A process and equipment for producing assembled cavity formwork using phosphogypsum

Abstract

The present invention develops a process and equipment for producing assembled cavity formwork using phosphogypsum. In terms of the production process, the acidic neutralization process of phosphogypsum is adjusted to improve the neutralization uniformity of raw materials; the material composition formula and process flow of the cavity formwork are optimized to achieve that the casting and forming effect is adapted to the quality of phosphogypsum and the assembled mortise and tenon structure of the cavity formwork. In terms of equipment, structural innovations and integration solutions for the forming unit, mold opening unit, mold lifting unit, pulping unit, and raw material supply unit are developed to achieve high-efficiency automation of the entire production process of the cavity formwork. After the implementation of the present invention, phosphogypsum can be consumed on a large scale. The produced cavity formwork belongs to carbon-free calcium sulfate-based building materials and can largely replace high-carbon calcium carbonate-based cement and lime-based building materials in many building scenarios, realizing both the high-value environmental protection utilization of bulk industrial solid waste and reflecting the energy-saving, emission-reduction, and low-carbon effects.

Description

Technical Field

[0001] The present invention relates to the environmental protection utilization and low-carbon emission reduction of industrial solid waste, belonging to the field of high-end equipment manufacturing, and particularly relates to a process and equipment for producing assembled cavity formwork using phosphogypsum. Background Art

[0002] Phosphogypsum is a large amount of solid waste associated with phosphate fertilizer production. Its main component, calcium sulfate dihydrate, is a building material raw material that can be recycled. However, the impurity components in phosphogypsum are complex, with strong acidity, and poor cementitious qualities such as viscosity, fluidity, and foaming properties. Therefore, gypsum building materials produced from phosphogypsum are prone to quality defects such as wrinkling, warping, or deformation. The resource treatment cost of phosphogypsum is very high, and it is mainly stored or landfilled, occupying a large amount of land and posing a great environmental pollution risk.

[0003] A cavity formwork is a new type of gypsum material building profile, mainly used in medium and high-rise buildings, underground industrial and civil engineering. By filling the cavity formwork in the concrete hollow floor slab, the non-load-bearing space is occupied, saving the amount of cement poured within the storey height. Experiments have found that after the raw material formula and structure are optimized, the cavity formwork can be mass-produced using phosphogypsum. The principle of its resource utilization is called the casting and forming of gypsum profiles, that is: First, phosphogypsum removes the main impurities through calcination heat treatment and is transformed 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, generating solid calcium sulfate dihydrate with stable physical and chemical properties and solidifying into a gypsum profile with a specific structure. The hydration reaction time of hemihydrate gypsum is very short. It starts to initially set from the liquid state to a non-fluid gel state in as short as dozens of seconds and can be completely solidified into a hard solid state within ten minutes. When using the casting method to produce cavity formwork with complex three-dimensional structures, the production process involved includes multiple processes such as pulping, grouting, joint grouting, 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;

[0007] 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;

[0008] Step 1, raw material mixing and supply process: Set up a raw material supply unit. First, calcium chloride powder and borax are added to the water storage tank according to the formula ratio and fully dissolved to generate process water. Synchronously, the building gypsum powder in the external storage silo is transported to the powder transfer bin by a metering conveyor, and calcium oxide powder is added to the metering conveyor proportionally at the same time, and evenly mixed and transported to the powder transfer bin. Synchronously, after the glass fiber is cut to a fixed length, it is transported to the glass fiber transfer bin;

[0009] Step 2, pulping process: Set up a pulping unit, including six workstations: flushing, water injection, powder adding, glass fiber adding, stirring, and slurry dropping. Set six stirring barrels to rotate intermittently and pass through each workstation in turn to complete cyclic pulping and fixed-point slurry dropping;

[0010] Step 3, pouring and molding process: Set up a molding unit, including seven workstations: slurry receiving, leveling, mold opening, mold lifting, cleaning, mold covering, and mold release agent spraying. Each mold passes through the seven workstations in turn for pouring and molding;

[0011] Step 4, mold opening process: Set up a mold opening unit to lift the shell sleeve located at the mold opening workstation and press it on the upper mold cover at the mold covering workstation;

[0012] Step 5, mold lifting process: Set up a mold lifting unit to lift the upper mold cover box and the lower mold cover box located at the mold lifting workstation in turn, hoist them, and stack them;

[0013] Step 6, mold release agent spraying process: Set up a mold release agent spraying device to spray the mold release agent on the inner side wall of the shell sleeve and the upper surface of the core located at the mold release agent spraying workstation.

[0014] An equipment for producing assembled cavity formwork using phosphogypsum, including: a molding unit, a mold opening unit, a mold lifting unit, a pulping unit, a raw material supply unit, and a cavity formwork;

[0015] The forming unit is a slewing support platform structure, fixedly arranged on the ground, and includes: a mold, a mold release agent spraying device, a leveling device, a slewing platform, a sprocket, a chain, a water spray head, and a diversion groove; the slewing platform is a platform structure with two parallel rows in the front and back and arc-shaped connections at both left and right ends. A plurality of molds are arranged on the slewing platform in series by the chain from head to tail. The chain is connected and driven by sprockets at both left and right ends. The sprocket on the right is connected to a rotating motor, and the rotating motor drives the sprocket 1-5 and the chain 1-6 to make the series-connected mold 1-1 rotate intermittently in the clockwise direction; seven working stations of the forming unit are sequentially arranged on the slewing platform. The slurry receiving station is arranged in the back row of the slewing platform and directly below the slurry dropping station. The mold 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 slewing platform, the mold lifting station is arranged on the left of the mold opening station, and the cleaning station is arranged on the left of the mold lifting station; the mold covering station is arranged in the back row of the slewing platform and on the left of the mold release agent spraying station. The mold covering station and the mold opening station are symmetrical based on the front and back rows of the slewing platform; the mold release agent spraying device, the leveling device, and the water spray head are respectively arranged at the mold release agent spraying station, the leveling station, and the cleaning station, and the diversion groove 1-8 is arranged below the cleaning station;

[0016] The mold opening unit is a cross-rotation structure, arranged in the middle of the front and back rows of the slewing platform, and includes: a rotating frame, a mold opening cylinder, and a mold opening mechanism. The mold opening mechanism is composed of a mold opening driving module, a mold opening hanging frame, a fixed guide rod, and a limiting plate; the rotating frame is a cross structure supported by a single column rotation. A set of mold opening mechanisms is suspended by a mold opening cylinder at the lower part of the protruding end of each cross. Four fixed guide rods in the mold opening mechanism are vertically arranged evenly, fixed at the protruding end of the rotating frame at the top, and connected to the mold opening driving module at the lower end; the mold opening hanging frame is provided with two groups of left-right and front-back, respectively arranged on the four sides of the mold opening driving module to form a four-sided clamping plate structure. The side of the mold opening hanging frame is a vertical plate structure, the upper end is a horizontal push-pull rod structure, and the lower end is two parallel inner-folded 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 sides of the shell sleeve;

[0017] The mold lifting unit is a gantry lifting structure, arranged on the left side of the mold opening unit, and the pulp making unit and the raw material supply unit are arranged at the rear side of the forming unit;

[0018] The mold includes: a shell sleeve, a core, a base, outer core bars, and inner core bars; the shell sleeve is a frustum-shaped cube outer shell structure with openings at both upper and lower ends. The shape and size of the inner side wall of the frustum are adapted to the shape and size of the outer side of the cavity mold box. A rectangular strip-shaped rigid handle is respectively arranged on the four outer sides of the shell sleeve; the core is a rigid cube structure, the base is a rigid cube groove structure, the core is centered on the groove bottom surface of the base, and the outer core bars and inner core bars are respectively arranged around the groove bottom surface of the base in a square shape.

