, gate closing device B3, opening and closing assembly B4, guide wheel B6, chain drive device B7, first tilting seat B21, first tilting arm B22, first lifting cylinder B23, first blocking block B24, first angle limiting frame B25, gate closing assembly B31, sliding frame B41, gate plate B42, discharge space B43, unloading station B51, second tilting seat B311, second tilting arm B312, second lifting cylinder B313, second blocking block B314, connecting plate B315, second angle limiting frame B316, first guide bar B411, limit stop bar B412, receiving hopper B511;

[0071] The following components are included: a real-time waste material recycling device D; a bottom recycling belt D1; a baffle plate D10; an inclined belt D2; a side conveyor belt D3; a waste material dispersing mechanism D4; a feeding device D5; and a lifting belt D6.

[0072] Ferry belt E, mold conveyor E1, transfer track E2;

[0073] Vacuum vibration pressing device F, vacuum vibration press F1, pressing conveyor belt F2;

[0074] Mold flipping and demolding device G, arc track G1, sliding ring G2, flipping table G3. Detailed Implementation

[0075] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0076] In the description of this invention, it should be understood that the terms "longitudinal," "lateral," "upper," "lower," "front," "rear," "left," "right," "vertical," "horizontal," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for 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 the invention. Furthermore, features defined with "first" and "second" may explicitly or implicitly include one or more of these features, used to distinguish and describe features, without any order or emphasis.

[0077] In the description of this invention, unless otherwise stated, "a number" means two or more.

[0078] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0079] The following is combined Figures 1 to 15 This invention describes an efficient production line for dry-process fabrication of eco-friendly stone that mimics natural stone throughout.

[0080] A high-efficiency production line for dry-process fabrication of eco-friendly stone that mimics natural stone throughout includes a powder dispersing device, a feeding device, a fabrication device, a mold conveyor belt, a waste material recycling device, a transfer belt, a vacuum vibration pressing device, and a mold flipping and demolding device.

[0081] The powder dispersing equipment, feeding equipment and cloth spreading equipment are connected in sequence. The mold conveyor belt is located below the cloth spreading equipment. The residual material recycling device is set around the cloth spreading equipment. The shuttle belt is used to connect the cloth spreading equipment, the vacuum vibration pressing device and the mold flipping and demolding device. The shuttle belt is used to transfer the mold from the cloth spreading equipment to the vacuum vibration pressing device and from the vacuum vibration pressing device to the mold flipping and demolding device.

[0082] The powder dispersing equipment includes several powder dispersing components, and the feeding equipment includes multiple feeding lines. Each feeding line has a transfer hopper that moves along the feeding line. The feeding line has at least one loading station and several unloading stations. The unloading stations are equipped with receiving hoppers. The discharge end of one powder dispersing component is located above a loading station. The transfer hopper receives a single-color powder from the discharge end of one powder dispersing component at a loading station and transfers the single-color powder to an unloading station.

[0083] The fabric feeding equipment includes a mold conveyor belt A2, a main material feeding mechanism, a large texture pressing and breaking mechanism A4, and a fabric feeding mechanism. The mold conveyor belt A2 carries the mold through the main material feeding mechanism, the large texture pressing and breaking mechanism A4, and the fabric feeding mechanism in sequence. The mold conveyor belt A2 carries the mold back and forth multiple times in the main material feeding mechanism. Both the main material feeding mechanism and the fabric feeding mechanism include a frame and several feeding units. The several feeding units are arranged side by side and installed at intervals on the frame.

[0084] Each fabric unit includes several fabric hoppers, and each fabric hopper in the fabric unit corresponds to a feeding line, and the positions of the fabric hopper and the receiving hopper are corresponding.

[0085] The waste material recycling device includes a bottom recovery belt, a side conveyor belt, an inclined belt, a recycling and dispersing mechanism, a lifting belt, and a replenishment device;

[0086] The bottom recovery belt is located below the output end of the mold conveyor belt, and the side conveyor belt is located on the side of the mold conveyor belt and is connected to the bottom recovery belt. The side conveyor belt is used to transport the residual material collected by the bottom recovery belt to the inclined belt. The discharge end of the inclined belt is located above the feed end of the return material dispersing mechanism.

[0087] The discharge end of the material return and dispersing mechanism is connected to the lifting belt, which transports the dispersed residual material to the feeding hopper of the feeding device.

[0088] The material recycling and dispersing mechanism is used to disperse the recycled surplus material, and the material replenishing device is used to replenish the dispersed surplus material into the mold of the mold conveyor belt.

[0089] This invention proposes a high-efficiency production line for dry-process ecological stone fabrication that mimics natural stone throughout. It integrates powder dispersing equipment, feeding equipment, fabrication equipment, waste material recycling device, ferry belt, vacuum vibration pressing device, and mold flipping and demolding device into one unit. This realizes the assembly line of feeding, fabrication, waste material recycling, pressing and molding, and demolding in the dry-process ecological stone fabrication process, achieving the goal of high-efficiency production.

[0090] The material distribution equipment uses multiple material distribution lines to coordinate the transfer of hoppers, enabling a small number of feeding lines to distribute materials to a large number of cloth hoppers. This allows each cloth hopper to hold a single color of material, and the powder in each cloth unit can be of a variety of colors, thus achieving diversified cloth distribution. This greatly reduces the difficulty of material distribution and simplifies the structure of the material distribution equipment.

[0091] This technical solution features a transfer hopper on each batching line and several unloading stations B51. Below each unloading station is a feeding hopper from a feeding unit A3. Simultaneously, several powder dispersing components are located above the feeding equipment B, each transporting a single-color powder. By selecting several single-color powders from the transfer hoppers B1 and combining them, various mixed powders can be obtained. Specifically, each transfer hopper B1 transports a selected single-color powder to the receiving hopper of the unloading station B51 for batching. Each transfer hopper B1 corresponds to an independent batching line, ensuring it reaches each unloading station B51 without interference between the batching processes of multiple transfer hoppers B1. Since the unloading station B51 is located above the material distribution unit A3, and the position of the discharge port of the receiving hopper B511 corresponds to the position of the inlet of the material distribution hopper A31, the material in the transfer hopper B1 can directly enter the material distribution hopper A31 through the receiving hopper B511.

