Ceramsite production equipment and production process

Abstract

The ceramsite production equipment comprises a mounting frame, a spiral conveyor is mounted at the top of the mounting frame, a granulator is arranged below the spiral conveyor, a granulation plate is arranged in the granulator, a plurality of granulation grooves are uniformly formed in the granulation plate, and an extrusion roller is arranged above the granulation plate; the extrusion roller and the granulation plate rotate relatively to extrude a mixed material on the granulation plate; a cutting knife assembly is arranged in the forming discharge bin, is arranged below the granulation plate and rotates relative to the granulation plate so as to cut and form materials extruded from the bottom of the granulation plate; the extrusion rollers revolve around the central axis of the granulation plate while rotating to form composite motion, plasticization uniformity is enhanced through rotation, the whole surface of the granulation plate is covered through revolution, and consistency of particle compactness is guaranteed; the variable-pitch spiral grooves and the balls are arranged in the extrusion rollers, high-frequency micro-vibration is generated during autorotation, the adhesive force between materials and the roller surfaces is effectively damaged, and the roller sticking phenomenon is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of building material production equipment, and particularly to a ceramsite production equipment and a production process. Background Art

[0002] Ceramsite is a lightweight and porous artificial aggregate, generally in the shape of regular spherical particles. It is usually made from clay, shale, fly ash or industrial waste residue as the main raw materials and roasted and expanded at high temperature (1100–1300 °C). Uniform honeycomb-like pore structures are formed inside it, and the surface is hard and dense. It has the characteristics of low density, high strength, heat insulation, corrosion resistance, etc., and is an environment-friendly building material. The density of ceramsite is only 1 / 3 to 1 / 2 of that of ordinary concrete (usually 300–1000 kg / m 3 ), which can greatly reduce the load of building structures. It is especially suitable for high-rise buildings, long-span bridges and soft soil foundation projects, reducing the foundation cost. Generally speaking, due to its light weight, energy saving, environmental protection and other characteristics, ceramsite has become an important material for modern green buildings, especially suitable for the fields of prefabricated buildings, super high-rise structures and passive low-energy consumption buildings.

[0003] In the production process of ceramsite, other additives such as clay, water and binder need to be mixed and stirred evenly, and then the granulating equipment for ceramsite is used to granulate the mixed material after mixing. However, when the mixed material is extruded into particles by an extrusion roller, since the mixed material contains a bonding component, on the one hand, the mixed material is likely to bond and accumulate together in the granulator, resulting in uneven subsequent particle distribution; on the other hand, for materials containing fiber impurities or clay with high moisture content in the mixed material, they are easily adhered to the surface of the extrusion roller during the extrusion granulation process, and the adhesion of the material will cause poor granulation, uneven particle forming, and even affect the continuous operation of the equipment, reducing the production efficiency.

[0004] A ceramsite production device and process are disclosed in Chinese Patent CN118682900A, which relates to the technical field of ceramsite production. It sequentially includes a granulator assembly, a first conveyor assembly, a dryer assembly, a second conveyor assembly, a sintering furnace assembly, a third conveyor assembly, and a screening machine assembly. A granulation structure is provided inside the granulator assembly, and a mixing structure is provided inside the granulator assembly and above the granulation structure; in the present invention, the mixing structure is used to stir and disperse the mixture, so that the mixture can be more evenly dispersed into the next processing stage; the mixture is extruded and compressed on the granulation plate by the rotation of the extrusion roller, and during the rotation of the rotating shaft, the cutting blade will be driven to rotate to cut and granulate the material at the bottom of the granulation plate; however, in the present invention, the fixed sleeve is fixedly connected to the granulation plate, the granulation plate is fixed, and the extrusion roller only rotates by itself driven by the second motor, and can only locally extrude the mixture at a fixed position. The movement path of the material on the granulation plate is single, which may lead to uneven extrusion or local accumulation; and when granulating highly viscous mixed materials, it cannot reduce the situation of the material sticking to the roller surface, which will affect the continuous operation of the equipment and reduce the production efficiency. Summary of the Invention

[0005] The purpose of the present invention is to solve the above problems. After improvement, a ceramsite production device and production process are proposed to improve the ceramsite granulation production device and production process and improve the production efficiency.

