An automated masonry structure for refractory bricks in a cement rotary kiln

Abstract

This invention relates to an automated refractory bricklaying structure for cement rotary kilns. It includes a refractory brick supply structure at the kiln opening and a circumferential refractory bricklaying structure that retracts into the kiln body. The circumferential refractory bricklaying structure includes a positioning and walking base structure, an unfolding control structure, an unfolding formwork structure, and an automatic positioning and laying structure. The automatic positioning and laying structure includes a segmental position control connection structure, a rotation laying point limiting support frame structure, and an automatic opposing laying structure for refractory bricks. The developed bricklaying robot can be used in kiln openings measuring 2*2.3 meters and inlet bridges 2 meters wide. It achieves automatic grasping and laying of bricks in each ring within the kiln, ensuring that the longitudinal joints are no greater than 1 mm and the gap between the bricks and the kiln shell is no greater than 1 mm, thus guaranteeing higher laying quality. This invention has a positive effect on reducing the labor intensity of bricklaying workers, improving the production environment, and increasing kiln construction efficiency and safety.

Description

Technical Field

[0001] This invention relates to the field of cement rotary kilns, and in particular to an automated masonry structure for refractory bricks in cement rotary kilns. Background Technology

[0002] During the cement clinker firing process, the refractory brick lining inside the rotary kiln is affected by high temperature and temperature fluctuations, as well as the scouring and abrasion of materials and airflow and chemical erosion. As a result, the bricks become thinner, and their heat insulation and heat preservation effects deteriorate, causing "red kiln". It is necessary to stop the kiln, cool it down to 45 degrees Celsius, and have personnel enter the kiln to replace the bricks.

[0003] The refractory bricklaying in rotary kilns is primarily done manually using the arch-frame method. This method effectively ensures the concentricity of the brick lining with the kiln shell, minimizes the use of locking steel plates, and extends the lifespan of the brick lining. It is mainly used in large kilns with a diameter of 4m or more in China. However, this method has drawbacks: the overall structure is large, making direct entry from the kiln door impossible; assembly requires 5 hours of manual labor inside the kiln. The adhesive bonding method is currently the main method used in developed Western countries, and has been tested in a few kilns in China. This method has very high requirements for the construction environment and material quality; otherwise, quality problems are likely to occur. Due to the confined space and poor ventilation of the kiln, filled with high concentrations of dust and harmful gases produced during material firing, and each brick weighing 11kg, fewer and fewer workers are willing to perform this work. Currently, there is no robotic bricklaying equipment available domestically or internationally. Therefore, it is necessary to develop automated refractory bricklaying equipment for rotary kilns to quickly replace manual labor in completing bricklaying. Summary of the Invention

[0004] The purpose of this invention is to provide an automated refractory bricklaying structure for cement rotary kilns. This addresses the challenges of refractory bricklaying operations within the kiln, which are characterized by confined spaces, poor ventilation, high temperatures, and frequent dust and harmful gases, posing significant safety risks. Furthermore, each brick weighs 11 kg, leading to a decline in the number of willing and capable personnel for this work, making construction organization increasingly difficult. Therefore, there is an urgent need for intelligent transformation of the bricklaying operation to reduce manpower, increase efficiency, lower labor intensity, and reduce safety risks.

[0005] The technical solution adopted by this invention to solve its technical problem is: an automated refractory brick laying structure for a cement rotary kiln, including a refractory brick supply structure set at the kiln mouth of the cement rotary kiln and a circumferential refractory brick laying structure with a kiln inward retraction method set corresponding to the refractory brick supply structure. The circumferential refractory brick laying structure with a kiln inward retraction method includes a positioning and walking seat structure, an unfolding control structure set on the upper part of the positioning and walking seat structure, an unfolding formwork structure connected to the unfolding control structure, and an automatic positioning and laying structure connected to the unfolding control structure. The automatic positioning and laying structure includes a segmental position control connection structure connected to the unfolding control structure, a rotating laying point limiting support frame structure set at the front end of the segmental position control connection structure, and an automatic opposing refractory brick laying structure set on the segmental position control connection structure at intervals from the rotating laying point position supporting frame structure.