[0092] In this invention, a main material feeding mechanism, a large texture breaking mechanism A4, and a fabric feeding mechanism are used to achieve an overall effect of natural stone color blocks. Furthermore, the material layers form fracture patterns to mimic the fracture textures in natural stone, achieving a complete natural stone-like effect. Simultaneously, the real-time waste material recycling device in this invention can collect waste material that falls onto the mold conveyor belt or falls outside the mold conveyor belt during the feeding process. Waste material recycling is synchronized with the feeding process, making the entire waste material recycling process simple, fast, and timely, requiring no manual intervention. A recycling belt collects fallen powder in real time and promptly transports it to a waste material dispersing mechanism for crushing and to a replenishing device for reuse. This real-time collection and reuse of fallen powder not only saves labor and ensures the cleanliness of the reused powder but also prevents the fallen powder from becoming excessively dry and difficult to crush. This invention creatively uses reused powder in the final powder sprinkling step of the dry feeding process, achieving not only timely use of reused powder but also improving the simulation effect of the eco-stone. Recycled powder is a mixture of more colored powders, and the colors are different from those of the powders in each fabric unit. The recycled powder is sprinkled into the mold. Due to the uneven surface of the material layer in the mold and the tilted state of some small pieces, the recycled powder slides on the surface of the material layer and can accumulate at the edges of some small pieces, forming a wrapping texture, simulating the color accumulation at the edges of large color spots in natural stone, and further improving the simulation effect.

[0093] Specifically, the bottom recovery belt and the side conveyor belt recover the leftover material scattered during the process of ecological stone fabrication. At the same time, the bottom recovery belt and the side conveyor belt are connected, so that the leftover material scattered on the side of the mold conveyor belt is collected with the leftover material scattered at the output end of the mold conveyor belt and then gathered at the bottom recovery belt. The bottom recovery belt is then conveyed to the material return and dispersing mechanism. The material return and dispersing mechanism wets and disperses the recovered leftover material. Finally, the processed leftover material is conveyed to the feeding device, which feeds the leftover material into the mold on the mold conveyor belt.

[0094] Furthermore, the opening and closing components slide at the bottom of the transfer hopper to block and open the discharge port of the transfer hopper;

[0095] Each unloading station is equipped with a liftable gate opening device, which is installed on the side of the receiving hopper away from the loading station. When the gate opening device is raised, it blocks the moving opening and closing components, thus opening the discharge port of the transfer hopper.

[0096] The loading station is equipped with a liftable gate device. When the gate device is raised, it blocks both sides of the opening and closing components, and the material is moved along the feeding line by the transfer hopper, thus blocking the discharge port of the transfer hopper.

[0097] It is worth noting that this technical solution does not include a power mechanism for opening and closing the discharge port of the transfer hopper B1. Instead, it uses a non-powered opening and closing component B4, making the overall weight of the transfer hopper B1 lighter and reducing the requirements for the batching line B5. With the same drive power, the transfer hopper B1 achieves higher batching efficiency, further improving batching efficiency. Furthermore, since this technical solution does not include a drive component on the transfer hopper B1 (i.e., it does not include a cylinder or servo motor to drive the discharge port of the transfer hopper B1 to open or close), the opening device B2 and closing device B3 are installed on the batching line B5. This makes the movement of the transfer hopper B1 smoother, prevents electrical wires and air supply lines from interfering with the movement of the transfer hopper B1, and reduces the control difficulty of the entire material distribution equipment.

[0098] Furthermore, the opening and closing assembly includes a sliding frame and a gate. The gate is fixedly installed in the middle of the sliding frame, and a discharge space is formed between the end of the gate and the end of the sliding frame. Both ends of the sliding frame have discharge spaces.

[0099] The sliding frame is slidably installed at the bottom of the transfer hopper. The sliding frame slides so that the gate and the discharge hole correspond to the positions of the discharge port of the transfer hopper; the receiving hopper is located below the travel path of the sliding frame.

[0100] The principle of the opening and closing component B4 in this technical solution for blocking and opening the discharge port of the transfer hopper B1 is as follows: The opening and closing component B4 includes a sliding frame B41 and a gate B42. The gate B42 is fixedly installed in the middle of the sliding frame, and a discharge space B43 is formed between the end of the gate B42 and the end of the sliding frame B41. Both ends of the sliding frame B41 have discharge spaces B43. Since the sliding frame B41 is slidably installed at the bottom of the transfer hopper B1, when the position of the discharge port of the transfer hopper B1 corresponds to the position of the gate B42, the discharge port of the transfer hopper B1 is blocked and can be used for receiving and transporting materials; when the position of the discharge port of the transfer hopper B1 corresponds to the discharge space B43, the discharge port of the transfer hopper B1 is opened, and the material in the transfer hopper B1 can be unloaded into the designated receiving hopper B511. After the transfer hopper B1 receives material, the position of the discharge port of the transfer hopper B1 corresponds to the position of the gate B42, thus blocking the discharge port of the transfer hopper B1. The chain drive device then transports the transfer hopper B1 to the designated feeding station B51, where the receiving hopper B511 is located. During the movement of the transfer hopper B1, the sliding frame B41 moves synchronously with the transfer hopper B1, ensuring that the discharge port of the transfer hopper B1 remains blocked. Since the receiving hopper B511 is equipped with a gate opening device B2 on the side away from the loading station B52, when the sliding frame B41 approaches the receiving hopper B511... At 11:00, the gate opening device B2 rises upward, blocking the sliding frame B41 and stopping its movement. At the same time, the transfer hopper B1 continues to move, driven by the feeding line B5, causing displacement between the transfer hopper B1 and the sliding frame B41, making it impossible to maintain synchronous movement. Driven by the feeding line B5, the discharge port of the transfer hopper B1 moves from the position of the gate plate B42 to the discharge empty position B43, opening the discharge port of the transfer hopper B1. The material in the transfer hopper B1 falls through the discharge port of the transfer hopper B1 to the designated receiving hopper B511, completing the discharge.After the material is unloaded, the transfer hopper B1 is moved to the loading station B52 by the batching line B5, ready for the next material intake. Since the gate device B3 is vertically mounted at the loading station B52 and is located below the powder dispersing component B9, when the transfer hopper B1 moves to the loading station B52, the gate device B3 rises, blocking both sides of the sliding frame B41 and fixing its position. At this time, the batching line B5 stops driving, and the transfer hopper B1 continues to move forward due to inertia until it contacts the sliding frame B41. When the moving frame B41 reaches its end, the transfer hopper B1 stops moving. At this time, the position of the discharge port of the transfer hopper B1 corresponds to the discharge empty space B43. The transfer hopper B1 is driven to move in the opposite direction by the feeding line B5, so that the discharge port of the transfer hopper B1 moves from the discharge empty space B43 to the gate plate B42. The discharge port of the transfer hopper B1 is blocked, and the gate closing device B3 descends, so that the material in the powder dispersing component B9 can be sprinkled into the transfer hopper B1. After the loading is completed, the transfer hopper B1 can continue to move by the feeding line B5 until it reaches the designated unloading station B51.