[0006] The present invention realizes the above purpose through the following technical solutions: A ceramsite production device includes a mounting frame. A screw conveyor for stirring and conveying the mixed material is installed on the top of the mounting frame. A granulator is provided directly below the discharge port of the screw conveyor. The mixed material enters the granulator for granulation after being stirred. The granulator includes a feeding bin communicated with the discharge port of the screw conveyor, and a granulation bin is provided below the feeding bin; A granulation plate is provided in the granulation bin. A plurality of granulation grooves are evenly formed on the granulation plate. An extrusion roller is provided above the granulation plate. The extrusion roller and the granulation plate rotate relative to each other to extrude the mixed material on the granulation plate. A forming discharge bin is provided below the granulation bin; A cutting knife assembly is provided in the forming discharge bin. The cutting knife assembly is arranged below the granulation plate and rotates relative to the granulation plate to cut and form the material extruded from the bottom of the granulation plate.

[0007] Further, the screw conveyor includes a U-shaped trough, the top of the trough is provided with a feed inlet, a screw body is rotatably arranged in the trough, the screw body includes a screw shaft and screw blades, one end of the screw shaft penetrates through the trough and is fixedly connected with a first pulley at the end, and a discharge port is opened at one end of the bottom of the trough; a driving motor is installed on the mounting frame, and a second pulley is connected to the output end of the driving motor, and the first pulley and the second pulley are connected by a belt drive.

[0008] Further, a first motor is installed on the inner bottom surface of the forming discharge bin of the granulator, and a rotating shaft is connected to the output end of the first motor, and the rotating shaft extends from the forming discharge bin into the blanking bin.

[0009] Further, the granulation plate is fixedly installed in the granulation bin by screws, the center of the granulation plate is rotatably connected to the rotating shaft, a fixed sleeve is fixedly connected to the rotating shaft above the granulation plate, and at least two second motors are embedded and installed on the outer side wall of the fixed sleeve, and the output ends of the second motors are fixedly connected with the extrusion rollers, and the extrusion rollers rotate around their own axes under the drive of the second motors and revolve around the central axis of the granulation plate under the drive of the rotating shaft; the cutting knife assembly is fixedly installed on the rotating shaft.

[0010] Further, the granulation plate is fixedly connected to the rotating shaft, the granulation plate is rotatably arranged in the granulation bin, two upper and lower limiting plates are fixedly arranged on the inner bin wall of the granulation bin, the granulation plate rotates between the two upper and lower limiting plates, an installation sleeve is arranged above the granulation plate, the rotating shaft is rotatably arranged in the installation sleeve, the installation sleeve is fixedly connected to the bin wall of the granulation bin through a connecting rod, and at least two third motors are embedded and installed on the outer side wall of the installation sleeve, and the output ends of the third motors are fixedly connected with the extrusion rollers, and the extrusion rollers rotate around their own axes under the drive of the third motors and revolve around the central axis of the granulation plate relative to the rotating granulation plate; the cutting knife assembly is fixedly installed on the inner bin wall of the granulation bin.

[0011] Further, a hollow cavity is formed in the extrusion roller, a variable pitch spiral groove is machined on the inner side wall of the hollow cavity, the pitch of the spiral line of the variable pitch spiral groove gradually decreases along the axis direction of the roller body, forming a spiral track with one end sparse and one end dense, the variable pitch spiral groove is a trapezoidal groove, and a number of balls are distributed in the variable pitch spiral groove.

[0012] Further, a material distribution plate is provided in the blanking bin. The material distribution plate is fixedly connected to the blanking bin by screws. Three through grooves are formed in the material distribution plate. A rotating block is fixedly provided at the top of the rotating shaft. The rotating block is rotatably arranged at the center of the material distribution plate. A connecting baffle is fixedly connected to the outer side wall of the rotating block. The connecting baffle is located below the material distribution plate and is matched with the through groove. A connecting sleeve is fixedly connected to the outer side wall of the rotating block and located above the material distribution plate. Six dial rods are fixedly connected to the outer side wall of the connecting sleeve at equal angles.

[0013] Further, the cutting knife assemblies are symmetrically arranged in the forming and discharging bin. The cutting knife assembly includes a mounting plate. A cutting knife handle is fixedly mounted on the mounting plate by screws. One end of the cutting knife handle is fixedly connected with a cutting blade. The cutting blade is located at the bottom of the granulating plate and rotates relative to the granulating plate for cutting materials.

[0014] Further, a hopper in the shape of a frustum of a cone is sleeved outside the first motor. An outlet is formed in the bin wall of the forming and discharging bin. A receiving hopper is connected to the outlet.