[0019] A further solution is that the interior of the mold is divided into two structures. The first structure: the horizontal distance between the outer core bar and the inner side of the groove is equal to the shell thickness of the shell sleeve, and the height and width of the outer core bar are equal to the height and width of the outer concave and inner convex stepped structure of the lower cover mold box assembly tenon and mortise. The second structure: the inner side of the inner core bar contacts the outer side 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 upper cover mold box assembly tenon and mortise.

[0020] Drain holes are provided on the bottom surface of the groove of the base, and the drain holes are respectively provided at the lower position of the core and at the position close to the inner side of the groove; the diameter of the drain hole close to the inner side of the groove is lower than the shell thickness of the shell sleeve.

[0021] A further solution is that the mold further includes: a limiter, a connecting plate, rollers, guide posts, a conduction plate, and an inner groove rail; 4 guide through holes are evenly distributed on the bottom surface of the groove, 4 rollers are symmetrically installed on the left and right of the bottom surface of the base, and limiters and connecting plates are symmetrically installed on the left and right sides; the bottom surface of the core is a plane, and 4 guide posts are fixedly arranged on the bottom surface, and the guide posts respectively pass through the guide through holes to maintain a sliding connection; the parts of the 4 guide posts extending below the base are integrally and rigidly connected to a conduction plate, and the inner groove rail is rigidly installed in the middle of the lower part of the conduction plate.

[0022] 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, and 4 guide through holes are evenly distributed on it, 4 fixed guide rods pass downward through the guide through holes and are slidably connected to them, mold opening slide rails perpendicular to the square sides are arranged at the middle positions of each square side, the push rod of the mold opening hanger is arranged in the mold opening slide rail and is slidably connected to it, the cross wheel is arranged 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 rod 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 arranged at the center of the cross wheel, and the lower telescopic end of the mold opening cylinder passes through the through hole and is fixed on the support plate; the mold opening servo is arranged 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;

[0023] The limit pressing plate is centrally arranged within the four-sided clamping plates of the mold opening hanger, and the limit pressing plate includes: a fixed table, a connector, and a pressing plate; both the fixed table and the pressing plate are rigid square flat plates, the fixed table is rigidly fixed at the lower ends of the 4 fixed guide rods, and the pressing plate is rigidly connected to the fixed table through the connector and remains horizontal.

[0024] 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 receiving module, and a transport module; the mold lifting bracket is of a rigid gantry structure, with the right end spanning and arranged in the middle of two parallel structures of the rotary platform, the left end spanning and arranged on the stacking mold receiving module, a horizontal slide rail is arranged at the upper end, the mold lifting drive module is arranged on the horizontal slide rail, and the mold lifting module is suspended and arranged below the mold lifting drive module; the pallet supply module is arranged on the left side of the stacking mold receiving module, the transport module is arranged on the right side of the stacking mold receiving module, and the three are connected by a roller shaft group.

[0025] The mold lifting module includes: a mold lifting cylinder, a lifting guide rod, a support table, left and right hanging brackets, front and rear hanging brackets, a circular wheel, a connecting rod, a mold lifting slide rail, a tension spring, and a mold lifting servo motor; the support table is a square rigid flat plate, with 4 guide through holes arranged on it, a circular wheel is rotatably installed at the central position, and a mold lifting slide rail perpendicular to the square side is arranged at the middle position of each square side;

[0026] The upper ends and sides of the left and right hanging brackets and the front and rear hanging brackets are the same as those of the upper ends and sides of the mold opening hanging bracket, and the push rods at the upper ends are respectively installed in the mold lifting slide rails; the lower ends of the left and right hanging brackets are single-piece inward-folded horizontal pallets, and the lower ends of the front and rear hanging brackets are inward-folded single-step structure pallets.

[0027] A through hole is arranged at the center of the circular wheel, arc-shaped slot holes are respectively arranged at the edges of the upper right circular surface and the lower left circular surface regions, the outer ends of 4 connecting rods are respectively rotatably connected to the push rods of the left and right hanging brackets and the front and rear hanging brackets, the inner ends are respectively arranged in the slot holes, and respectively contact the top of the horizontal end and the top of the vertical end of the slot holes; 4 tension springs are arranged, one end is fixed on the support table, 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 left and right connecting rods and a counterclockwise pulling force on the inner end of the up and down connecting rods.

[0028] The lifting guide rods are vertically and uniformly arranged, the lower ends pass through the guide through holes of the support table and are slidably connected to the support table, and the upper ends are fixedly connected to the mold lifting drive module; the upper end of the mold lifting cylinder is fixed on the mold lifting drive module, and the lower end passes through the central through hole of the circular wheel and is fixed on the support table; the mold lifting servo motor is arranged at the lower part of the support table, and the central shaft of the mold lifting servo motor passes through the support table and is rotationally drivingly connected to the circular wheel.

[0029] A further solution is that the mold release agent spraying device includes: a fixed bracket, a lifting rod, and a multi-directional spray head. The fixed bracket is installed at the mold release agent spraying station, the lifting rod is controllably connected to the multi-directional spray head to perform intermittent up and down movement, and downward and obliquely upward spray ports are arranged on the multi-directional spray head.

[0030] A further solution is that a water spray head is arranged at the cleaning station, and a diversion groove is arranged at the lower part.

[0031] For a further solution, chamfers are provided on the inner edge of the lower bottom surface of the shell of the first mold, and chamfers are provided on the inner edge of the upper surface of the side of the base; chamfers are provided on the outer edge of the lower bottom surface of the core of the second mold, and chamfers are provided on the inner edge of the upper surface of the side of the base. Brief Description of the Drawings

[0032] Figure 1 It is a top view layout diagram of the overall structure;

[0033] Figure 2 It is a three-dimensional cross-sectional view of the cavity mold box;

[0034] Figure 3 It is a three-dimensional structure diagram of the forming unit;

[0035] Figure 4 It is a three-dimensional structure diagram of the mold opening unit;

[0036] Figure 5 It is a three-dimensional structure diagram of the mold lifting unit;

[0037] Figure 6 It is a three-dimensional structure diagram of the mold;

[0038] Figure 7 It is a two-dimensional cross-sectional view of the mold of the first structure;

[0039] Figure 8 It is a two-dimensional cross-sectional view of the mold of the second structure;

[0040] Figure 9 It is a three-dimensional structure diagram of the mold opening drive module;

[0041] Figure 10 It is a three-dimensional structure diagram of the limit pressing plate;

[0042] Figure 11 It is a three-dimensional structure diagram of the mold lifting module;

[0043] Figure 12 It is a top view layout diagram of the mold lifting module;

[0044] Figure 13 It is a connection schematic diagram of the mold lifting module and the mold lifting drive module;

[0045] Figure 14 It is a schematic structural diagram in the A direction of the mold lifting module;

[0046] Figure 15 It is a schematic structural diagram of the mold release agent spraying device;

[0047] Figure 16 It is a schematic working structural diagram of the mold opening unit. Detailed Implementation Manner

[0048] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present application.

