A method for manufacturing lightweight mullite bricks and high-strength mullite bricks

Abstract

The present invention provides a method for manufacturing lightweight mullite bricks, which includes a batching process, a stamping process, a drying process, and a testing process. In the testing process, a sample is clamped by providing a panel mechanism, and the sample is turned over by a turning mechanism so that different surfaces of the sample are aligned with a camera respectively. This allows all surfaces of the sample to be tested, thereby improving work efficiency and being suitable for assembly line operation.

Description

Technical Field

[0001] The invention relates to the production of mullite bricks, and in particular to a method for manufacturing lightweight mullite bricks and high-strength mullite bricks. Background Art

[0002] Ultra-lightweight shaped refractories are a leading research area in the refractory industry. Their primary application is insulation for industrial furnace linings. Due to their ultra-low bulk density, their thermal conductivity is significantly superior to conventional lightweight insulation bricks. The lower the bulk density, the lower the thermal conductivity of the lightweight insulation brick, resulting in better insulation performance and greater energy savings.

[0003] When testing refractory bricks, it is necessary to check whether there are defects such as cracks and chipped corners in the sample. It is necessary to determine whether the crack is a crack that runs through one edge and two sides, because different types of cracks have different requirements. The specific requirements are: ① The length of a crack that runs through one edge and two sides shall not be greater than 1 / 3 of the sum of the crack direction dimensions of the surface where the crack is located; ② The length of the crack on any surface shall not be greater than 1 / 2 of the crack direction dimension; crack detection adopts visual inspection method; during inspection: every 10,000 bricks are a batch, and 50 samples are randomly selected. The number of tests is large, and the manual visual inspection method is time-consuming and labor-intensive, and is prone to detection errors due to worker fatigue.

[0004] Chinese patent CN 107369136 B discloses a method for visually detecting surface cracks on polycrystalline diamond composite sheets, comprising: (1) using a combined vertical frontal illumination system of dome and coaxial light, and using an R-axis precision displacement platform to assist the workpiece in rotating and photographing to obtain the original image of the polycrystalline diamond composite sheet; (2) performing digital image processing on the acquired original image, specifically including: a. removing non-interested regions based on a boundary extraction method based on the extreme value of the grayscale projection histogram projection gradient; b. image filtering to suppress low-frequency components in the image and enhance image details; c. using image segmentation technology to separate defects from the image; (3) the image processed in step (2) contains only the crack connected domain, and four feature quantities of length, width, circularity, and aspect ratio are selected to analyze the crack defects. The present invention can realize automated, efficient, and high-precision detection of PDC surface crack defects.

[0005] However, there are still some problems in this technical solution. When detecting cracks that penetrate two sides of an edge, it is necessary to compare and analyze the shooting data of different sides of the sample to determine the coordinate values of the cracks on different sides in order to determine whether the cracks on the two sides are the same crack. In order to ensure the uniformity of the coordinate values, it is necessary to ensure the positional relationship between the side of the sample and the camera before testing the sample. When testing all sides of the sample, the sample needs to be flipped, and the flipping action will affect the position of the surface to be tested. The above technical solution cannot detect and judge cracks that penetrate two sides of an edge, and cannot flip the sample and conduct comprehensive testing. The work efficiency is low and the use effect is limited. Summary of the Invention

[0006] The purpose of the present invention is to address the shortcomings of the existing technology and provide a method for manufacturing lightweight mullite bricks. The sample is automatically turned over by a turning mechanism so that different surfaces of the sample are aligned and detected with a camera respectively. The top surface of the turned sample is adjusted and corrected by a correction mechanism so that the surface to be detected on the top of the sample is aligned with the camera, thereby improving the detection effect and judging whether the crack on the surface of the sample is a crack that penetrates one edge and two faces. By setting a panel mechanism to surround the surface to be detected of the sample, it can be detected whether the sample is missing a corner.

[0007] To achieve the above object, the present invention provides the following technical solutions:

[0008] A method for manufacturing lightweight mullite bricks, comprising a batching process, a stamping process, a drying process, and a testing process, wherein the testing process comprises:

[0009] Step 1: Place the sample in the support, stagger the control plate and the support rod, support the sample with the support rod, and clamp the sample with the first and second clamps. The support moves in the X-axis direction along the conveyor belt.

[0010] Step 2: The sample contacts the first pressing plate, which presses the top surface of the sample until it is parallel to the camera;

[0011] Step 3: Only the second bevel section is provided on the first fixed plate. The extended plate contacts the second bevel section on the fixed plate. The extended plate and the control plate move in the negative direction of the Y axis. The control plate tightens the support rod. The specimen remains stable under the action of the support rod and the pressure plate.

[0012] Step 4: The support continues to move, the top surface of the sample is aligned with the camera, and the camera takes a picture of the sample for inspection;

[0013] Step 5: The extended plate contacts the first beveled edge of the next fixed plate. The extended plate and the control plate move in the positive direction along the Y axis. The control plate, through the wedge plate, squeezes the support rod and moves in the negative direction along the Z axis, so that the bottom of the specimen is suspended in the air, leaving space for the specimen to flip. At the same time, the control plate, moving in the positive direction along the Y axis, drives the second slider through the second driven plate, so that the second clamping plate moves away from the specimen, leaving space for the specimen to flip. At this time, only the first clamping plate holds the specimen.