[0006] The positioning and walking seat structure includes a walking seat, a walking track mechanism located on the outside of the walking seat, a built-in drive structure located in the walking track mechanism, and a main connecting platform located on the upper part of the walking seat. The built-in drive structure includes a drive motor and a reducer.

[0007] The unfolding frame control structure includes a retraction control console located on the upper part of the main connecting body, a telescopic control cylinder assembly located on the upper part of the retraction control console, a hinged seat connected to the inner end of the retraction control console, and a main connecting seat located on the upper part of the hinged seat and connected to the telescopic control cylinder assembly.

[0008] The segmental position control connection structure includes a movable connecting cylinder housed in the main connecting seat, a movable control cylinder housed at the lower end of the movable connecting cylinder, and a rotating seat housed between the movable control cylinder and the movable connecting cylinder.

[0009] The aforementioned rotating masonry point limiting support rice rack structure includes a rice rack connecting seat on the movable connecting cylinder, a folding and retracting rice rack structure on the upper part of the rice rack connecting seat, and multiple sets of radial clamping cylinders and a diffuser radial support assembly at the rear end of the rice rack connecting seat on the folding and retracting rice rack structure.

[0010] The automatic opposing masonry structure for refractory bricks includes an automatic masonry connecting frame set on a movable connecting cylinder, multiple sets of rotating masonry structures set at one end of the automatic masonry connecting frame, and a masonry closing side tightening structure set at the other end of the automatic masonry connecting frame. The rotating masonry structure is set opposite to another set of rotating masonry structures on the automatic masonry connecting frame.

[0011] The rotating masonry structure includes a main brick-connecting assembly on the automatic masonry connecting frame and a secondary brick-connecting assembly on the opposite surface of the main brick-connecting assembly. The masonry closing side tightening structure includes a masonry closing side tightening frame on the automatic masonry connecting frame and a closing tightening cylinder in the masonry closing side tightening frame.

[0012] The aforementioned unfoldable mold frame structure includes a base connecting frame located at the left end of the movable connecting cylinder, unfoldable wing frames located on both sides of the base connecting frame and hinged together, and a kiln inner surface clamping cylinder component located in the unfoldable wing frame.

[0013] The refractory brick supply structure includes a conveyor platform located at the outer end of the cement rotary kiln opening, a brick supply point located behind the conveyor platform, a brick configuration center, and a configuration conveyor trolley.

[0014] The beneficial effects of this invention are as follows: This project focuses on solving common scientific problems and technical difficulties in the automated masonry of cement rotary kilns, and creates a prototype of a complete automated arch masonry equipment based on a 5000t cement rotary kiln automated masonry equipment. It can also be derived into automated masonry products applicable to various types of rotary kilns.

[0015] 1. The developed bricklaying robot can enter the rotary kiln under harsh conditions, such as a kiln door of 2*2.3 meters and a kiln access bridge of 2 meters wide, and requires climbing. It can move freely on the uneven surface of the old bricks in the kiln and can stabilize itself. This changes the current situation where the existing bricklaying equipment is bulky and requires manual handling and assembly in the kiln.

[0016] 2. By scanning the ellipticity of the kiln body, using two types of refractory bricks (A and B) through a permutation and combination algorithm, as well as a vision servo system and a robotic arm automatic stacking system, the automatic grasping and laying of each ring of bricks in the kiln is achieved. It is required that the longitudinal joint of the laying is no more than 1mm, and the tightness gap between the bricks and the kiln shell is no more than 1mm, thus ensuring the quality of the laying.

[0017] 3. The research and development project on key technologies of special robots for rotary kiln construction is the first of its kind in the world. It plays a positive role in reducing the labor intensity of construction workers, improving the production environment, and increasing the efficiency and safety of kiln construction. The development of this set of automated equipment is of great significance to cement production security and even the development of the entire cement industry. It solves a major problem faced by the industry both domestically and internationally.

