Process and equipment for producing assembled cavity mold box by utilizing phosphogypsum

Abstract

According to the process and equipment for producing the assembly type cavity mold box by utilizing the phosphogypsum, in the aspect of the production process, the acid neutralization procedure of the phosphogypsum is adjusted, and the neutralization uniformity of raw materials is improved; the material component formula and the process flow of the cavity mold box are optimized, and the pouring forming effect is matched with the quality of ardealite and the assembly mortise and tenon joint structure of the cavity mold box. On the aspect of equipment, a structural innovation and integration scheme of a forming unit, a mold opening unit, a mold drawing unit, a pulping unit and a raw material supply unit is developed, and efficient automation of the whole production process of the cavity mold box is achieved. After the method is implemented, the ardealite can be consumed on a large scale, the produced cavity die box belongs to a carbon-free calcium sulfate building material and can replace a large number of high-carbon calcium carbonate cement and lime building materials in many building scenes, high-value environment-friendly utilization of a large amount of industrial solid waste is achieved, and the effects of energy conservation, emission reduction and low carbon are achieved.

Description

Technical Field

[0001] The present invention relates to the environmentally friendly utilization of industrial solid waste and low-carbon emission reduction, belongs to the field of high-end equipment manufacturing, and in particular to a process and equipment for producing an assembled cavity mold box using phosphogypsum. Background Art

[0002] Phosphogypsum is a large solid waste associated with the production of phosphate fertilizers. Its main component, calcium sulfate dihydrate, is a recyclable building material. However, the impurity components in phosphogypsum are complex, it is highly acidic, and its cementing qualities such as viscosity, fluidity, and foaming are poor. Therefore, gypsum building materials produced with phosphogypsum as raw material are prone to wrinkling, warping, or deformation. The cost of resource processing of phosphogypsum is very high, and it is mainly stored or landfilled, which occupies a large amount of land and poses a great risk of environmental pollution.

[0003] The cavity mold box is a new type of gypsum material building profile, which is mainly used in medium and high-rise buildings, underground industries and civil engineering. By filling the cavity mold box in the concrete hollow floor slab to occupy the non-load-bearing space, the amount of cement pouring in the floor height can be saved. The experiment found that the cavity mold box after the raw material formula and structure optimization can be mass-produced with phosphogypsum as the material. Its resource utilization principle is called the casting and molding of gypsum profiles, that is: first, the phosphogypsum is calcined and heat treated to remove the main impurities and turn into hemihydrate gypsum; then, the hemihydrate gypsum is mixed with water to form a gypsum slurry with good fluidity and injected into the mold. The gypsum slurry undergoes a rapid hydration reaction in the mold to generate a solid phase calcium sulfate dihydrate with stable physical and chemical properties, which solidifies into a gypsum profile with a specific structure. The hydration reaction time of hemihydrate gypsum is very short. It takes at least tens of seconds to initially solidify from a liquid state to a non-fluid gel state, and it can be completely solidified into a hard solid state in more than ten minutes. When using the casting method to produce hollow mold boxes with complex three-dimensional structures, the production processes involved include slurry preparation, grouting, slurry connection, mold opening and closing, demolding, and mold unloading. All processes must be completed within the hydration reaction time of the gypsum slurry.

[0004] The present invention designs a cavity mold box with an assembled mortise and tenon structure, which is more complex than the traditional cavity mold box structure and can be connected by the bite of the tenon and the mortise, significantly improving the construction efficiency and assembly stability. At present, there is no equipment in the industry that can produce a cavity mold box with an assembled mortise and tenon structure. Only some production equipment can be seen for producing mold box profiles without an assembly structure, and some of the processes can only be operated manually, and fully automated production cannot be achieved. For example, in the invention patent "Gypsum mold box production line and production process (CN2020100953027)", the mold opening and closing process of the mold cart requires two manual positions to perform manual operation; another example is the invention patent "A fiber-reinforced gypsum mold box high-efficiency production device (CN2024111271208)", which uses a mold opening linkage mechanism to automatically open the four-sided outer mold plates of the mold cart. However, due to the viscosity of the solidified gypsum, even with the use of a release agent, the outer mold plates are often firmly bonded to the initially solidified mold box, causing the mold opening linkage mechanism to be unable to open automatically, resulting in very unstable working control of the entire machine. The mold boxes in the above two technical solutions do not involve assembly of mortise and tenon structures.

[0005] The present invention develops a process and equipment for producing assembled cavity mold boxes using phosphogypsum. The main innovations are: in terms of process, the acid neutralization process of phosphogypsum is adjusted to improve the uniformity of raw material neutralization; the raw material formula and process scheme of the cavity mold box are optimized to make the cavity mold box molding effect adapt to the quality of phosphogypsum. In terms of equipment, a mold adapted to assemble the mortise and tenon structure is developed, and a mold opening unit and a mold removal unit are developed to realize the full automation of the cavity mold box production process. After the implementation of the present invention, phosphogypsum can be consumed on a large scale, and the cavity mold boxes produced are carbon-free calcium sulfate building materials, which can replace a large number of high-carbon calcium carbonate cement and lime building materials in many construction scenarios, which not only realizes the high-value environmentally friendly utilization of industrial solid waste, but also reflects the low-carbon energy-saving and emission reduction effects. Summary of the invention

[0006] A process for producing an assembled cavity mold box using phosphogypsum, wherein the cavity mold box is composed of an upper cover mold box and a lower cover mold box that are butt-jointed through four edge surfaces, the upper cover mold box and the lower cover mold box are single-sided open hollow frustum-shaped quadrilateral structures, and after being buckled together, they present a hollow shell structure, and assembly mortise and tenon structures are arranged on the four edge surfaces; The raw material formula is calculated by weight and includes: building gypsum powder: 100 parts; calcium oxide powder: 0.6 parts; glass fiber: 0.5 parts, length 20-30 mm, diameter 15-25 μm; water: 75 parts; calcium chloride powder: 0.5 parts; borax: 0.5 parts; Step 1, raw material mixing and supply process: set up a raw material supply unit, first, calcium chloride powder and borax are added into the water tank according to the formula ratio to fully dissolve and generate process water; simultaneously, the building gypsum powder in the external storage silo is transported to the powder transfer bin through the metering conveyor, and the calcium oxide powder is simultaneously added into the metering conveyor according to the proportion, uniformly mixed and transported to the powder transfer bin; simultaneously, the glass fiber is cut into a fixed length and transported to the glass fiber transfer bin; Step 2, pulping process: set up a pulping unit, including six stations of flushing, water injection, powder addition, glass fiber addition, stirring, and pulping. Set up six stirring barrels to intermittently rotate through each station in turn to complete the cyclic pulping and fixed-point pulping; Step 3, casting and molding process: setting up a molding unit, including seven stations including slurry connection, leveling, mold opening, mold removal, cleaning, mold covering, and mold release agent spraying, and each mold is cast and molded through the seven stations in turn; Step 4, mold opening process: set up a mold opening unit, lift the shell at the mold opening station, and transport it to the mold cover at the mold cover station for pressing; Step 5, mold demolding process: set up a demolding unit, demold, lift, stack and palletize the upper cover mold box and the lower cover mold box located at the demolding station in sequence; Step 6, release agent spraying process: a release agent spraying device is provided to spray the release agent on the inner wall of the shell sleeve and the upper surface of the core located at the release agent spraying station.