[0014] Step 6: Gear 1 contacts rack plate 1, gear 1 rotates, and drives rotating rod 1 and clamping plate 1 to rotate, and clamping plate 1 drives the sample to rotate in the XZ plane;

[0015] Step 7: After the sample is turned over, the next pressing plate presses the top surface of the sample to a horizontal position;

[0016] Step 8: Separate the extended plate from the first bevel section of the fixed plate, reset the control plate, support the specimen upward with the support rod, and re-clamp the second clamp on the outside of the specimen;

[0017] Step 9: The extended plate contacts the second bevel section on the fixed plate. The extended plate and the control plate move in the negative direction of the Y axis. The control plate tightens the support rod. At this time, the sample is aligned with the camera, and the camera takes a picture of the sample in a stable state.

[0018] As an advantage, it also includes:

[0019] Step 10: Repeat steps 5 to 9 to complete the flipping and testing of the four sides of the sample on the XZ plane.

[0020] As an advantage, the method further includes step 11:

[0021] The support continues to move, and the extended plate contacts another fixed plate. The first beveled edge section of this fixed plate is longer. Therefore, this first beveled edge section drives the control plate to move a longer distance along the positive direction of the Y axis, causing the driven plate 1 to drive the slider 1 to move along the positive direction of the Y axis. The clamping plate 1 separates from the specimen. At this time, only the clamping plate 2 holds the specimen.

[0022] Step 12: The support continues to move. After the gear 2 contacts the rack plate 2, the clamping plate 2 drives the sample to rotate in the YZ plane.

[0023] Preferably, the method further includes step 13, repeating steps 7 to 9 to complete the detection of the other two surfaces of the sample on the YZ plane.

[0024] Preferably, the method further includes step fourteen, wherein the visual inspection system analyzes the captured data to determine whether the sample has a chipped corner, whether the crack is a crack that penetrates one edge and two sides, and whether the sample is qualified based on the length of the crack.

[0025] Preferably, the visual inspection system is used to inspect the surface of the sample, and the visual inspection system includes a shooting unit and an analysis unit. The shooting unit is used to shoot the sample, and the analysis unit is used to analyze the shooting data.

[0026] A high-strength mullite brick is prepared from raw materials with the following proportions: 10-15% Guangxi mud, 10-15% kyanite, 15-35% alumina, 10-20% kaolin, 15-20% mullite, 1-3% styrene balls, and 2-4% sawdust.

[0027] Preferably, the high-strength mullite bricks are prepared from raw materials with the following proportions: 15% Guangxi mud, 15% kyanite, 30% alumina, 15% kaolin, 20% mullite, 2% styrene balls, and 3% sawdust.

[0028] Preferably, the density of the high-strength mullite brick is 500-1050kg / m³.

[0029] Preferably, the classification temperature of high-strength mullite bricks is 1100-1650°C, and the continuous use temperature is 1070-1570°C.

[0030] The present application also provides an apparatus for manufacturing lightweight mullite bricks compatible with a method for manufacturing lightweight mullite bricks, comprising a transmission mechanism for transmitting a sample, the transmission mechanism comprising a transmission belt and a plurality of supports, the transmission belt being mounted on a platform, the supports moving along the transmission belt, and the sample being placed in the supports;

[0031] A visual inspection system, which is used to inspect the surface of a sample. The visual inspection system includes a shooting unit and an analysis unit. The shooting unit is used to shoot the sample, and the analysis unit is used to analyze the shooting data. The shooting unit includes multiple cameras for shooting the sample, and the analysis unit uses a host software analysis method to determine the surface crack condition of the sample. Specifically, the visual inspection system can adopt the Sensairui visual monitoring technology system.

[0032] A plate mechanism, which surrounds the outside of the sample and is used to determine the edges of the sample. The plate mechanism includes a clamp for clamping the sample;

[0033] a turning mechanism, the turning mechanism being used to turn the sample over, the turning mechanism comprising a rotating portion for controlling the movement of the clamp; and

[0034] The correction mechanism is used to adjust the turned-over sample so that the turned-over sample is aligned with the shooting unit. The correction mechanism includes a pressing part for flattening the sample and a supporting part for supporting the sample.

[0035] As another preferred embodiment, the method for manufacturing lightweight mullite bricks further comprises a separation mechanism for separating unqualified samples. Specifically, the separation mechanism can be a sprayer for spraying unqualified samples or a push rod device for pushing unqualified samples away.

[0036] When testing brick samples, the samples are placed in a support, and the support moves along a conveyor belt. During the movement of the sample, the sample is turned over by a turning mechanism so that different surfaces of the sample are aligned with the camera respectively. After the sample is turned over, the surface to be tested of the sample is adjusted by a correction mechanism so that the surface to be tested of the sample remains parallel to the camera, and the outer side of the sample is surrounded by a panel mechanism, and then the surface of the sample is photographed and tested by the camera; by setting up a correction mechanism, each surface of the sample is aligned with the camera, and the edges of each photograph are relatively aligned, so that it can be more accurately determined whether the cracks in the two adjacent surfaces are cracks that pass through one edge and two surfaces, realizing the function of detecting cracks that pass through one edge and two surfaces. At the same time, it can also improve the problem that when the sample surface and the camera have an inclined angle, it is easy to be affected by refraction and reflection and the accuracy of the shooting test results is affected; by setting up a panel mechanism, the camera only shoots a single surface of the sample, which improves the problem that when two adjacent surfaces of the sample are tilted, part of the other inclined surface will also be photographed, causing interference with the shooting test results.