[0101] Furthermore, the gate opening device B2 includes a first tilting seat B21, a first tilting arm B22, a first lifting cylinder B23, and a first angle limiting frame B25. The first tilting seat B21 is connected to the feeding line B5. One end of the first tilting arm B22 is hinged to the first tilting seat B21, and the other end of the first tilting arm B22 is fixedly installed with a first blocking block B24. The first lifting cylinder B23 is located below the first tilting arm B22, and the telescopic end of the first lifting cylinder B23 corresponds to the position of the first tilting arm B22.

[0102] The first tilting seat B21, the first tilting arm B22, and the first lifting cylinder B23 are respectively located below the travel path of the sliding frame B41. When the extension end of the first lifting cylinder B23 is in the retracted state, the first tilting arm B22 is tilted downward, causing the first blocking block B24 to descend below the travel path of the sliding frame B41. When the extension end of the first lifting cylinder B23 is in the extended state, the first lifting cylinder B23 drives the first tilting arm B22 to rise, which in turn drives the first blocking block B24 to rise. The position of the first blocking block B24 after it rises corresponds to the position of the sliding frame B41, so that the first blocking block B24 after it rises blocks the sliding frame B41.

[0103] The first angle limiting frame B25 is in the shape of an inverted "U". The opening of the first angle limiting frame B25 is fixedly installed on the first flip base B21 with the opening facing downward. The end of the first flip arm B22 near the first flip base B21 is accommodated in the first angle limiting frame B25.

[0104] The first angle limiting frame B25 is located below the travel trajectory of the sliding frame B41.

[0105] It is worth noting that in this technical solution, the gate opening device B2 is installed on the side of the receiving hopper B511 away from the loading station B52. That is, when the receiving hopper B511 is located to the left of the loading station B52, the gate opening device B2 is installed on the left side of the receiving hopper B511; when the receiving hopper B511 is located to the right of the loading station B52, the gate opening device B2 is installed on the right side of the receiving hopper B511. This allows the raised gate opening device B2 to block the moving sliding frame B41. It should also be noted that this technical solution includes a material level detection component above the loading station B52, used to detect the powder level height inside the transfer hopper and output a material level detection signal.

[0106] Understandably, batching line B5 is equipped with a chain drive device to drive each transfer hopper to move along the batching line.

[0107] Each batching line is equipped with a chain drive device. The transfer hopper is fixed to the chain, and the chain moves the transfer hopper when it is driven.

[0108] It is worth noting that several gate opening devices B2 located below the travel trajectory of the same transfer hopper B1 are respectively located on the side of the corresponding receiving hopper B511 away from its corresponding powder dispersing component C1. That is, when the receiving hopper B511 is on the left side of the powder dispersing component C1, the gate opening device B2 is set on the left side of the receiving hopper B511, and when the receiving hopper B511 is on the right side of the powder dispersing component C1, the gate opening device B2 is set on the right side of the receiving hopper B511, so that the raised gate opening device B2 can block the moving sliding frame B41.

[0109] Furthermore, the batching line B5 includes a chain drive device B7, which drives the transfer hopper B1 to move along the batching line B5. The gate closing device B33 includes two gate closing components B31 arranged in a mirror image symmetrically. The two gate closing components B31 are located on both sides of the loading station B52. The two gate closing components B31 are used to block both sides of the sliding frame B41, so that the position of the sliding frame B41 is fixed. The chain drive device B7 drives the transfer hopper B1 to move, so that the discharge port of the transfer hopper B1 moves from the discharge hole B43 to the gate plate B42.

[0110] The gate closing assembly B31 includes a second tilting seat B311, a second tilting arm B312, a second lifting cylinder B313, a second blocking block B314, and a connecting plate B315. The second tilting seat B311 is connected to the mounting rod of the feeding line B5. One end of the second tilting arm B312 is hinged to the second tilting seat B311, and the other end of the second tilting arm B312 is connected to the connecting plate B315. The second blocking block B314 is installed on the connecting plate B315. The second lifting cylinder B313 is installed on the mounting rod of the feeding line B5, and the second lifting cylinder B313 is located below the second tilting arm B312.

[0111] The blocking end of the second blocking block B314 faces the second flip seat B311, and the blocking end of the second blocking block B314 is provided with a sensor (preferably a pressure sensor).

[0112] The second tilting seat B311, the second tilting arm B312, and the second lifting cylinder B313 are respectively located below the travel path of the sliding frame B41. When the extension end of the second lifting cylinder B313 is in the retracted state, the second tilting arm B312 is tilted downward, causing the second blocking block B314 to descend below the travel path of the sliding frame B41. When the extension end of the second lifting cylinder B313 is in the extended state, the second lifting cylinder B313 drives the second tilting arm B312 to rise, causing the second blocking block B314 to rise. The position of the second blocking block B314 after rising corresponds to the position of the sliding frame B41, so that the second blocking block B314 after rising blocks one side of the sliding frame B41.

[0113] The distance between the two second blocking blocks B314, which are located in two mirror-symmetrical gate assemblies B31, after rising, corresponds to the length of the sliding frame B41, so that the two second blocking blocks B314 after rising are used to block the two sides of the sliding frame B41 respectively.

