Vertical ultra-high temperature continuous high-purification spheroidizing furnace and production method

Abstract

The invention relates to the technical field of spheroidizing furnaces, and discloses a vertical ultra-high temperature continuous high-purification spheroidizing furnace and a production method, comprising a spheroidizing furnace, a feeding pipe connected to and arranged at the top of the spheroidizing furnace, a crushing and screening mechanism arranged at the top of the spheroidizing furnace, a frame unloading mechanism arranged below the crushing and screening mechanism, the crushing and screening mechanism comprising a crushing box connected to and arranged at the top of the feeding pipe, a fixed plate fixedly connected to the outer wall of the crushing box, a motor fixedly connected to the inner outer wall of the fixed plate, a first gear fixedly connected to the output end of the motor, a first crushing roller fixedly connected to the end of the first gear away from the motor, a first crushing roller rotatably connected to the inner wall of the crushing box at the end away from the first gear, the first gear meshes with a second gear, a second crushing roller fixedly connected to one end of the second gear, a rotating push rod fixedly connected to the outer wall of the output end of the motor, and a force-bearing rod contacting the top of the rotating push rod.

Description

Technical Field

[0001] The invention belongs to the technical field of spheroidizing furnaces, and in particular relates to a vertical ultra-high temperature continuous high-purification spheroidizing furnace and a production method. Background Art

[0002] In the field of modern metallurgy and material processing, especially in the preparation of high-performance metal alloys, spheroidization is a common pretreatment method, which aims to improve the fluidity, filling and sintering properties of raw material powders or particles by converting them into spherical forms, thereby facilitating the smooth progress of subsequent molding and sintering processes, and ultimately improving the density, strength and other key properties of the product. As a special equipment, the vertical ultra-high temperature continuous high-purification spheroidization furnace is widely used in the spheroidization treatment of metal powders and ceramic powder materials, especially in situations where strict purity requirements are required and the processing temperature is extremely high. However, the existing vertical ultra-high temperature continuous high-purification spheroidization furnace still faces some challenges in practical applications, which are mainly reflected in the following aspects:

[0003] Uneven crushed particle size: Raw material powders that have not been refined often have a wide particle size distribution. The presence of oversized particles leads to incomplete spheroidization, while overly small particles are excessively oxidized or evaporated at high temperatures, affecting the quality and performance of the final product. Existing crushing equipment has deficiencies in processing capacity, energy consumption control, and particle size distribution regulation, making it difficult to achieve accurate and efficient crushing of raw material powders.

[0004] Low screening efficiency: Some spheroidizing furnaces lack effective screening mechanisms or have low screening efficiency, resulting in large particles of materials that are not fully crushed being mixed into the spheroidizing furnace. This not only reduces the spheroidizing effect, but also causes problems such as uneven distribution of materials in the furnace and incomplete combustion, affecting the overall spheroidizing efficiency and equipment safety. Summary of the invention

[0005] The basic concept of the technical solution adopted in the present invention is:

[0006] Vertical ultra-high temperature continuous high-purification spheroidizing furnace, including spheroidizing furnace;

[0007] The feeding pipe is connected to the top of the spheroidizing furnace, and a crushing and screening mechanism is provided at the top of the spheroidizing furnace. A frame unloading mechanism is provided below the crushing and screening mechanism. The crushing and screening mechanism includes a crushing box connected to the top of the feeding pipe:

[0008] The outer wall of the motor is fixedly connected to a fixing plate, and an inner outer wall of the fixing plate is fixedly connected to a motor, and an output end of the motor is fixedly connected to a first gear, and one end of the first gear is fixedly connected to a first crushing roller away from one end of the motor, and the first crushing roller is rotatably connected to the inner wall of the crushing box, and the first gear meshes with a second gear, and one end of the second gear is fixedly connected to the second crushing roller. The outer wall of the motor output end is fixedly connected to a rotating push rod, and the top of the rotating push rod contacts and is provided with a force-bearing rod, and the force-bearing rod is fixedly connected to a sliding block away from one end of the rotating push rod. The inner wall of the sliding block is slidably connected to a sliding rod, and the inner wall of the crushing box is provided with a sliding groove, and both ends of the sliding rod are fixedly connected to the inner wall of the sliding groove, and the bottom end of the sliding block is fixedly connected to a spring, and the spring is fixedly connected to the bottom end of the inner wall of the sliding groove away from one end of the sliding block. The outer wall of the sliding block is provided with a clamping groove, and the inner wall of the clamping groove is clamped and connected with a clamping plate, and the outer wall of the clamping plate is fixedly connected to the screening frame.

[0009] As a preferred embodiment of the present invention, the frame unloading mechanism includes a support block fixedly connected to the bottom end of the screening frame, the bottom end of the support block is rotatably connected to a roller, the bottom end of the inner wall of the crushing box is fixedly connected to an inclined plate, the outer wall of the crushing box is fixedly connected to a first limit plate, the top of the first limit plate is provided with a first limit groove, the inner wall of the first limit groove is clamped and connected with a baffle, and the outer wall of the crushing box is fixedly connected to a second limit plate.

[0010] As a preferred implementation manner of the present invention, the number of the sliders is two, and the sliders are distributed on the left and right sides of the screening frame in a bilaterally symmetrical structure.

[0011] As a preferred embodiment of the present invention, the inner wall of the card slot formed on the outer wall of the slider fits snugly with the outer wall of the card plate, and the horizontal position of the card slot is in an inclined state.

[0012] As a preferred embodiment of the present invention, the inner outer wall of the second limiting plate fits snugly with the outer wall of the baffle.

[0013] As a preferred embodiment of the present invention, the top end of the inclined plate is hollow, and the number of the support blocks and the number of rollers are two respectively, and they are distributed at the bottom end of the screening frame in a bilaterally symmetrical structure.