[0007] A device for producing an assembled cavity mold box using phosphogypsum, comprising: a molding unit, a mold opening unit, a demoulding unit, a pulping unit, a raw material supply unit, and a cavity mold box; The molding unit is a rotary support platform structure, which is fixedly arranged on the ground, and includes: a mold, a release agent spraying device, a leveling device, a rotary platform, a sprocket, a chain, a water nozzle, and a guide groove; the rotary platform is a platform structure with two parallel rows in front and back, and arc-shaped rotary connection at both ends. A plurality of molds are arranged, which are installed in series on the rotary platform through chains. The chain is connected and driven by the sprockets at the left and right ends. The sprocket on the right is connected to a rotating motor. The rotating motor drives the sprocket 1-5 and the chain 1-6 to make the serial mold 1-1 rotate intermittently in the clockwise direction; the seven stations of the molding unit are arranged on the rotary platform in sequence, and the slurry receiving station is arranged It is arranged in the rear row of the rotary platform and is located directly below the slurry dropping station, the release agent spraying station is arranged on the left of the slurry dropping station, and the leveling station is arranged on the right of the slurry dropping station; the mold opening station is arranged in the front row of the rotary platform, the mold removal station is arranged on the left of the mold opening station, and the cleaning station is arranged on the left of the mold removal station; the mold covering station is arranged in the rear row of the rotary platform and is located on the left of the release agent spraying station, and the mold covering station and the mold opening station are symmetrical based on the front and rear rows of the rotary platform; the release agent spraying device, the leveling device, and the water nozzle are respectively arranged at the release agent spraying station, the leveling station, and the cleaning station, and the guide grooves 1-8 are arranged below the cleaning station; The mold opening unit is a cross rotating structure, which is arranged in the middle of the front and rear rows of the rotating platform, and includes: a rotating frame, a mold opening cylinder and a mold opening mechanism, and the mold opening mechanism is composed of a mold opening drive module, a mold opening hanger, a fixed guide rod and a pressure limiting plate; the rotating frame is a cross structure supported by a single column rotation, and a set of mold opening mechanisms is suspended at the lower part of the protruding end of each cross through the mold opening cylinder, and 4 fixed guide rods in each set of mold opening mechanisms are vertically and evenly arranged, and the top is fixedly installed on the protruding end of the rotating frame, and the lower end is connected to the mold opening drive module; the mold opening hanger is provided with two groups, left and right and front and back, which are respectively arranged on the four sides of the mold opening drive module to form a four-sided splint structure, and the side of the mold opening hanger is a vertical plate structure, the upper end is a horizontal push-pull rod structure, and the lower end is two parallel inward-folding horizontal support plate structures, and the vertical distance between the two horizontal support plates is greater than the thickness of the rigid handles on the four outer surfaces of the shell; The demoulding unit is a gantry lifting structure, which is arranged on the left side of the mold opening unit, and the pulping unit and the raw material supply unit are arranged on the rear side of the molding unit; The mold includes: a shell, a core, a base, an outer core strip, and an inner core strip; the shell is a frustum-shaped quadrilateral outer shell structure that is open at the top and bottom, the shape and size of the inner side wall of the frustum are adapted to the shape and size of the outer side surface of the cavity mold box, and a rectangular rigid handle is respectively arranged on the four outer sides of the shell; the core is a rigid quadrilateral structure, and the base is a rigid quadrilateral groove structure, the core is centrally arranged on the bottom surface of the groove of the base, and the outer core strip and the inner core strip are respectively arranged in a square shape on the bottom surface of the groove of the base.

[0008] A further solution is that the internal arrangement of the mold is divided into two structures. In the first structure, the horizontal distance between the outer core strip and the inner side surface of the groove is equal to the shell thickness of the shell sleeve, and the height and width of the outer core strip are equal to the height and width of the outer concave and inner convex stepped structure of the mortise and tenon of the lower cover mold box; in the second structure, the inner side surface of the inner core strip contacts the outer side surface of the core, and the height and width are equal to the height and width of the outer convex and inner concave structure of the mortise and tenon of the upper cover mold box; Drain holes are arranged on the bottom surface of the groove of the base, and the drainage holes are respectively arranged at the lower position of the core and at the position close to the inner side of the groove; the diameter of the drainage hole close to the inner side of the groove is lower than the shell thickness of the shell sleeve.

[0009] A further solution is that the mold also includes: a limiter, a connecting plate, a roller, a guide column, a conduction plate, and an inner groove rail; four guide through holes are evenly distributed on the bottom surface of the groove, four rollers are symmetrically installed on the lower bottom surface of the base, and the limiters and connecting plates are symmetrically installed on the left and right sides; the lower bottom surface of the core is a plane, and four guide columns are fixedly arranged on the lower bottom surface, and the guide columns pass through the guide through holes to maintain a sliding connection; the four guide columns extend out of the position under the base, and are rigidly connected to a conduction plate as a whole, and the inner groove rail is rigidly installed in the middle of the lower part of the conduction plate.

[0010] A further solution is that the mold opening drive module includes: a support plate, a mold opening slide rail, a mold opening pull rod, a cross wheel, and a mold opening servo; the support plate is a square rigid flat plate with 4 guide through holes evenly distributed on it, 4 fixed guide rods pass downward through the guide through holes and are slidably connected thereto, a mold opening slide rail perpendicular to the square edge is provided in the middle position of each square edge, the push-pull rod of the mold opening hanger is provided in the mold opening slide rail and is slidably connected thereto, the cross wheel is provided at the center of the support plate and is rotatably connected, the outer ends of the 4 mold opening pull rods are respectively rotatably connected to the push-pull rods of the mold opening hanger, and the inner ends are respectively rotatably connected to the cross ends of the cross wheel; a through hole is provided in the center of the cross wheel, the lower telescopic end of the mold opening cylinder passes through the through hole and is fixed to the support plate; the mold opening servo is provided at the lower center position of the support plate, and the drive shaft of the mold opening servo passes through the support plate and rotatably drives the cross wheel; The pressure limiting plate is centrally arranged within the four clamping plates of the mold opening hanger, and the pressure limiting plate includes: a fixed platform, a connector, and a pressure plate; the fixed platform and the pressure plate are both rigid square plane plates, the fixed platform is rigidly fixed to the lower ends of the four fixed guide rods, and the pressure plate is rigidly connected to the fixed platform through the connector and kept horizontal.

[0011] A further solution is that the mold-lifting unit includes: a mold-lifting bracket, a mold-lifting module, a mold-lifting drive module, a horizontal slide rail, a pallet supply module, a stacking mold connection module, and a transportation module; the mold-lifting bracket is a rigid gantry structure, the right end of which is spanned between two rows of parallel structures on the rotating platform, the left end of which is spanned on the stacking mold connection mechanism, the upper end is provided with a horizontal slide rail, the mold-lifting drive module is provided on the horizontal slide rail, and the mold-lifting module is suspended at the bottom of the mold-lifting drive module; the pallet supply module is provided on the left side of the stacking mold connection module, and the transportation module is provided on the right side of the stacking mold connection module, and the three are connected by a roller group.

[0012] The demoulding module comprises: a demoulding cylinder, a lifting guide rod, a support platform, left and right hangers, front and rear hangers, a circular wheel, a connecting rod, a demoulding slide rail, a tension spring, and a demoulding servo; the support platform is a square rigid flat plate, on which 4 guide through holes are arranged, a circular wheel is rotatably installed at the center position, and a demoulding slide rail perpendicular to the square edge is arranged at the middle position of each square edge; The upper ends and sides of the left and right hangers and the front and rear hangers are the same as the upper ends and sides of the mold opening hanger, and the push-pull rods at the upper ends are respectively installed in the mold removal slide rails; the lower ends of the left and right hangers are single-piece inward-folding horizontal support plates, and the lower ends of the front and rear hangers are inward-folding single-step structure support plates.

[0013] A through hole is set in the center of the circular wheel, and an arc-shaped slot hole is set at the edge of the upper right circular surface and the lower left circular surface area respectively. The outer ends of the four connecting rods are respectively rotatably connected to the push-pull rods of the left and right hangers and the front and rear hangers, and the inner ends are respectively set in the slot holes and respectively contact the horizontal end top and the vertical end top of the slot holes; four tension springs are set, one end is fixed on the support platform, and the other end is connected to the inner end of the connecting rod, so that the tension spring generates a clockwise pulling force on the inner end of the connecting rod in the left and right directions, and generates a counterclockwise pulling force on the inner end of the connecting rod in the up and down directions.

[0014] The lifting guide rods are vertically and evenly arranged, with the lower ends passing through the guide through holes of the support platform and being slidably connected to the support platform, and the upper ends being fixedly connected to the demoulding drive module; the upper end of the demoulding cylinder is fixed to the demoulding drive module, and the lower end passes through the central through hole of the circular wheel and is fixed to the support platform; the demoulding servo is arranged at the lower part of the support platform, and the central axis of the demoulding servo passes through the support platform and is rotationally driven to connect the circular wheel.

[0015] A further solution is that the release agent spraying device includes: a fixed bracket, a lifting rod, and a multi-directional spray head. The fixed bracket is installed at the release agent spraying station, the lifting rod controls the multi-directional spray head to intermittently rise and fall, and the multi-directional spray head is provided with downward and obliquely upward spray outlets.

[0016] A further solution is to provide a water nozzle on the cleaning station and a guide groove at the bottom.

[0017] A further solution is that the inner edge of the lower bottom surface of the shell sleeve of the first mold is chamfered, and the inner edge of the side upper surface of the base is chamfered; the outer edge of the lower bottom surface of the core of the second mold is chamfered, and the inner edge of the side upper surface of the base is chamfered. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a bird's-eye view of the overall structure. Figure 2 It is a three-dimensional cross-sectional view of the cavity mold box; Figure 3 It is the three-dimensional structure diagram of the molding unit; Figure 4 It is the three-dimensional structure diagram of the mold opening unit; Figure 5 It is the three-dimensional structure diagram of the demoulding unit; Figure 6 It is the three-dimensional structure diagram of the mold; Figure 7 It is a two-dimensional cross-sectional view of the mold of the first structure; Figure 8 It is a two-dimensional cross-sectional view of the mold of the second structure; Fig. 9 It is the three-dimensional structure diagram of the mold opening drive module; Fig.10 It is the three-dimensional structure diagram of the pressure limiting plate; Fig.11 The three-dimensional structure diagram of the demoulding module; Fig.12 The top view layout diagram of the demoulding module; Fig.13 It is a schematic diagram of the connection between the demoulding module and the demoulding driving module; Fig.14 The A-axis structural diagram of the demoulding module; Fig.15 It is a schematic diagram of the structure of the release agent spraying device; Fig.16 Schematic diagram of the working structure of the mold opening unit. DETAILED DESCRIPTION

[0019] The technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application.