[0015] A ceramsite production process includes the following steps:

[0016] S1. Material mixing and conveying: Continuously stirring and conveying the mixed raw materials of ceramsite to the blanking bin of the granulator through a screw conveyor;

[0017] S2. Material distribution and diversion: Using the through grooves on the material distribution plate and the dial rods connected to the rotating block, evenly dispersing the mixed materials onto the granulating plate of the granulating bin;

[0018] S3. Double - way extrusion granulation: Driving the extrusion roller to revolve around the central axis of the granulating plate while rotating, forming relative rotation with the granulating plate, and extruding the materials from the granulating grooves to form strip - shaped blanks;

[0019] S4. Dynamic cutting and forming: Synchronously cutting the strip - shaped blanks extruded from the bottom of the granulating plate through the cutting knife assembly to obtain homogeneous ceramsite green blanks;

[0020] S5. Directional collection: The cut ceramsite green blanks are guided to the receiving device through the hopper of the forming and discharging bin to complete continuous discharging.

[0021] Compared with the prior art, the beneficial effects of the present invention are:

[0022] 1. The extrusion roller revolves around the central axis of the granulating plate while rotating, forming a compound motion. The shear force generated by the rotation destroys the material agglomeration and enhances the plasticization uniformity; the revolution covers the entire surface of the granulating plate, avoiding the "edge under - pressure" problem of the traditional fixed extrusion roller, ensuring the consistency of particle density, and broadening the raw material adaptability.

[0023] 2. The extrusion roller is equipped with variable pitch spiral grooves and balls inside. When rotating, the balls are subject to centrifugal force and move regularly along the spiral grooves and hit the roller wall, generating high-frequency micro-vibration, effectively destroying the adhesion between the material and the roller surface, reducing the "roller sticking" phenomenon, and ensuring continuous and stable operation of the equipment.

[0024] 3. The material distribution plate and the lever work together to control the material feeding rhythm through the rotating block and the connecting baffle, so that the mixed material is evenly dispersed on the surface of the granulation plate to avoid local accumulation and improve the granulation efficiency. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a schematic diagram of the three-dimensional structure of the present invention;

[0026] Figure 2 is a schematic diagram of the screw conveyor in the present invention;

[0027] Figure 3 is an internal cross-sectional view of a granulator in Example 1 of the present invention;

[0028] Figure 4 This is an internal view of the granulator in Example 1 of the present invention;

[0029] Figure 5 is an internal cross-sectional view of a granulator in Example 2 of the present invention;

[0030] Figure 6 This is an internal view of a granulator in Example 2 of the present invention;

[0031] Figure 7 The internal cross-sectional view of the two halves of the squeezing roller in Example 3 of the present invention;

[0032] Figure 8 1 and 2 are the internal view and cross-sectional view of the extrusion roller in Example 3 of the present invention.

[0033] In the figure: 1-mounting frame, 2-screw conveyor, 3-granulator, 4-discharging bin, 5-granulating bin, 6-granulating plate, 7-squeezing roller, 8-forming discharging bin, 9-cutting knife assembly, 10-first motor, 11-rotating shaft, 12-fixing sleeve, 13-second motor, 14-limiting plate, 15-mounting sleeve, 16-third motor, 17-discharging hopper;

[0034] 21- material trough, 22- spiral body, 23- driving motor, 41- material dividing plate, 42- rotating block, 43- connecting baffle, 44- connecting sleeve, 45- lever, 71- hollow cavity, 72- variable pitch spiral groove, 73- ball, 91- mounting plate, 92- cutting handle, 93- cutting blade, 151- connecting rod, 411- through groove. DETAILED DESCRIPTION

[0035] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0036] In the description of the present invention, it should be understood that the orientation or positional relationships indicated by the terms "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc. are based on the orientation or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and thus should not be construed as a limitation to the present invention.

[0037] Embodiment 1

[0038] Combined with Figures 1 to 8 Shown is a ceramsite production device, including a mounting frame 1. At the top of the mounting frame 1, a screw conveyor 2 for stirring and conveying the mixed materials is installed. Right below the discharge port of the screw conveyor 2, there is a granulator 3. After being stirred, the mixed materials enter the granulator 3 for granulation. The granulator 3 includes a feeding bin 4 communicated with the discharge port of the screw conveyor 2. Below the feeding bin 4, there is a granulation bin 5. In the granulation bin 5, there is a granulation plate 6. A plurality of granulation grooves are evenly formed on the granulation plate 6. Above the granulation plate 6, there is a pressing roller 7. The pressing roller 7 and the granulation plate 6 rotate relative to each other to press the mixed materials on the granulation plate 6. Below the granulation bin 5, there is a forming and discharging bin 8. In the forming and discharging bin 8, there is a cutting knife assembly 9. The cutting knife assembly 9 is arranged below the granulation plate 6 and rotates relative to the granulation plate 6 to cut and form the materials extruded from the bottom of the granulation plate 6.