[0014] The vertical ultra-high temperature continuous high-purification spheroidizing furnace production method of the present application includes:

[0015] Put the material to be processed into the crushing box through the slot at the top of the crushing box;

[0016] The motor is turned on synchronously, and its output end drives the first gear to rotate, and then drives the first crushing roller and the second gear to rotate; because the first gear is meshed with the second gear, the first crushing roller and the second crushing roller rotate in opposite directions to crush the input materials; after crushing, the materials fall into the screening frame;

[0017] The output end of the motor drives the rotating push rod to rotate at the same time; when the rotating push rod rotates and contacts the force rod, it pushes the force rod to move upward, thereby driving the slider to move upward on the outer wall of the slide rod; the slider stretches the spring, and the screening frame moves upward accordingly; when the rotating push rod continues to rotate and separates from the force rod, the spring rebounds and resets, driving the slider and the screening frame to move downward; this is repeated, and the screening frame vibrates up and down to screen the crushed materials inside; larger pieces of material are accumulated to the right through the slope at the bottom of the screening frame;

[0018] When too much material accumulates on the right side of the screening frame, pull the baffle upwards to disengage it from the screening frame; the screening frame moves to the left along the inclined plate through the rollers, and at the same time, the card plate on the outer wall of the screening frame disengages from the engagement connection with the card groove on the outer wall of the slider; the screening frame is completely moved out of the crushing box, and the accumulated material is collected and cleaned; then, the screening frame is pushed back into the crushing box to ensure that the card plate and the slider are re-engaged, and the next cycle of crushing and screening work is continued.

[0019] Further: according to the material properties and the ideal crushing particle size requirements, the Rittinger, Kick or Bond crushing work index is used, combined with the material hardness and toughness characteristic parameters, to establish a mathematical model of the crushing roller speed and material particle size; by controlling the motor output power, the speed of the first crushing roller and the second crushing roller is adjusted to ensure that the particle size of the crushed material meets the requirements of the subsequent spheroidization process;

[0020] Based on the vibration screening theory, determine the appropriate frequency range of the up and down vibration of the screening frame; this frequency is related to the material particle size, density and the aperture of the screening frame; calculate the optimal vibration frequency through the Archimedean principle and particle dynamics model, and adjust the elastic coefficient or preload of the spring accordingly to ensure that the screening frame vibrates at this frequency, improve screening efficiency, and reduce the residue of large particles;

[0021] Set the opening angle threshold between the baffle and the horizontal plane, which should correspond to the maximum allowable amount of material accumulated on the right side of the screening frame; measure the material stacking height or weight in real time through the sensor installed inside the screening frame to calculate the material accumulation; when the accumulation exceeds the set threshold, the baffle is triggered to automatically open upward to the set angle, allowing the screening frame to slide out along the inclined plate through the roller;

[0022] According to the material characteristics and the rolling resistance of the roller, the appropriate inclination angle of the inclined plate is calculated using the principle of static friction and gravity balance or the dynamic model; the installation angle of the inclined plate is adjusted to ensure that the material slides smoothly down the slope at the bottom of the screening frame to avoid blockage or accumulation, and to prevent the material from sliding too quickly, resulting in insufficient screening.

[0023] Compared with the prior art, the present invention has the following beneficial effects:

[0024] The present invention starts the motor, and its output end drives the first gear to rotate, thereby driving the first crushing roller and the second crushing roller to rotate, so that the first crushing roller and the second crushing roller can rotate in opposite directions to crush the materials put therein, and the materials will fall into the screening frame after crushing. At the same time, the motor output end will drive the rotating push rod to rotate, and when the rotating push rod rotates, it can contact and squeeze the force-bearing rod to move upward, so that the force-bearing rod drives the slider to move upward on the outer wall of the slider, and at the same time, the slider stretches the spring, and when the slider moves upward, it can drive the screening frame to move upward, and when the rotating push rod continues to rotate and no longer contacts the force-bearing rod, the spring rebounds and resets, driving the slider and the screening frame to move downward, so that the screening frame can be repeatedly driven to vibrate up and down, and the crushed materials inside can be screened, and larger pieces of materials will be accumulated to the right through the slope at the bottom of the screening frame, thereby completing the crushing and screening of the materials.

[0025] According to the present invention, when too much material is accumulated on the right side of the screening frame, the baffle can be pulled upwards, and the baffle will be out of contact with the screening frame at this time. Then the screening frame will move to the left through the roller and the inclined plate, and at the same time, the card plate on the outer wall of the screening frame will be out of the engagement connection with the card slot provided on the outer wall of the slider, until the screening frame is completely moved out of the crushing box, and then the accumulated material is collected, and then the screening frame is pushed into the crushing box, the card plate is re-engaged with the slider, and then the collected material is put into the crushing box for crushing again.

[0026] The specific implementation modes of the present invention are further described in detail below in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] In the attached picture:

[0028] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0029] Figure 2 It is a schematic diagram of the internal cross-sectional structure of the present invention;

[0030] Figure 3 The schematic diagram of the crushing and screening mechanism of the present invention is shown in FIG. Figure 1 ;

[0031] Figure 4This is a schematic diagram of the partial structure of the crushing and screening mechanism of the present invention. Figure 2 ;

[0032] Figure 5 It is a structural schematic diagram of the frame unloading mechanism of the present invention.

[0033] In the figure: 1, spheroidizing furnace; 2, feeding pipe; 31, crushing and screening mechanism; 311, crushing box; 312, fixing plate; 313, motor; 314, first gear; 315, first crushing roller; 316, second gear; 317, second crushing roller; 318, rotating push rod; 319, force rod; 3110, slider; 3111, slide bar; 3112, spring; 3113, clamping plate; 3114, screening frame; 32, frame unloading mechanism; 321, supporting block; 322, roller; 323, inclined plate; 324, first limit plate; 325, baffle; 326, second limit plate. DETAILED DESCRIPTION

[0034] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. The following embodiments are used to illustrate the present invention.