[0049] A process for producing assembled cavity formwork using phosphogypsum, the cavity formwork 6 is as Figure 2 shown, and is composed of an upper cover formwork and a lower cover formwork which are butt-jointed and buckled through four edge faces. The upper cover formwork and the lower cover formwork are single-sided open hollow frustum-shaped cube structures, and after being buckled, they form a hollow shell structure. Assembly tenon and mortise structures are arranged on the four edge faces. The assembly tenon and mortise of the upper cover formwork is an outward convex and inward concave stepped structure, and the width ratio of the outward convex part to the inward concave part is 2:1; the assembly tenon and mortise of the lower cover formwork is an outward concave and inward convex stepped structure, and the width ratio of the outward concave part to the inward convex part is 2:1; the thickness of the edge face of the cavity formwork is 45 mm, the thickness of the top surface is 35 mm, the side length of the frustum is 600 mm, and the height is 2×120 mm.

[0050] The reason for setting the width ratio of the above-mentioned assembly tenon and mortise structure is as follows: due to the quality characteristics of phosphogypsum, the fragility and peelability of its profiles are slightly large. To ensure the quality of mold opening and demolding, the width of the outward convex part of the upper cover formwork is twice that of the inward concave part, and the width of the outward concave part of the lower cover formwork is twice that of the inward convex part, so as to enhance the strength of the four edge faces near the outer side and make the strength of the assembly tenon and mortise structure relatively higher after butt-joint and buckling.

[0051] By weight, the raw material formula includes: building gypsum powder: 100 parts; calcium oxide powder: 0.6 parts; glass fiber: 0.5 parts, with a length of 20-30 mm and a diameter of 15-25 μm; water: 75 parts; calcium chloride powder: 0.5 parts; borax: 0.5 parts; the proportion values described below are all set according to the weight ratio in the original formula; the building gypsum powder is hemihydrate calcium sulfate generated by the heat treatment and phase transformation of first-grade phosphogypsum. The definition of first-grade phosphogypsum originates from the requirements specified in GB / T 23456-2009, and the impurity content meets the requirements of GB / T 23456—2018 "Phosphogypsum", GB 5085.3-2007 "Identification Standard for Toxicity of Hazardous Wastes - Leaching Toxicity Identification", and GB 38400 "Limit Requirements for Toxic and Hazardous Substances in Fertilizers"; based on common understanding, hemihydrate calcium sulfate is commonly known as building gypsum or plaster of Paris, and dihydrate calcium sulfate is commonly known as raw gypsum. The building gypsum powder in the present invention refers to the one generated by the heat treatment and phase transformation of phosphogypsum.

[0052] The above raw material formula is optimized based on the quality characteristics of phosphogypsum. For example, calcium oxide powder is used to neutralize the acidity of the impurities contained in phosphogypsum, and glass fiber is used to improve the strength of the cured cavity formwork. The water-plaster 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 plays a coagulation-promoting effect. The determination of the above raw material ratios and parameters is based on the effect comparison verified by experiments. If the phosphogypsum material used is different from the national standard, users can adjust the experiments according to this raw material formula. The experimental method of the raw material formula is a well-known technology. The creativity of this formula lies in clarifying the composition and ratio of the raw material components according to the quality characteristics of phosphogypsum.

[0053] The technological process of producing assembled cavity formwork with phosphogypsum is as follows:

[0054] Step 1, raw material mixing and supply process: Set up a raw material supply unit. First, calcium chloride powder and borax are added to the water storage tank according to the formula ratio and fully dissolved to generate process water. Synchronously, the building gypsum powder in the external storage silo is transported to the powder transfer bin by a metering conveyor, and calcium oxide powder is added to the metering conveyor proportionally at the same time and evenly mixed and transported to the powder transfer bin. Synchronously, after the glass fiber is cut to a fixed length, it is transported to the glass fiber transfer bin.

[0055] Step 2, pulping process: Set up a pulping unit, including six workstations: flushing, water injection, powder addition, glass fiber addition, stirring, and slurry dropping. The pulping unit includes six mixing tanks for rotary circulation pulping and intermittent fixed-point slurry dropping. First, the process water is quantitatively filled into the mixing tank that rotates intermittently to the water injection workstation. Then, the mixed powder in the powder transfer bin is quantitatively fed into the mixing tank that rotates to the powder addition workstation. Furthermore, the glass fiber in the glass fiber transfer bin is quantitatively added to the mixing tank that rotates to the glass fiber addition workstation. When the mixing tank rotates to the stirring workstation, it is fully stirred evenly. When the mixing tank rotates to the slurry dropping workstation, the gypsum slurry falls into the mold by gravity. When the mixing tank rotates to the flushing workstation, an external water gun flushes the inside of the mixing tank after the slurry dropping. The intermittent time for each workstation is set to 20 seconds, of which the rotation time is set to 5 seconds and the stationary time is set to 15 seconds. The addition of the above raw materials must be completed when the mixing tank is in a stationary state, and the above time settings can also be optimized according to the characteristics of the raw materials.

[0056] Step 3, pouring and forming process: Set up a forming unit, including seven workstations: slurry receiving, leveling, mold opening, mold lifting, cleaning, mold covering, and release agent spraying; the molds for pouring the upper cover formwork and the molds for pouring the lower cover formwork are arranged alternately, connected in series with the head and tail rotated, and rotated intermittently. Each mold passes through each workstation in turn for slurry receiving and pouring to form. The intermittent movement time of the mold is consistent with the intermittent time rhythm of the pulping process.

[0057] 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.

[0058] 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.

[0059] 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.

[0060] 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 3 As 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.

[0061] The structures of the leveling device 1-3, rotary platform 1-4, sprocket 1-5, chain 1-6, water spray head 1-7, and diversion trough 1-8 of the forming unit 1 are well-known technical contents. The creativity in this patent lies in: through the interconnected scheme designed in this patent, the full-automatic adaptation of the mold 1-1 with a specific structure to the mold opening unit 2 and mold lifting unit 3 is achieved.

[0062] The mold opening unit 2 is a cross-rotation structure. As Figure 1 shown, it is arranged in the middle of the front and rear rows of the rotary platform 1-4; as Figure 4 shown, it includes: a rotary frame 2-1, a mold opening cylinder 2-2, and a mold opening mechanism. The mold opening mechanism consists of a mold opening drive module 2-3, a mold opening suspension bracket 2-4, a fixed guide rod 2-5, and a limit pressing plate 2-6; the rotary frame 2-1 is a cross structure with a single-column rotary support. The lower part of each protruding end of the cross suspends a set of mold opening mechanisms through the mold opening cylinder 2-2. Four fixed guide rods 2-5 are vertically and evenly arranged in each set of mold opening mechanisms, and are fixedly installed at the protruding end of the rotary frame 2-1 at the top, and are connected to the mold opening drive module 2-3 at the lower end; the mold opening suspension brackets 2-4 are as Figure 4 and Figure 9 shown, and two groups of left-right and front-back are arranged, and 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 suspension bracket 2-4 is a vertical plate structure, the upper end is a horizontal push-pull rod structure, and the lower end is a structure of two parallel inward-folded horizontal support plates. The vertical distance between the two horizontal support plates is greater than the thickness of the rigid handles on the four outer sides of the shell sleeve 1-11.

[0063] The mold lifting unit 3 is a gantry lifting structure. As Figure 1 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 at the rear side of the forming unit 1.

[0064] Through Figure 1 the specific spatial structure positions and connection relationships of each unit can be clearly understood. The mechanical structures and control schemes of the raw material supply unit 5 and the pulping unit 4 are well-known technical contents. The creativity in this patent lies in that the raw material supply unit 5 and the pulping unit 4 execute the process flow according to the said step 1 and step 2.