[0020] A process for producing an assembled cavity mold box using phosphogypsum, wherein the cavity mold box 6 is as follows Figure 2 As shown, it is composed of an upper cover mold box and a lower cover mold box which are fastened together through four edge surfaces. The upper cover mold box and the lower cover mold box are single-sided open hollow cone-shaped cubic structures, which present a hollow shell structure after being fastened. Assembly mortise and tenon structures are arranged on the four edge surfaces. The assembly mortise and tenon of the upper cover mold box is an outer convex and inner concave stepped structure, and the width of the outer convex part and the width of the inner concave part are in a ratio of 2:1; the assembly mortise and tenon of the lower cover mold box is an outer concave and inner convex stepped structure, and the width of the outer concave part and the width of the inner convex part are in a ratio of 2:1; the thickness of the edge surface of the cavity mold box is 45mm, the thickness of the top surface is 35mm, the side length of the cone is 600mm, and the height is 2X120mm.

[0021] The reason for setting the width ratio of the above-mentioned assembly mortise and tenon structure is that due to the quality characteristics of phosphogypsum, the fragility and peelability of its profile are slightly greater. In order to ensure the quality of mold opening and demolding, the width of the convex part of the upper cover mold box is designed to be twice that of the concave part, and the width of the concave part of the lower cover mold box is designed to be twice that of the convex part, thereby enhancing the strength of the four edge surfaces close to the outer side surfaces and making the strength of the assembly mortise and tenon structure relatively higher after docking and fastening.

[0022] The raw material formula includes, by weight, 100 parts of building gypsum powder, 0.6 parts of calcium oxide powder, 0.5 parts of glass fiber, 20-30 mm in length and 15-25 μm in diameter, 75 parts of water, 0.5 parts of calcium chloride powder and 0.5 parts of borax. The proportion values ​​described below are all set according to the weight proportion in the original formula. The building gypsum powder is calcium sulfate hemihydrate generated by heat-treatment of primary phosphogypsum. The definition of primary phosphogypsum is derived from the requirements specified in GB / T23456-2009, wherein the impurity content meets the requirements of GB / T23456-2018 "Phosphogypsum", GB5085.3-2007 "Identification Standard for Hazardous Waste Leaching Toxicity Identification" and GB38400 "Limit Requirements for Toxic and Hazardous Substances in Fertilizers". Based on common understanding, calcium sulfate hemihydrate is commonly known as building gypsum or plaster of Paris, and calcium sulfate dihydrate is commonly known as raw gypsum. The building gypsum powder in the present invention refers to the one generated by heat-treatment of phosphogypsum.

[0023] The above raw material formula is optimized based on the quality characteristics of phosphogypsum, such as: calcium oxide powder is used to neutralize the acidity of impurities contained in phosphogypsum, and glass fiber is used to improve the strength of the cavity mold box after curing; the water-to-paste ratio is higher than the traditional ratio of 0.7 to improve the fluidity of the phosphogypsum slurry, but the addition of calcium chloride powder and borax has a accelerating effect; the above raw material proportions and parameters are determined based on the comparison of experimentally verified effects. If the phosphogypsum material used is different from the national standard, the user can make experimental adjustments based on this raw material formula. The experimental method of the raw material formula is a well-known technology, and the creativity of this formula is reflected in the fact that the raw material composition and proportion are clarified according to the quality characteristics of phosphogypsum.

[0024] A process for producing an assembled cavity mold box using phosphogypsum is as follows: Step 1, raw material mixing and supply process: set up a raw material supply unit, first, add calcium chloride powder and borax into the water tank according to the formula ratio to fully dissolve and generate process water; simultaneously, the building gypsum powder in the external storage silo is transported to the powder transfer bin through the metering conveyor, and the calcium oxide powder is simultaneously added into the metering conveyor according to the proportion, evenly mixed and transported to the powder transfer bin; simultaneously, the glass fiber is cut into a fixed length and transported to the glass fiber transfer bin.

[0025] Step 2, pulping process: set up a pulping unit, including six stations of flushing, water injection, powder addition, glass fiber addition, stirring, and pulping. The pulping unit includes six stirring barrels for rotary circulation pulping and intermittent fixed-point pulping. First, process water is quantitatively added to the stirring barrel that intermittently rotates to the water injection station; then, the mixed powder in the powder transfer bin is quantitatively added to the stirring barrel that rotates to the powder adding station; then, the glass fiber in the glass fiber transfer bin is quantitatively added to the stirring barrel that rotates to the glass fiber adding station; when the stirring barrel rotates to the stirring station, it is fully stirred; when the stirring barrel rotates to the pulping station, the gypsum slurry falls into the mold by gravity; when the stirring barrel rotates to the flushing station, the external water gun rinses the inside of the mixing barrel after the pulping; set the interval time of each station to 20 seconds, of which the rotation time is set to 5 seconds and the static time is set to 15 seconds. The addition of the above raw materials must be completed when the stirring barrel is stationary, and the above time settings can also be optimized according to the characteristics of the raw materials.

[0026] Step 3, casting and molding process: set up a molding unit, including seven stations: slurry connection, leveling, mold opening, mold removal, cleaning, mold covering, and mold release agent spraying; the mold for casting the upper cover mold box and the mold for casting the lower cover mold box are staggered, rotated in series, and rotated intermittently in sequence, and each mold passes through each station in turn for slurry connection and casting; the intermittent movement time of the mold is consistent with the intermittent time rhythm of the slurry making process.

[0027] Step 4, mold opening process: set up the mold opening unit, intermittently lift the shell sleeve on the mold located at the mold opening station, rotate it to the mold at the cover mold station, and press the shell sleeve tightly into place.

[0028] Step 5, mold demolding process: set up a demolding unit, demold and lift the upper cover mold box and the lower cover mold box that have been completely solidified and formed in the mold located at the demolding station in turn, and stack the upper cover mold box and the lower cover mold box alternately; after demolding the mold, clean the inside of the mold.

[0029] Step 6, release agent spraying process: a release agent spraying device is provided to spray the release agent on the inner wall of the shell sleeve and the upper surface of the core located at the release agent spraying station.

[0030] A device for producing an assembled cavity mold box using phosphogypsum, such as Figure 1 As shown, it includes: a molding unit 1, a mold opening unit 2, a demoulding unit 3, a pulping unit 4, a raw material supply unit 5, and a cavity mold box 6; the molding unit 1 is a rotary support platform structure, which is fixedly arranged on the ground, such as Figure 3As shown, it includes: a mold 1-1, a release agent spraying device 1-2, a leveling device 1-3, a rotating platform 1-4, a sprocket 1-5, a chain 1-6, a water nozzle 1-7, and a guide groove 1-8; the rotating platform 1-4 is a platform structure with two parallel rows in the front and rear and arc-shaped rotating connection at both ends. A plurality of molds 1-1 are arranged, which are installed in series on the rotating platform 1-4 through chains 1-6. The chain 1-6 is connected and driven by the sprockets 1-5 at the left and right ends, and the sprocket on the right is connected to a rotating motor. The rotating motor drives the sprockets 1-5 and the chain 1-6 to make the serially connected molds 1-1 rotate intermittently in the clockwise direction. The seven stations of the molding unit 1 are arranged on the rotary platform 1-4 in sequence. The slurry receiving station is arranged in the rear row of the rotary platform 1-4 and is located directly below the slurry dropping station. The mold release agent spraying station is arranged on the left side of the slurry dropping station. The leveling station is arranged on the right side of the slurry dropping station. The mold opening station is arranged in the front row of the rotary platform 1-4. The mold removal station is arranged on the left side of the mold opening station. The cleaning station is arranged on the left side of the mold removal station. The mold covering station is arranged in the rear row of the rotary platform 1-4 and is located on the left side of the mold release agent spraying station. The mold covering station and the mold opening station are symmetrical based on the front and rear rows of the rotary platform 1-4; the mold release agent spraying device 1-2, the leveling device 1-3, and the water nozzle 1-7 are respectively arranged at the mold release agent spraying station, the leveling station, and the cleaning station, and the guide groove 1-8 is arranged below the cleaning station.

[0031] The structures of the leveling device 1-3, rotating platform 1-4, sprocket 1-5, chain 1-6, water nozzle 1-7 and guide groove 1-8 of the molding unit 1 are well-known technical contents. The creativity in this patent is reflected in: through the interconnection scheme designed by this patent, the fully automatic adaptation of the mold 1-1 with a specific structure and the mold opening unit 2 and the demolding unit 3 is achieved.