[0035] like Figures 1 to 5 As shown, the vertical ultra-high temperature continuous high-purification spheroidizing furnace comprises a spheroidizing furnace 1, a feeding pipe 2 connected to the top of the spheroidizing furnace 1, a crushing and screening mechanism 31 is arranged at the top of the spheroidizing furnace 1, a frame unloading mechanism 32 is arranged below the crushing and screening mechanism 31, the crushing and screening mechanism 31 comprises a crushing box 311 connected to the top of the feeding pipe 2, a fixed plate 312 is fixedly connected to the outer wall of the crushing box 311, a motor 313 is fixedly connected to the inner outer wall of the fixed plate 312, a first gear 314 is fixedly connected to the output end of the motor 313, a first crushing roller 315 is fixedly connected to the end of the first gear 314 away from the motor 313, the end of the first crushing roller 315 away from the first gear 314 is rotatably connected to the inner wall of the crushing box 311, and the first gear 314 is meshed with a second gear 316 , one end of the second gear 316 is fixedly connected to the second crushing roller 317, the outer wall of the output end of the motor 313 is fixedly connected to a rotating push rod 318, the top of the rotating push rod 318 is contacted with a force rod 319, the force rod 319 is fixedly connected to a slider 3110 at one end away from the rotating push rod 318, the inner wall of the slider 3110 is slidably connected to a slide bar 3111, a slide groove is provided on the inner wall of the crushing box 311, both ends of the slide bar 3111 are fixedly connected to the inner wall of the slide groove, the bottom end of the slider 3110 is fixedly connected to a spring 3112, the end of the spring 3112 away from the slider 3110 is fixedly connected to the bottom end of the inner wall of the slide groove, the outer wall of the slider 3110 is provided with a card slot, the inner wall of the card slot is card-connected with a card plate 3113, and the outer wall of the card plate 3113 is fixedly connected to a screening frame 3114.

[0036] Furthermore, there are two sliders 3110, and the sliders 3110 are distributed on the left and right sides of the screening frame 3114 in a left-right symmetrical structure, so that the left and right sides of the screening frame 3114 can be supported to move up and down synchronously, thereby improving the stability during the up and down movement.

[0037] Furthermore, the inner wall of the slot opened on the outer wall of the slider 3110 fits snugly with the outer wall of the card plate 3113, and the horizontal position of the slot is inclined. When the screening frame 3114 is pushed, the inclined plate 323 is inclined, so the screening frame 3114 will be inclined during the movement. This arrangement makes it convenient for the card plate 3113 to be inserted into the inner wall of the slot opened on the outer wall of the slider 3110.

[0038] The frame unloading mechanism 32 includes a support block 321 fixedly connected to the bottom end of the screening frame 3114, the bottom end of the support block 321 is rotatably connected to a roller 322, the bottom end of the inner wall of the crushing box 311 is fixedly connected to an inclined plate 323, the outer wall of the crushing box 311 is fixedly connected to a first limit plate 324, the top of the first limit plate 324 is provided with a first limit groove, the inner wall of the first limit groove is snap-connected to a baffle 325, and the outer wall of the crushing box 311 is fixedly connected to a second limit plate 326.

[0039] Furthermore, the inner outer wall of the second limiting plate 326 fits snugly with the outer wall of the baffle 325 , thereby limiting and blocking the upper portion of the baffle 325 to prevent the baffle 325 from tipping over.

[0040] Furthermore, the top of the inclined plate 323 is hollow, and the number of support blocks 321 and rollers 322 are respectively two, and they are distributed at the bottom of the screening frame 3114 in a left-right symmetrical structure, so that the inclined plate 323 will not block the discharge of materials. At the same time, the support blocks 321 and rollers 322 are arranged on the left and right sides of the screening frame 3114, which can improve the stability of the screening frame 3114 during movement.

[0041] The implementation principle of the vertical ultra-high temperature continuous high-purification spheroidizing furnace of this embodiment is as follows: first, the material is put into the crushing box 311 through the through slot at the top thereof, and the motor 313 is turned on synchronously, and its output end drives the first gear 314 to rotate, thereby driving the first crushing roller 315 and the second gear 316 to rotate, so that the first crushing roller 315 and the second crushing roller 317 can rotate in opposite directions to crush the material put therein, and after the crushing is completed, the material will fall into the screening frame 3114, and at the same time, the output end of the motor 313 will drive the rotating push rod 318 to rotate, and when the rotating push rod 318 rotates, it can contact and squeeze the force-bearing rod 319 to move upward, The force-bearing rod 319 drives the slider 3110 to move upward on the outer wall of the slider 3111, and the slider 3110 stretches the spring 3112. When the slider 3110 moves upward, the screening frame 3114 can be driven to move upward. When the rotating push rod 318 continues to rotate and no longer contacts the force-bearing rod 319, the spring 3112 rebounds and resets, driving the slider 3110 and the screening frame 3114 to move downward. This can repeatedly drive the screening frame 3114 to vibrate up and down, thereby screening the crushed material inside. Larger pieces of material will be accumulated to the right through the slope at the bottom of the screening frame 3114, thereby completing the crushing and screening of the material.