[0065] The mold 1-1 is as Figure 6As shown in the figure, it includes: a shell sleeve 1-11, a core 1-12, a base 1-13, a stopper 1-14, a connecting plate 1-15, rollers 1-16, guide posts 1-17, a conduction plate 1-18, and an inner groove rail 1-19; the shell sleeve 1-11 is a frustum-shaped cuboid outer shell structure with open upper and lower ends. The shape and size of the inner side wall of the frustum are adapted to the outer side shape and size of the cavity mold box 6. A rectangular strip-shaped rigid handle is provided on each of the four outer sides of the shell sleeve 1-11; the base 1-13 is a rigid cuboid 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 sleeve 1-11, and the inner depth of the groove is not less than 10 mm. Four guide through holes are evenly arranged on the bottom surface of the groove; four rollers 1-16 are symmetrically installed on the lower bottom surface of the base 1-13, and stoppers 1-14 and connecting plates 1-15 are symmetrically installed on the left and right side surfaces; the core 1-12 is a rigid cuboid 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 side of the shell sleeve 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 and is centered on the bottom surface of the groove of the base 1-13. Four guide posts 1-17 are fixedly arranged on the lower bottom surface of the core 1-12. The guide posts 1-17 pass through the guide through holes respectively to realize the up and down sliding connection between the core 1-12 and the groove of the base 1-13; the parts of the four guide posts 1-17 extending below the base 1-13 are integrally and rigidly connected to a conduction plate 1-18. The inner groove rail 1-19 is rigidly installed in the middle of the lower part of the conduction plate 1-18. The direction of the slot of the inner groove rail is consistent with the movement guide of the rollers 1-16.

[0066] The conduction plate 1-18 is a rigid plate. After being 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, and then evenly push the core 1-12 to move up and down; the function of the stopper 1-14 is to ensure that during the mold opening process, when the shell sleeve 1-11 of the mold 1-1 is lifted, and during the subsequent mold lifting process, when the core 1-12 is jacked up, the base 1-13 can always be fixedly in contact with the rotary platform 1-4 and will not be jacked 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 connect the mold 1-1 to the chain 1-6 and be driven. The structure and connection method of the connecting plate 1-15 are well-known technologies.

[0067] The internal structure of the mold 1-1 is divided into two types. The first type is as Figure 7 shown. Outer core strips 1-21 are arranged in a square layout around the bottom surface of the groove of the base 1-13. 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. 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 lower cover mold box assembly mortise and tenon; the second type is asFigure 8 As shown, on the bottom surface of the groove of the base 1-13, inner core strips 1-22 arranged in a square layout are circumferentially provided. The inner side surfaces of the inner core strips 1-22 are in contact with the outer side surfaces of the core 1-12, and the height and width are equal to the height and width of the outwardly convex and inwardly concave structure of the upper cover die box assembly tenon and mortise.

[0068] When the shell sleeve 1-11 is located inside the groove of the base 1-13 and at the same time the core 1-12 is located on the bottom surface of the groove of the base 1-13, the space between the shell sleeve 1-11 and the core 1-12 forms the casting cavity of the mold 1-1. The molds of the two structures can respectively cast and form the outwardly convex and inwardly concave stepped structure of the upper cover die box and the outwardly concave and inwardly convex stepped structure of the lower cover die box. As Figure 7 and Figure 8 shown, drain holes 1-20 are provided on the bottom surface of the groove of the base 1-13. The drain holes are respectively provided at the lower position of the core 1-12 and at the position close to the inner side surface of the groove; the diameter of the drain hole 1-20 close to the inner side surface of the groove is lower than the shell thickness of the shell sleeve 1-11.

[0069] The mold opening drive module 2-3 is as Figure 9 shown, and 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 servo 2-35; the support plate 2-31 is a square rigid flat plate, and 4 guiding through holes are evenly arranged on it. 4 fixed guiding rods 2-5 pass downward through the guiding through holes and are slidably connected to them up and down. A mold opening slide rail 2-32 perpendicular to the square side is arranged at the middle position of each square side. The push and pull rod of the mold opening hanger 2-4 is arranged in the mold opening slide rail 2-32 and is slidably connected to it. 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 4 mold opening pull rods 2-33 are respectively rotatably connected to the push and pull rod 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 servo 2-35 is arranged 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.

[0070] 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 made by a sleeve shaft structure. The driving connection between the mold opening servo 2-35 and the cross wheel 2-34 also adopts 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 backward, it drives the cross wheel 2-34 to rotate forward or backward. Then, the 4 mold opening pull rods 2-33 drive the push-pull rod of the mold opening hanger 2-4 to perform a horizontal reciprocating motion along the mold opening slide rail 2-32, so as to realize the uniform inward horizontal closing or outward horizontal opening of the four-sided clamping plates of the mold opening hanger 2-4.

[0071] As Figure 4 shown, the limit pressing plate 2-6 is centrally arranged within the four-sided clamping plates of the mold opening hanger 2-4. As Figure 10 shown, it includes: a fixed table 2-61, a connector 2-62, and a pressing plate 2-63. Both the fixed table 2-61 and the pressing plate 2-63 are rigid square planar plates. As Figure 16 shown, the fixed table 2-61 is rigidly fixed at the lower ends of the 4 fixed guide rods 2-5, and the pressing plate 2-63 is rigidly connected to the fixed table 2-61 through the connector 2-62 and remains horizontal. The side length of the pressing plate 2-63 is smaller than the side length of the upper open end of the conical shell of the shell sleeve 1-11. The connector 2-62 is a well-known technology.

[0072] The mold lifting unit 3 is as Figure 5 shown, and 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 receiving module 3-6, and a transport module 3-7. The mold lifting bracket 3-1 is a rigid gantry structure, with its right end spanning and arranged in the middle of the two parallel structures of the rotary platform 1-4, and its left end spanning and arranged on the stacking mold receiving module 3-6. A horizontal slide rail 3-4 is arranged at the upper end, and the mold lifting drive module 3-3 is arranged on the horizontal slide rail 3-4. The mold lifting module 3-2 is suspended and arranged below the mold lifting drive module 3-3. The pallet supply module 3-5 is arranged on the left side of the stacking mold receiving module 3-6, and the transport module 3-7 is arranged on the right side of the stacking mold receiving module 3-6. The three are connected through a roller shaft group.

[0073] The specific structures and connection methods of the mold lifting drive module 3-3, the pallet supply module 3-5, the stacking mold receiving module 3-6, and the transport module 3-7 are well-known technologies. The creativity in this patent lies in the specific mechanism design of the mold lifting module 3-2 for clamping and lifting the assembly tenon and mortise structure of the cavity mold box, as well as the spatial connection scheme and process flow design of each module.

[0074] The mold lifting module 3-2 is as Figure 11 、 Figure 12 and Figure 13As shown in the figure, it includes: a mold-lifting cylinder 3-21, a lifting guide rod 3-22, a support table 3-23, left and right hanging brackets 3-24, front and rear hanging brackets 3-25, a circular wheel 3-26, a connecting rod 3-27, a mold-lifting slide rail 3-28, a tension spring 3-29, and a mold-lifting servo 3-30; the support table 3-23 is a square rigid flat plate, with 4 guiding through holes provided on it, a circular wheel 3-26 is rotatably installed at the central position, and mold-lifting slide rails 3-28 perpendicular to the square sides are provided at the middle positions of each square side.

[0075] The upper ends and sides of the left and right hanging brackets 3-24 and the front and rear hanging brackets 3-25 are the same as those of the upper ends and sides of the mold-opening hanging bracket 2-4, and the push rods at the upper ends are respectively installed in the mold-lifting slide rails 3-28; as Figure 13 shown, the lower end of the left and right hanging brackets 3-24 is a single-piece inward-folded horizontal support plate; as Figure 14 shown, the lower end of the front and rear hanging brackets 3-25 is an inward-folded single-step structure support plate.