[0032] The mold opening unit 2 is a cross-rotating structure. Figure 1 As shown, it is arranged between the front and rear rows of the rotary platform 1-4; Figure 4 As shown, it includes: a rotating frame 2-1, a mold opening cylinder 2-2 and a mold opening mechanism, and the mold opening mechanism is composed of a mold opening drive module 2-3, a mold opening hanger 2-4, a fixed guide rod 2-5 and a pressure limiting plate 2-6; the rotating frame 2-1 is a cross structure supported by a single column rotation, and a set of mold opening mechanisms is suspended at the lower part of the extended end of each cross through the mold opening cylinder 2-2. Four fixed guide rods 2-5 in each set of mold opening mechanisms are evenly arranged vertically, and the top is fixedly installed on the extended end of the rotating frame 2-1, and the lower end is connected to the mold opening drive module 2-3; the mold opening hanger 2-4 is as shown Figure 4 and Fig. 9As shown, two groups, left and right and front and back, are set, respectively, and are arranged on the four sides of the mold opening drive module 2-3 to form a four-sided splint structure. The side of the mold opening hanger 2-4 is a vertical plate structure, the upper end is a horizontal push-pull rod structure, and the lower end is two parallel inward-folding horizontal support plate structures. The vertical distance between the two horizontal support plates is greater than the thickness of the rigid handles on the four outer surfaces of the shell 1-11.

[0033] The demoulding unit 3 is a gantry lifting structure. Figure 1 As shown, it is arranged on the left side of the mold opening unit 2; the pulping unit 4 and the raw material supply unit 5 are arranged on the rear side of the molding unit 1.

[0034] pass Figure 1 The specific spatial structural position and connection relationship of each unit can be clearly understood. The mechanical structure and control scheme of the raw material supply unit 5 and the pulping unit 4 are well-known technical contents. The creativity in this patent is reflected in that the raw material supply unit 5 and the pulping unit 4 execute the process flow according to the steps 1 and 2.

[0035] The mold 1-1 is as Figure 6 As shown, it includes: a shell 1-11, a core 1-12, a base 1-13, a limiter 1-14, a connecting plate 1-15, a roller 1-16, a guide column 1-17, a conductive plate 1-18, and an inner groove rail 1-19; the shell 1-11 is a cone-shaped quadrilateral shell structure with upper and lower openings, the shape and size of the inner side wall of the cone are adapted to the shape and size of the outer side of the cavity mold box 6, and a rectangular strip-shaped rigid handle is respectively arranged on the four outer sides of the shell 1-11; the base 1-13 is a rigid quadrilateral groove structure, the bottom surface of the groove is a plane, the inner width of the groove is equal to the outer width of the lower part of the shell 1-11, the inner depth of the groove is not less than 10mm, and 4 guide through holes are evenly distributed on the bottom surface of the groove; 4 rollers 1-16 are symmetrically installed on the lower bottom surface of the base 1-13, and the limiters 1-16 are symmetrically installed on the left and right sides. -14 and connecting plate 1-15; the core 1-12 is a rigid cubic structure, the upper surface of the core 1-12 is adapted to the hollow shape and size of the cavity mold box 6, the distance between the side of the core 1-12 and the inner edge of the shell 1-11 is equal to the wall thickness of the cavity mold box 6, the lower bottom surface of the core 1-12 is a plane, which is centrally arranged on the bottom surface of the groove of the base 1-13, and four guide columns 1-17 are fixedly arranged on the lower bottom surface of the core 1-12, and the guide columns 1-17 pass through the guide through holes respectively to realize the upper and lower sliding connection between the core 1-12 and the groove of the base 1-13; the four guide columns 1-17 extend out of the part below the base 1-13, and are rigidly connected to a conductive plate 1-18 as a whole, and the inner groove rail 1-19 is rigidly installed in the middle of the lower part of the conductive plate 1-18, and the groove direction of the inner groove rail is consistent with the movement guide of the roller 1-16.

[0036] The conductive plate 1-18 is a rigid plate, which is rigidly connected to the four guide posts 1-17. When the guide plate 1-18 moves up and down, it can drive the four guide posts 1-17 to move up and down synchronously, thereby evenly pushing the core 1-12 to move up and down. The function of the stopper 1-14 is to ensure that when the shell 1-11 of the mold 1-1 is lifted during the mold opening process, and when the core 1-12 is lifted during the subsequent demolding process, the base 1-13 can always be fixedly contacted on the rotary platform 1-4 and not lifted up at the same time. The structure and connection method of the stopper 1-14 are well-known technologies. The function of the connecting plate 1-15 is to ensure that the mold 1-1 is connected to the chain 1-6 and driven. The structure and connection method of the connecting plate 1-15 are well-known technologies.

[0037] The internal arrangement of the mold 1-1 is divided into two structures. The first structure is as follows: Figure 7 As shown, an outer core strip 1-21 with a square layout is arranged around the bottom surface of the groove of the base 1-13, and the horizontal distance between the outer side surface of the outer core strip 1-21 and the inner side surface of the groove is equal to the shell thickness of the shell sleeve 1-11, and the height and width of the outer core strip 1-21 are equal to the height and width of the outer concave and inner convex stepped structure of the mortise and tenon of the lower cover mold box; the second structure is as shown Figure 8 As shown, an inner core strip 1-22 with a square layout is arranged around the bottom surface of the groove of the base 1-13, and the inner side surface of the inner core strip 1-22 contacts the outer side surface of the core 1-12, and the height and width are equal to the height and width of the convex and concave structure of the mortise and tenon of the upper cover mold box.

[0038] When the shell 1-11 is located inside the groove of the base 1-13, and the core 1-12 is located at the bottom of the groove of the base 1-13, the space between the shell 1-11 and the core 1-12 constitutes the casting cavity of the mold 1-1. The two structures of the mold can respectively cast the outer convex and inner concave stepped structure of the upper cover mold box and the outer concave and inner convex stepped structure of the lower cover mold box. Figure 7 and Figure 8 As shown, drainage holes 1-20 are arranged on the bottom surface of the groove of the base 1-13, and the drainage holes are arranged respectively at the lower position of the core 1-12 and at a position close to the inner side surface of the groove; the diameter of the drainage holes 1-20 close to the inner side surface of the groove is lower than the shell thickness of the shell sleeve 1-11.

[0039] The mold opening drive module 2-3 is as follows Fig. 9As shown, it includes: a support plate 2-31, a mold opening slide rail 2-32, a mold opening pull rod 2-33, a cross wheel 2-34, and a mold opening steering gear 2-35; the support plate 2-31 is a square rigid flat plate, on which 4 guide holes are evenly arranged, 4 fixed guide rods 2-5 pass downward through the guide holes and are connected with them in an upward and downward sliding manner, a mold opening slide rail 2-32 perpendicular to the square edge is arranged in the middle position of each square edge, the push-pull rod of the mold opening hanger 2-4 is arranged in the mold opening slide rail 2-32 and is connected with it in a sliding manner, and the cross wheel 2-34 is arranged At the center of the support plate 2-31 and rotatably connected, the outer ends of the four mold opening pull rods 2-33 are respectively rotatably connected to the push-pull rods of the mold opening hanger 2-4, and the inner ends are respectively rotatably connected to the cross ends of the cross wheel 2-34; a through hole is set in the center of the cross wheel 2-34, and the lower telescopic end of the mold opening cylinder 2-2 is fixed on the support plate 2-31 through the through hole; the mold opening servo 2-35 is set at the lower center position of the support plate 2-31, and the driving shaft of the mold opening servo 2-35 passes through the support plate 2-31 and rotationally drives the cross wheel 2-34.

[0040] Since a through hole is provided at the center of the cross wheel 2-34, the rotational connection between the cross wheel 2-34 and the support plate 2-31 is preferably connected by a sleeve shaft structure, and the mold opening servo 2-35 drives the cross wheel 2-34 to also adopt a sleeve shaft structure. The sleeve shaft and the solid shaft achieve the same effect, and both are well-known technologies; when the mold opening servo 2-35 rotates forward or reversely, the cross wheel 2-34 is driven to rotate forward or reversely, and then the four mold opening pull rods 2-33 drive the push-pull rods of the mold opening hanger 2-4 to make horizontal reciprocating motion along the mold opening slide rail 2-32, so that the four-sided splints of the mold opening hanger 2-4 are uniformly closed horizontally inward or opened horizontally outward.

[0041] like Figure 4 As shown, the pressure limiting plate 2-6 is centrally arranged within the four clamping plates of the mold opening hanger 2-4. Fig.10 As shown, it includes: a fixing platform 2-61, a connector 2-62, and a pressing plate 2-63; the fixing platform 2-61 and the pressing plate 2-63 are both rigid square plane plates, such as Fig.16 As shown, the fixed platform 2-61 is rigidly fixed to the lower ends of the four fixed guide rods 2-5, and the pressure plate 2-63 is rigidly connected to the fixed platform 2-61 through the connector 2-62 and kept horizontal. The side length of the pressure plate 2-63 is smaller than the side length of the open opening on the cone of the shell 1-11, and the connector 2-62 is a well-known technology.