[0042] When too much material is accumulated on the right side of the screening frame 3114, the baffle 325 can be pulled upwards. At this time, the baffle 325 will be out of contact with the screening frame 3114, and then the screening frame 3114 will move to the left through the roller 322 and the inclined plate 323. At the same time, the card plate 3113 on the outer wall of the screening frame 3114 will be out of the engagement connection with the card slot opened on the outer wall of the slider 3110, until the screening frame 3114 is completely moved out of the crushing box 311, and then the accumulated material is collected, and then the screening frame 3114 is pushed into the crushing box 311, the card plate 3113 is re-engaged with the slider 3110, and then the collected material is put into the crushing box 311 for crushing again.

[0043] The vertical ultra-high temperature continuous high-purification spheroidization furnace of the present application crushes and screens the materials through a crushing and screening mechanism, aiming to improve the efficiency of spheroidization. In order to further improve the technical effect and accuracy of the present application, the mathematical relationship between different components can be configured from the following aspects:

[0044] 1. Relationship between the speed of the crushing roller and the particle size of the material

[0045] According to the material properties and the ideal crushing particle size requirements, a mathematical model between the crushing roller speed and the material particle size is established through crushing theory or experimental data. For example, the crushing work index theory of Rittinger, Kick or Bond can be used, combined with the material hardness and toughness characteristic parameters, to calculate the crushing roller speed required to achieve the expected particle size. By controlling the output power of the motor 313, the speed of the first crushing roller 315 and the second crushing roller 317 is adjusted to ensure that the particle size of the crushed material meets the requirements of the subsequent spheroidization process.

[0046] 2. Relationship between screening frame vibration frequency and screening efficiency

[0047] Based on the vibration screening theory, the appropriate frequency range of the up and down vibration of the screening frame 3114 is determined. The frequency should be related to the material particle size, density and the aperture of the screening frame. The optimal vibration frequency can be calculated through the Archimedean principle and the particle dynamics model to ensure that the screening frame vibrates at this frequency under the drive of the spring 3112, thereby improving the screening efficiency and reducing the residue of large particles.

[0048] 3. Relationship between the opening angle of baffle 325 and the amount of material accumulation

[0049] The opening angle threshold between the baffle 325 and the horizontal plane is set, and the angle should correspond to the maximum allowable amount of material accumulated on the right side of the screening frame 3114. The material accumulation amount is calculated by measuring the material accumulation height or weight in the screening frame 3114. When the accumulation amount exceeds the set threshold, the baffle 325 is triggered to open upward to the set angle, so that the screening frame 3114 slides out along the inclined plate 323 through the roller 322 to clean the material.

[0050] 4. Relationship between the inclination angle of the inclined plate and the sliding speed of the material

[0051] According to the material properties (such as friction coefficient, particle size distribution) and the rolling resistance of the roller 322, the appropriate inclination angle of the inclined plate 323 is calculated using the principle of static friction and gravity balance or a dynamic model. The appropriate inclination angle should ensure that the material slides down the slope at the bottom of the screening frame 3114 smoothly to avoid blockage or accumulation, and prevent the material from sliding down too quickly, resulting in insufficient screening.

[0052] 5. Relationship between material flow control and spheroidization efficiency

[0053] By monitoring the material flow rate of the feed pipe 2, it is matched with the processing capacity of the spheroidizing furnace 1. According to the material properties, the temperature and pressure parameters in the spheroidizing furnace, a mathematical model of material flow rate and spheroidizing efficiency is established. By adjusting the opening of the feed pipe valve or the speed of the conveying equipment, the appropriate material flow rate is maintained to ensure that the spheroidizing furnace operates in an efficient working state, avoiding energy waste and process instability caused by overload or no-load operation.

[0054] Through the configuration and application of the above mathematical relationship, the vertical ultra-high temperature continuous high-purification spheroidization furnace of the present application can achieve the technical purpose more accurately, which is specifically manifested as follows:

[0055] Precisely control the particle size: by adjusting the rotation speed of the crushing roller, ensure that the material reaches the ideal crushing particle size, improve the spheroidization efficiency and product quality.

[0056] Improve screening efficiency: optimize the vibration frequency of the screening frame, effectively separate the material particles that meet the requirements, reduce the large particles entering the spheroidizing furnace, and reduce the energy consumption of spheroidization.

[0057] Automatic cleaning of accumulated materials: Intelligently control the opening angle of the baffle according to the amount of material accumulation, and clean up the accumulated materials in the screening frame in time to ensure continuous and stable operation of the equipment.

[0058] Materials slide down smoothly: Reasonably set the inclination angle of the inclined plate to ensure that materials slide down smoothly at the bottom of the screening frame to avoid blockage and improve overall work efficiency.

[0059] Material flow adaptation: Accurately control the material flow to match the processing capacity of the spheroidizing furnace, maintain the spheroidizing furnace in an efficient working state, reduce energy consumption, and improve spheroidizing efficiency.

[0060] The vertical ultra-high temperature continuous high-purification spheroidization furnace of the present application crushes and screens the materials through a crushing and screening mechanism, aiming to improve the efficiency of spheroidization. In order to further improve the technical effect and accuracy of the present application, in specific implementation, the production method of the vertical ultra-high temperature continuous high-purification spheroidization furnace of the present application includes:

[0061] Embodiment 1:

[0062] Material delivery: the material to be processed is delivered into the crushing box through the slot at the top of the crushing box 311;

[0063] Crushing operation: The motor 313 is started synchronously, and its output end drives the first gear 314 to rotate, thereby driving the first crushing roller 315 and the second gear 316 to rotate; since the first gear 314 is meshed with the second gear 316, the first crushing roller 315 and the second crushing roller 317 rotate in opposite directions to crush the input materials; after the crushing is completed, the materials fall into the screening frame 3114;