[0076] The size and shape of the inward-folded single-step at the lower end of the front and rear hanging brackets 3-25 are adapted to the outwardly concave and inwardly convex stepped structure of the lower cover mold box. The reason is that: the width of the inwardly convex part of the lower cover mold box is relatively small. If a single-piece horizontal support plate structure is used, the dragging force during mold lifting by the support plate may damage the inwardly convex structure. Therefore, a single-step structure support plate with a size and shape adaptation is adopted. During mold lifting, the support plate of the single-step structure is in full contact with the outwardly concave and inwardly convex stepped structure of the lower cover mold box, increasing the contact surface and not easily damaging the outwardly concave and inwardly convex stepped structure of the lower cover mold box. While the width of the outwardly convex part of the upper cover mold box is relatively large, a horizontal support plate structure can be used.

[0077] The circular wheel 3-26 is as Figure 12 shown, with a through hole provided at the center, and an arc-shaped slot hole is respectively provided at the edges of the upper right circular surface and the lower left circular surface regions. The outer ends of the 4 connecting rods 3-27 are respectively rotatably connected to the push rods of the left and right hanging brackets 3-24 and the front and rear hanging brackets 3-25, and the inner ends are respectively arranged 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; 4 tension springs 3-29 are provided, one end is fixed on the support table 3-23, and the other end is connected to the inner end of the connecting rod 3-27, so that the tension springs 3-29 generate a clockwise pulling force on the inner ends of the left and right connecting rods 3-27 in the left and right directions and a counterclockwise pulling force on the inner ends of the up and down connecting rods 3-27.

[0078] As Figure 13As shown, the lifting guide rods 3-22 are vertically and evenly arranged. The lower ends pass through the guide through holes of the support platform 3-23 and are slidably connected to the support platform 3-23, and the upper ends are fixedly connected to the mold lifting drive module 3-3; the upper end of the mold lifting cylinder 3-21 is fixed on the mold lifting 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 mold lifting servo 3-30 is arranged at the lower part of the support platform 3-23, and the central axis of the mold lifting servo 3-30 passes through the support platform 3-23 and is rotationally drivingly connected to the circular wheel 3-26.

[0079] 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 driving connection between the mold lifting servo 3-30 and the circular wheel 3-26 also adopts a sleeve shaft structure.

[0080] As Figure 12 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 contact-drives the pin shaft at the inner end of the left and right connecting rods 3-27 in the left and right directions. The pin shaft drives the left and right connecting rods 3-27, and further drives the left and right hanging brackets 3-24 to move horizontally towards the middle. The slot holes at the upper and lower ends do not contact-drive the pin shaft at the inner end of the up and down connecting rods 3-27, that is, the front and rear hanging brackets 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 hanging brackets 3-25 to move towards the middle, while the left and right hanging brackets 3-24 remain stationary; the function of the tension spring 3-29 is to pull the front and rear hanging brackets 3-25 and the left and right hanging brackets 3-24 to move horizontally outwards and reset when the mold lifting servo 3-30 rotates and resets.

[0081] The mold release agent spraying device 1-2 is as Figure 15 shown, including: 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 mold release agent spraying station. The lifting rod 1-24 controls the connection of the multi-directional spray head 1-25 to perform intermittent up and down movements, realizing intermittent entry into and exit from the mold cavity inside the mold, and spraying liquid mold release agent on the inner side wall of the shell sleeve 1-11, the surface of the core 1-12, and the surface of the base 1-13; to ensure that the inner inclined cone surface of the shell sleeve 1-11 can be sprayed with mold release agent, downward and obliquely upward spray ports are provided on the multi-directional spray head 1-25.

[0082] As Figure 1 and Figure 3 shown, the cleaning station is arranged on the left side of the mold lifting unit 3 on the rotary platform 1-4. A water spray head 1-7 is arranged at the cleaning station, and a diversion groove 1-8 is arranged at the lower part.

[0083] As Figure 7As shown, chamfers are provided on the inner edge of the lower bottom surface of the shell sleeve 1-11 of the first mold, and chamfers are provided on the inner edge of the upper surface of the side of the base 1-13, facilitating the downward entry of the shell sleeve 1-11 between the side of the groove and the outer core bar 1-21; As Figure 8 shown, chamfers are provided on the outer edge of the lower bottom surface of the core 1-12 of the second mold, facilitating the downward entry of the core 1-12 into the inner core bar 1-22 with a square surrounding layout. Chamfers are provided on the inner edge of the upper surface of the side of the base 1-13, facilitating the downward entry of the shell sleeve 1-11 into the groove of the base 1-13.

[0084] Example 1, Process flow of the raw material supply unit 5 and the pulping unit 4:

[0085] The raw material supply unit 5 realizes the mixing and supply of various raw materials, and the pulping unit 4 realizes the production and injection of gypsum slurry.

[0086] (1) Calcium chloride powder and borax are added to the water storage tank in proportion and stirred and dissolved to generate process water. When the mixing barrel of the pulping unit 4 rotates to the water injection station and stops, the process water in the water storage tank is quantitatively injected into the mixing barrel according to the proportion;

[0087] (2) The building gypsum powder and calcium oxide powder in the external storage silo are evenly mixed in the metering conveyor and transported to the powder transfer bin. When the mixing barrel rotates to the powder adding station and stops, the powder in the transfer bin is quantitatively added to the mixing barrel;

[0088] (3) After the glass fiber is cut to a fixed length, it is transported to the glass fiber transfer bin. When the mixing barrel rotates to the glass fiber adding station and stops, the glass fiber is quantitatively added to the mixing barrel;

[0089] (4) A mixing station is set up to increase the mixing time and achieve the full and even mixing of various raw materials in the mixing barrel;

[0090] (5) When the mixing barrel rotates to the slurry dropping station and stops, the evenly mixed gypsum slurry falls into the mold by gravity;

[0091] (6) When the mixing barrel rotates to the flushing station and stops, an external water gun flushes the inside of the mixing barrel after the slurry drops to prevent the residual slurry from locally solidifying in the mixing barrel.

[0092] The intermittent time for each station is set to 20 seconds, among which the rotation time is set to 5 seconds and the stationary time is 15 seconds. These three time values are specifically determined according to the curing reaction time generated by the raw material formula and are optimized values obtained through repeated experiments. Users can also perform secondary optimization on the formula and production control characteristics according to the actual quality characteristics of the phosphogypsum raw materials. However, after the time values are optimized and determined, do not easily modify the formula ratio, because the formula ratio and time control are related. If the formula ratio is modified, the optimized time values need to be re-experimentally determined.

[0093] 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.

[0094] Embodiment 2, the working process of the molding unit 1 is as follows Figure 1 and Figure 3 As shown:

[0095] (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;

[0096] (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;

[0097] (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;

[0098] (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;

[0099] (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;

[0100] (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;

[0101] (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;

[0102] (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.

[0103] The control and positioning methods of each component in this embodiment are all well-known technologies.

[0104] Embodiment 3, working process of the mold opening unit 2:

[0105] (1) When the mold 1-1 reaches the mold opening station below the mold opening unit 2 and stops, as shown in the left part of Figure 16 , the mold opening cylinder 2-2 above the mold 1-1 drives the mold opening drive module 2-3 and the mold opening suspension bracket 2-4 to move downward synchronously. The fixed guide rod 2-5 plays a role in guiding and stabilizing. When the two horizontal support plates of the mold opening suspension bracket 2-4 move downward to the position of the rigid handle of the shell sleeve 1-11, the mold opening cylinder 2-2 stops driving. At this time, vertically, the rigid handle of the shell sleeve 1-11 is located between the two horizontal support plates, as shown in Figure 4 the right side, that is, in the front-back and left-right directions, the 4 rigid handles are simultaneously located between the two horizontal support plates of the 4 mold opening suspension brackets 2-4.