[0018] 4. The successful development of this equipment optimizes the working environment of the masonry platform, placing higher demands on the technical skills of workers. This will help improve the educational level and age structure of masonry workers, playing a significant role in optimizing human resource allocation and attracting high-end technical talent. This equipment is not only suitable for laying refractory bricks in cement rotary kilns, but with improvements, it can also be applied to similar rotary kilns in other industries, reducing the labor intensity of operators.

[0019] The present invention will now be described in more detail with reference to the accompanying drawings and embodiments. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the structure of the present invention.

[0021] Figure 2 for Figure 1 The state diagram upon entering the state.

[0022] Figure 3 for Figure 1 A schematic diagram of the circumferential masonry structure of the refractory bricks in the inward-facing manner within the kiln body.

[0023] Figure 4 for Figure 3 Side view.

[0024] Figure 5 for Figure 3 Top view.

[0025] Figure 6 for Figure 3 The structure diagram of the storage state.

[0026] Figure 7 for Figure 6 Side view.

[0027] Figure 8 for Figure 3 A three-dimensional image.

[0028] Figure 9 This is a diagram showing the kiln interior construction state of the present invention.

[0029] Figure 10 This is a layout diagram of the masonry arm of the present invention.

[0030] Figure 11 for Figure 9 A magnified view of a portion of the image.

[0031] In the diagram: 1. Cement rotary kiln inlet, 2. Conveyor platform, 3. Brick supply point, 4. Brick configuration center, 5. Configuration and conveyor trolley, 6. Walking seat, 7. Walking track mechanism, 8. Main connecting body connecting platform, 9. Curve unfolding controller, 10. Drive motor, 11. Reducer, 12. Hinge seat, 13. Telescopic control cylinder assembly, 14. Main connecting seat, 15. Moving connecting cylinder, 16. Moving control cylinder, 17. Rotating seat, 18. Meter frame connecting seat, 19. Radial clamping cylinder, 20. Diffusion radial support assembly, 21. Main brick receiving assembly, 22. Secondary brick receiving assembly, 23. Masonry finishing side clamping frame, 24. Finishing clamping cylinder, 25. Foundation connecting frame, 26. Unfolding wing frame, 27. Kiln inner surface clamping cylinder, 28. Automatic masonry connecting frame, 29. Counterweight. Detailed Implementation

[0032] The terms "upper," "lower," "inner," "outer," "front end," "rear end," "both ends," "one end," and "the other end" used in the application text to indicate orientations or positional relationships are based on the orientations or positional relationships shown in the accompanying drawings. They are used solely 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, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0033] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installed," "equipped with," "connected," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can be a connection within two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0034] (1) Research on the technology of how rotary kiln masonry equipment can move freely back and forth; (2) Research on the detection technology of key parameters such as ellipticity and local deformation of kiln shell; Using a radar scanning sensor system, the ellipticity of the kiln shell is detected to determine the proportion of refractory bricks to be laid, and the presence of pits, bulges and other deformations inside the shell is detected to determine whether manual intervention such as grinding and planing is required. (3) Research on online detection method of refractory brick masonry quality. Research on refractory brick masonry quality detection method based on visual sensors, including accurately detecting the size of the gap between bricks, between bricks and kiln shell, and between rings, whether the four corners of the large end of the brick are tightly attached to the shell, and whether there are steps on the small end of the brick, to ensure that the refractory brick masonry quality meets the process requirements of cement kiln masonry. (4) Research and development of automated refractory brick masonry platform and research on the construction of whole-ring bricks: Design of kiln body moving mechanism and rotating lifting mechanism adapted to different arc surfaces; design of single-arm sorting and stacking mechanism and double-arm cooperative grasping and stacking mechanism based on vision servo; design of gap tightening and elimination mechanism; design of mechanism control drive system and sensing system; and construction of automated masonry platform. (5) Development and functional verification of prototype: A 5000T / D cement rotary kiln automated masonry prototype was developed and its functions were verified and index tested at the Conch Group simulation test site and the cement rotary kiln site.