[0037] Preferably, the panel mechanism includes a slider assembly slidably mounted within a support, the fixture includes two sets of staggered clamps, the clamps being rotatably mounted within the slider assembly via a rotating rod, and a reset member being mounted on the slider assembly. Specifically, the reset member may be a compression spring, the slider assembly includes a first slider and a second slider, both of which are slidably mounted within the support, and the fixture includes a first clamp and a second clamp, which are staggered. The first clamp is rotatably mounted within the first slider via a rotating rod, and the second clamp is rotatably mounted within the second slider via a rotating rod.

[0038] Preferably, the rotating portion includes a rack plate assembly mounted on the platform, a gear assembly meshing with the rack plate assembly mounted on the fixture, and transmission between the fixtures is achieved via a chain belt assembly. Specifically, the gear assembly includes a first gear mounted on a first rotating rod and a second gear mounted on a second rotating rod. The rack plate assembly includes a first rack plate and a second rack plate. The first rack plate and the second rack plate mesh with the first gear and the second gear, respectively, and the first rack plate and the second rack plate are staggered. The chain belt assembly includes a gear mechanism for adjusting the steering direction and a chain for transmission. The two second rotating rods are synchronized by the chain belt assembly.

[0039] Preferably, the compression unit includes a plurality of pressure plates positioned above the support, with the top of the specimen extending outside the support. The bottom ends of the pressure plates are provided with slopes for compressing the specimen. Specifically, before testing the specimen, the top of the specimen contacts the pressure plates, which compress the specimen so that the top surface of the specimen remains horizontal in the XY plane, thereby maintaining alignment between the top surface of the specimen and the camera.

[0040] As another preferred embodiment, the rack plate assembly is arranged to match the pressure plate, and the camera unit is installed between the rack plate assembly and the pressure plate. Specifically, as the sample moves along the conveyor belt, it first contacts the pressure plate, aligning the top surface of the sample with the camera. The camera then photographs and inspects the top surface of the sample. After the photograph is taken, the gear contacts the rack plate, driving the sample to flip over for inspection of the next side. This allows for automated assembly line operation.

[0041] Preferably, the support portion includes a support rod movably inserted into the support, a reset member mounted on the support rod, and a control panel mounted inside the support for pulling the support rod. Specifically, the support rod is positioned below the specimen, a partition is fixedly mounted inside the support, the support rod is movably inserted into the partition, the reset member may be a compression spring, a convex plate is mounted on the support rod, and a wedge plate is mounted on the control panel for compressing the convex plate.

[0042] As another preferred embodiment, the control board has a through slot corresponding to the support rod, and the control board is used to secure the support rod. Specifically, after the control board is moved in the negative direction of the Y-axis, the sidewalls of the through slot of the control board contact the support rod. Under the action of friction, the control board secures the support rod, thereby improving the stability of the support rod and the specimen. The camera can capture the specimen in a stable state, achieving better detection results.

[0043] As another preferred embodiment, the platform is mounted with multiple fixed plates for pulling the control panel, the fixed plates comprising a straight edge segment and two beveled edge segments. The control panel is provided with an operating panel for pulling the slider, the slider being provided with a driven panel corresponding to the operating panel, and a return spring being mounted on the control panel. Specifically, the control panel is provided with an extended plate having grooves corresponding to the beveled edge segments. The operating panels comprise operating panel 1 and operating panel 2, and the driven panels comprise driven panel 1 mounted on slider 1 and driven panel 2 mounted on slider 2. Operating panel 1 pulls slider 1 via driven panel 1, and operating panel 2 pulls slider 2 via driven panel 2.

[0044] By designing the positions of the rack plate and the fixed plate, when the support moves in the conveyor belt, the extended plate contacts the bevel section of the fixed plate, and the extended plate is squeezed and moves, driving the control plate to move. After the control plate moves, the clamp is driven to move through the operating panel, allowing the clamp to clamp or release the sample.

[0045] Preferably, the operating plate is positioned adjacent to one end of the driven plate, with a gap between the operating plate and the other end of the driven plate. Specifically, driven plate 1 includes two sides, with operating plate 1 positioned adjacent to one side of driven plate 1, and a gap between the operating plate 1 and the other side of driven plate 1. Operating plate 2 is provided with a ramp for pushing slider 2.

[0046] The extended plate contacts the first oblique edge section on the fixed plate. By designing the size of the first oblique edge section, when the control plate moves in the positive direction along the Y axis, the operating plate 1 may or may not contact the side of the driven plate 1.

[0047] The beneficial effects of the present invention are:

[0048] (1) The present invention clamps the sample by setting a panel mechanism and flips the sample by a flipping mechanism, so that different sides of the sample are aligned with the camera respectively, and all sides of the sample can be inspected, thereby improving work efficiency and being suitable for assembly line operation.

[0049] (2) The present invention adjusts the top surface of the sample after turning over by setting a correction mechanism, so that the surface to be tested on the top of the sample remains parallel to the camera, and the edges of each photograph are relatively aligned. It can more accurately determine whether the cracks in the two adjacent surfaces are cracks that penetrate one edge and two surfaces, and realize the function of detecting cracks that penetrate one edge and two surfaces. At the same time, it improves the problem that when the sample surface is tilted and forms an angle with the camera, it is easy to be affected by refraction and reflection, which affects the accuracy of the shooting and detection results.