[0106] (2) As shown in Figure 9 , 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. The cross wheel 2-34 drives the 4 mold opening pull rods 2-33 to pull the telescopic rods at the upper ends of the mold opening suspension brackets 2-4 along the mold opening slide rails 2-32, realizing the synchronous contraction and translation of the horizontal support plates of the 4 mold opening suspension brackets 2-4 towards the center, and further realizing that the 4 rigid handles respectively enter between the two horizontal support plates of the 4 mold opening suspension brackets 2-4.

[0107] (3) As shown in the left side of Figure 16 , 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 suspension bracket 2-4 to move upward. The lower plate of the two horizontal support plates of the mold opening suspension bracket 2-4 pulls the rigid handle of the shell sleeve 1-11 upward, lifting the shell sleeve 1-11 off the base 1-13. When the lowermost part of the shell sleeve 1-11 is higher than the upper surface of the cured cavity mold box in the mold 1-1, the mold opening cylinder 2-2 stops driving. At this time, the rotating frame 2-1 rotates counterclockwise by 90°. The lifted shell sleeve 1-11 rotates 90° synchronously. Then, the mold 1-1 with the lifted shell sleeve 1-11 moves a intermittent distance towards the mold lifting station, and the rotating frame 2-1 starts to lift the shell sleeve of the next mold 1-1 to be opened.

[0108] (4) As shown in Figure 1 , within two intermittent rotation times, the lifted shell sleeve 1-11 is rotated 180° and transported above the mold 1-1 at the cover mold station of the rotary platform 1-4. The mold opening cylinder 2-2 drives the support plate 2-31 downward, placing the shell sleeve 1-11 in the base 1-13. At the same time, the upper plate of the two horizontal support plates of the mold opening suspension bracket 2-4 presses the rigid handle of the shell sleeve 1-11 downward, making the shell sleeve 1-11 in place downward sufficiently, as shown in Figure 16Shown on the right side. The reason for using four mold-opening hanging brackets 2-4 to lift the shell sleeve 1-11 simultaneously is as follows: Firstly, the shell sleeve 1-11 is relatively heavy, and the stability of clamping on four sides simultaneously is high; moreover, the mold-opening hanging bracket 2-4 needs to press the shell sleeve 1-11 into the base 1-13 at the mold-covering station. Since both the pressed shell sleeve 1-11 and the base 1-13 are rigid bodies, and considering the frictional resistance of the outer core bar 1-21 or the inner core bar 1-22, the required downward pressure is not only large but also must be stable and accurate in direction.

[0109] (5)Even if the release agent is sprayed, there is still a certain adhesion force between the inner side wall of the shell sleeve 1-11 and the side wall of the just-cured cavity mold box. Similarly, there is also a certain adhesion force between the bottom surface of the cavity mold box and the core 1-12 and the base 1-13. If the adhesion force between the shell sleeve 1-11 and the side wall of the cavity mold box is greater than the adhesion force between the bottom surface of the cavity mold box and the core 1-12 and the base 1-13, the cavity mold box will be adhesively lifted synchronously when the shell sleeve 1-11 is lifted, resulting in mold-opening failure. Therefore, a limiting pressure plate 2-6 is set. As Figure 16 shown on the left side, if the cavity mold box is not lifted together, the limiting pressure plate does not work; if the cavity mold box is adhesively 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 at the lower part of the fixed guide rod 2-5 and always remains stationary, that is, the height of the pressure plate 2-63 always 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 then separate from the inner wall of the shell sleeve 1-11 and fall back onto the core 1-12 in the mold 1-1.

[0110] The cylinder control, the control and positioning methods of each component, and the servo control in this embodiment are all well-known technologies.

[0111] Embodiment 4, the working process of the mold-lifting unit 3:

[0112] (1)The mold 1-1 from which the shell sleeve 1-11 has been lifted away reaches the mold-lifting station. Since the molds of the two structures are staggered and connected in series, that is, the upper cover mold box and the lower cover mold box will alternately reach the mold-lifting station, the pallets of the left and right hanging brackets 3-24 and the front and rear hanging brackets 3-25 of the mold-lifting unit 3 need to be adapted to the assembly mortise and tenon structures of the upper cover mold box and the lower cover mold box respectively; a mold-lifting device is arranged at the corresponding position below the rotary platform 1-4 at the mold-lifting station. When the mold 1-1 reaches the mold-lifting station and stops, as Figure 6 shown, the mold-lifting device on the rotary platform 1-4 extends into the inner groove rail 1-19 and lifts upward. The inner groove rail 1-19 lifts the conduction plate 1-18 upward, and the conduction plate 1-18 pushes the guide post 1-17 upward. Further, the guide post 1-17 lifts the core 1-12 above the base 1-13, and the core 1-12 lifts the upper cover mold box or the lower cover mold box upward.

[0113] (2) If the upper cover die box is lifted at the mold lifting station, as Figure 12 and Figure 13 shown, the driving end of the mold lifting cylinder 3-21 of the mold lifting module 3-2 moves downward, driving the support platform 3-23 to move downward along the lifting guide rod 3-22. The left and right hanging frames 3-24, the front and rear hanging frames 3-25, the circular wheel 3-26, the connecting rod 3-27, the mold lifting 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 hanging frames 3-24 is at the lower horizontal position of the upper cover die box, the mold lifting cylinder 3-21 stops driving. The mold lifting servo 3-30 drives the circular wheel 3-26 to rotate counterclockwise by a certain angle. The top of the arc-shaped slot hole on the circular wheel 3-26 drives the connecting rod 3-27 at the left side to rotate downward, and the connecting rod 3-27 at the right side rotates upward. That is, the connecting rods 3-27 on the left and right positions pull the telescopic rods of the left and right hanging frames 3-24 to move towards the center within the mold lifting slide rail 3-28. The horizontal support plates of the left and right hanging frames 3-24 move towards the middle and reach the bottom of the upper cover die box. Then, the mold lifting cylinder 3-21 drives upward to lift the upper cover die box, and then it is transported above the pallet of the stacking and mold receiving module 3-6 through the mold lifting drive module 3-3 and the horizontal slide rail 3-4. Then, the mold lifting 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 on the left and right positions to reset, realizing the separation of the left and right hanging frames 3-24 in the left and right directions, thereby placing the upper cover die box on the pallet. When the circular wheel 3-26 drives the left and right hanging frames 3-24 to clamp the upper cover die box, the two connecting rods 3-27 in the upper and lower positions are not driven by the arc-shaped slot holes on the circular wheel 3-26. Since the width ratio of the convex part to the concave part of the assembly tenon and mortise of the upper cover die box is 2:1, when the horizontal support plates at the lower ends of the left and right hanging frames 3-24 are used for mold lifting and hoisting, the contact area between them is relatively large, and the assembly tenon and mortise structure will not be damaged.

[0114] (3) If the lower cover die box is lifted at the mold lifting station, as Figure 12 and Figure 14 shown, the mold lifting servo 3-30 drives the circular wheel 3-26 to rotate clockwise, realizing the drive of the front and rear hanging frames 3-25 and the single-step structure support plate at the lower end to move towards the middle and lift and hoist the lower cover die box. Since the width ratio of the concave part to the convex part of the lower cover die box is 2:1, if a separate horizontal support plate mechanism is used, the contact area between them is relatively small, which may damage the assembly tenon and mortise structure of the lower cover die box. Therefore, an inward-folded single-step structure support plate is adopted to increase the contact area between them.