[0042] The demoulding unit 3 is as follows Figure 5As shown, it includes: a mold lifting bracket 3-1, a mold lifting module 3-2, a mold lifting drive module 3-3, a horizontal slide rail 3-4, a pallet supply module 3-5, a stacking mold connection module 3-6, and a transportation module 3-7; the mold lifting bracket 3-1 is a rigid gantry structure, the right end of which is arranged across the middle of the two rows of parallel structures of the rotary platform 1-4, the left end of which is arranged across the stacking mold connection mechanism 3-6, the upper end is arranged with a horizontal slide rail 3-4, the mold lifting drive module 3-3 is arranged on the horizontal slide rail 3-4, and the mold lifting module 3-2 is suspended at the lower part of the mold lifting drive module 3-3; the pallet supply module 3-5 is arranged on the left side of the stacking mold connection module 3-6, and the transportation module 3-7 is arranged on the right side of the stacking mold connection module 3-6, and the three are connected by a roller shaft group.

[0043] The specific structures and connection methods of the demoulding drive module 3-3, the pallet supply module 3-5, the stacking mold module 3-6, and the transportation module 3-7 are well-known technologies. The creativity in this patent is reflected in the specific mechanism design of the demoulding module 3-2 for clamping and lifting the assembly mortise and tenon structure of the cavity mold box, as well as the spatial connection scheme and process flow design of each module.

[0044] The demoulding module 3-2 is as follows Fig.11 , Fig.12 and Fig.13 As shown, it includes: a demolding cylinder 3-21, a lifting guide rod 3-22, a support platform 3-23, left and right hangers 3-24, front and rear hangers 3-25, a circular wheel 3-26, a connecting rod 3-27, a demolding slide rail 3-28, a tension spring 3-29, and a demolding servo 3-30; the support platform 3-23 is a square rigid flat plate, 4 guide through holes are arranged on it, a circular wheel 3-26 is rotatably installed at the center position, and a demolding slide rail 3-28 perpendicular to the square edge is arranged in the middle position of each square edge.

[0045] The upper ends and sides of the left and right hangers 3-24 and the front and rear hangers 3-25 are the same as the upper ends and sides of the mold opening hanger 2-4, and the push-pull rods at the upper ends are respectively installed in the mold removal slide rails 3-28; Fig.13 As shown, the lower ends of the left and right hangers 3-24 are single-piece inward-folding horizontal support plates; Fig.14 As shown, the lower ends of the front and rear hangers 3-25 are inwardly folding single-step structure support plates.

[0046] The size and shape of the inward folding single step at the lower end of the front and rear hangers 3-25 are adapted to the outer concave and inner convex step structure of the lower cover mold box. The reason is that: the width of the inner convex part of the lower cover mold box is small. If a single-piece horizontal support plate structure is used, the dragging force of the support plate during demoulding may damage the inner convex structure. Therefore, a single-step structure support plate with a matching size and shape is used. When demoulding, the support plate of the single-step structure is in full contact with the outer concave and inner convex step structure of the lower cover mold box, which increases the contact surface and is not easy to damage the outer concave and inner convex step structure of the lower cover mold box. The outer convex part of the upper cover mold box has a larger width, so a horizontal support plate structure can be used.

[0047] The circular wheel 3-26 is as follows Fig.12 As shown, a through hole is set in the center, and an arc-shaped slot hole is set at the edge of the upper right circular surface and the lower left circular surface area respectively. The outer ends of the four connecting rods 3-27 are respectively rotatably connected to the push-pull rods of the left and right hangers 3-24 and the front and rear hangers 3-25, and the inner ends are respectively set in the slot holes through pin shafts, and respectively contact the top of the horizontal end and the top of the vertical end of the slot holes; the tension spring 3-29 is provided with 4 pieces, one end of which is fixed on the support platform 3-23, and the other end is connected to the inner end of the connecting rod 3-27, so that the tension spring 3-29 generates a clockwise pulling force on the inner end of the connecting rod 3-27 in the left and right direction, and generates a counterclockwise pulling force on the inner end of the connecting rod 3-27 in the up and down direction.

[0048] like Fig.13 As shown, the lifting guide rod 3-22 is vertically evenly arranged, the lower end passes through the guide through hole of the support platform 3-23 and is slidably connected to the support platform 3-23, and the upper end is fixedly connected to the demoulding drive module 3-3; the upper end of the demoulding cylinder 3-21 is fixed on the demoulding drive module 3-3, and the lower end passes through the central through hole of the circular wheel 3-26 and is fixed on the support platform 3-23; the demoulding servo 3-30 is arranged at the lower part of the support platform 3-23, and the central axis of the demoulding servo 3-30 passes through the support platform 3-23 and rotationally drives the connected circular wheel 3-26.

[0049] Since a through hole is provided at the center of the circular wheel 3-26, the rotational connection between the circular wheel 3-26 and the support platform 3-23 adopts a sleeve shaft structure, and the demolding servo 3-30 drives and connects the circular wheel 3-26 and also adopts a sleeve shaft structure.

[0050] like Fig.12As shown, when the mold-lifting servo 3-30 drives the circular wheel 3-26 to rotate counterclockwise, the top of the horizontal end of the slot on the circular wheel 3-26 contacts and drives the pin at the inner end of the left and right connecting rod 3-27, and the pin drives the left and right connecting rod 3-27, thereby driving the left and right hangers 3-24 to move horizontally toward the middle, while the slots at the upper and lower ends do not produce a contact drive for the pin at the inner end of the upper and lower connecting rod 3-27, that is, the front and rear hangers 3-25 remain stationary; conversely, when the mold-lifting servo 3-30 drives the circular wheel 3-26 to rotate clockwise, it drives the front and rear hangers 3-25 to move toward the middle, while the left and right hangers 3-24 remain stationary; the function of the tension spring 3-29 is to pull the front and rear hangers 3-25 and the left and right hangers 3-24 to move horizontally outward and reset when the mold-lifting servo 3-30 rotates to reset.

[0051] The release agent spraying device 1-2 is as follows Fig.15 As shown, it includes: a fixed bracket 1-23, a lifting rod 1-24, and a multi-directional spray head 1-25. The fixed bracket 1-23 is installed at the release agent spraying station. The lifting rod 1-24 controls the connected multi-directional spray head 1-25 to intermittently rise and fall, so as to intermittently enter and exit the mold cavity inside the mold, and spray liquid release agent to the inner wall of the shell sleeve 1-11, the surface of the core 1-12, and the surface of the base 1-13; in order to ensure that the inner oblique cone surface of the shell sleeve 1-11 can be sprayed with the release agent, the multi-directional spray head 1-25 is provided with downward and oblique upward spray ports.

[0052] like Figure 1 and Figure 3 As shown, the cleaning station is arranged on the left side of the demoulding unit 3 on the rotary platform 1-4, a water nozzle 1-7 is arranged on the cleaning station, and a guide groove 1-8 is arranged at the lower part.

[0053] like Figure 7 As shown, the inner edge of the lower bottom surface of the shell sleeve 1-11 of the first mold is chamfered, and the inner edge of the upper surface of the side edge of the base 1-13 is chamfered to facilitate the shell sleeve 1-11 to enter downward between the side of the groove and the outer core strip 1-21; Figure 8 As shown, the outer edge of the lower bottom surface of the core 1-12 of the second mold is chamfered to facilitate the core 1-12 to downwardly enter the inner core strip 1-22 of the square surrounding layout, and the inner edge of the side upper surface of the base 1-13 is chamfered to facilitate the shell 1-11 to downwardly enter the groove of the base 1-13.

[0054] Example 1, process flow of the raw material supply unit 5 and the pulping unit 4: The raw material supply unit 5 realizes the mixing and supply of various raw materials, and the slurry making unit 4 realizes the production and grouting of gypsum slurry.

[0055] (1) Calcium chloride powder and borax are added into the water tank in proportion and stirred to dissolve to generate process water. When the mixing barrel of the pulping unit 4 rotates to the water injection position and stops, the process water in the water tank is quantitatively injected into the mixing barrel in proportion; (2) The building gypsum powder and calcium oxide powder in the external storage silo are evenly mixed in proportion in the metering conveyor and transported to the powder transfer silo. When the mixing barrel rotates to the powder adding station and stops, the powder in the transfer silo is quantitatively added to the mixing barrel; (3) After the glass fiber is cut to a fixed length, it is transported to the glass fiber transfer bin. When the mixing drum rotates to the glass fiber adding position and stops, the glass fiber is quantitatively added into the mixing drum; (4) Setting up a stirring station is to increase the stirring time and ensure that all raw materials in the mixing barrel are fully and evenly stirred; (5) After the mixing barrel rotates to the slurry dropping position and stops, the evenly mixed gypsum slurry falls into the mold by gravity; (6) After the mixing barrel rotates to the flushing position and stops, an external water gun will flush the inside of the mixing barrel after the slurry falls to prevent the residual slurry from condensing locally in the mixing barrel.

[0056] The interval time of each workstation is set to 20 seconds, of which the rotation time is set to 5 seconds and the static time is 15 seconds. The three time values ​​are determined based on the curing reaction time generated by the raw material formula and are optimized values ​​obtained through repeated experiments. Users can also perform secondary optimization of the formula and production control characteristics based on the quality characteristics of the actual phosphogypsum raw materials. However, after the time value is optimized, do not modify the formula ratio easily, because the formula ratio and time control are related. If the formula ratio is modified, the optimized time value needs to be re-determined through experiments.