[0114] This technical solution achieves the effect of closing the discharge port of the transfer hopper B1 through the cooperation of the gate device B3 and the chain drive device. When the transfer hopper B1 needs to receive material, it moves towards the loading station B52. When the transfer hopper B1 approaches the loading station B52, the gate assembly B31 on the side away from the transfer hopper B1 rises, blocking one side of the sliding frame B41. At this time, driven by the chain drive device B7, the transfer hopper B1 continues to move until the end of the transfer hopper B1 contacts the sliding frame B41. At this time, the other gate assembly B31 rises (because a sensor is provided at the blocking end of the second blocking block B314, when the sensor senses that it has been hit twice, the other gate assembly B31, which is symmetrically arranged, rises, blocking the other side of the sliding frame B41). The system blocks the flow. Alternatively, the control program can be configured such that when one side of the sliding frame B41 touches the gate assembly B31, the other gate assembly B31, symmetrically positioned, rises to block the other side of the sliding frame B41. This blocks both ends of the sliding frame B41, fixing its position. Then, the chain drive device B7 drives the transfer hopper B1 to move, moving its discharge port from the discharge empty position B43 to the gate plate B42, thus closing the discharge port of the transfer hopper B1, enabling it to receive and transport materials.

[0115] Since both gate-closing components B31 in this technical solution are installed on the mounting rod of the feeding line B5, they do not need to be installed on the transfer hopper B1, which effectively reduces the load on the transfer hopper B1 and simplifies its structure, making the transportation process faster and less disruptive. Furthermore, the gate-opening device B2, the two gate-closing components B31, and the chain drive device in this technical solution are all electrically connected to the PLC automatic control system, enabling automatic opening and closing of the discharge port of the transfer hopper B1.

[0116] Further explanation: the gate assembly B31 also includes a second angle limiting frame B316, which is in the shape of an inverted "U". The opening of the second angle limiting frame B316 is fixedly installed on the second flip base B311 with the opening facing downward. The end of the second flip arm B312 near the second flip base B311 is accommodated in the second angle limiting frame B316.

[0117] The second angle limit frame B316 is located below the travel trajectory of the sliding frame B41.

[0118] It is worth noting that this technical solution sets a second angle limiting frame B316 on the gate assembly B31. The second angle limiting frame B316 can constrain the flipping angle of the second flipping arm B312 to ensure that the position of the second blocking block after it is raised corresponds to the position of the sliding frame B41's travel trajectory. This ensures that the second blocking block B314 can complete the blocking and limiting of the sliding frame B41, and prevents the second flipping arm B312 from failing to block and limit the sliding frame B41 due to an excessively large flipping angle.

[0119] To further explain, guide wheels B6 are installed on both sides of the discharge port of the transfer hopper B1. The rotating shaft of the guide wheel B6 is vertically arranged relative to the sliding frame B41, and the wheel surface of the guide wheel B6 is provided with a guide groove.

[0120] Both sides of the sliding frame B41 are fixedly provided with first guide bars B411, and the two first guide bars B411 extend into the guide grooves of the guide wheel B6 respectively.

[0121] Both ends of the sliding frame B41 are equipped with limit bars B412 (to prevent the guide wheel B6 from sliding out of the sliding frame B41).

[0122] It is worth noting that the guide wheel B6 is installed on both sides of the discharge port of the transfer hopper B1 via the mounting plate. Through the cooperation between the guide wheel B6 and the guide strip, the sliding frame B41 can be slidably installed at the bottom of the transfer hopper B1, thereby allowing the discharge port of the transfer hopper B1 to be opened and closed.

[0123] The sliding structure of the sliding frame B41 in this technical solution, in conjunction with the guide wheel B6, has less friction compared to the sliding groove structure, allowing the sliding frame B41 to be moved with less force.

[0124] Furthermore, the fabric feeding unit A3 includes several fabric feeding hoppers A31, several discharge belts A32, a collection belt A33, a collection hopper A34, a briquetting device A35, and a briquetting belt A36. Several fabric feeding hoppers A31 are arranged side by side on the frame A1. Each fabric feeding hopper A31 has a discharge belt A32 below its discharge port, and the collection belt A33 is located below the discharge belt A32. One fabric feeding hopper A31 is located below a receiving hopper B511, and the position of the discharge port of the receiving hopper B511 corresponds to the position of the inlet of the fabric feeding hopper A31.

[0125] The collecting hopper A34 is located below the collecting belt A33, and the feeding port of the collecting hopper A34 corresponds to the end of the conveying direction of the collecting belt A33. The briquetting belt A36 is located below the collecting hopper A34, and the briquetting device A35 is installed above the briquetting belt A36. The briquetting device A35 is used to pre-press the mixed powder on the briquetting belt A36 into blocks.

[0126] A spiral cutter A37 is provided above the end of the conveying direction of the briquetting belt A36. The spiral cutter A37 is used to cut the block-shaped mixed powder into strips. A cloth toothed plate A38 is connected to the end of the conveying direction of the briquetting belt A36. The cut strip-shaped powder falls into the mold through several teeth of the cloth toothed plate A38.

[0127] The edge of the fabric toothed plate A38 consists of several teeth A381 connected in sequence, and the size and shape of the teeth A381 are different.

[0128] The two adjacent teeth A381 transition smoothly. The spacing between the tips of the adjacent teeth A381 in a number of teeth A381 is different. The teeth A381 are arc-shaped or corner-shaped.

[0129] First, in the main material feeding mechanism and the fabric feeding mechanism, each sub-feeding device contains powder of multiple colors. These powders are spread and mixed to a certain extent on the collecting belt, resulting in pressed blocks with diverse color combinations and irregularly sized color areas. As the blocks pass through the feeding toothed plate, gravity causes them to be cut and dispersed into smaller blocks by the plate's edges. These smaller blocks fall randomly into the mold, and may even break further into smaller, irregular particles as they fall. Several sub-feeding devices feed material sequentially inside the mold, layering the small blocks to create a textured effect reminiscent of natural stone. Furthermore, the irregular shapes and sizes of the small blocks, along with their color combinations, result in different shapes, color combinations, and sizes of color blocks within each layer, achieving an effect similar to granite or marble. Understandably, when small blocks of material are laid in the mold, they are in an inclined or horizontal state. Multiple layers of small blocks will have an overlapping effect, and the cut surface of the eco-stone can still show color patches, giving the eco-stone a better simulation effect.