[0035] Example 1, such as Figure 1 As shown, an automated refractory bricklaying structure for a cement rotary kiln includes a refractory brick supply structure installed at the kiln opening 1 of the cement rotary kiln and a circumferential refractory bricklaying structure installed corresponding to the refractory brick supply structure in a kiln-inward manner.

[0036] The circumferential masonry structure for the kiln body retraction method includes a positioning and walking seat structure, an unfolding control structure located on the upper part of the positioning and walking seat structure, an unfolding formwork structure connected to the unfolding control structure, and an automatic positioning and masonry structure connected to the unfolding control structure.

[0037] The automatic positioning masonry structure includes a segmental position control connection structure connected to the deployment control structure, a rotation masonry point limiting support frame structure located at the front end of the segmental position control connection structure, and an automatic opposing masonry structure for refractory bricks located on the segmental position control connection structure at intervals from the rotation masonry point position support frame structure.

[0038] The refractory brick supply structure includes a conveyor platform 2 located at the outer end of the cement rotary kiln opening, a brick supply point 3 located after the conveyor platform, a brick configuration center 4, and a configuration conveyor trolley 5.

[0039] The positioning and walking seat structure includes a walking seat 6, a walking track mechanism 7 located on the outside of the walking seat, a built-in drive structure located in the walking track mechanism, a main connecting platform 8 located on the upper part of the walking seat, and an arc deployment controller 9 located between the two walking track mechanisms 7. The built-in drive structure includes a drive motor 10 and a reducer 11.

[0040] The deployment control structure includes a hinged seat 12 located on the upper part of the main connecting platform 8, a telescopic control cylinder assembly 13 located on the upper part of the retraction control platform, and a main connecting seat 14 located on the upper part of the hinged seat and connected to the telescopic control cylinder assembly 13.

[0041] The segmental position control connection structure includes a movable connecting cylinder 15 disposed in the main connecting base 8, a movable control cylinder 16 disposed at the lower end of the movable connecting cylinder, and a rotating base 17 disposed between the movable control cylinder 16 and the movable connecting cylinder 15.

[0042] The rotating masonry point limiting support rice rack structure includes a rice rack connecting seat 18 on the movable connecting cylinder, a folding and retracting rice rack structure on the upper part of the rice rack connecting seat, multiple sets of radial clamping cylinders 19 on the folding and retracting rice rack structure, and a diffused radial support component 20 at the rear end of the rice rack connecting seat.

[0043] The automatic opposing masonry structure for refractory bricks includes an automatic masonry connecting frame 28 set on a movable connecting cylinder, multiple sets of rotating masonry structures set at one end of the automatic masonry connecting frame, and a masonry closing side tightening structure set at the other end of the automatic masonry connecting frame. The rotating masonry structure is set opposite to another set of rotating masonry structures on the automatic masonry connecting frame 28.

[0044] The rotating masonry structure includes a main brick-connecting component 21 on the automatic masonry connecting frame 28 and a secondary brick-connecting component 22 on the opposite surface of the main brick-connecting component. The masonry closing side tightening structure includes a masonry closing side tightening frame on the automatic masonry connecting frame 28 and a closing tightening cylinder 24 in the masonry closing side tightening frame 23.

[0045] The aforementioned unfoldable mold frame structure includes a base connecting frame 25 located at the left end of the movable connecting cylinder 15, unfoldable wing frames 26 located on both sides of the base connecting frame and hinged together, and a kiln inner surface pressing cylinder component 27 located in the unfoldable wing frame.

[0046] Current parameters of the furnace body

[0047] 1) The kiln interior is 4800mm wide and 70000mm long. The maximum ellipse of the kiln cavity is approximately 20-30mm.

[0048] 2) The width of the suspension bridge passage is 1900mm (the width can be expanded to no more than 2500mm later as needed).