[0057] The module device, spatial structure and control model of the raw material supply unit 5 and the pulping unit 4 are well-known technical contents in the gypsum building materials machinery industry. The creativity of the raw material supply unit 5 and the pulping unit 4 in the present invention is reflected in: the adaptation of the mixing process content according to the quality characteristics of phosphogypsum.

[0058] Embodiment 2, the working process of the molding unit 1 is as follows Figure 1 and Figure 3 As shown: (1) Multiple molds 1-1 are installed in series on the rotating platform 1-4 through chains 1-6. When each mold 1-1 passes through the slurry receiving station intermittently in turn, the gypsum slurry in the mixing barrel is injected into the casting cavity of the mold 1-1. The minimum number of molds in series is related to the curing time of the gypsum slurry. For example, the number of molds in this embodiment is 56, that is, the time for the mold to rotate one circle is 1120 seconds; (2) When the mold 1-1 is intermittently rotating on the rotating platform 1-4, the gypsum slurry in the mold 1-1 is initially solidified; when the mold 1-1 passes through the leveling station, the initially solidified gypsum slurry at the opening of the shell 1-11 of the mold 1-1 is rolled and leveled by the leveling device 1-3; (3) When the mold 1-1 reaches the mold opening station, the gypsum slurry in the mold 1-1 has completely solidified and hardened, and the mold opening unit 2 lifts the shell 1-11 and rotates it to the cover mold station of the rotary platform 1-4; (4) When the mold 1-1 with the shell 1-11 lifted away arrives at the demolding station, the demolding unit 3 demolds the cavity mold box in the mold casting cavity and lifts it, and then stacks and pallets it; (5) When the mold 1-1 reaches the cleaning station after demolding, water is used to wash the inside of the mold to remove gypsum residues to ensure the quality of the next casting. The sewage flows away and is collected from the diversion groove 1-8; (6) When the mold 1-1 reaches the cover mold station after demolding, the mold opening unit 2 puts the shell 1-11 into the base 1-13 and presses it down tightly; (7) When the mold 1-1 reaches the release agent spraying station, the release agent spraying device 1-2 sprays a mist of liquid release agent onto the inner side wall of the shell 1-11 and the upper surface and side surface of the core 1-12; (8) The mold 1 - 1 sprayed with the release agent arrives at the slurry receiving station of the slurry making unit 4 to be slurried again.

[0059] The control and positioning methods of each component in this embodiment are all well-known technologies.

[0060] Embodiment 3, the working process of the mold opening unit 2: (1) When the mold 1-1 reaches the mold opening station below the mold opening unit 2 and stops, Fig.16 As shown in the left part of the figure, the mold opening cylinder 2-2 above the mold 1-1 drives the mold opening drive module 2-3 and the mold opening hanger 2-4 to move downward synchronously, and the fixed guide rod 2-5 plays a guiding and stabilizing role; when the two horizontal support plates of the mold opening hanger 2-4 move downward to the position of the rigid handle of the shell 1-11, the mold opening cylinder 2-2 stops driving. At this time, in the vertical direction, the rigid handle of the shell 1-11 is located between the two horizontal support plates, as shown in FIG. Figure 4 As shown on the right side, in the front-to-back and left-to-right directions, the four rigid handles are simultaneously located between the two horizontal support plates of the four mold hangers 2-4.

[0061] (2) If Fig. 9As shown, the mold opening servo 2-35 at the center position below the support plate 2-31 drives the cross wheel 2-34 to rotate a certain angle, and the cross wheel 2-34 drives the four mold opening pull rods 2-33 to pull the telescopic rod at the upper end of the mold opening hanger 2-4 along the mold opening slide rail 2-32, so that the horizontal support plates of the four mold opening hangers 2-4 can be simultaneously retracted and translated toward the center, thereby realizing that the four rigid handles can enter between the two horizontal support plates of the four mold opening hangers 2-4 respectively.

[0062] (3) If Fig.16 As shown on the left side, the mold opening cylinder 2-2 drives the support plate 2-31 upward, driving the mold opening drive module 2-3 and the mold opening hanger 2-4 to move upward, and the lower plate of the two horizontal support plates of the mold opening hanger 2-4 pulls the rigid handle of the shell sleeve 1-11 upward, and lifts the shell sleeve 1-11 from the base 1-13. When the lower part of the shell sleeve 1-11 is higher than the upper surface of the solidified cavity mold box in the mold 1-1, the mold opening cylinder 2-2 stops driving, and the rotating frame 2-1 rotates 90° counterclockwise at this time, and the lifted shell sleeve 1-11 rotates 90° synchronously; then, the mold 1-1 with the lifted shell sleeve 1-11 moves an intermittent distance to the demolding station, and the rotating frame 2-1 starts to lift the shell sleeve of the next mold 1-1 for mold opening.

[0063] (4) If Figure 1 As shown, during the two intermittent rotation times, the lifted shell 1-11 is rotated 180° and transported to the top of the mold 1-1 at the cover mold station of the rotary platform 1-4, and the mold opening cylinder 2-2 drives the support plate 2-31 downward to place the shell 1-11 in the base 1-13, and at the same time, the upper plate of the two horizontal support plates of the mold opening hanger 2-4 presses down the rigid handle of the shell 1-11, so that the shell 1-11 is fully moved downward, as shown in FIG. Fig.16 The reason for using four mold hangers 2-4 to simultaneously lift the shell 1-11 is that the shell 1-11 is heavy, and the stability of clamping on four sides at the same time is high; moreover, the mold hanger 2-4 needs to press the shell 1-11 into the base 1-13 at the mold cover station. Since the shell 1-11 and the base 1-13 are both rigid bodies, and the friction resistance of the outer core strip 1-21 or the inner core strip 1-22 is added, the required downward pressure is not only large, but also must be stable and accurate.

[0064] (5) Even if the release agent is sprayed, there is still a certain bonding force between the inner wall of the shell 1-11 and the newly solidified cavity mold box side wall. Similarly, there is also a certain bonding force between the bottom surface of the cavity mold box and the core 1-12 and the base 1-13. If the bonding force between the shell 1-11 and the cavity mold box side wall is greater than the bonding force between the bottom surface of the cavity mold box and the core 1-12 and the base 1-13, when the shell 1-11 is lifted, the cavity mold box will be stuck and lifted synchronously, causing mold opening failure. Therefore, a pressure limiting plate 2-6 is set, such as Fig.16As shown on the left side, if the cavity mold box is not lifted together, the pressure limiting plate does not work; if the cavity mold box is lifted by the shell sleeve 1-11, when the upper surface height of the cavity mold box reaches the position of the pressure plate 2-63, since the fixed platform 2-61 is rigidly fixed to the lower part of the fixed guide rod 2-5, it always remains stationary, that is, the height of the pressure plate 2-63 remains unchanged. When the upper surface of the cavity mold box contacts the lower surface of the pressure plate 2-63, the shell sleeve 1-11 can continue to rise, but the cavity mold box is rigidly blocked by the stationary pressure plate 2-63, and the cavity mold box will break away from the inner wall of the shell sleeve 1-11 and fall back onto the core 1-12 in the mold 1-1.

[0065] The cylinder control, the control and positioning methods of each component, and the steering gear control in this embodiment are all well-known technologies.

[0066] Embodiment 4, the working process of the demoulding unit 3: (1) The mold 1-1 with the shell 1-11 lifted away arrives at the demolding station. Since the molds of the two structures are staggered in series, that is, the upper cover mold box and the lower cover mold box will arrive at the demolding station alternately, the left and right hangers 3-24 and the front and rear hangers 3-25 of the demolding unit 3 should be respectively adapted to the assembly mortise and tenon structures of the upper cover mold box and the lower cover mold box; a top mold device is set at the corresponding position of the lower part of the rotary platform 1-4 of the demolding station. When the mold 1-1 arrives at the demolding station and stops, as shown in FIG. Figure 6 As shown, the top mold device on the rotating platform 1-4 extends into the inner groove rail 1-19 and pushes up, the inner groove rail 1-19 pushes up the conductive plate 1-18, the conductive plate 1-18 pushes upward the guide column 1-17, and then the guide column 1-17 pushes up the core 1-12 on the upper part of the base 1-13, and the core 1-12 pushes up the upper cover mold box or the lower cover mold box.

