Accurate batching method for electrical porcelain production

Abstract

The invention discloses a precise batching method for electrical porcelain production, and belongs to the technical field of porcelain insulator manufacturing. The method comprises the following steps: classifying raw materials, elutriating clay, refining and pulping, dynamically storing slurry and barren materials, warehousing, and quantitatively compensating moisture. The method comprises the following steps: dividing qualified raw materials into elutriation clay and barren materials, respectively treating the elutriation clay and barren materials, weighing the elutriation clay, hydrating, stirring and slurrying, sieving, removing iron and detecting moisture to form standardized slurry, and dynamically storing the slurry through a slurry storage tank with a stirring device; barren raw materials are put into a ball mill together with the clay slurry according to a dry basis mass calculation system ratio after being stored in a warehouse, and the water amount is adjusted in real time based on water content detection data. According to the invention, the slurry uniformity is improved, the moisture compensation error is reduced, the ball milling time is shortened, the uniformity and stability of the performance of the insulator are improved, and a safety guarantee is provided for stable operation of a power transmission line.

Description

Technical Field

[0001] The present invention relates to the technical field of porcelain insulator manufacturing, and in particular to a precise batching method for producing electric porcelain. Background Art

[0002] Porcelain insulators, as key insulating components in power systems, are widely used in transmission lines and substations, providing insulation and supporting conductors, directly impacting the safe and stable operation of transmission and transformation lines. The electromechanical performance of insulators is influenced by their formulation and process. Traditionally, dry clay and lean raw materials are directly mixed after moisture content is measured in the conventional batching process for insulator production. This extensive batching method has the following drawbacks: It fails to consider the impact of impurity content in the clay raw material on slurry uniformity. Failure to pre-treat the clay results in unstable slurry viscosity control. Inadequate moisture adjustment during mixing leads to fluctuations in slurry moisture, impacting subsequent mud extraction efficiency. Uneven raw material moisture content causes deviations between the dry-to-dry ratio of raw materials added to the ball mill and the formulated ratio. These drawbacks leave room for improvement in the performance uniformity and stability of porcelain insulators produced using conventional methods. Therefore, it is necessary to develop a precise batching method for insulator production to address these issues. Summary of the Invention

[0003] The purpose of the present invention is to provide a method for accurately proportioning ingredients in the production of electrical porcelain, so as to solve the problem that the uniformity and stability of the performance of porcelain insulators prepared by the prior art need to be improved.

[0004] The present invention provides a precise batching method for producing electric porcelain, comprising:

[0005] Step 1: Conduct physical and chemical tests on incoming raw materials, remove unqualified raw materials, and separate qualified raw materials into washed clay raw materials and barren raw materials;

[0006] Step 2: weighing, hydrating, stirring, slurrying, screening, iron removal and moisture testing the washed clay raw material in sequence to form a standardized slurry;

[0007] Step 3: pumping the standardized slurry into a slurry storage tank with a stirring device for dynamic storage, and maintaining the slurry composition uniform by stirring;

[0008] Step 4: storing the lean raw material in a silo and stirring to keep its composition uniform;

[0009] Step 5: Based on the dry mass calculation system, the dynamically stored clay slurry and the lean raw materials in the silo are added to the ball mill according to the formula ratio, and the water content is compensated according to the moisture content test data of each raw material to complete precise batching.

[0010] Furthermore, in step one, the physical and chemical testing includes testing of moisture content, impurity content and mineral composition.

[0011] Furthermore, in step 2, the hydration is performed by putting the washed clay raw material into a hydration tank, adding water to a solid content of 50%-60%, and then standing for hydration.

[0012] Furthermore, in step 2, the screening uses a vibrating screen to remove sand, gravel and plant residues; and the iron removal is used to remove iron components in the slurry.

[0013] Furthermore, in step three, the slurry storage tank is provided with a flow meter and a valve for controlling the delivery amount of the slurry to the ball mill.

[0014] Furthermore, in step four, the silo is connected to the weighing chamber via a pipeline, and a valve for controlling the flow rate is provided between the pipeline and the weighing chamber, and the flow rate gradually slows down according to the mass of the injected raw materials.

[0015] Furthermore, in step 5, the dry mass calculation system is as follows: set the ball mill to prepare a blank with a total dry mass m and a target moisture content x, the total slurry mass M = m / (1-x), and the total water requirement w = x·M; and distribute the dry mass of each raw material according to the formula ratio.

[0016] Furthermore, in step 5, the calculation formula for compensating the amount of water according to the moisture content detection data of each raw material is: Z = x·m / (1-x)-Σ[m i ·x i / (1-x i )], i = 1 ~ n, where Z is the compensation water volume, m i is the dry basis mass of the i-th raw material, x i is the moisture content of the i-th raw material.