[0130] Between the main material fabrication mechanism and the surface fabrication mechanism is a large-texture crushing mechanism A4. This mechanism A4 creates fracture lines within the main material layer, breaking small pieces of material to form groove-like textures. The surface layer covers these groove-like textures, but due to the limited amount of surface material used, it cannot completely conceal them. Ultimately, the surface of the eco-stone forms a fracture-like texture, further enhancing its simulation effect. It is understandable that fracture lines are common in natural stone; this invention allows the eco-stone to mimic these natural fracture lines, further improving the simulation effect. Moreover, the fracture lines in this invention are formed using the large-texture crushing mechanism A4, allowing the fracture lines to penetrate deep into the interior of the eco-stone, ensuring that the cut surface of the eco-stone still maintains a good simulation effect.

[0131] Furthermore, the conveying speed of the aggregate conveyor belt affects the thickness of the material layer on the briquetting belt, which in turn affects the feeding speed and shape / size of small blocks. The conveying speed of the die conveyor belt affects the density of small blocks within the die. Therefore, by adjusting the conveying speeds of the aggregate conveyor belt, briquetting belt, and die conveyor belt, the feeding rate and density can be adjusted.

[0132] Understandably, on the pressing belt, the pressure plate exerts relatively low pressure on the powder, only enough to form the powder into lumps and maintain a certain shape during its descent. The spiral cutter A37 includes a rotating shaft A371 and several circular blades A372, which are spaced apart on the rotating shaft A371. Therefore, based on the cutting effect of the circular blades A372 and the dispersing effect of the fabric toothed plate, the lumps can be dispersed into irregular small lumps. Moreover, due to the diversity of the teeth on the fabric toothed plate, the shape and size of the small lumps are more diverse, which is beneficial to improving the simulation effect of the eco-stone.

[0133] Specifically, in this technical solution, each tooth on the fabric toothed plate is different in size and shape. Some teeth are longer, some are shorter, some are wider, and some are narrower. This allows the cut strips of powder to be irregularly dispersed, forming small pieces of varying sizes and shapes. These pieces are then irregularly dispersed in the mold, thereby enhancing the randomness and irregularity of the pattern in the product and making the overall effect more natural.

[0134] A powder-spreading mechanism A5 is also provided between the fabric-spreading mechanisms. The powder-spreading mechanism A5 includes a screen, a screen holder, and a vibrator, with both the screen and the vibrator mounted on the screen holder. A spraying mechanism is provided corresponding to the powder-spreading mechanism, used for spraying water or colored slurry. The dry powder sprinkled by the powder-spreading mechanism A5 falls into the mold. Due to the uneven surface of the material layer inside the mold, some small pieces are tilted, causing the powder to slide on the surface and accumulate at the edges of some small pieces, forming a wrapping texture. This simulates the color accumulation at the edges of large color spots in natural stone, further improving the simulation effect. Specifically, the material-feeding screen A51 is equipped with a vibrator to facilitate the powder falling into the mold.

[0135] Specifically, the spraying mechanism A6 includes a spraying pipe, which is installed above the mold conveyor belt A2. The spraying pipe is equipped with several nozzles to evenly spray water or colored slurry into the mold.

[0136] When spraying mechanism A6 sprays water, it increases the adhesion between the various layers in the mold. When spraying mechanism A6 sprays colored slurry, it not only increases the adhesion between the various layers in the mold but also enhances the decorative effect on the surface of the eco-stone. Preferably, spraying mechanism A6 for spraying colored slurry is located at the downstream end of the main material spreading mechanism and / or the downstream end of the fabric spreading mechanism. Understandably, the raw materials for colored slurry include cement, pigments, and water.

[0137] Furthermore, the large texture breaking mechanism A4 includes a lifting frame A41 and a lifting drive component A42. The lifting drive component A42 is installed on the side of the mold conveyor belt A2, the lifting frame A41 is located above the mold conveyor belt A2, and the driving end of the lifting drive component A42 is connected to the lifting frame A41.

[0138] Several pressure-breaking knives A43 are arranged in a staggered pattern at the bottom of the lifting frame A41. The pressure-breaking knives A43 are flat.

[0139] Understandably, the cracks in natural stone are usually straight. Therefore, the pressing blade A43 in the large-texture pressing mechanism A4 of this invention is flat to form straight cracks. The cracks need to penetrate a certain depth into the eco-stone to achieve a better simulation effect on the top and cross-section of the eco-stone. Therefore, in this invention, the depth to which the pressing blade A43 presses into the material layer is less than or equal to the thickness of the material layer. Specifically, the lifting drive component A42 is a cylinder, and this cylinder is installed at each of the four corners of the lifting frame A41. The four cylinders synchronously drive the lifting drive component A42 to rise and fall.

[0140] Furthermore, the real-time recycling device A for surplus materials includes a bottom recycling belt D1, a side conveyor belt D3, an inclined belt D2, a lifting belt D6, a recycling and dispersing mechanism D4, and a feeding device D5;

[0141] The bottom recovery belt D1 is located below the output end of the mold conveyor belt A2, and the side conveyor belt is located on the side of the mold conveyor belt A2;

[0142] The side conveyor belt D3 is connected to the bottom recycling belt D1. The side conveyor belt is used to transport the residual material collected by the bottom recycling belt to the inclined belt. The discharge end of the inclined belt is located above the feed end of the material recycling and dispersing mechanism. A water replenishment mechanism is installed above the inclined belt.

[0143] The discharge end of the material return and dispersing mechanism D4 is connected to the lifting belt, which transports the dispersed residual material to the feeding hopper of the feeding device D5.

[0144] The water replenishment mechanism is used to replenish the water in the recovered residual material, the material dispersing mechanism D4 is used to disperse the recovered residual material, and the material replenishing device D5 is used to replenish the dispersed residual material into the mold of the mold conveyor belt A2.

[0145] The waste material recycling device in this invention can recycle waste material that falls onto the mold conveyor belt A2 or falls outside the MUJU during fabric production. Waste material recycling is carried out simultaneously with fabric production. The entire waste material recycling process is simple, fast and timely, and requires no manual intervention.

[0146] Specifically, in the dry-process molding of eco-stone, a feeding device typically places the powder into a mold. The mold moves below the feeding device, driven by a conveyor belt A2. During this process, powder inevitably spills onto the conveyor surface of belt A2 and falls to the ground, wasting powder and polluting the production environment. Current technology only involves manually collecting the powder from the ground and then crushing it for reuse once a certain amount is collected. However, due to the long storage time, the moisture has completely evaporated and some cement has hardened, making crushing difficult. Furthermore, the collection process often involves collecting dust from the ground, causing powder pollution and requiring significant manual labor.