[0067] (2) If the mold-lifting station lifts the upper cover mold box, such as Fig.12 and Fig.13As shown, the driving end of the demolding cylinder 3-21 of the demolding module 3-2 moves downward, driving the support platform 3-23 to move downward along the lifting guide rod 3-22, and the left and right hangers 3-24, the front and rear hangers 3-25, the circular wheel 3-26, the connecting rod 3-27, the demolding slide rail 3-28, and the tension spring 3-29 move downward synchronously. When the horizontal support plate at the lower end of the left and right hangers 3-24 is located at the lower horizontal position of the upper cover mold box, the demolding cylinder 3-21 stops driving, and the demolding servo 3-30 drives the circular wheel 3-26 to rotate a certain angle counterclockwise. The top of the arc-shaped slot hole on the circular wheel 3-26 drives the connecting rod 3-27 at the left position to rotate downward, and the connecting rod 3-27 at the right position to rotate upward, that is, the connecting rod 3-27 at the left and right positions pulls the telescopic rods of the left and right hangers 3-24 to move toward the center in the demolding slide rail 3-28, and the horizontal support plates of the left and right hangers 3-24 move to the middle and reach the upper The bottom of the cover mold box, and then the demolding cylinder 3-21 is driven upward to lift the upper cover mold box, and then it is transported to the top of the support plate of the stacking mold module 3-6 through the demolding drive module 3-3 and the horizontal slide rail 3-4; then, the demolding servo 3-30 drives the circular wheel 3-26 to reset clockwise, and at the same time, the tension spring 3-29 pulls the two connecting rods 3-27 at the left and right positions to reset, so that the left and right hangers 3-24 are separated to the left and right directions, thereby placing the upper cover mold box on the support plate; when the circular wheel 3-26 drives the left and right hangers 3-24 to clamp the upper cover mold box, the two connecting rods 3-27 at the upper and lower positions are not driven by the arc-shaped slots on the circular wheel 3-26; because the width of the convex part and the concave part of the assembly mortise and tenon of the upper cover mold box is in a ratio of 2:1, the horizontal support plate at the lower ends of the left and right hangers 3-24 is demolded and lifted, and the contact area between each other is large, which will not cause damage to the assembly mortise and tenon structure.

[0068] (3) If the mold-lifting station lifts the lower cover mold box, such as Fig.12 and Fig.14 As shown, the demoulding servo 3-30 drives the circular wheel 3-26 to rotate clockwise, so as to drive the front and rear hangers 3-25 and the single-step structure support plate at the lower end to move toward the middle and demould and lift the lower cover mold box; since the width ratio of the outer concave part and the inner convex part of the lower cover mold box is 2:1, if a separate horizontal support plate mechanism is used, the contact area between them is small, which may cause damage to the assembly mortise and tenon structure of the lower cover mold box, so an inward folding single-step structure support plate is used to increase the contact area between them.

[0069] In this embodiment, the working principle of the rotary platform 1-4 and the top mold device adopts a T-head cylinder push-pull scheme, which is a well-known technology, and the control method of each device is a well-known technology.

[0070] Example 5: Working process of mold 1-1 and water nozzle 1-7 (1) The contact state of the shell 1-11 and the core 1-12 to the base 1-13 can realize the opening and closing control of the drainage hole 1-20. When the passage is open, the sewage can be discharged smoothly when flushing the inside of the mold. When closed, the mold does not leak when receiving the slurry.

[0071] (2) When the mold 1-1 reaches the cleaning station after demolding, a mold-lifting device is set at the cleaning station of the rotary platform 1-4. After the core 1-12 is lifted up, a water nozzle 1-7, the core 1-12 and the base 1-13 are set outside. The sewage is discharged from the drainage hole 1-20 of the base 1-13 and collected and flowed away through the guide groove 1-8. When the mold 1-1 is cleaned, the mold-lifting device restores the core 1-12 to the groove surface of the base 1-13.

[0072] (3) When the mold 1-1 reaches the mold covering station, the lower bottom surface of the shell side wall and the lower bottom surface of the core 1-12 are in close contact with the surface of the groove of the base 1-13, which is equivalent to blocking the drainage hole 1-20. Therefore, when the mold 1-1 is receiving the slurry, the gypsum slurry will not leak out of the drainage hole.

[0073] Example 6: Release agent spraying process The release agent spraying station is located behind the mold covering station. When the mold 1-1 reaches the release agent spraying station, the release agent spraying device 1-2 retracts and reciprocates up and down in and out of the casting mold cavity between the shell 1-11 and the core 1-12, and evenly sprays liquid release agent on the inner wall of the shell 1-11 and the upper surface and side surface of the core 1-12, and then the mold 1-1 moves to the slurry connection station again.

[0074] Advantages: The process flow developed by the present invention based on the quality characteristics of phosphogypsum is scientific and reasonable, so that the cavity mold box molding effect is adapted to the quality of phosphogypsum; the innovatively designed mechanical device is complete and ingenious, with high production efficiency, and can realize full automation of the production process, which is easy to promote and implement.

Claims

1. A process for producing an assembled cavity mold box using phosphogypsum, characterized in that: The cavity mold box is composed of an upper cover mold box and a lower cover mold box that are connected and buckled together through four edge surfaces. The upper cover mold box and the lower cover mold box are single-sided open hollow cone-shaped cubic structures. After buckling, they form a hollow shell structure, and assembly mortise and tenon structures are arranged on the four edge surfaces; By weight, the raw material formula includes: building gypsum powder: 100 parts; calcium oxide powder: 0.6 parts; glass fiber: 0.5 parts, length 20-30mm, diameter 15-25μm; water: 75 parts; calcium chloride powder: 0.5 parts; borax: 0.5 parts; The process steps are as follows: Step 1, raw material mixing and supply process: set up a raw material supply unit, first, calcium chloride powder and borax are added into the water tank according to the formula ratio to fully dissolve and generate process water; simultaneously, the building gypsum powder in the external storage silo is transported to the powder transfer bin through the metering conveyor, and the calcium oxide powder is simultaneously added into the metering conveyor according to the proportion, uniformly mixed and transported to the powder transfer bin; simultaneously, the glass fiber is cut into a fixed length and transported to the glass fiber transfer bin; Step 2, pulping process: set up a pulping unit, including six stations of flushing, water injection, powder addition, glass fiber addition, stirring, and pulping. Set up six stirring barrels to intermittently rotate through each station in turn to complete the cyclic pulping and fixed-point pulping; Step 3, casting and molding process: setting up a molding unit, including seven stations including slurry connection, leveling, mold opening, mold removal, cleaning, mold covering, and mold release agent spraying, and each mold is cast and molded through the seven stations in turn; Step 4, mold opening process: set up a mold opening unit, lift the shell at the mold opening station, and transport it to the mold cover at the mold cover station for pressing; Step 5, mold demolding process: set up a demolding unit, demold, lift, stack and palletize the upper cover mold box and the lower cover mold box located at the demolding station in sequence; Step 6, release agent spraying process: a release agent spraying device is provided to spray the release agent on the inner wall of the shell sleeve and the upper surface of the core located at the release agent spraying station.

2. A device for producing an assembled cavity mold box using phosphogypsum, characterized in that: include: A molding unit (1), a mold opening unit (2), a demoulding unit (3), a pulping unit (4), a raw material supply unit (5), and a cavity mold box (6); The molding unit (1) is a rotary support platform structure, fixedly arranged on the ground, and comprises: a mold (1-1), a mold release agent spraying device (1-2), a leveling device (1-3), a rotary platform (1-4), a sprocket (1-5), a chain (1-6), a water spray head (1-7), and a guide groove (1-8); the rotary platform (1-4) is a platform structure with two parallel rows in front and back and arc-shaped rotary connection at both ends; a plurality of molds (1-1) are arranged, and are mounted on the rotary platform (1-4) in series via chains (1-6); the chain (1-6) is connected and driven by the sprockets (1-5) at the left and right ends, and the sprocket at the right end is connected to a rotating motor; The seven workstations of the molding unit (1) are sequentially arranged on the rotary platform (1-4); the slurry receiving workstation is arranged in the rear row of the rotary platform (1-4) and is located directly below the slurry dropping workstation; the mold release agent spraying workstation is arranged on the left of the slurry dropping workstation; and the leveling workstation is arranged on the right of the slurry dropping workstation; the mold opening workstation is arranged in the front row of the rotary platform (1-4); the mold removal workstation is arranged on the left of the mold opening workstation; and the cleaning workstation is arranged on the left of the mold removal workstation; the mold covering workstation is arranged in the rear row of the rotary platform (1-4) and is located on the left of the mold release agent spraying workstation; the mold covering workstation and the mold opening workstation are symmetrical based on the front and rear rows of the rotary platform (1-4); the mold release agent spraying device (1-2), the leveling device (1-3), and the water spray head (1-7) are respectively arranged at the mold release agent spraying workstation, the leveling workstation, and the cleaning workstation; and the guide groove (1-8) is arranged below the cleaning workstation; The mold opening unit (2) is a cross rotating structure, which is arranged in the middle of the front and rear rows of the rotary platform (1-4), and comprises: a rotating frame (2-1), a mold opening cylinder (2-2) and a mold opening mechanism, wherein the mold opening mechanism is composed of a mold opening drive module (2-3), a mold opening hanger (2-4), a fixed guide rod (2-5) and a pressure limiting plate (2-6); the rotating frame (2-1) is a cross structure supported by a single column rotation, and a set of mold opening mechanisms is suspended at the lower part of the extended end of each cross through the mold opening cylinder (2-2). , four fixed guide rods (2-5) are evenly distributed vertically in each mold opening mechanism, the top of which is fixedly mounted on the protruding end of the rotating frame (2-1), and the lower end is connected to the mold opening drive module (2-3); the mold opening hanger (2-4) is provided with two groups, left and right and front and back, which are respectively arranged on the four sides of the mold opening drive module (2-3) to form a four-sided clamping plate structure, the side of the mold opening hanger (2-4) is a vertical plate structure, the upper end is a horizontal push-pull rod structure, and the lower end is two parallel inward folding horizontal support plate structures; The demoulding unit (3) is a gantry lifting structure and is arranged on the left side of the mold opening unit (2); the pulping unit (4) and the raw material supply unit (5) are arranged on the rear side of the molding unit (1); The mold (1-1) comprises: a shell (1-11), a core (1-12), a base (1-13), an outer core strip (1-21), and an inner core strip (1-22); the shell (1-11) is a cone-shaped quadrilateral outer shell structure with upper and lower openings extending therethrough, and a rectangular rigid handle is respectively arranged on four outer sides of the shell (1-11); the core (1-12) is a rigid quadrilateral structure, and the base (1-13) is a rigid quadrilateral groove structure; the core (1-12) is centrally arranged on the bottom surface of the groove of the base (1-13), and the outer core strip (1-21) and the inner core strip (1-22) are respectively arranged in a square shape and surround the bottom surface of the groove of the base (1-13).