[0115] In this embodiment, the working principle of the rotary platform 1-4 and the mold lifting device adopts the T-shaped head cylinder push-pull scheme, which is a well-known technology, and the control methods of each device are well-known technologies.

[0116] Example 5: Working process of the mold 1-1 and the water spray head 1-7

[0117] (1) The contact state of the shell sleeve 1-11 and the core 1-12 with the base 1-13 can realize the opening and closing control of the drain hole 1-20. When it is in the open state, sewage can be smoothly discharged when flushing the inside of the mold. When it is closed, no slurry will leak when the mold receives the slurry.

[0118] (2) When the mold 1-1 after demolding reaches the cleaning station, a mold lifting device is set at the cleaning station of the rotary platform 1-4. After the core 1-12 is lifted, the water spray head 1-7, the core 1-12 and the base 1-13 are arranged outside. Sewage is discharged from the drain hole 1-20 of the base 1-13 and flows away through the diversion groove 1-8. When the mold 1-1 is cleaned, the mold lifting device resets the core 1-12 to the groove surface of the base 1-13.

[0119] (3) When the mold 1-1 reaches the mold covering station, the lower bottom surface of the shell sleeve side wall and the lower bottom surface of the core 1-12 are in close contact with the groove surface of the base 1-13, which is equivalent to blocking the drain hole 1-20. Therefore, when the mold 1-1 receives the slurry, the gypsum slurry will not leak from the drain hole.

[0120] Example 6: Process of spraying release agent

[0121] The release agent spraying station is located after the mold covering station. When the mold 1-1 reaches the release agent spraying station, the release agent spraying device 1-2 reciprocates up and down and in and out of the casting cavity between the shell sleeve 1-11 and the core 1-12, and evenly sprays the liquid release agent on the inner side wall of the shell sleeve 1-11, the upper surface and the side surface of the core 1-12, and then the mold 1-1 moves to the slurry receiving station again.

[0122] Advantages: The process flow developed based on the quality characteristics of phosphogypsum in the present invention is scientific and reasonable, enabling the forming effect of the cavity mold box to adapt to the quality of phosphogypsum; the innovatively designed mechanical device is complete and ingenious, with high production efficiency, capable of realizing the full automation of the production and manufacturing process, and facilitating popularization and implementation.

Claims

1. A process for producing assembled cavity formwork using phosphogypsum, characterized in that, The cavity formwork is composed of an upper cover formwork and a lower cover formwork which are butted and fastened through four edge faces. The upper cover formwork and the lower cover formwork are four-sided hollow frustum structures with a single-sided opening, and after being fastened, they form a hollow shell structure. Assembly tenon and mortise structures are arranged on the four edge faces; By weight, the raw material formula includes: building gypsum powder: 100 parts; calcium oxide powder: 0.6 parts; glass fiber: 0.5 parts, with a length of 20 - 30 mm and a diameter of 15 - 25 μm; water: 75 parts; calcium chloride powder: 0.5 parts; borax: 0.5 parts; The technological 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 to the water storage tank according to the formula ratio and fully dissolved to generate process water. Synchronously, the building gypsum powder in the external storage silo is transported to the powder transfer silo through a metering conveyor, and calcium oxide powder is added to the metering conveyor proportionally synchronously and evenly mixed and transported to the powder transfer silo. Synchronously, after the glass fiber is cut to a fixed length, it is transported to the glass fiber transfer silo; Step 2, pulping process: Set up a pulping unit, including six workstations: flushing, water injection, powder addition, glass fiber addition, stirring, and slurry discharging. Set six stirring barrels to rotate intermittently and pass through each workstation in turn to complete cyclic pulping and fixed-point slurry discharging; Step 3, pouring and molding process: Set up a molding unit, including seven workstations: slurry receiving, leveling, mold opening, mold lifting, cleaning, mold covering, and release agent spraying. Each mold passes through the seven workstations in turn for pouring and molding; Step 4, mold opening process: Set up a mold opening unit to lift the shell sleeve located at the mold opening workstation and press it on the upper mold of the mold at the mold covering workstation; Step 5, mold lifting process: Set up a mold lifting unit to lift, transport, stack and palletize the upper cover formwork and the lower cover formwork located at the mold lifting workstation in turn; Step 6, release agent spraying process: Set up a release agent spraying device to spray the release agent on the inner side wall of the shell sleeve and the upper surface of the core at the release agent spraying workstation.

2. An equipment for producing assembled cavity formwork by using phosphogypsum, characterized in that, Including: A molding unit (1), a mold opening unit (2), a mold lifting unit (3), a pulping unit (4), a raw material supply unit (5), and a cavity formwork (6); The molding unit (1) is a slewing support platform structure fixedly arranged on the ground, including: a mold (1 - 1), a release agent spraying device (1 - 2), a leveling device (1 - 3), a slewing platform (1 - 4), a sprocket (1 - 5), a chain (1 - 6), a water spray head (1 - 7), and a diversion trough (1 - 8); The slewing platform (1 - 4) is a platform structure with two parallel rows in the front and back and arc-shaped slewing connections at the left and right ends. A plurality of molds (1 - 1) are arranged and installed on the slewing platform (1 - 4) in series end to end through a chain (1 - 6). The chain (1 - 6) is connected and driven by sprockets (1 - 5) at the left and right ends, and the sprocket on the right is connected to a rotating motor; The seven working stations of the forming unit (1) are sequentially arranged on the rotary platform (1-4). The slurry receiving station is arranged in the rear row of the rotary platform (1-4) and directly below the slurry dropping station. The mold 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 (1-4). The mold lifting station is arranged on the left of the mold opening station, and the cleaning station is arranged on the left of the mold lifting station. The mold covering station is arranged in the rear row of the rotary platform (1-4) and on the left of the mold release agent spraying station. The mold covering station and the mold opening station are symmetrical with respect to 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 station, the leveling station, and the cleaning station. The flow guide groove (1-8) is arranged below the cleaning station. The mold opening unit (2) is a cross-rotating structure and is arranged in the middle of the front and rear rows of the rotary platform (1-4). It includes: a rotating frame (2-1), a mold opening cylinder (2-2), and a mold opening mechanism. The mold opening mechanism is composed of a mold opening drive module (2-3), a mold opening hanging frame (2-4), a fixed guide rod (2-5), and a limit pressing plate (2-6). The rotating frame (2-1) is a cross structure supported by a single column rotation. A set of mold opening mechanisms is suspended by a mold opening cylinder (2-2) at the lower part of the protruding end of each cross. Four fixed guide rods (2-5) in each set of mold opening mechanisms are vertically and evenly distributed, with the top fixedly installed on the protruding end of the rotating frame (2-1) and the lower end connected to the mold opening drive module (2-3). The mold opening hanging frames (2-4) are arranged in two groups, left and right, and front and back, respectively 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 hanging frame (2-4) is a vertical plate structure, the upper end is a horizontal push-pull rod structure, and the lower end is a structure of two parallel inward-folded horizontal support plates. The mold lifting unit (3) is a gantry lifting structure and is arranged on the left of the mold opening unit (2). The pulp making unit (4) and the raw material supply unit (5) are arranged at the rear of the forming unit (1). The mold (1-1) includes: a shell sleeve (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 sleeve (1-11) is a frustum-shaped cube outer shell structure with openings at the top and bottom. A rectangular strip-shaped rigid handle is respectively arranged on each of the four outer sides of the shell sleeve (1-11). The core (1-12) is a rigid cube structure, and the base (1-13) is a rigid cube groove structure. The core (1-12) is centrally arranged on the groove bottom surface of the base (1-13). The outer core strip (1-21) and the inner core strip (1-22) are respectively arranged in a square around the groove bottom surface of the base (1-13).