[0050] (3) The present invention can detect whether the sample has a missing corner by setting a panel mechanism to surround the surface to be tested, so that the camera can only shoot a single surface of the sample. This improves the problem that when two adjacent surfaces of the sample are tilted, part of the other tilted surface will also be photographed, causing interference with the shooting and detection results, thereby improving the detection accuracy.

[0051] (4) The present invention provides more space for the sample to flip over by setting an elastic support rod. The support rod cooperates with the pressure plate so that after the sample is flipped over, even if the different sides of the sample are of different sizes, the different sides of the sample can be located between the support rod and the pressure plate. The pressure plate can smoothly squeeze the top surface of the sample to a horizontal state, so that the sample can smoothly complete the flipping operation between different sides.

[0052] (5) The present invention sets a control plate and a rack plate assembly. Before the sample is turned over, one set of clamps is loosened so that the sample can rotate smoothly. After the rotation, the support rod is fixed, thereby improving the stability of the support rod and the sample. The camera shoots the sample in a stable state, and the shooting and detection effect is better.

[0053] (6) In the present invention, the turning and fixing of the sample are both performed automatically, without the need for manual operation or the need for an additional electric drive mechanism, which is energy-saving and environmentally friendly. In the assembly line operation, it not only improves the detection efficiency but also reduces the cost of use.

[0054] In summary, the present invention has the advantages of performing crack detection and chip detection on the sample, automatically flipping, tightening and testing the sample, and judging whether the crack on the surface of the sample is a crack that penetrates one edge and two sides. It has high detection efficiency, energy saving and environmental protection. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] Figure 1 It is a schematic diagram of the overall structure of the present invention;

[0056] Figure 2 It is a partial schematic diagram of the support and rack plate assembly;

[0057] Figure 3 Schematic diagram of the support structure;

[0058] Figure 4 Explode the diagram of the internal installation structure of the support;

[0059] Figure 5 Schematic diagram of the calibration mechanism and the specimen;

[0060] Figure 6 is a cross-sectional view of the support portion;

[0061] Figure 7 Schematic diagram for judging cracks on the sample surface;

[0062] Figure 8 This is a schematic diagram of the platform and conveyor belt of Example 2;

[0063] Figure 9 A comparison chart of different fixing plates. DETAILED DESCRIPTION

[0064] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0065] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", "clockwise", "counterclockwise" and the like to indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first" and "second" are used for descriptive purposes only and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, the features defined as "first" and "second" may explicitly or implicitly include one or more of the features. In the description of the present invention, "multiple" means two or more, unless otherwise clearly and specifically defined.

[0066] Example 1

[0067] like Figure 1-3 and Figure 7 As shown, this embodiment provides a device for manufacturing lightweight mullite bricks, comprising

[0068] A conveying mechanism 1 is used to convey the sample 8. The conveying mechanism 1 includes a conveyor belt 11 and a plurality of supports 12. The conveyor belt 11 is mounted on a platform 13. The supports 12 move along the conveyor belt 11. The sample 8 is placed in the supports 12.

[0069] A visual inspection system is used to inspect the surface of the sample 8. The visual inspection system includes a shooting unit and an analysis unit. The shooting unit is used to shoot the sample 8, and the analysis unit is used to analyze the shooting data. The shooting unit includes multiple cameras 21 for shooting the sample 8. The analysis unit uses a host software analysis method to determine the surface crack condition of the sample 8. Specifically, the visual inspection system can adopt the Sensairui visual monitoring technology system.

[0070] A plate-enclosing mechanism 3 , which surrounds the outside of the sample 8 and is used to determine the edges of the sample 8 . The plate-enclosing mechanism 3 includes a clamp 32 for clamping the sample 8 ;

[0071] a turning mechanism 4 for turning the sample 8 over, the turning mechanism 4 including a rotating portion for controlling the movement of the clamp 32; and

[0072] The correction mechanism 5 is used to adjust the turned-over sample 8 so that the turned-over sample 8 is aligned with the shooting unit. The correction mechanism 5 includes a pressing portion for flattening the sample 8 and a supporting portion for supporting the sample 8.

[0073] The method for manufacturing lightweight mullite bricks further includes a separation mechanism 6 for separating unqualified samples 8. Specifically, the separation mechanism 6 can be a sprayer for spraying unqualified samples 8 or a push rod device for pushing unqualified samples 8 away.

[0074] When testing the brick sample 8, the sample 8 is placed in the support 12, and the support 12 moves along the conveyor belt 11. During the movement of the sample 8, the sample 8 is turned over by the turning mechanism 4 so that different surfaces of the sample 8 are aligned with the camera 21. After the sample 8 is turned over, the surface to be tested of the sample 8 is adjusted by the correction mechanism 5 so that the surface to be tested of the sample 8 is kept parallel to the camera 21. The outer side of the sample 8 is surrounded by the enclosure mechanism 3, and then the surface of the sample 8 is photographed and tested by the camera 21. By setting the correction mechanism 5, each surface of the sample 8 is aligned with the camera 21. Keeping alignment, the edge lines of each photo taken are relatively aligned, which can more accurately determine whether the cracks in the two adjacent surfaces are cracks that penetrate one edge and two surfaces, realizing the function of detecting cracks that penetrate one edge and two surfaces. At the same time, it can also improve the problem that when the surface of the sample 8 and the camera 21 have an inclined angle, it is easy to be affected by refraction and reflection and the accuracy of the shooting and detection results; by setting the enclosure mechanism 3, the camera 21 only shoots a single surface of the sample 8, which improves the problem that when two adjacent surfaces of the sample 8 are tilted, part of the other inclined surface will also be photographed, causing interference with the shooting and detection results.