3. The device for producing an assembly type cavity mold box using phosphogypsum according to claim 2, characterized in that: The internal arrangement of the mold (1-1) is divided into two structures. In the first structure, the horizontal distance between the outer core strip (1-21) and the inner side surface of the groove is equal to the shell thickness of the shell sleeve (1-11), and the height and width of the outer core strip (1-21) are equal to the height and width of the outer concave and inner convex stepped structure of the mortise and tenon of the lower cover mold box; in the second structure, the inner side surface of the inner core strip (1-22) contacts the outer side surface of the mold core (1-12), and the height and width are equal to the height and width of the outer convex and inner concave structure of the mortise and tenon of the upper cover mold box; Drain holes (1-20) are arranged on the bottom surface of the groove of the base (1-13), and the drainage holes are respectively arranged at the lower position of the core (1-12) and at a position close to the inner side surface of the groove.

4. The device for producing an assembly type cavity mold box using phosphogypsum according to claim 2 or claim 3, characterized in that: The mold (1-1) further comprises: a stopper (1-14), a connecting plate (1-15), a roller (1-16), a guide column (1-17), a conductive plate (1-18), and an inner groove rail (1-19); four guide through holes are evenly arranged on the bottom surface of the groove of the base (1-13); four rollers (1-16) are symmetrically mounted on the lower bottom surface of the base (1-13); and the stopper (1-14) and the connecting plate (1-15) are symmetrically mounted on the left and right sides; the lower bottom surface of the core (1-12) is a plane; four guide columns (1-17) are fixedly mounted on the lower bottom surface; the guide columns (1-17) pass through the guide through holes to maintain sliding connection; the four guide columns (1-17) extend out of the portion below the base (1-13) and are rigidly connected to a conductive plate (1-18); and the inner groove rail (1-19) is rigidly mounted in the middle of the lower portion of the conductive plate (1-18).

5. The device for producing an assembly-type cavity mold box using phosphogypsum according to claim 2, characterized in that: The mold opening drive module (2-3) comprises: a support plate (2-31), a mold opening slide rail (2-32), a mold opening pull rod (2-33), a cross wheel (2-34), and a mold opening steering gear (2-35); the support plate (2-31) is a square rigid flat plate, on which four guide through holes are evenly arranged, four fixed guide rods (2-5) pass downward through the guide through holes and maintain a sliding connection, a mold opening slide rail (2-32) perpendicular to the square edge is arranged in the middle position of each square edge, a push-pull rod of the mold opening hanger (2-4) is arranged in the mold opening slide rail (2-32) and maintains a sliding connection, and the cross wheel (2-34 ) is arranged at the center of the support plate (2-31) and is rotatably connected, the outer ends of the four mold opening pull rods (2-33) are respectively rotatably connected to the push-pull rods of the mold opening hanger (2-4), and the inner ends are respectively rotatably connected to the cross ends of the cross wheel (2-34); a through hole is arranged at the center of the cross wheel (2-34), and the lower telescopic end of the mold opening cylinder (2-2) passes through the through hole and is fixed on the support plate (2-31); the mold opening steering gear (2-35) is arranged at the lower center position of the support plate (2-31), and the driving shaft of the mold opening steering gear (2-35) passes through the support plate (2-31) and rotatably drives the cross wheel (2-34); The pressure limiting plate (2-6) is centrally arranged within the four clamping plates of the mold opening hanger (2-4), and comprises: a fixed platform (2-61), a connector (2-62), and a pressing plate (2-63); the fixed platform (2-61) and the pressing plate (2-63) are both rigid square plane plates, the fixed platform (2-61) is rigidly fixed to the lower ends of the four fixed guide rods (2-5), and the pressing plate (2-63) is rigidly connected to the fixed platform (2-61) through the connector (2-62) and maintained horizontally.

6. The device for producing an assembled cavity mold box using phosphogypsum according to claim 2, characterized in that: The die-lifting unit (3) comprises: a die-lifting support (3-1), a die-lifting module (3-2), a die-lifting drive module (3-3), a horizontal slide rail (3-4), a pallet supply module (3-5), a stacking and connecting module (3-6), and a transport module (3-7); the die-lifting support (3-1) is a rigid gantry structure, the right end of which is arranged across the middle of two rows of parallel structures of the rotary platform (1-4), the left end of which is arranged across the stacking and connecting mechanism (3-6), the upper end of which is arranged with a horizontal slide rail (3-4), the die-lifting drive module (3-3) is arranged on the horizontal slide rail (3-4), and the die-lifting module (3-2) is suspended at the bottom of the die-lifting drive module (3-3); the pallet supply module (3-5) is arranged on the left side of the stacking and connecting module (3-6), the transport module (3-7) is arranged on the right side of the stacking and connecting module (3-6), and the three are connected by a roller assembly; The demoulding module (3-2) comprises: a demoulding cylinder (3-21), a lifting guide rod (3-22), a support platform (3-23), left and right hangers (3-24), front and rear hangers (3-25), a circular wheel (3-26), a connecting rod (3-27), a demoulding slide rail (3-28), a tension spring (3-29), and a demoulding steering gear (3-30); the support platform (3-23) is a square rigid flat plate, on which four guide through holes are arranged, a circular wheel (3-26) is rotatably mounted at the center, and a demoulding slide rail (3-28) is arranged at the middle of each square edge; The upper ends and sides of the left and right hangers (3-24) and the front and rear hangers (3-25) are the same as the upper ends and sides of the mold opening hanger (2-4), and the push-pull rods at the upper ends are respectively installed in the mold removal slide rails (3-28); the lower ends of the left and right hangers (3-24) are single-piece inward-folding horizontal support plates; the lower ends of the front and rear hangers (3-25) are inward-folding single-step structure support plates; A through hole is provided at the center of the circular wheel (3-26), and an arc-shaped slot hole is provided at the edge of the upper right circular surface and the lower left circular surface area respectively; the outer ends of the four connecting rods (3-27) are rotatably connected to the push-pull rods of the left and right hangers (3-24) and the front and rear hangers (3-25), and the inner ends are respectively provided in the slot holes and contact the top of the horizontal end and the top of the vertical end of the slot holes respectively; four tension springs (3-29) are provided, one end of which is fixed on the support platform (3-23) and the other end is connected to the inner end of the connecting rod (3-27); The lifting guide rods (3-22) are evenly distributed vertically, with their lower ends passing through guide through holes of the support platform (3-23) and being slidably connected to the support platform (3-23), and their upper ends being fixedly connected to the demoulding drive module (3-3); the upper end of the demoulding cylinder (3-21) is fixed to the demoulding drive module (3-3), and the lower end passes through a central through hole of the circular wheel (3-26) and is fixed to the support platform (3-23); the demoulding steering gear (3-30) is arranged at the bottom of the support platform (3-23), and the central axis of the demoulding steering gear (3-30) passes through the support platform (3-23) and is rotationally driven to connect to the circular wheel (3-26).

7. The device for producing an assembly type cavity mold box using phosphogypsum according to claim 2, characterized in that: The release agent spraying device (1-2) comprises: a fixed bracket (1-23), a lifting rod (1-24), and a multi-directional spray head (1-25); the fixed bracket (1-23) is installed at a release agent spraying station; the lifting rod (1-24) controls the multi-directional spray head (1-25) to intermittently rise and fall; and the multi-directional spray head (1-25) is provided with downward and obliquely upward spray ports.

8. The device for producing an assembly-type cavity mold box using phosphogypsum according to claim 2, characterized in that: A water spray head (1-7) is arranged on the cleaning station, and a guide groove (1-8) is arranged at the lower part.

9. The device for producing an assembly type cavity mold box using phosphogypsum according to claim 2 or claim 3, characterized in that: The inner edge of the lower bottom surface of the shell sleeve (1-11) of the first structure is chamfered, and the inner edge of the upper side surface of the base (1-13) is chamfered; the outer edge of the lower bottom surface of the core (1-12) of the second structure is chamfered, and the inner edge of the upper side surface of the base (1-13) is chamfered.

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