[0049] 3) The furnace cavity inspection door is 2300mm wide and approximately 2500mm high (accessible from the kiln head).

[0050] 4) Levelness of the suspension bridge (depending on whether there is a downward or upward slope on site), the load-bearing capacity of the suspension bridge is 0-3000kg. A laser rotary scanner is installed at the center of the equipment formwork. Through rotational scanning, the core algorithm detects the ellipticity inside the cylinder. The core algorithm converts the engineering quantity signal into an analog quantity and controls the built-in digital electric cylinder of the Mizi support to perform ellipticity correction with a correction accuracy of ±2mm.

[0051] Figure 10 A circular support bracket is used, with a built-in double-row multi-channel control cylinder. A rotating and telescopic robotic arm is responsible for receiving bricks (12 pieces), rotating and laying them, and using angle algorithm control.

[0052] (like Figure 9 , 11 As shown, the rotating bricklaying arm is equipped with a main brick receiving box and a secondary brick receiving box. The main brick receiving box holds 12 pieces of combined bricks, and the secondary brick receiving box holds 9 pieces of combined bricks.

[0053] The rotating robotic arm for bricklaying is equipped with an automatic storage double-acting hydraulic cylinder, which expands the arc-shaped assembly gap and allows for adjustable load size, ensuring that the assembly gap of the 192 refractory bricks being laid is within the quality requirements.

[0054] (like Figure 11 (As shown) After the pre-tightening expansion cylinder built into the masonry rotating robotic arm expands and retracts into its original position, the rotating arm rotates and the 9 PCS assembly, which is received by the auxiliary brick receiving box, is sent to the sealing position through a mechanical device.

[0055] The final process involves manual operation to add additional cutting edge pieces according to the actual assembly gap. The pre-tightening control of the assembly gap of the entire ring of brick blanks is identified and evaluated manually.

[0056] This project focuses on solving common scientific problems and technical difficulties in automated masonry construction in cement rotary kilns. It aims to create a prototype of a complete automated arch masonry system based on a 5000t cement rotary kiln automated masonry equipment, which can be extended to various automated masonry products suitable for different types of rotary kilns.

[0057] 1. The developed bricklaying robot can enter the rotary kiln under harsh conditions, such as a kiln door of 2*2.3 meters and a kiln access bridge of 2 meters wide, and requires climbing. It can move freely on the uneven surface of the old bricks in the kiln and can stabilize itself. This changes the current situation where the existing bricklaying equipment is bulky and requires manual handling and assembly in the kiln.

[0058] 2. By scanning the ellipticity of the kiln body, using two types of refractory bricks (A and B) through a permutation and combination algorithm, as well as a vision servo system and a robotic arm automatic stacking system, the automatic grasping and laying of each ring of bricks in the kiln is achieved. It is required that the longitudinal joint of the laying is no more than 1mm, and the tightness gap between the bricks and the kiln shell is no more than 1mm, thus ensuring the quality of the laying.

[0059] 3. The research and development project on key technologies of special robots for rotary kiln construction is the first of its kind in the world. It plays a positive role in reducing the labor intensity of construction workers, improving the production environment, and increasing the efficiency and safety of kiln construction. The development of this set of automated equipment is of great significance to cement production security and even the development of the entire cement industry. It solves a major problem faced by the industry both domestically and internationally.

[0060] 4. The successful development of this equipment optimizes the working environment of the masonry platform, placing higher demands on the technical skills of workers. This will help improve the educational level and age structure of masonry workers, playing a significant role in optimizing human resource allocation and attracting high-end technical talent. This equipment is not only suitable for laying refractory bricks in cement rotary kilns, but with improvements, it can also be applied to similar rotary kilns in other industries, reducing the labor intensity of operators.

[0061] The above embodiments are merely descriptions of preferred embodiments of the present invention and are not intended to limit the scope of the present invention. Various modifications and improvements made by those skilled in the art to the technical solutions of the present invention without departing from the spirit of the present invention should fall within the protection scope defined by the claims of the present invention.