[0064] Screening vibration: The output end of the motor 313 drives the rotating push rod 318 to rotate at the same time; when the rotating push rod 318 rotates and contacts the force rod 319, the force rod 319 is pushed to move upward, thereby driving the slider 3110 to move upward on the outer wall of the slide rod 3111; the slider 3110 stretches the spring 3112, and the screening frame 3114 moves upward accordingly; when the rotating push rod 318 continues to rotate and disengages from the force rod 319, the spring 3112 rebounds and resets, driving the slider 3110 and the screening frame 3114 to move downward; this is repeated, and the screening frame 3114 vibrates up and down to screen the crushed materials inside; larger pieces of materials are accumulated to the right through the slope at the bottom of the screening frame 3114;

[0065] Material cleaning: When too much material is accumulated on the right side of the screening frame 3114, the baffle 325 is pulled upward to make it out of contact with the screening frame 3114; the screening frame 3114 moves to the left along the inclined plate 323 through the roller 322, and at the same time, the clamping plate 3113 on the outer wall of the screening frame is disconnected from the clamping connection with the outer wall of the slider 3110; the screening frame 3114 is completely moved out of the crushing box 311, and the accumulated material is collected and cleaned; then, the screening frame 3114 is pushed back into the crushing box to ensure that the clamping plate 3113 and the slider 3110 are re-engaged, and the next cycle of crushing and screening is continued;

[0066] Embodiment 2:

[0067] On the basis of Example 1, the following contents are added to optimize the accuracy and efficiency of the vertical ultra-high temperature continuous high-purification spheroidization furnace: Configuration of the relationship between the rotation speed of the grinding roller and the particle size of the material: According to the material properties and the ideal crushing particle size requirements, the Rittinger, Kick or Bond crushing work index is used, combined with the material hardness and toughness characteristic parameters, to establish a mathematical model of the rotation speed of the grinding roller and the particle size of the material; by controlling the output power of the motor 313, the rotation speed of the first grinding roller 315 and the second grinding roller 317 is adjusted to ensure that the particle size of the crushed material meets the requirements of the subsequent spheroidization process; the specific details are as follows:

[0068] Select the crushing work index theory:

[0069] Rittinger theory: Crushing energy consumption is proportional to the newly generated surface area.

[0070] Kick theory: Crushing energy consumption is proportional to the square root of the crushing ratio.

[0071] Bond theory: Crushing energy consumption is proportional to the first power of crushing ratio.

[0072] According to the characteristics of the material to be processed (hardness, toughness, brittleness), the applicable crushing work index theory is selected as the basis for establishing the mathematical model.

[0073] Material characteristic parameter determination:

[0074] Hardness: The hardness value of the material is measured by Rockwell hardness, Brinell hardness and Vickers hardness test methods, which reflects the material's ability to resist crushing.

[0075] Toughness: The toughness value of the material is measured through impact toughness test and bending test, which reflects the ability of the material to absorb and consume energy during the crushing process.

[0076] Particle size distribution: The original particle size distribution of the material is determined by screening test or laser particle size analyzer to provide initial conditions for model calculation.

[0077] Establish a mathematical model of crushing roller speed and material particle size:

[0078] According to the selected crushing work index theory, combined with the material hardness H, toughness E, original average particle size Dp, target average particle size Dt parameters, the following mathematical model is constructed:

[0079] f(Dt,H,E,Dp,n)=0

[0080] Where f is the crushing energy consumption function and n is the crushing roller speed. The model reflects the crushing roller speed required to achieve the required crushing energy consumption under given material properties and target particle size conditions.

[0081] For the Rittinger theory, the model is:

[0082] K*(Dt / Dp)^2*(H / E)=C*n

[0083] Where K and C are empirical coefficients, which are determined by fitting experimental data.

[0084] For Kick or Bond theory, the model form is similar, but the power exponent of the relationship between crushing energy consumption and particle size is different.

[0085] Motor output power control:

[0086] According to the established mathematical model, given the target material particle size Dt and known material characteristic parameters, the grinding roller speed n is solved. According to the functional relationship between motor power and speed P(n) (usually provided by the motor manufacturer or measured through experiments), the corresponding motor output power P is calculated.

[0087] The power supply voltage, current or frequency control parameters of the motor 313 are adjusted so that the motor output power P is close to the calculated value, thereby achieving accurate control of the rotation speed n of the grinding roller.

[0088] Optimization of the vibration frequency of the screening frame: Based on the vibration screening theory, determine the appropriate frequency range of the up and down vibration of the screening frame 3114; this frequency is related to the material particle size, density and the aperture of the screening frame; calculate the optimal vibration frequency through the Archimedean principle and particle dynamics model, and adjust the elastic coefficient or preload of the spring 3112 accordingly to ensure that the screening frame vibrates at this frequency, improve the screening efficiency, and reduce the residue of large particles; based on the vibration screening theory, the specific details of determining the appropriate frequency range of the up and down vibration of the screening frame 3114 are as follows:

[0089] Vibration screening theory:

[0090] Basic concept: Vibration screening theory mainly studies the movement law and separation efficiency of materials when they are subjected to periodic vibration on the vibrating screen surface. The vibration screening efficiency is closely related to the vibration frequency, amplitude, screen surface inclination, material particle size, material density, and the friction coefficient between the material and the screen.

[0091] Screening efficiency: Screening efficiency refers to the percentage of the mass of material passing through the screen hole to the total mass of the feed, and is a key indicator for measuring screening effect. The vibration frequency of the screening frame 3114 directly affects the jumping height, retention time and chance of collision between particles on the screen surface, thus affecting the screening efficiency.

[0092] Determine the appropriate frequency range:

[0093] Material particle size: There is a certain matching relationship between material particle size and vibration frequency. Generally speaking, materials with smaller particle sizes are suitable for higher frequencies so that the particles can jump quickly on the screen surface to avoid particle impaction; materials with larger particle sizes are suitable for lower frequencies to ensure that the particles have enough kinetic energy to penetrate the screen holes.