3. The equipment for producing assembled cavity formwork using phosphogypsum according to claim 2, characterized in that, The interior of the mold (1-1) is divided into two structures. The first structure: the horizontal distance between the outer core bar (1-21) and the inner side of the groove is equal to the shell thickness of the shell sleeve (1-11), and the height and width of the outer core bar (1-21) are equal to the height and width of the outer concave and inner convex stepped structure of the lower cover mold box assembly tenon and mortise. The second structure: the inner side of the inner core bar (1-22) contacts the outer side of the 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 upper cover mold box assembly tenon and mortise. Drainage holes (1-20) are provided on the groove bottom surface of the base (1-13), and the drainage holes are respectively provided at the lower part of the core (1-12) and at positions close to the inner side of the groove.

4. An apparatus for producing assembled cavity formwork using phosphogypsum according to claim 2 or claim 3, characterized in that, The mold (1-1) further includes: a limiter (1-14), a connecting plate (1-15), rollers (1-16), guide posts (1-17), a conduction plate (1-18), and an inner groove rail (1-19). Four guide through holes are evenly distributed on the groove bottom surface of the base (1-13). Four rollers (1-16) are symmetrically installed on the lower bottom surface of the base (1-13), and limiters (1-14) and connecting plates (1-15) are symmetrically installed on the left and right side surfaces. The lower bottom surface of the core (1-12) is a plane, and four guide posts (1-17) are fixedly arranged on the lower bottom surface. The guide posts (1-17) pass through the guide through holes and maintain a sliding connection. The parts of the four guide posts (1-17) extending below the base (1-13) are integrally and rigidly connected to a conduction plate (1-18), and the inner groove rail (1-19) is rigidly installed in the middle of the lower part of the conduction plate (1-18).

5. The device for producing assembled cavity formwork using phosphogypsum according to claim 2, characterized in that, The mold opening drive module (2-3) 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 servo (2-35). The support plate (2-31) is a square rigid flat plate, and four guide through holes are evenly distributed on it. Four fixed guide rods (2-5) pass downward through the guide through holes and maintain a sliding connection. Mold opening slide rails (2-32) perpendicular to the square sides are arranged at the middle positions of each square side. The push and pull rod of the mold opening hanger (2-4) is arranged in the mold opening slide rail (2-32) and maintains a sliding connection. 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 and pull rod 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 provided 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 servo (2-35) is arranged at the lower center position of the support plate (2-31), and the drive shaft of the mold opening servo (2-35) passes through the support plate (2-31) and rotatably drives the cross wheel (2-34). The limiting pressure plate (2-6) is centrally arranged within the four-sided clamping plates of the mold opening hanger (2-4). The limiting pressure plate (2-6) includes: a fixed table (2-61), a connector (2-62), and a pressure plate (2-63). Both the fixed table (2-61) and the pressure plate (2-63) are rigid square flat plates. The fixed table (2-61) is rigidly fixed at the lower ends of 4 fixed guide rods (2-5). The pressure plate (2-63) is rigidly connected to the fixed table (2-61) through the connector (2-62) and remains horizontal.

6. The equipment for producing assembled cavity formwork using phosphogypsum according to claim 2, characterized in that The mold lifting unit (3) includes: a mold lifting bracket (3-1), a mold lifting module (3-2), a mold lifting drive module (3-3), a horizontal sliding rail (3-4), a pallet supply module (3-5), a stacking and mold receiving module (3-6), and a transportation module (3-7). The mold lifting bracket (3-1) is a rigid gantry structure, with its right end spanning and arranged in the middle of the two parallel structures of the rotary platform (1-4), its left end spanning and arranged on the stacking and mold receiving module (3-6), a horizontal sliding rail (3-4) is arranged at the upper end, the mold lifting drive module (3-3) is arranged on the horizontal sliding rail (3-4), and the mold lifting module (3-2) is suspended and arranged below the mold lifting drive module (3-3). The pallet supply module (3-5) is arranged on the left side of the stacking and mold receiving module (3-6), the transportation module (3-7) is arranged on the right side of the stacking and mold receiving module (3-6), and the three are connected by a roller shaft group. The mold lifting module (3-2) includes: a mold lifting cylinder (3-21), a lifting guide rod (3-22), a support table (3-23), left and right hanging brackets (3-24), front and rear hanging brackets (3-25), a circular wheel (3-26), a connecting rod (3-27), a mold lifting sliding rail (3-28), a tension spring (3-29), and a mold lifting servo (3-30). The support table (3-23) is a square rigid flat plate, with 4 guide through holes arranged on it, and a circular wheel (3-26) is rotatably installed at the central position. Mold lifting sliding rails (3-28) are arranged at the middle positions of each square side. The upper ends and sides of the left and right hanging brackets (3-24) and the upper ends and sides of the front and rear hanging brackets (3-25) are the same as those of the mold opening hanger (2-4). The push-pull rods at the upper ends are respectively installed within the mold lifting sliding rails (3-28). The lower ends of the left and right hanging brackets (3-24) are single-piece inward-folded horizontal pallets. The lower ends of the front and rear hanging brackets (3-25) are inward-folded single-step structure pallets. The center of the circular wheel (3-26) is provided with a through hole, and arc-shaped slot holes are respectively arranged at the edges of the upper right circular surface and the lower left circular surface regions. The outer ends of 4 connecting rods (3-27) are respectively rotatably connected to the push-pull rods of the left and right hanging brackets (3-24) and the front and rear hanging brackets (3-25), and the inner ends are respectively arranged within the slot holes and respectively contact the top of the horizontal end and the top of the vertical end of the slot holes. 4 tension springs (3-29) are arranged, with one end fixed on the support table (3-23) and the other end connected to the inner end of the connecting rod (3-27). The lifting guide rods (3-22) are vertically and uniformly arranged, with their lower ends passing through the 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 mold-lifting drive module (3-3); the upper end of the mold-lifting cylinder (3-21) is fixed to the mold-lifting drive module (3-3), and its lower end passes through the central through-hole of the circular wheel (3-26) and is fixed to the support platform (3-23); the mold-lifting servo (3-30) is arranged at the lower part of the support platform (3-23), and the central axis of the mold-lifting servo (3-30) passes through the support platform (3-23) and is rotationally drivingly connected to the circular wheel (3-26).

7. An apparatus for producing assembled cavity formwork using phosphogypsum according to claim 2, characterized in that, The mold release agent spraying device (1-2) 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 mold release agent spraying station, the lifting rod (1-24) controls the intermittent up-and-down movement of the multi-directional spray head (1-25), and the multi-directional spray head (1-25) is provided with downward and obliquely upward spray openings.

8. An apparatus for producing assembled cavity formwork using phosphogypsum according to claim 2, characterized in that, A water spray head (1-7) is arranged at the cleaning station, and a diversion groove (1-8) is arranged at the lower part.

9. An apparatus for producing assembled cavity formwork using phosphogypsum according to claim 2 or claim 3, characterized in that, At the inner edge of the lower bottom surface of the shell sleeve (1-11) of the first structure, a chamfer is provided, and at the inner edge of the upper surface of the side of the base (1-13), a chamfer is provided; at the outer edge of the lower bottom surface of the core (1-12) of the second structure, a chamfer is provided, and at the inner edge of the upper surface of the side of the base (1-13), a chamfer is provided.

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