[0147] In this invention, a recycling conveyor belt is used to collect fallen powder in real time and promptly transport it to a material return and dispersing mechanism for crushing, as well as to a feeding device D5 for reuse. This achieves real-time collection and reuse of fallen powder, saving labor, ensuring the cleanliness of the reused powder, and preventing the fallen powder from becoming too dry and difficult to crush. This invention creatively uses the reused powder in the final powder-sprinkling step of dry-laying materials, achieving not only timely use of the reused powder but also improving the simulation effect of the eco-stone.

[0148] Specifically, the recycled powder is a mixture of more colored powders, and the colors are different from those of the powders in each fabric unit. The recycled powder is sprinkled into the mold. Due to the uneven surface of the material layer in the mold and the tilted state of some small pieces, the recycled powder slides on the surface of the material layer and can accumulate at the edges of some small pieces, forming a wrapping texture, simulating the color accumulation at the edges of large color spots in natural stone, and further improving the simulation effect.

[0149] Specifically, the bottom recycling belt D1 and the side conveyor belt collect the leftover material scattered during the process of recycling the ecological stone cloth. At the same time, the bottom recycling belt D1 and the side conveyor belt are connected, so that the leftover material scattered on the side of the mold conveyor belt A2 is collected on the bottom recycling belt D1 and then conveyed to the bottom recycling belt D1 at the front end via the side conveyor belt. It is then conveyed to the material return and dispersing mechanism. The material return and dispersing mechanism humidifies and disperses the recycled leftover material. Finally, the processed leftover material is conveyed to the feeding device D5, which feeds the leftover material into the mold on the mold conveyor belt A2.

[0150] The material return and dispersing mechanism is located on one side of the mold conveyor belt A2, and the side conveyor belt is located on the other side of the mold conveyor belt A2;

[0151] The mold conveyor belt A2 consists of multiple segments arranged sequentially, with a powder leakage gap between the conveying surfaces of adjacent segments of the mold conveyor belt A2;

[0152] Each mold conveyor belt A2 has a corresponding bottom recovery belt D1 at its output end;

[0153] Several bottom recovery belts D1 are divided into collection belts and powder leakage recovery belts. The collection belt is located at the front end of the conveying direction of several mold conveyor belts A2. The powder leakage recovery belt is located below the powder leakage gap. The discharge ends of several powder leakage recovery belts are all located above the side conveyor belts. The feed end of the collection belt is located below the discharge end of the side conveyor belt, and the discharge end of the collection belt is located above the feed end of the return material dispersing mechanism.

[0154] In some embodiments, to reduce the production area occupied by the recycling device during the production of eco-stones and to ensure that the residual material during the laying process can be fully recycled and reused, the recycling device in this embodiment is arranged along both sides of the mold conveyor belt A2 of the eco-stone. Specifically, the side conveyor belt D3 is located on one side of the mold conveyor belt A2, while the material return and dispersing mechanism 4 is located on the other side of the mold conveyor belt A2, and the bottom recycling belt D1 is located at the discharge end of the mold conveyor belt A2, connecting the side conveyor belt D3 and the material return and dispersing mechanism 4. This ensures the continuity of the entire production line of the recycling device used for dry laying of eco-stones, so that the scattered residual material can be recycled in a timely manner, reducing the recycling cycle of residual material. In addition, the bottom recycling belt D1 can also recycle the residual material scattered at the discharge end of the mold conveyor belt A2, thereby achieving full recycling of residual material.

[0155] Each mold conveyor belt A2 has a bottom recovery belt D1 at its output end. Several mold conveyor belts A2 are arranged side-by-side, creating a powder leakage gap between adjacent belts A2. This allows residual powder that falls onto the conveying surface of the mold conveyor belts A2 during the feeding process to fall along the powder leakage gap as the belts A2 are conveyed. The bottom recovery belt D1, located below the powder leakage gap, is used to collect this residual powder. The belt D1 is positioned at the forefront of the conveying direction of the mold conveyor belts A2. The bottom recovery belt D1 at the end is a collection belt. The output direction of the collection belt is opposite to the feeding direction of the powder leakage recovery belt. The residual material scattered in the powder leakage gap is transported by the powder leakage recovery belt to the side conveyor belt D3, and then collected and transported by the side conveyor belt D3 to the collection belt. The residual material is then transported to the return material dispersing mechanism 4 to wet and disperse the residual material before being transported to the feeding hopper D51. The feeding hopper D51 distributes the residual material into the mold through the feeding belt D511, reducing the waste of residual material and improving the recycling efficiency of residual material.

[0156] Specifically, the number of side conveyor belts D3 corresponds to the number of mold conveyor belts A2, meaning that each mold conveyor belt has a side conveyor belt D3. In this embodiment, the number of side conveyor belts D3 can be flexibly adjusted according to the number of mold conveyor belts A2 in production, thereby reducing the installation space and the installation area of ​​the waste material recycling device. The conveying surface of the side conveyor belts D3 is inclined upward along the conveying direction of the side conveyor belts D3, and the discharge end and feed end of two adjacent side conveyor belts D3 are connected. Since the waste material of the ecological stone is in powder form and is directly conveyed on the conveying surface of the side conveyor belts D3, in order to prevent the waste material from flowing out through the gap between the two side conveyor belts D3 during the transfer of waste material between two adjacent side conveyor belts D3, in this embodiment, the conveying surface of the side conveyor belts D3 is inclined upward along the conveying direction, and in two adjacent side conveyor belts D3, the discharge end of one side conveyor belt D3 is located above the feed end of the other side conveyor belt D3, so that the waste material of the two adjacent side conveyor belts D3 can be conveyed.

[0157] Both sides of the bottom recovery belt D1 and the side conveyor belt D3 are equipped with baffles D10. The baffles D10 reduce the possibility of residual material scattering in all directions during the conveying process. The two baffles D10 of the side conveyor belt D3 are inclined relative to each other along the conveying direction of the side conveyor belt D3, so that the opening of the feed end of the side conveyor belt D3 is larger than the opening of the discharge end. During the transfer process, the residual material is gradually concentrated and moved from the feed end of the side conveyor belt D3 along the two baffles D10 to the discharge end of the side conveyor belt D3, and then conveyed to the feed end of the next side conveyor belt D3, reducing the possibility of residual material falling off during the transfer of residual material between different side conveyor belts D3.