[0039] As Figure 2As shown, the screw conveyor 2 includes a U-shaped trough 21, a feed port is provided at the top of the trough 21, a spiral body 22 is rotatably provided in the trough 21, the spiral body 22 includes a spiral shaft and a spiral blade, one end of the spiral shaft passes through the trough 21 and is fixedly connected with a first pulley at the end, and a discharge port is provided at one end of the trough bottom of the trough 21; a driving motor 23 is installed on the mounting frame 1, and a second pulley is connected to the output end of the driving motor 23, and the first pulley and the second pulley are connected by a belt transmission; when in use, the mixed clay and other mixed materials are put into the trough 21 from the feed port of the screw conveyor 2, the driving motor 23 is started to drive the spiral body 22 to stir the mixed materials, and the stirred mixed materials are transported to the lower silo 4 of the granulator 3 through the discharge port.

[0040] like Figures 3 - 6 As shown, a first motor 10 is installed on the inner bottom surface of the forming discharge bin 8 of the granulator 3, and a rotating shaft 11 is connected to the output end of the first motor 10, and the rotating shaft 11 extends from the forming discharge bin 8 to the lower bin 4; a dividing plate 41 is provided in the lower bin 4, and the dividing plate 41 is fixedly connected to the lower bin 4 by screws, and three through grooves 411 are opened on the dividing plate 41, and a rotating block 42 is fixedly provided on the top of the rotating shaft 11, and the rotating block 42 is rotatably set in the center of the dividing plate 41, and a connecting baffle 43 is fixedly connected to the outer side wall of the rotating block 42, and the connecting baffle 43 is located below the dividing plate 41 and cooperates with the through groove 411, and a connecting sleeve 44 is fixedly connected on the outer side wall of the rotating block 42 and on the upper side of the dividing plate 41, and the outer side wall of the connecting sleeve 44, etc. Six levers 45 are fixedly connected at an angle; after the stirred mixed material enters the lower hopper 4, the first motor 10 is started to drive the rotating shaft 11 to rotate, and during the rotation of the rotating shaft 11, the connecting sleeve 44 fixedly connected to the rotating block 42 and the six levers 45 are driven to rotate, thereby, the six levers 45 can evenly stir the mixed material, and the rotation of the rotating shaft 11 also drives the connecting baffle 43 to rotate, thereby, during the rotation of the connecting baffle 43, the through groove 411 on the dividing plate 41 is gradually exposed, and under the stirring of the lever 45, the mixed material can evenly fall downward from the through groove 411 and evenly dispersed to the surface of the granulation plate 6 of the granulation bin 5, so as to carry out the next stage of the granulation process.

[0041] like Figures 3 - 4As shown in the figure, the granulation plate 6 is fixedly installed in the granulation bin 5 by screws. The central part of the granulation plate 6 can be rotatably connected to the rotating shaft 11 through a bearing. A fixed sleeve 12 is fixedly connected to the rotating shaft 11 above the granulation plate 6. At least two second motors 13 are embedded and installed on the outer side wall of the fixed sleeve 12. In this embodiment, four second motors 13 are embedded and installed on the outer side wall of the fixed sleeve 12 at equal angles. An extrusion roller 7 is fixedly connected to the output end of the second motor 13. The extrusion roller 7 rotates self - rotatably driven by the second motor 13 and revolves around the central axis of the granulation plate 6 driven by the rotating shaft 11. The cutting knife assembly 9 is fixedly installed on the rotating shaft 11. The cutting knife assembly 9 includes a mounting plate 91. In this embodiment, the mounting plate 91 is fixedly connected to the rotating shaft 11. A cutting knife handle 92 is fixedly installed on the mounting plate 91 by screws. One end of the cutting knife handle 92 is fixedly connected with a cutting blade 93. The cutting blade 93 is located at the bottom of the granulation plate 6 and rotates relative to the granulation plate 6 for cutting materials.