[0075] Specifically, Figure 7 For example, the detection method for a crack that penetrates two sides of an edge is as follows:

[0076] The two adjacent surfaces of sample 8 are surface I and surface II. Cracks are detected on both surfaces I and II. The coordinates of the crack on surface I, close to the end of surface II, are Xb and Yb. The coordinates of the crack on surface II, close to the end of surface I, are Yc and Zc.

[0077] If the values of Yb and Yc are the same or close, the crack on surface I and the crack on surface II can be considered as a crack that runs through two sides of an edge. The length of the crack shall not be greater than 1 / 3 of the sum of the directional dimensions of the cracks on surfaces I and II. If it is greater, the specimen 8 is unqualified.

[0078] If the values of Yb and Yc differ greatly, the crack on surface I and the crack on surface II can be considered as two independent cracks. The length of each crack shall not be greater than 1 / 2 of the crack direction dimension. If it is greater, the specimen 8 is unqualified.

[0079] By setting up the enclosure mechanism 3, when photographing surface I of the sample 8, the other adjacent surfaces will be blocked. Even if there are cracks on the adjacent surfaces, these cracks will not be captured in the photograph of surface I, thereby solving the problem that when two adjacent surfaces of the sample 8 are tilted, part of the other tilted surface will also be photographed, causing interference with the shooting and detection results, thereby improving the accuracy of the detection. In addition, if the sample 8 has a missing corner, the missing corner will produce a shadow between the enclosure mechanisms, which can be directly displayed in the photograph. Therefore, it is also possible to detect and judge whether the sample 8 has a missing corner.

[0080] like Figure 2-4 As shown, further, the enclosure mechanism 3 includes a slider assembly 31 slidably mounted in the support 12, and a clamp 32 includes two groups of staggered clamps, which are rotatably mounted inside the slider assembly 31 via a rotating rod, and a reset member is installed on the slider assembly 31. Specifically, the reset member can be a compression spring, and the slider assembly 31 includes a slider 1 311 and a slider 2 312, both of which are slidably mounted in the support 12. The clamp 32 includes a staggered clamp 1 321 and a clamp 2 322, and the clamp 1 321 is rotatably mounted inside the slider 1 311 via a rotating rod 1 331, and the clamp 2 322 is rotatably mounted inside the slider 2 312 via a rotating rod 2 332.

[0081] The two first clamps 321 and the two second clamps 322 are symmetrically distributed about the sample 8. Both the first clamp 321 and the second clamp 322 can slide in the support 12. The first clamp 321 and the second clamp 322 surround the ring side of the sample 8 to block the four sides of the sample 8 to obtain a better shooting effect.

[0082] like Figure 1-5 As shown, further, the rotating part includes a rack plate assembly 14 mounted on the platform 13, and a gear assembly 34 meshing with the rack plate assembly 14 is mounted on the clamp 32. The clamps 32 are transmitted through the chain belt assembly 7. Specifically, the gear assembly 34 includes a gear 1 341 mounted on the rotating rod 1 331 and a gear 2 342 mounted on the rotating rod 2 332. The rack plate assembly 14 includes a rack plate 1 141 and a rack plate 2 142. The rack plate 1 141 and the rack plate 2 142 are meshed with the gear 1 341 and the gear 2 342 respectively, and the rack plate 1 141 and the rack plate 2 142 are staggered. The chain belt assembly 7 includes a gear mechanism for adjusting the steering and a chain for transmission. The two rotating rods 2 332 are synchronously rotated by the chain belt assembly 7.

[0083] During the movement of the support 12 along the conveyor belt 11, after completing the shooting of one side of the sample 8, the gear 1 341 contacts the rack plate 141. Since the rack plate 141 is fixed, the gear 1 341 rotates, and drives the rotating rod 1 331 and the clamping plate 1 321 to rotate. The clamping plate 1 321 drives the sample 8 to rotate in the XZ plane, so that different sides of the sample 8 are aligned with the camera 21. Similarly, after the gear 2 342 contacts the rack plate 2 142, the clamping plate 2 322 drives the sample 8 to rotate in the YZ plane. In this way, the six sides of the sample 8 can be aligned with the camera 21 respectively, completing the comprehensive inspection of the sample 8.

[0084] like Figure 2 As shown, the pressing portion further includes a plurality of pressing plates 51, which are located above the support 12. The top of the sample 8 extends to the outside of the support 12. The bottom of the pressing plates 51 is provided with a slope for pressing the sample 8. Specifically, before testing the sample 8, the top of the sample 8 contacts the pressing plates 51, which press the sample 8 so that the top surface of the sample 8 remains horizontal in the XY plane, thereby ensuring that the top surface of the sample 8 is aligned with the camera 21.

[0085] like Figure 1-2 As shown, the rack plate assembly 14 is arranged to match the pressure plate 51, and the camera unit is installed between the rack plate assembly 14 and the pressure plate 51. Specifically, as the sample 8 moves along the conveyor belt 11, it first contacts the pressure plate 51, aligning the top surface of the sample 8 with the camera 21. The camera 21 then photographs and inspects the top surface of the sample 8. After the photograph is taken, the gear contacts the rack plate, driving the sample 8 to flip over for inspection of the next side. This allows for automated assembly line operation.