[0158] Furthermore, the transfer belt E includes a mold conveying platform E1 and a transfer track E2. The mold conveying platform E1 moves along the transfer track E2. One end of the transfer track E2 extends from the output end of the mold conveying belt to the end of the pressing transfer belt F2, thereby transferring the mold from the mold conveying belt to the pressing transfer belt F2. Specifically, the mold conveying platform E1 is a belt conveyor platform.

[0159] The vacuum vibration pressing device F includes a vacuum vibration press F1 and a pressing conveyor belt F2. The pressing conveyor belt F2 is positioned corresponding to the vacuum vibration press F1 and is used to feed the mold into or out of the vacuum vibration press F1.

[0160] The mold flipping and demolding device G includes an arc-shaped track G1, a sliding ring G2, and a flipping table G3. The flipping table G3 is installed inside the sliding ring G2, which is vertically oriented. The outer wall of the sliding ring G2 slides in engagement with the arc-shaped track G1. The flipping table G3 is used to position the mold. Specifically, the flipping table G3 consists of two opposing platforms. The mold is positioned between the two platforms. After flipping, the formed eco-stone blank inside the mold can be supported by the platforms for easy removal of the mold. The arc of the arc-shaped track G1 corresponds to that of the sliding ring, and the arc-shaped track G1 is equipped with pulleys that slide in engagement with the sliding ring G2.

[0161] The mold conveyor platform E1, mold conveyor belt, pressing transfer belt F2, and tilting table G3 are arranged in parallel. The mold conveyor platform E1 moves along the transfer track E2 and connects with the mold conveyor belt, pressing transfer belt F2, and tilting table G3 respectively. Specifically, the pressing transfer belt F2 and the tilting table G3 are arranged opposite each other, and the mold conveyor platform E1 can move between the pressing transfer belt and the tilting table to transfer the mold on the pressing transfer belt to the tilting table.

[0162] As can be seen, the mold can be transferred from the fabrication line to the pressing line and from the pressing line to the demolding line by means of the transfer belt E, thus achieving efficient mold transfer.

[0163] Preferably, the material recycling and dispersing mechanism and the vacuum vibration pressing device F are located on both sides of the fabric feeding equipment to ensure a reasonable layout of the efficient production line and reduce the floor space occupied.

[0164] Other components and operations of the high-efficiency production line for dry-process fabrication of eco-stone that mimics natural stone throughout, according to embodiments of the present invention, are known to those skilled in the art and will not be described in detail here.

[0165] In the description of this specification, references to the terms "embodiment," "example," etc., indicate that a specific feature, structure, material, or characteristic described in connection with that embodiment or example is included in at least one embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0166] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A high-efficiency production line for dry-process fabrication of eco-friendly stone that mimics natural stone throughout, characterized in that, This includes powder dispersing equipment, material feeding equipment, material spreading equipment, mold conveyor belt, waste material recycling device, transfer belt, vacuum vibration pressing device, and mold flipping and demolding device. The powder dispersing device, the feeding device, and the cloth spreading device are connected in sequence. The mold conveyor belt is located below the cloth spreading device. The residual material recycling device is arranged around the mold conveyor belt. The shuttle belt is used to connect the cloth spreading device, the vacuum vibration pressing device, and the mold flipping and demolding device. The shuttle belt is used to transfer the mold from the cloth spreading device to the vacuum vibration pressing device and from the vacuum vibration pressing device to the mold flipping and demolding device. The powder dispersing equipment includes several powder dispersing components, and the feeding equipment includes multiple feeding lines, each feeding line having a transfer hopper. The transfer hopper moves along the feeding line, and the feeding line has at least one loading station and several unloading stations. The unloading station is equipped with a receiving hopper. The discharge end of one of the powder dispersing components is located above one of the loading stations. The transfer hopper receives a single-color powder from the discharge end of one of the powder dispersing components at one of the loading stations and transfers the single-color powder to one of the unloading stations. The fabric equipment includes a main fabric fabrication mechanism, a large texture pressing and breaking mechanism, and a fabric fabrication mechanism. The mold conveyor belt carries the mold sequentially through the main fabric fabrication mechanism, the large texture pressing and breaking mechanism, and the fabric fabrication mechanism. The mold conveyor belt carries the mold back and forth multiple times in the main fabric fabrication mechanism. Both the main fabric fabrication mechanism and the fabric fabrication mechanism include a frame and several fabric units. The several fabric units are arranged side by side and installed at intervals on the frame. Each fabric unit includes several fabric hoppers, each fabric hopper in the fabric unit corresponds to one of the feeding lines, and the positions of the fabric hopper and the receiving hopper are opposite to each other; The bottom of the transfer hopper is connected to an opening and closing component, which slides at the bottom of the transfer hopper to block and open the discharge port of the transfer hopper. Each of the unloading stations is equipped with a liftable gate opening device, and the gate opening device is installed on the side of the receiving hopper away from the loading station. When the gate opening device is raised, it blocks the moving opening and closing components, thereby opening the discharge port of the transfer hopper. The loading station is equipped with a liftable gate device. When the gate device is raised, it blocks both sides of the opening and closing components. The material is moved on the feeding line by the transfer hopper, and the discharge port of the transfer hopper is blocked. The opening and closing assembly includes a sliding frame and a gate. The gate is fixedly installed in the middle of the sliding frame, and a discharge space is formed between the end of the gate and the end of the sliding frame. Both ends of the sliding frame have the discharge space. The sliding frame is slidably installed at the bottom of the transfer hopper. The sliding frame slides so that the gate and the discharge slot correspond to the discharge port of the transfer hopper. The receiving hopper is located below the travel path of the sliding frame.