[0042] The specific granulation process of this embodiment is as follows: The four second motors 13 on the fixed sleeve 12 are started synchronously to drive the four extrusion rollers 7 to rotate self - rotatably. At the same time, the first motor 10 drives the fixed sleeve 12 and the extrusion rollers 7 to revolve around the central axis of the granulation plate 6 through the rotating shaft 11. Among them, the self - rotation causes a relative sliding friction between the surface of the extrusion roller 7 and the granulation plate 6, generating a shear force on the material, destroying the material agglomeration, improving the plasticization uniformity of the mixed material, and the centrifugal force generated by the self - rotation can throw off the material adhering to the roller surface, reducing the "sticking roller" phenomenon and ensuring continuous production. The revolution makes the extrusion roller 7 move along a circular track, covering all the granulation grooves from the center to the edge of the granulation plate 6, solving the "under - pressure at the edge" problem of the traditional fixed extrusion roller (the particles in the edge area are loose due to fewer extrusion times). Thus, the combined movement of the self - rotation and revolution of the extrusion roller 7 can enhance the shear breakage for highly viscous materials during self - rotation; for low - plasticity materials, the revolution provides stable rolling, and the combined mode broadens the raw material adaptability. As the extrusion roller 7 rotates self - rotatably and revolves, the mixed material is extruded through the granulation grooves on the granulation plate 6. When the extruded strip - shaped blank extends from the bottom of the granulation plate 6, the rotating shaft 11 drives the cutting knife assembly 9 to rotate synchronously, and the strip - shaped blank is cut into equal - length ceramsite green blanks by the cutting blade 93.

[0043] Embodiment Two

[0044] As Figures 5 - 6As shown in the figure, compared with that in the first embodiment, the rotating shaft 11 drives the fixed sleeve 12 to rotate, thereby driving the extrusion roller 7 to revolve around the central axis of the granulation plate 6; in this embodiment, the granulation plate 6 is fixedly connected to the rotating shaft 11, and the granulation plate 6 is rotatably arranged in the granulation bin 5. Two upper and lower limiting plates 14 are fixedly arranged on the inner wall of the granulation bin 5. The granulation plate 6 rotates between the two upper and lower limiting plates 14. An installation sleeve 15 is arranged above the granulation plate 6. The rotating shaft 11 is rotatably arranged in the installation sleeve 15. The installation sleeve 15 is fixedly connected to the wall of the granulation bin 5 through a connecting rod 151. At least two third motors 16 are embedded and installed on the outer side wall of the installation sleeve 15. An extrusion roller 7 is fixedly connected to the output end of the third motor 16. The extrusion roller 7 rotates around its own axis under the drive of the third motor 16, and the extrusion roller 7 revolves around the central axis of the granulation plate 6 relative to the rotating granulation plate 6; the cutting knife assembly 9 is fixedly installed on the inner wall of the granulation bin 5. In this embodiment, the mounting plate 91 is fixedly connected to the inner wall of the forming and discharging bin 8. A cutting knife handle 92 is fixedly installed on the mounting plate 91 through screws. One end of the cutting knife handle 92 is fixedly connected with a cutting blade 93. The cutting blade 93 is located at the bottom of the granulation plate 6 and rotates relative to the granulation plate 6 to cut the material.

[0045] The specific granulation process of this embodiment is as follows: the granulation plate 6 is fixed on the rotating shaft 11 and rotates with the rotating shaft 11, driving the surface material to rotate synchronously. The extrusion roller 7 is fixed on the side wall of the granulation bin 5 through the connecting rod 151 on the installation sleeve 15. The extrusion roller 7 and the granulation plate 6 form a relative revolving motion, and the extrusion track covers the entire surface of the granulation grooves on the granulation plate 6; when the granulation plate 6 rotates, the two upper and lower limiting plates 14 limit the granulation plate 6. The rotation of the granulation plate 6 enables the material to continuously enter the extrusion area. The extrusion roller 7 forms a revolving path relative to the rotating granulation plate 6, ensuring that each granulation groove is periodically pressed, and the material is forced into the granulation groove to form a dense strip-shaped blank. When the strip-shaped blank extends from the bottom of the granulation plate 6, the cutting knife assembly 9 fixed on the inner wall of the forming and discharging bin 8 comes into play. The rotation of the granulation plate 6 drives the strip-shaped blank to move at a circumferential linear velocity, and the fixed cutting blade 93 cuts the blank in a "relative motion" manner.