[0094] Material density: Material density will affect the movement of particles on the screen surface. Under the same vibration conditions, materials with higher density will have a smaller jumping height, and the vibration frequency needs to be appropriately increased to enhance its ability to pass through the screen holes; conversely, materials with lower density can appropriately reduce the vibration frequency to prevent excessive jumping and particle splashing.

[0095] Screening frame aperture: The size of the screening frame aperture determines the minimum particle size that can pass through the sieve. In order to ensure that fine particles can pass smoothly, a screening frame with a small aperture requires a higher vibration frequency to enhance the power of particles passing through the sieve holes; a screening frame with a large aperture can appropriately reduce the vibration frequency to prevent large particles from vibrating excessively and failing to pass through the sieve holes effectively.

[0096] Archimedean principle and particle dynamics model:

[0097] Archimedes principle: used to calculate the buoyancy and resistance of particles on the screen surface when subjected to vibration. The Archimedes principle can be used to analyze the relative movement between particles and the screen surface during vibration, as well as the effect of interaction between particles on screening efficiency, thus providing theoretical support for determining the vibration frequency.

[0098] Particle dynamics model: Based on Newton's second law and the contact mechanics between material particles and the screen surface, the motion equation of particles on the vibrating screen surface is established. By solving this equation, the key parameters of particle jump height, retention time, and penetration probability under different vibration frequencies can be predicted, and the optimal vibration frequency can be determined.

[0099] Adjustment of the elastic coefficient or preload of spring 3112:

[0100] Elastic coefficient: The elastic coefficient (k) of spring 3112 directly affects the vibration frequency (f) of screening frame 3114. According to vibration screening theory and vibration machinery design principles, the vibration frequency is related to spring stiffness, screening frame mass and amplitude factors. By changing the material, cross-sectional dimensions or winding method of spring 3112, its elastic coefficient can be adjusted to achieve the purpose of setting the vibration frequency.

[0101] Preload: The preload (F0) of spring 3112 will affect the initial displacement and vibration stability of the screening frame 3114. Properly increasing the preload can improve the stability of the screening frame during vibration and reduce noise and mechanical wear caused by vibration. When adjusting the preload, the vibration frequency setting requirements must be taken into account to ensure that the screening frame 3114 vibrates stably within the optimal frequency range. In summary, based on the vibration screening theory, by comprehensively considering the material particle size, density, and screening frame aperture factors, combined with the Archimedes principle and particle dynamics model calculation, the appropriate frequency range for the up and down vibration of the screening frame 3114 is determined. Then, by adjusting the elastic coefficient or preload of the spring 3112, ensure that the screening frame vibrates at the optimal frequency, thereby improving the screening efficiency and reducing the residue of large particles. The implementation of this series of specific details will help ensure that the vertical ultra-high temperature continuous high-purification spheroidization furnace of this application is more accurate in achieving the technical objectives.

[0102] Baffle opening angle threshold setting: Set the opening angle threshold between the baffle 325 and the horizontal plane, which should correspond to the maximum allowable amount of material accumulated on the right side of the screening box 3114; measure the material stacking height or weight in real time through the sensor installed inside the screening box to calculate the material accumulation; when the accumulation exceeds the set threshold, trigger the baffle 325 to automatically open upward to the set angle, so that the screening box slides out along the inclined plate through the roller to clean the material; set the opening angle threshold between the baffle 325 and the horizontal plane, which should correspond to the maximum allowable amount of material accumulated on the right side of the screening box 3114. The specific details are as follows:

[0103] Modeling the relationship between material stacking height and angle threshold:

[0104] A mathematical model between the material stacking height H and the baffle opening angle θ is established. Considering the material stacking form, the internal space size of the screening frame, and the material stacking angle, empirical formulas, geometric relationships, or physical simulations (such as discrete element method DEM) can be used for modeling. For example, assuming that the material stacking is approximately conical, the following relationship exists between H and θ: H = f (θ, D screening frame, α stacking angle, ρ material, V stacking volume) where D screening frame is the internal width of the screening frame, α stacking angle is the natural stacking angle of the material, ρ material is the material density, and V stacking volume is the maximum allowable stacking volume of the material.

[0105] Material weight sensor installation and data collection:

[0106] Install a weight sensor at a suitable position inside the screening frame (such as the bottom or side of the material accumulation area) to monitor the material accumulation weight W in real time. Ensure that the sensor has high accuracy and good stability and can adapt to high temperature and vibration working environment.

[0107] Set up a data acquisition system to collect weight sensor signals periodically or continuously, and convert them into digital storage to provide data support for subsequent calculation of material accumulation.

[0108] Calculation of material accumulation:

[0109] According to the relationship between the material stacking height H and the weight W (such as the volume mass method), the current material accumulation Vaccumulation is calculated. Taking into account the material particle size distribution and stacking density factors, a correction coefficient can be introduced to correct the calculation result: Vaccumulation = W / (ρmaterial×kcorrection) where kcorrection is a correction coefficient considering the particle size distribution and stacking density factors.

[0110] Opening angle threshold setting and adjustment:

[0111] According to the material properties, screening efficiency requirements and spheroidizing furnace processing capacity, the baffle 325 opening angle threshold θthreshold is set. When the material accumulation amount Vaccumulation exceeds the set maximum allowable amount Vmax, it is considered that the material is too accumulated and the baffle needs to be opened for cleaning.

[0112] The setting of the θ threshold can be determined through experiments or simulations, or it can be dynamically adjusted according to actual operating conditions. For example, if it is found that material accumulation is too fast and the screening efficiency is reduced, the θ threshold can be appropriately reduced and the cleaning frequency can be increased.