2. The high-efficiency production line according to claim 1, characterized in that, The gate opening device includes a first tilting seat, a first tilting arm, a first lifting cylinder, and a first angle limiting frame. The first tilting seat is connected to the feeding line. One end of the first tilting arm is hinged to the first tilting seat, and a first blocking block is fixedly installed on the other end of the first tilting arm. The first lifting cylinder is located below the first tilting arm, and the telescopic end of the first lifting cylinder corresponds to the position of the first tilting arm. The first tilting seat, the first tilting arm, and the first lifting cylinder are respectively located below the travel path of the sliding frame. When the extension end of the first lifting cylinder is in the retracted state, the first tilting arm is tilted downward, causing the first blocking block to descend below the travel path of the sliding frame. When the extension end of the first lifting cylinder is in the extended state, the first lifting cylinder drives the first tilting arm to rise, causing the first blocking block to rise. The position of the first blocking block after it rises corresponds to the position of the sliding frame, so that the first blocking block after it rises blocks the sliding frame. The first angle limiting frame is in the shape of an inverted "U". The opening of the first angle limiting frame is fixedly installed on the first flipping base with the opening facing downward. The end of the first flipping arm near the first flipping base is accommodated in the first angle limiting frame. The first angle limiting frame is located below the walking trajectory of the sliding frame.

3. The high-efficiency production line according to claim 2, characterized in that, The feeding line includes a chain drive device for driving the transfer hopper to move along the feeding line. The gate closing device includes two gate closing components arranged in a mirror image, located on both sides of the loading station. The two gate closing components are used to block both sides of the sliding frame, fixing the position of the sliding frame. The chain drive device drives the transfer hopper to move, causing the discharge port of the transfer hopper to move from the discharge space to the gate. The gate closing assembly includes a second tilting seat, a second tilting arm, a second lifting cylinder, a second blocking block, and a connecting plate. The second tilting seat is connected to the mounting rod of the feeding line. One end of the second tilting arm is hinged to the second tilting seat, and the other end of the second tilting arm is connected to the connecting plate. The second blocking block is mounted on the connecting plate. The second lifting cylinder is mounted on the mounting rod of the feeding line, and the second lifting cylinder is located below the second tilting arm. The blocking end of the second blocking block faces the second flip base, and the blocking end of the second blocking block is equipped with a sensor; The second tilting seat, the second tilting arm, and the second lifting cylinder are respectively located below the travel path of the sliding frame. When the extension end of the second lifting cylinder is in the retracted state, the second tilting arm is tilted downward, causing the second blocking block to descend below the travel path of the sliding frame. When the extension end of the second lifting cylinder is in the extended state, the second lifting cylinder drives the second tilting arm to rise, causing the second blocking block to rise. The position of the second blocking block after it rises corresponds to the position of the sliding frame, so that the second blocking block after it rises blocks one side of the sliding frame. The distance between the two second blocking blocks of the two mirror-symmetrical gate assemblies after they rise corresponds to the length of the sliding frame, so that the two second blocking blocks after rising are used to block the two sides of the sliding frame respectively.

4. The high-efficiency production line according to claim 1, characterized in that, The fabric feeding mechanism includes several fabric feeding hoppers, several discharge belts, a collection belt, a collection hopper, a briquetting belt, a briquetting device, a spiral cutter, and a fabric feeding toothed plate. Several fabric feeding hoppers are arranged side by side, and each fabric feeding hopper has a discharge belt at its discharge port. The discharge belts are located above the collection belts. One fabric feeding hopper is located below a receiving hopper, and the position of the discharge port of the receiving hopper corresponds to the position of the inlet of the fabric feeding hopper. The collecting hopper is located below the collecting belt, and the feeding port of the collecting hopper corresponds to the end of the collecting belt in the conveying direction. The briquetting belt is located below the collecting hopper, and the briquetting device is installed above the briquetting belt. The briquetting device is used to pre-press the mixed powder on the briquetting belt into blocks. A spiral cutter is provided above the end of the conveying direction of the briquetting belt. The spiral cutter is used to cut the pre-pressed mixed powder into strips. A fabric toothed plate is connected to the end of the conveying direction of the briquetting belt. The cut strips of powder fall into the mold through several teeth of the fabric toothed plate. The edge of the fabric toothed plate has several teeth connected in sequence, and the size and shape of the teeth are different. The transition between two adjacent teeth is smooth, and the spacing between the tips of adjacent teeth in a plurality of teeth is different, and the teeth are arc-shaped or corner-shaped.

5. The high-efficiency production line according to claim 4, characterized in that, A powder-spreading mechanism is also provided between the fabric-spreading mechanisms. The powder-spreading mechanism includes a screen, a screen fixing frame, and a vibrator. The screen and the vibrator are both installed on the screen fixing frame. A spraying mechanism is provided corresponding to the powder spreading mechanism. The spraying mechanism is used to spray water or colored slurry.

6. The high-efficiency production line according to claim 1, characterized in that, The real-time recycling device for residual materials includes a bottom recovery belt, a side conveyor belt, an inclined belt, a material recycling and dispersing mechanism, a lifting belt, and a replenishing device. The bottom recovery belt is located below the output end of the mold conveyor belt, the side conveyor belt is located on the side of the mold conveyor belt and is connected to the bottom recovery belt, and the side conveyor belt is used to transport the residual materials collected by the bottom recovery belt to the inclined belt. A water replenishment mechanism is provided above the inclined belt. The discharge end of the inclined belt is located above the feed end of the material recycling and dispersing mechanism. The discharge end of the material return and dispersing mechanism is connected to the lifting belt, and the lifting belt transports the dispersed residual material to the feeding hopper of the feeding device; The water replenishment mechanism is used to replenish the water in the recovered residual material, the material dispersing mechanism is used to disperse the recovered residual material, and the material replenishing device is used to replenish the dispersed residual material into the mold of the mold conveyor belt.

7. The high-efficiency production line according to claim 1, characterized in that, The shuttle belt includes a mold transport platform and a transfer track, and the mold transport platform moves along the transfer track; The vacuum vibration pressing device includes a vacuum vibration press and a pressing conveyor belt. The pressing conveyor belt is positioned corresponding to the vacuum vibration press and is used to feed the mold into or out of the vacuum vibration press. The mold flipping and demolding device includes an arc-shaped track, a sliding ring, and a flipping table. The flipping table is installed inside the sliding ring, which is vertically arranged. The outer wall of the sliding ring slides in conjunction with the arc-shaped track. The flipping table is used to position the mold. The mold conveying platform, the mold conveying belt, the pressing and transferring belt, and the tilting platform are arranged in parallel; the mold conveying platform moves along the transfer track and connects with the mold conveying belt, the pressing and transferring belt, and the tilting platform respectively.

8. The high-efficiency production line according to claim 6, characterized in that, The material recycling and dispersing mechanism and the vacuum vibration pressing device are respectively located on both sides of the fabric feeding equipment.

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