[0017] Furthermore, in step five, the moisture content of the dynamically stored clay slurry is lower than the target moisture content of the formulation, leaving room for regulating the amount of water to be compensated.

[0018] Furthermore, in step five, the lean raw material and clay slurry are directly added to the ball mill through a pipeline, wherein the lean raw material is weighed in a weighing chamber and then added, and the clay slurry is pumped in after the volume is controlled by a flow meter in a slurry storage tank.

[0019] The present invention has the following beneficial effects: The present invention provides a precise batching method for the production of electrical porcelain, wherein the washed clay and the lean material are processed in separate areas, thereby improving the utilization rate of the raw materials, and cooperating with the continuous stirring of the slurry storage tank and the silo agitator to improve the composition uniformity of the slurry and the lean raw materials. The slurry storage tank system realizes closed-loop control of the moisture content, which improves the moisture measurement accuracy compared with the traditional process, and with the cooperation of the compensation water calculation model, the accuracy of the compensation water volume is improved. The moisture content of the pretreated clay slurry is preset to be lower than the formula value, leaving room for regulation for subsequent compensation, so that the moisture content of the discharge from the ball milling process fluctuates less, the viscosity tends to be consistent, and the efficiency of subsequent mud extraction is improved. The dry mass calculation system and the slurry storage tank flowmeter are linked to achieve precise batching, which can effectively improve the uniformity and stability of product performance. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] In order to more clearly illustrate the technical solution of the present invention, the following briefly introduces the drawings required for use in the embodiments. Obviously, for ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0021] Figure 1 The present invention is a flow chart of a precise batching method for producing electrical porcelain. DETAILED DESCRIPTION

[0022] It should be noted that, unless otherwise specified, the embodiments and features in the embodiments of the present application may be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and in conjunction with the embodiments. It should be noted that the following detailed descriptions are illustrative and are intended to provide further explanation of the present application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by those of ordinary skill in the art to which this application belongs.

[0023] See also Figure 1 The embodiment of the present invention provides a method for accurately proportioning ingredients in electric porcelain production, comprising:

[0024] Step 1: Conduct physical and chemical tests on the raw materials entering the factory, eliminate unqualified raw materials, and divide the qualified raw materials into washed clay raw materials and barren raw materials.

[0025] Specifically, physical and chemical testing includes moisture content, impurity content and mineral composition testing.

[0026] Step 2: The washed clay raw material is weighed, hydrated, stirred to form a slurry, sieved, iron removed, and moisture tested in sequence to form a standardized slurry.

[0027] Specifically, the hydration process involves placing washed clay raw materials into a hydration tank, adding water until the solid content reaches 50%-60%, and then allowing the materials to stand for hydration. Screening involves using a vibrating screen to remove sand, gravel, and plant debris. Iron removal is used to remove iron from the slurry.

[0028] Step three: pump the standardized slurry into a slurry storage tank with a stirring device for dynamic storage, and keep the slurry composition uniform by stirring.

[0029] Specifically, the slurry storage tank is provided with a flow meter and a valve for controlling the amount of slurry delivered to the ball mill.

[0030] Step 4: storing the lean raw material in a silo and keeping its composition uniform by stirring.

[0031] Specifically, the silo is connected to the weighing chamber through a pipeline, and a valve for controlling the flow rate is set between the pipeline and the weighing chamber. The flow rate gradually slows down according to the mass of the injected raw materials.

[0032] Step 5: Based on the dry mass calculation system, the dynamically stored clay slurry and the lean raw materials in the silo are added to the ball mill according to the formula ratio, and the water content is compensated according to the moisture content test data of each raw material to complete precise batching.

[0033] Specifically, the dry mass calculation system is as follows: The ball mill is required to produce a billet with a total dry mass m and a target moisture content x, with the total slurry mass M = m / (1-x) and the total water requirement w = x·M. The dry mass of each raw material is then distributed according to the recipe ratio. The moisture content of the dynamically stored clay slurry is lower than the recipe target, allowing for adjustment to compensate for the water content. The lean raw materials and clay slurry are fed directly into the ball mill via pipelines. The lean raw materials are weighed in a weighing chamber before being added, while the clay slurry is pumped into the slurry storage tank using a flowmeter to control its volume.

[0034] Example: A blank with a dry mass of m = 1000 kg and a moisture content of x = 55% is prepared. The blank is composed of 55% lean raw material 1, 10% washed clay 2, 15% washed clay 3, and 20% washed clay 4. The total water required, w, is 1222 kg, and the total slurry mass, M, is 2222 kg.