[0086] like Figure 4-6 As shown, the support portion further includes a support rod 52 movably inserted into the interior of the support 12, a reset member is installed on the support rod 52, and a control panel 53 for pulling the support rod 52 is installed inside the support 12. Specifically, the support rod 52 is located below the specimen 8, a partition 121 is fixedly installed inside the support 12, and the support rod 52 is movably inserted into the interior of the partition 121. The reset member can be a compression spring, a convex plate 521 is installed on the support rod 52, and a wedge plate 531 for pressing the convex plate 521 is installed on the control panel 53.

[0087] After the control plate 53 is moved in the positive direction along the Y-axis, the control plate 53 squeezes the support rod 52 through the wedge plate 531 to move negatively on the Z-axis, providing more space for the flipping of the sample 8, so that the sample 8 can smoothly complete the flipping operation; after the sample 8 is flipped over, the control plate 53 is reset, and the support rod 52 pushes the sample 8 upward again; by setting the elastic support rod 52, after the sample 8 is flipped over, even if different sides of the sample 8 have different sizes, different sides of the sample 8 can be located between the support rod 52 and the pressure plate 51, and the pressure plate 51 can smoothly squeeze the top surface of the sample 8 to a horizontal state.

[0088] like Figure 3-5 As shown, the control board 53 further has a through slot formed therein corresponding to the support rod 52, and the control board 53 is used to secure the support rod 52. Specifically, after the control board 53 is moved in the negative direction of the Y-axis, the sidewall of the through slot of the control board 53 contacts the support rod 52. Under the action of friction, the control board 53 secures the support rod 52, improving the stability of the support rod 52 and the specimen 8. The camera 21 can capture the specimen 8 in a stable state, achieving better capture and detection results.

[0089] like Figure 4-6 As shown, the platform 13 is further equipped with multiple fixed plates 15 for pulling the control plate 53. The fixed plates 15 include a straight edge segment and two beveled edge segments. The control plate 53 is provided with an operating plate for pulling the slider. The slider is provided with a driven plate corresponding to the operating plate. A return spring is installed on the control plate 53. Specifically, the control plate 53 is provided with an extended plate 532, which has grooves corresponding to the beveled edge segments. The operating plate includes an operating plate 1 5331 and an operating plate 2 5332. The driven plate includes a driven plate 1 3111 mounted on the slider 1 311 and a driven plate 2 3121 mounted on the slider 2 312. The operating plate 1 5331 pulls the slider 1 311 via the driven plate 1 3111, and the operating plate 2 5332 pulls the slider 2 312 via the driven plate 2 3121.

[0090] By designing the positions of the rack plate and the fixed plate 15, when the support 12 moves within the conveyor belt 11, the extended plate 532 contacts the bevel section of the fixed plate 15, and the extended plate 532 is squeezed and moved, driving the control plate 53 to move. After the control plate 53 moves, the operating panel drives the clamp 32 to move, allowing the clamp 32 to clamp or release the sample 8.

[0091] During this process, the extended plate 532 first contacts the first beveled edge section of the fixed plate 15. The extended plate 532 and the control plate 53 then move in the positive direction along the Y-axis. The control plate 53, through the wedge plate 531, squeezes the support rod 52, causing it to move in the negative direction along the Z-axis, leaving the bottom of the specimen 8 suspended in the air, allowing space for the specimen 8 to flip. Simultaneously, the control plate 53, moving in the positive direction along the Y-axis, drives the second slider 312 through the second driven plate 3121, causing the second clamping plate 322 to move away from the specimen 8, leaving space for the specimen 8 to flip. At this point, only the first clamping plate 321 holds the specimen 8.

[0092] Then, the gear 1 341 contacts the rack plate 141, and the clamping plate 1 321 drives the sample 8 to turn over;

[0093] Secondly, after the sample 8 is turned over, the pressing plate 51 presses the top surface of the sample 8 to a horizontal position;

[0094] Next, the outward extension plate 532 is separated from the first bevel section on the fixed plate 15, the control plate 53 is reset, the support rod 52 supports the sample 8 upward, and the second clamping plate 322 is clamped on the outside of the sample 8 again;

[0095] Then, the extended plate 532 contacts the second bevel section of the fixed plate 15. The extended plate 532 and the control plate 53 move in the negative direction of the Y-axis. The control plate 53 secures the support rod 52. At this point, the specimen 8 is aligned with the camera 21, and the camera 21 photographs the specimen 8 in a stable state.

[0096] Similarly, the other sides of the sample 8 are turned over and tested;

[0097] In this way, the functions of automatically turning over, fixing and photographing the sample 8 are realized, with a simple structure, automatic operation and convenient operation.

[0098] like Figure 5 As shown, the operating plate is located near one end of the driven plate, with a gap between the operating plate and the other end of the driven plate. Specifically, driven plate 1 3111 includes two sides, and operating plate 1 5331 is located near one of the sides of driven plate 1 3111, with a gap between the operating plate 1 5331 and the other side of driven plate 1 3111. Operating plate 2 5332 is provided with a ramp for pushing slider 2 312.

[0099] The extended plate 532 contacts the first oblique edge section on the fixed plate 15. By designing the size of the first oblique edge section, when the control plate 53 moves in the positive direction along the Y-axis, the operating plate 1 5331 can contact the side of the driven plate 1 3111 or not.

[0100] In this embodiment, further, the conveyor belt 11 is ring-shaped, and a support platform corresponding to the conveyor belt 11 is provided on the platform 13. Specifically, according to the actual installation environment on site, the conveyor belt 11 can be ring-shaped on a horizontal plane or a vertical plane.