[0062] All parts not covered in this invention are the same as or can be implemented using existing technologies.

Claims

1. An automated masonry structure for refractory bricks in a cement rotary kiln, characterized in that: The system includes a refractory brick supply structure installed at the kiln inlet of a cement rotary kiln and a circumferential refractory brick masonry structure with a retractable kiln interior corresponding to the refractory brick supply structure. The circumferential refractory brick masonry structure with a retractable kiln interior includes a positioning and walking base structure, an unfolding control structure located on top of the positioning and walking base structure, an unfolding formwork structure connected to the unfolding control structure, and an automatic positioning masonry structure connected to the unfolding control structure. The automatic positioning masonry structure includes a segmental position control connection structure connected to the unfolding control structure, a rotation masonry point limiting support frame structure located at the front end of the segmental position control connection structure, and a segmental position control... The connecting structure is spaced apart from the rotation masonry point limiting support frame structure, which is an automatic refractory brick facing masonry structure; the positioning and walking seat structure includes a walking seat, a walking track mechanism on the outside of the walking seat, a built-in drive structure in the walking track mechanism, and a main connecting platform on the upper part of the walking seat, the built-in drive structure including a drive motor and a reducer; the unfolding control structure includes a retractable control console on the upper part of the main connecting platform, a telescopic control cylinder assembly on the upper part of the retractable control console, a hinged seat connected to the inner end of the retractable control console, and a main connecting seat on the upper part of the hinged seat and connected to the telescopic control cylinder assembly.

2. The automated masonry structure for refractory bricks in a cement rotary kiln as described in claim 1, characterized in that: The segmental position control connection structure includes a movable connecting cylinder housed in the main connecting seat, a movable control cylinder housed at the lower end of the movable connecting cylinder, and a rotating seat housed between the movable control cylinder and the movable connecting cylinder.

3. The automated masonry structure for refractory bricks in a cement rotary kiln as described in claim 1, characterized in that: The aforementioned rotating masonry point limiting support rice rack structure includes a rice rack connecting seat on the movable connecting cylinder, a folding and retracting rice rack structure on the upper part of the rice rack connecting seat, and multiple sets of radial clamping cylinders and a diffuser radial support assembly at the rear end of the rice rack connecting seat on the folding and retracting rice rack structure.

4. The automated masonry structure for refractory bricks in a cement rotary kiln as described in claim 1, characterized in that: The automatic opposing masonry structure for refractory bricks includes an automatic masonry connecting frame set on a movable connecting cylinder, multiple sets of rotating masonry structures set at one end of the automatic masonry connecting frame, and a masonry closing side tightening structure set at the other end of the automatic masonry connecting frame. The rotating masonry structure is set opposite to another set of rotating masonry structures on the automatic masonry connecting frame.

5. The automated masonry structure for refractory bricks in a cement rotary kiln as described in claim 4, characterized in that: The rotating masonry structure includes a main brick-connecting assembly on the automatic masonry connecting frame and a secondary brick-connecting assembly on the opposite surface of the main brick-connecting assembly. The masonry closing side tightening structure includes a masonry closing side tightening frame on the automatic masonry connecting frame and a closing tightening cylinder in the masonry closing side tightening frame.

6. The automated masonry structure for refractory bricks in a cement rotary kiln as described in claim 1, characterized in that: The aforementioned unfoldable mold frame structure includes a base connecting frame located at the left end of the movable connecting cylinder, unfoldable wing frames located on both sides of the base connecting frame and hinged together, and a kiln inner surface clamping cylinder component located in the unfoldable wing frame.

7. The automated masonry structure for refractory bricks in a cement rotary kiln as described in claim 1, characterized in that: The refractory brick supply structure includes a conveyor platform located at the outer end of the cement rotary kiln opening, a brick supply point located behind the conveyor platform, a brick configuration center, and a configuration conveyor trolley.

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