[0046] The second embodiment is different from the first embodiment. Instead, it uses the rotation of the granulation plate 6 to achieve the relative revolution of the extrusion roller 7 while rotating around its own axis, thereby similarly achieving the effect of the compound motion of the extrusion roller in the first embodiment.

[0047] Embodiment Three

[0048] As Figures 7 - 8As shown, in this embodiment, the extrusion roller 7 in the first and second embodiments is further improved so that when facing a highly viscous mixed material, the "roller sticking" phenomenon can be further reduced to ensure continuous production; therefore, a hollow cavity 71 is provided in the extrusion roller 7, and a variable pitch spiral groove 72 is processed on the inner side wall of the hollow cavity 71, and the pitch of the spiral line of the variable pitch spiral groove 72 gradually decreases along the axis direction of the roller body; as shown in FIG. Figure 8 In the embodiment, the variable pitch spiral groove 72 becomes denser as it moves to the right in the axial direction, forming a spiral track with sparseness at one end and denseness at the other end. The variable pitch spiral groove 72 is a trapezoidal groove, and a plurality of balls 73 are distributed in the variable pitch spiral groove 72;

[0049] When the extrusion roller 7 rotates, under the constraints of centrifugal force and groove wall, the ball 73 will roll toward the end with smaller pitch and collide with the groove wall repeatedly. Due to the change of pitch, the rolling speed and direction of the ball 73 continue to change. Each time it collides with the groove wall and the inner roller wall, it will exert impact force on the groove wall and the inner roller wall. The reaction force of the groove wall on the ball 73 temporarily changes the movement state of the ball 73, but the centrifugal force continues to drive the ball 73 to continue rolling along the groove and hit the groove wall again; in this way, a single ball forms a cyclical motion of "rolling-collision-rebound-rolling again"; thus, the variable pitch spiral groove 72 and the centrifugal force work together to make the ball 73 roll along a specific trajectory and continuously collide with the groove wall and the inner roller wall, ultimately achieving percussion vibration of the extrusion roller 7. Compared with directly placing the ball 73 in the hollow cavity 71, the ball 73 moves irregularly, and the vibration frequency and amplitude are uncontrollable, making it difficult to effectively reduce material adhesion; the variable pitch spiral groove 72 provides a clear movement trajectory for the ball 73, allowing it to roll regularly along the spiral path. When the extrusion roller 7 rotates, the ball is subjected to the effects of centrifugal force, groove wall support force, etc., and continues to move along the groove and repeatedly hits the roller wall, generating stable high-frequency micro-vibrations, which can destroy the adhesion between the material and the roller surface, thereby further reducing the roller sticking phenomenon.

[0050] In the first embodiment, the extrusion roller 7 is driven by the rotating shaft 11 to actively revolve itself, so that the extrusion roller 7 as a whole rotates around another axis, changing the spatial position and force direction of the ball 73. At this time, the direction of the centrifugal force of the ball changes periodically with the revolution, and its motion trajectory becomes a synthesis of the self-rotation spiral motion and the revolution circular motion, forming a more complex spatial spiral trajectory. However, the variable pitch spiral groove 72 still constrains the ball to prevent it from leaving the groove body; the revolution also changes the impact frequency and direction, forming a more complex vibration mode. For example, within one revolution, the ball 73 collides multiple times along the spiral groove due to self-rotation. The different speed ratios of revolution and self-rotation will cause the collision to show periodic changes, and also enhance the vibration effect, more effectively destroying the adhesion between the material and the roller surface.

[0051] like Figure 3As shown, a frustum-shaped blanking hopper 17 is provided outside the first motor 10, and a discharge port is provided on the wall of the forming discharge bin 8, and a receiving hopper is connected at the discharge port.

[0052] In the third embodiment, usually 3-6 balls are selected and evenly distributed in the circumferential direction to ensure uniform distribution of the knocking force, avoid eccentric load vibration of the roller body, and at the same time make the total mass of the balls account for 0.5%-1% of the total mass of the extrusion roller 7 to prevent excessive moment of inertia from affecting the motor load; the number of turns of the spiral groove: generally designed to be 5-10 turns. Specifically, it needs to be adjusted in combination with the length of the roller body and the change gradient of the pitch. For example, for high-viscosity materials, the number of turns can be increased to fully accelerate the balls to increase the impact frequency and enhance the vibration viscosity reduction effect; if the roller body is shorter or the requirement for the vibration frequency is lower, the number of turns can be appropriately reduced. The groove track of the variable pitch spiral groove can adopt quenched steel (HRC55-60) + wear-resistant coating, and the balls 73 are selected as tungsten carbide alloy balls (hardness HV1800), and the hardness difference between the two is controlled within 20% to avoid excessive wear.