[0113] Automatic opening control logic of the baffle:

[0114] When Vaccumulation>Vmax, the automatic opening procedure of the baffle is triggered. The control unit (such as PLC, microprocessor) receives the weight sensor data and determines whether the opening condition is met. If so, it sends a command to the baffle driving device (such as electric push rod, hydraulic cylinder) to open the baffle 325 upward to the set angle θthreshold.

[0115] During the opening process, the angle sensor monitors the actual opening angle of the baffle 325 in real time and compares it with the set θ threshold to ensure that the baffle reaches the set angle accurately. At the same time, the movement of the screening frame 3114 is monitored to ensure that it slides smoothly along the inclined plate 323 through the roller 322 to clean the material.

[0116] Material cleaning and baffle resetting:

[0117] When the screening frame 3114 is moved out of the crushing box 311, the material is cleaned manually or automatically. After the cleaning is completed, the screening frame is pushed back into the crushing box to ensure that the clamping plate 3113 and the slider 3110 are re-engaged. At the same time, the control unit issues an instruction to drive the baffle 325 to reset to the initial closed state and wait for the next opening instruction.

[0118] Through the implementation of the above-mentioned specific details, the vertical ultra-high temperature continuous high-purification spheroidization furnace of the present application realizes precise control of the opening angle of the baffle 325 and the material accumulation amount on the right side of the screening frame, ensuring that the baffle is automatically opened for cleaning when the accumulation amount of the material reaches the set threshold, avoiding manual intervention and the decrease in screening efficiency caused by excessive material accumulation, and improving the degree of automation and operational stability of the equipment.

[0119] Inclined plate angle adjustment: According to the material properties (such as friction coefficient, particle size distribution) and the rolling resistance of the roller 322, the appropriate inclination angle of the inclined plate 323 is calculated using the principle of static friction and gravity balance or a dynamic model; the inclined plate installation angle is adjusted to ensure that the material slides smoothly on the slope at the bottom of the screening frame to avoid blockage or accumulation, and to prevent the material from sliding too fast and causing insufficient screening; the specific details are as follows:

[0120] Material characteristics analysis:

[0121] Friction coefficient: The friction coefficient between the material and the surface of the inclined plate 323 is an important factor affecting the sliding speed of the material. By consulting relevant information or conducting laboratory tests, the static friction coefficient μs and dynamic friction coefficient μk of the material under specific working conditions are determined. The friction coefficient is related to the material material, surface roughness, and humidity factors. Accurately understanding this information helps to accurately calculate the inclination angle of the inclined plate.

[0122] Particle size distribution: The particle size and distribution of the material have a direct impact on the material's bulk density, fluidity, and contact area with the inclined plate surface. The material's particle size distribution data (such as average particle size, maximum particle size, and particle size distribution curve) is obtained through screening tests, and combined with the material's stacking angle (angle of repose) physical properties, its stacking behavior and sliding trend on the inclined plate are evaluated.

[0123] Rolling resistance analysis of roller 322:

[0124] Rolling resistance coefficient: The rolling resistance of the roller 322 on the inclined plate is mainly composed of the rolling friction between the roller and the inclined plate, the rolling resistance generated by the roller's own weight, and the friction factor of the roller bearing. The rolling resistance coefficient f of the roller under a specific load and speed can be determined by consulting the data provided by the roller manufacturer or conducting on-site tests.

[0125] Roller load: Roller load includes the weight of the screening frame and the material inside. Calculate the total load P on the roller based on the screening frame structure, material density and expected maximum material loading.

[0126] Roller rolling resistance calculation: Roller 322 rolling resistance on the inclined plane F_r = f × P × cos (θ), where θ is the inclination angle of the inclined plate. Roller rolling resistance has an indirect effect on the material sliding speed because it determines the difficulty of the screening frame sliding on the inclined plate.

[0127] Incline angle calculation:

[0128] Static friction and gravity balance: When the material remains stationary on the inclined plate, the static friction F_f it is subjected to is balanced with the gravity component F_g (parallel to the inclined plane), that is, F_f=F_g=mg sin(θ), where m is the mass of the material and g is the acceleration of gravity. When the inclined plate inclination angle θ increases to a certain critical value θ_c, the static friction force cannot prevent the material from sliding down, and at this time θ_c=arctan(μs). In practical applications, in order to ensure smooth sliding of the material, the inclined plate inclination angle should be slightly larger than θ_c.

[0129] Dynamic model: Considering the accelerated sliding process of materials on the inclined plane, a dynamic model including gravity, friction, and rolling resistance can be established. By solving differential equations or numerical simulations, the relationship between the sliding speed of the material and time, as well as the sliding distance of the material on the inclined plate, can be obtained. The inclined plate inclination angle is selected so that the material slides to the bottom within the specified time (to ensure sufficient screening) without accumulation or sliding too fast.

[0130] Inclined plate installation angle adjustment:

[0131] Design and manufacturing: Design and manufacture the inclined plate that meets the requirements according to the calculated appropriate inclination angle. Ensure that the inclined plate has a stable structure and a smooth surface to reduce additional friction resistance. For adjustable inclined plate designs, precise angle adjustment devices should be provided to facilitate fine-tuning according to actual conditions.

[0132] On-site commissioning and optimization: In the early stage of equipment operation, the inclination angle of the inclined plate is fine-tuned by observing the actual sliding of the material on the inclined plate. If necessary, the above calculation and analysis process can be repeated to adapt to changes in material characteristics or adjustments to equipment operating conditions.