[0101] Example 2

[0102] A method for manufacturing lightweight mullite bricks, comprising the following steps:

[0103] Step 1: Place the sample 8 in the support 12, stagger the control plate 53 and the support rod 52, support the sample 8 with the support rod 52, and surround the sample 8 with the clamping plate 1 321 and the clamping plate 2 322 to clamp the sample 8, and the support 12 moves in the X-axis direction along the conveyor belt 11;

[0104] Step 2: The sample 8 contacts the first pressing plate 51 , and the pressing plate 51 presses the top surface of the sample 8 until it is parallel to the camera 21 ;

[0105] Step 3: The first fixed plate 15 is provided with only the second beveled edge section. The extended plate 532 contacts the second beveled edge section of the fixed plate 15. The extended plate 532 and the control plate 53 move in the negative direction of the Y-axis. The control plate 53 tightens the support rod 52. The specimen 8 remains stable under the action of the support rod 52 and the pressure plate 51.

[0106] Step 4: The support 12 continues to move, the top surface of the sample 8 is aligned with the camera 21, and the camera 21 takes a picture of the sample 8 for inspection;

[0107] Step 5: The outward-extending plate 532 contacts the first oblique edge section of the next fixed plate 15. The outward-extending plate 532 and the control plate 53 move in the positive direction along the Y-axis. The control plate 53 squeezes the support rod 52 via the wedge plate 531, causing it to move in the negative direction along the Z-axis, leaving the bottom of the specimen 8 suspended in the air and allowing space for the specimen 8 to flip. Simultaneously, the control plate 53, moving in the positive direction along the Y-axis, drives the second slider 312 via the second driven plate 3121, causing the second clamping plate 322 to move away from the specimen 8, leaving space for the specimen 8 to flip. At this point, only the first clamping plate 321 holds the specimen 8.

[0108] Step 6: Gear 1 341 contacts rack plate 141, gear 1 341 rotates, and drives rotating rod 1 331 and clamping plate 1 321 to rotate, and clamping plate 1 321 drives sample 8 to rotate in the XZ plane;

[0109] Step 7: After the sample 8 is turned over, the next pressing plate 51 presses the top surface of the sample 8 to a horizontal position;

[0110] Step 8: The outward extension plate 532 is separated from the first bevel section on the fixed plate 15, the control plate 53 is reset, the support rod 52 supports the sample 8 upward, and the second clamping plate 322 is clamped on the outside of the sample 8 again;

[0111] Step 9: The extended plate 532 contacts the second bevel section of the fixed plate 15. The extended plate 532 and the control plate 53 move in the negative direction of the Y axis. The control plate 53 secures the support rod 52. At this point, the specimen 8 is aligned with the camera 21, and the camera 21 photographs the specimen 8 in a stable state.

[0112] Step 10: Repeat steps 5 to 9 to complete the flipping and testing of the four surfaces of the sample 8 on the XZ plane;

[0113] Step 11: The support 12 continues to move, and the extended plate 532 contacts the other fixed plate 15. The first beveled edge section of the fixed plate 15 is longer. Therefore, the first beveled edge section drives the control plate 53 to move a longer distance in the positive direction of the Y axis, causing the driven plate 1 3111 to drive the slider 1 311 to move in the positive direction of the Y axis. The clamping plate 1 321 separates from the specimen 8. At this time, only the clamping plate 2 322 clamps the specimen 8.

[0114] Step 11: The support 12 continues to move, and after the second gear 342 contacts the second rack plate 142, the second clamping plate 322 drives the sample 8 to rotate in the YZ plane;

[0115] Step 12: Repeat steps 7 to 9 to complete the inspection of the other two surfaces of the sample 8 on the YZ plane.

[0116] Step 13: The visual inspection system analyzes the captured data to determine whether the sample 8 has a chipped corner, whether the crack is a crack that penetrates one edge and two sides, and whether the sample 8 is qualified based on the length of the crack.

[0117] Example 3

[0118] A high-strength mullite brick is prepared from raw materials with the following proportions: 10-15% Guangxi mud, 10-15% kyanite, 15-35% alumina, 10-20% kaolin, 15-20% mullite, 1-3% styrene balls, and 2-4% sawdust.

[0119] Furthermore, the high-strength mullite brick is prepared from raw materials with the following proportions: 15% Guangxi mud, 15% kyanite, 30% alumina, 15% kaolin, 20% mullite, 2% styrene balls, and 3% sawdust.

[0120] Furthermore, the density of high-strength mullite bricks is 500-1050kg / m³.

[0121] Furthermore, the classification temperature of high-strength mullite bricks is 1100-1650°C, and the continuous use temperature is 1070-1570°C.

[0122] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the scope of protection of the present invention.