[0053] The ceramsite production process in the present invention includes the following steps:

[0054] S1. Material mixing and conveying: Continuously stir the mixed raw materials of ceramsite through the screw conveyor 2 and convey them into the blanking bin 4 of the granulator 3;

[0055] S2. Material distribution and diversion: Use the through groove 411 on the distribution plate 41 and the lever 45 connected to the rotating block 42 to evenly disperse the mixed materials onto the granulating plate 6 of the granulating bin 5;

[0056] S3. Bidirectional extrusion granulation: Drive the extrusion roller 7 to revolve around the central axis of the granulating plate 6 while rotating, forming a relative rotation with the granulating plate 6, and extruding the material from the granulating groove to form a strip-shaped blank;

[0057] S4. Dynamic cutting and forming: Synchronously cut the strip-shaped blank extruded from the bottom of the granulating plate 6 through the cutting knife assembly 9 to obtain a homogeneous ceramsite green blank;

[0058] S5. Directional collection: The cut ceramsite green blanks are guided by the blanking hopper 17 of the forming discharge bin 8 to the receiving device to complete continuous discharging.

[0059] For those skilled in the art, it is obvious that the present invention is not limited to the details of the above-mentioned exemplary embodiments, and without departing from the spirit or basic characteristics of the present invention, the present invention can be implemented in other specific forms. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-limiting. The scope of the present invention is defined by the appended claims rather than the above description. Therefore, all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be included in the present invention. Any reference signs in the claims should not be regarded as limiting the claimed rights.

[0060] In addition, it should be understood that although this specification is described according to embodiments, not every embodiment only contains an independent technical solution. This narrative way of the specification is only for clarity. Those skilled in the art should regard the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A ceramsite production device, including an installation frame (1), a screw conveyor (2) for stirring and conveying mixed materials is installed on the top of the installation frame (1), a granulator (3) is arranged directly below the discharge port of the screw conveyor (2), and the mixed materials enter the granulator (3) for granulation after being stirred. It is characterized in that: The granulator (3) includes a blanking bin (4) communicated with the discharge port of the screw conveyor (2), and a granulation bin (5) is arranged below the blanking bin (4); a granulation plate (6) is arranged in the granulation bin (5), and a plurality of granulation grooves are uniformly formed in the granulation plate (6). An extrusion roller (7) is arranged above the granulation plate (6), and the extrusion roller (7) and the granulation plate (6) rotate relative to each other to extrude the mixed material on the granulation plate (6). A forming and discharging bin (8) is arranged below the granulation bin (5); a cutting knife assembly (9) is arranged in the forming and discharging bin (8), and the cutting knife assembly (9) is arranged below the granulation plate (6) and rotates relative to the granulation plate (6) to cut and form the material extruded from the bottom of the granulation plate (6).

2. The ceramsite production equipment according to claim 1, characterized in that: The screw conveyor (2) includes a U-shaped trough (21), the top of the trough (21) is provided with a feed port, a screw body (22) is rotatably arranged in the trough (21), and the screw body (22) includes a screw shaft and screw blades. One end of the screw shaft penetrates through the trough (21) and is fixedly connected with a first pulley at the end. The discharge port is formed at one end of the bottom of the trough (21); a driving motor (23) is installed on the mounting frame (1), the output end of the driving motor (23) is connected with a second pulley, and the first pulley and the second pulley are connected by a belt in a transmission manner.

3. The ceramsite production equipment according to claim 1, characterized in that: A first motor (10) is installed on the inner bottom surface of the forming and discharging bin (8) of the granulator (3), the output end of the first motor (10) is connected with a rotating shaft (11), and the rotating shaft (11) extends from the forming and discharging bin (8) into the blanking bin (4).

4. The ceramsite production equipment according to claim 3, characterized in that: The granulation plate (6) is fixedly installed in the granulation bin (5) by screws, the central part of the granulation plate (6) is rotatably connected with the rotating shaft (11), a fixed sleeve (12) is fixedly connected to the rotating shaft (11) above the granulation plate (6), at least two second motors (13) are embedded and installed on the outer side wall of the fixed sleeve (12), the output ends of the second motors (13) are fixedly connected with the extrusion roller (7), the extrusion roller (7) rotates self-driven by the second motor (13) and revolves around the central axis of the granulation plate (6) driven by the rotating shaft (11); the cutting knife assembly (9) is fixedly installed on the rotating shaft (11).