[0133] In summary, by analyzing the material properties (friction coefficient, particle size distribution), the rolling resistance of the roller, and applying the principle of static friction and gravity balance or the dynamic model, the appropriate inclination angle of the inclined plate 323 is accurately calculated, and then the installation angle of the inclined plate is adjusted according to the calculation results, which can ensure that the material slides smoothly on the slope at the bottom of the screening frame to avoid blockage or accumulation, and prevent the material from sliding too fast and causing insufficient screening. This meticulous parameter configuration and optimization helps to improve the overall working efficiency and spheroidization effect of the vertical ultra-high temperature continuous high-purification spheroidization furnace.

Claims

1. A vertical ultra-high temperature continuous high-purification spheroidizing furnace, comprising a spheroidizing furnace (1); The feeding pipe (2) is connected to the top of the spheroidizing furnace (1), and is characterized in that: The top of the spheroidizing furnace (1) is provided with a crushing and screening mechanism (31), a frame unloading mechanism (32) is provided below the crushing and screening mechanism (31), and the crushing and screening mechanism (31) comprises a crushing box (311) which is connected to the top of the feeding pipe (2): The outer wall of the crushing box (311) is fixedly connected to a fixing plate (312), the inner outer wall of the fixing plate (312) is fixedly connected to a motor (313), the output end of the motor (313) is fixedly connected to a first gear (314), the end of the first gear (314) away from the motor (313) is fixedly connected to a first crushing roller (315), the end of the first crushing roller (315) away from the first gear (314) is rotatably connected to the inner wall of the crushing box (311), the first gear (314) is meshed with a second gear (316), one end of the second gear (316) is fixedly connected to a second crushing roller (317), the outer wall of the output end of the motor (313) is fixedly connected to a rotating push rod (318), the rotating push rod ( A force-bearing rod (319) is provided at the top of the movable push rod (318), and a slider (3110) is fixedly connected to the force-bearing rod (319) at one end away from the rotating push rod (318), and a slider (3110) is slidably connected to the inner wall of the slider (3110), and a slide groove is provided on the inner wall of the crushing box (311), and both ends of the slide rod (3111) are fixedly connected to the inner wall of the slide groove, and a spring (3112) is fixedly connected to the bottom end of the inner wall of the slide groove at the bottom end of the slider (3110), and one end of the spring (3112) away from the slider (3110) is fixedly connected to the bottom end of the inner wall of the slide groove, and a card slot is provided on the outer wall of the slider (3110), and a card plate (3113) is carded and connected to the inner wall of the card slot, and a screening frame (3114) is fixedly connected to the outer wall of the card plate (3113); The frame unloading mechanism (32) comprises a support block (321) fixedly connected to the bottom end of the screening frame (3114); the bottom end of the support block (321) is rotatably connected to a roller (322); the bottom end of the inner wall of the crushing box (311) is fixedly connected to an inclined plate (323); the outer wall of the crushing box (311) is fixedly connected to a first limiting plate (324); a first limiting groove is formed at the top end of the first limiting plate (324); a baffle (325) is snap-connected to the inner wall of the first limiting groove; and the outer wall of the crushing box (311) is fixedly connected to a second limiting plate (326); The operation method includes: Put the material to be processed into the crushing box through the slot at the top of the crushing box; The motor is turned on synchronously, and its output end drives the first gear to rotate, and then drives the first crushing roller and the second gear to rotate; because the first gear is meshed with the second gear, the first crushing roller and the second crushing roller rotate in opposite directions to crush the input materials; after crushing, the materials fall into the screening frame; The output end of the motor drives the rotating push rod to rotate at the same time; when the rotating push rod rotates and contacts the force rod, it pushes the force rod to move upward, thereby driving the slider to move upward on the outer wall of the slide rod; the slider stretches the spring, and the screening frame moves upward accordingly; when the rotating push rod continues to rotate and separates from the force rod, the spring rebounds and resets, driving the slider and the screening frame to move downward; this is repeated, and the screening frame vibrates up and down to screen the crushed materials inside; larger pieces of material are accumulated to the right through the slope at the bottom of the screening frame; When too much material is accumulated on the right side of the screening frame, pull the baffle upward to make it out of contact with the screening frame; the screening frame moves to the left along the inclined plate through the roller, and at the same time, the card plate on the outer wall of the screening frame is disengaged from the engagement connection with the card slot on the outer wall of the slider; the screening frame is completely moved out of the crushing box, and the accumulated material is collected and cleaned; then, the screening frame is pushed back into the crushing box to ensure that the card plate and the slider are re-engaged, and the next cycle of crushing and screening work is continued; According to the material properties and the ideal crushing particle size requirements, the Rittinger, Kick or Bond crushing work index is used, combined with the material hardness and toughness characteristic parameters, to establish a mathematical model of the crushing roller speed and material particle size; by controlling the motor output power, the speed of the first crushing roller and the second crushing roller is adjusted to ensure that the particle size of the crushed material meets the requirements of the subsequent spheroidization process.

2. The vertical ultra-high temperature continuous high-purification spheroidization furnace according to claim 1, characterized in that: There are two sliders (3110), and the sliders (3110) are distributed on the left and right sides of the screening box (3114) in a left-right symmetrical structure.

3. The vertical ultra-high temperature continuous high-purification spheroidization furnace according to claim 1, characterized in that: The inner wall of the card slot formed on the outer wall of the slider (3110) fits snugly with the outer wall of the card plate (3113), and the horizontal position of the card slot is in an inclined state.

4. The vertical ultra-high temperature continuous high-purification spheroidization furnace according to claim 1, characterized in that: The inner outer wall of the second limiting plate (326) fits snugly with the outer wall of the baffle (325).

5. The vertical ultra-high temperature continuous high-purification spheroidization furnace according to claim 1, characterized in that: The top of the inclined plate (323) is hollow, and the number of the supporting blocks (321) and the number of the rollers (322) are two respectively, and they are distributed at the bottom of the screening frame (3114) in a bilaterally symmetrical structure.

Images