Claims

1. A method for manufacturing lightweight mullite bricks, comprising a batching process, a stamping process, a drying process, and a testing process, characterized in that: The invention relates to an apparatus for manufacturing lightweight mullite bricks, comprising a transmission mechanism for transmitting a sample, the transmission mechanism comprising a transmission belt and a plurality of supports, the transmission belt being mounted on a platform, the supports moving along the transmission belt, the sample being placed in the supports, and the enclosure mechanism surrounding the outside of the sample; The enclosure mechanism includes a slider assembly slidably mounted in a support, a fixture including two sets of staggered plywood, the plywood being rotatably mounted inside the slider assembly via a rotating rod, the slider assembly including a slider 1 and a slider 2, both of which are slidably mounted in the support, and the fixture including a staggered plywood 1 and a plywood 2, the plywood 1 being rotatably mounted inside the slider 1 via a rotating rod 1, and the plywood 2 being rotatably mounted inside the slider 2 via a rotating rod 2; The platform is provided with a plurality of fixed plates for pulling the control plate, the fixed plates including a straight edge section and two oblique edge sections, the control plate is provided with an operating plate for pulling the slider, the slider is provided with a driven plate corresponding to the operating plate, the control plate is provided with an overhanging plate, the overhanging plate is provided with grooves corresponding to the oblique edge sections, the operating plate includes an operating plate 1 and an operating plate 2, the driven plate includes a driven plate 1 installed on the slider 1 and a driven plate 2 installed on the slider 2, the operating plate 1 pulls the slider 1 through the driven plate 1, and the operating plate 2 pulls the slider 2 through the driven plate 2; The detection process includes: Step 1: Place the sample in the support, stagger the control plate and the support rod, support the sample with the support rod, and clamp the sample with the first and second clamps. The support moves in the X-axis direction along the conveyor belt. Step 2: The sample contacts the first pressing plate, which presses the top surface of the sample until it is parallel to the camera; Step 3: Only the second bevel section is provided on the first fixed plate. The extended plate contacts the second bevel section on the fixed plate. The extended plate and the control plate move in the negative direction of the Y axis. The control plate tightens the support rod. The specimen remains stable under the action of the support rod and the pressure plate. Step 4: The support continues to move, the top surface of the sample is aligned with the camera, and the camera takes a picture of the sample for inspection; Step 5: The extended plate contacts the first beveled edge of the next fixed plate. The extended plate and the control plate move in the positive direction along the Y axis. The control plate, through the wedge plate, squeezes the support rod and moves in the negative direction along the Z axis, so that the bottom of the specimen is suspended in the air, leaving space for the specimen to flip. At the same time, the control plate, moving in the positive direction along the Y axis, drives the second slider through the second driven plate, so that the second clamping plate moves away from the specimen, leaving space for the specimen to flip. At this time, only the first clamping plate holds the specimen. Step 6: Gear 1 contacts rack plate 1, gear 1 rotates, and drives rotating rod 1 and clamping plate 1 to rotate, and clamping plate 1 drives the sample to rotate in the XZ plane; Step 7: After the sample is turned over, the next pressing plate presses the top surface of the sample to a horizontal position; Step 8: Separate the extended plate from the first bevel section of the fixed plate, reset the control plate, support the specimen upward with the support rod, and re-clamp the second clamp on the outside of the specimen; Step 9: The extended plate contacts the second bevel section on the fixed plate. The extended plate and the control plate move in the negative direction of the Y axis. The control plate tightens the support rod. At this time, the sample is aligned with the camera, and the camera takes a picture of the sample in a stable state.

2. A method for manufacturing lightweight mullite bricks according to claim 1, characterized in that: Also includes: Step 10: Repeat steps 5 to 9 to complete the flipping and testing of the four sides of the sample on the XZ plane.

3. A method for manufacturing lightweight mullite bricks according to claim 2, characterized in that: Also includes step 11: The support continues to move, and the extended plate contacts another fixed plate. The first beveled edge section of this fixed plate is longer. Therefore, this first beveled edge section drives the control plate to move a longer distance along the positive direction of the Y axis, causing the driven plate 1 to drive the slider 1 to move along the positive direction of the Y axis. The clamping plate 1 separates from the specimen. At this time, only the clamping plate 2 holds the specimen. Step 12: The support continues to move. After the second gear contacts the second rack plate, the second clamping plate drives the sample to rotate in the YZ plane.

4. A method for manufacturing lightweight mullite bricks according to claim 3, characterized in that: The method further includes step 13, repeating steps 7 to 9 to complete the detection of the other two surfaces of the sample on the YZ plane.

5. A method for manufacturing lightweight mullite bricks according to claim 4, characterized in that: The process also includes step 14, wherein the visual inspection system analyzes the captured data to determine whether the sample has a chipped corner, whether the crack is a crack that penetrates two sides of an edge, and whether the sample is qualified based on the length of the crack.

6. According to the method for manufacturing lightweight mullite bricks according to claim 5, the visual inspection system is used to inspect the surface of the sample, and the visual inspection system includes a shooting unit and an analysis unit, the shooting unit is used to shoot the sample, and the analysis unit is used to analyze the shooting data.

7. A high-strength mullite brick, manufactured based on the method for manufacturing lightweight mullite bricks according to any one of claims 1 to 6, characterized in that: It is made of raw materials with the following proportions: Guangxi mud 10-15%, kyanite 10-15%, alumina 15-35%, kaolin 10-20%, mullite 15-20%, styrene balls 1-3%, and sawdust 2-4%.

8. The high-strength mullite brick according to claim 7, characterized in that: It is made of raw materials with the following proportions: Guangxi mud 15%, kyanite 15%, alumina 30%, kaolin 15%, mullite 20%, styrene balls 2%, and sawdust 3%.

9. The high-strength mullite brick according to claim 8, characterized in that: Its density is 500-1050kg / m³.

10. The high-strength mullite brick according to claim 8, characterized in that: The classification temperature is 1100-1650℃, and the continuous use temperature is 1070-1570℃.

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