5. The ceramsite production equipment according to claim 3, characterized in that: The granulating plate (6) is fixedly connected to the rotating shaft (11). The granulating plate (6) is rotatably arranged in the granulating bin (5). On the inner wall of the granulating bin (5), two upper and lower limiting plates (14) are fixedly arranged. The granulating plate (6) rotates between the two upper and lower limiting plates (14). Above the granulating plate (6), there is an installation sleeve (15). The rotating shaft (11) is rotatably arranged in the installation sleeve (15). The installation sleeve (15) is fixedly connected to the wall of the granulating bin (5) through a connecting rod (151). At least two third motors (16) are embedded and installed on the outer side wall of the installation sleeve (15). The output end of the third motor (16) is fixedly connected with the extrusion roller (7). The extrusion roller (7) rotates self-driven by the third motor (16), and the extrusion roller (7) revolves around the central axis of the granulating plate (6) relative to the rotating granulating plate (6). The cutting knife assembly (9) is fixedly installed on the inner wall of the granulating bin (5).

6. The ceramsite production equipment according to claim 4 or 5, characterized in that: A hollow cavity (71) is formed in the extrusion roller (7). On the inner side wall of the hollow cavity (71), a variable pitch spiral groove (72) is machined. The pitch of the spiral line of the variable pitch spiral groove (72) gradually decreases along the axis direction of the roller body, forming a spiral track with one end sparse and one end dense. The variable pitch spiral groove (72) is a trapezoidal groove, and a number of balls (73) are distributed in the variable pitch spiral groove (72).

7. The ceramsite production equipment according to claim 3, characterized in that: A material distributing plate (41) is arranged in the feeding bin (4). The material distributing plate (41) is fixedly connected to the feeding bin (4) by screws. Three through grooves (411) are formed in the material distributing plate (41). At the top of the rotating shaft (11), a rotating block (42) is fixedly arranged. The rotating block (42) is rotatably arranged at the center of the material distributing plate (41). A connecting baffle (43) is fixedly connected to the outer side wall of the rotating block (42). The connecting baffle (43) is located below the material distributing plate (41) and is matched with the through groove (411). A connecting sleeve (44) is fixedly connected to the outer side wall of the rotating block (42) and above the material distributing plate (41). Six dial rods (45) are fixedly connected to the outer side wall of the connecting sleeve (44) at equal angles.

8. The ceramsite production equipment according to claim 6, characterized in that: The cutting knife assemblies (9) are symmetrically arranged in the forming and discharging bin (8). The cutting knife assembly (9) includes a mounting plate (91). A cutting knife handle (92) is fixedly installed on the mounting plate (91) by screws. One end of the cutting knife handle (92) is fixedly connected with a cutting blade (93). The cutting blade (93) is located at the bottom of the granulating plate (6) and rotates relative to the granulating plate (6) for cutting materials.

9. The ceramsite production equipment according to claim 8, characterized in that: A conical feeding hopper (17) is sleeved outside the first motor (10). An outlet is formed in the wall of the forming and discharging bin (8), and a receiving hopper is connected at the outlet.

10. A ceramsite production process, characterized in that: The ceramsite production process is applied to the ceramsite production equipment as described in any one of claims 1-9. The ceramsite production process includes the following steps: S1. Material mixing and conveying: Continuously stir the mixed raw materials of ceramsite through a screw conveyor (2) and convey them into the feeding bin (4) of a granulator (3); S2. Material distribution and diversion: Utilize the through slots (411) on a distribution plate (41) and a lever (45) connected to a rotating block (42) to evenly disperse the mixed materials onto a granulation plate (6) in a granulation chamber (5); S3. Bidirectional extrusion granulation: Drive an extrusion roller (7) to revolve around the central axis of the granulation plate (6) while rotating on its own axis, forming a relative rotation with the granulation plate (6), and extrude the materials from the granulation slots to form strip-shaped blanks; S4. Dynamic cutting and forming: Synchronously cut the strip-shaped blanks extruded from the bottom of the granulation plate (6) through a cutting knife assembly (9) to obtain homogeneous ceramsite green blanks; S5. Directional collection: Guide the cut ceramsite green blanks to a material receiving device through a discharge hopper (17) of a forming discharge bin (8) to complete continuous discharging.

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