[0035] The dry mass of each raw material that needs to be put into the ball mill is:

[0036] Lean raw material dry basis mass: m1 = 0.55m = 550kg

[0037] Washed clay second dry basis mass: m2 = 0.1m = 100kg

[0038] Washed clay three dry basis mass: m3 = 0.15m = 150kg

[0039] Washed clay four dry basis mass: m4 = 0.2m = 200kg

[0040] 1. Raw material inspection and storage:

[0041] Incoming raw materials undergo physical and chemical testing, including moisture content, impurity content, and mineral composition, to eliminate unqualified materials. Qualified raw materials are sorted and stored. Clay-based raw materials are washed and transported to the pulping workshop, while lean raw materials are stored in conical silos.

[0042] 2. Washing clay and refining pulping

[0043] Weighing: Weigh an appropriate amount of washed clay to make slurry;

[0044] Hydration: Place the washed clay into the hydration tank, add water to the solid content of 50%-60%, and let it stand for hydration;

[0045] Stirring and slurrying: Use a high-speed mixer to continuously stir to form a homogeneous slurry;

[0046] Screening: Use vibrating screen to remove impurities such as sand, gravel, and plant residues;

[0047] Iron removal: remove iron components;

[0048] Moisture detection: Use a moisture meter to detect the moisture content of the slurry;

[0049] Slurry storage in tank: Pump the slurry into the slurry storage tank for storage.

[0050] 3. Dynamic slurry storage

[0051] Dynamic slurry storage: The mixer in the tank continuously stirs to maintain slurry uniformity. The slurry in the slurry tank is dynamically monitored and water is added dynamically based on the solid content, preset moisture content, and monitored moisture content to ensure the slurry moisture content.

[0052] 4. Ball milling

[0053] Viscosity, moisture and density testing: Use a moisture meter to test the moisture content of different raw materials and record it as x i ,

[0054] Assume that at this time the moisture content of the lean raw material 1 in the silo is x1 = 2%, the moisture content of the washed clay slurry 2 is x2 = 40%, the moisture content of the washed clay slurry 3 is x3 = 45%, and the moisture content of the washed clay slurry 4 is x4 = 42%.

[0055] According to the dry mass of each raw material that needs to be put into the ball mill, the mass of water in each type of raw material entering the ball mill is:

[0056] The mass of water in the lean raw material 1: w1 = x1 / (1-x1)·m1 = 11.22 kg;

[0057] The mass of water in the second step of washing clay: w2 = x2 / (1-x2)·m2 = 66.67 kg;

[0058] The mass of water in the third step of washing clay: w3 = x3 / (1-x3)·m3 = 122.73 kg;

[0059] The mass of water used in washing clay: w4 = x4 / (1-x4)·m4 = 144.82 kg.

[0060] The mass of lean raw material 1 required for the machine is: M1 = m1 + w1 = 561.22 kg;

[0061] The mass of clay required for washing the second clay into the machine is: M2 = m2 + w2 = 166.67 kg;

[0062] The mass of clay required for washing clay 3 is: M3 = m3 + w3 = 272.73 kg;

[0063] The mass of clay 4 required for washing is: M4 = m4 + w4 = 344.82 kg;

[0064] The lean raw materials are transported from the silo into the weighing room for weighing and then put into the ball mill.

[0065] Use a density meter to test the density of different slurries and record it as ρ i Assume that the slurry density ρ2 of the washed clay 2 is 1.2 kg / m 3 The slurry density of washed clay 3 is ρ3, which is 1.3 kg / m 3 The slurry density of washed clay 4 is ρ4, which is 1.4 kg / m 3 .

[0066] The volume of each slurry entering the ball mill is controlled by the flow meter of the slurry storage tank:

[0067] Volume of the second inlet of the washed clay machine: v2 = M2 / ρ2 = 138.83m 3 ;

[0068] Volume of three-input machine for washing clay: v3=M3 / ρ3=209.79m 3 ;

[0069] Volume of the fourth inlet of the washing clay machine: v4 = M4 / ρ4 = 246.3m 3 ;

[0070] 5. Compensation water

[0071] The final water mass that needs to be added to the ball mill is: Z = w-(w1+w2+w3+w4) = 876.56 kg.

[0072] The blanks processed by the ball mill are transferred to the subsequent production process.

[0073] It can be seen from the above embodiments that the present invention effectively removes mineral impurities and iron components through a standardized process of weighing, hydration, screening, and iron removal. The present invention adopts a slurry storage tank with a stirring device in conjunction with a moisture detection and compensation system to achieve real-time regulation of the slurry moisture content and reduce the viscosity fluctuation range. Set the ball mill to prepare a blank with a total dry mass m and a moisture content x, calculate the total amount of slurry M = m / (1-x), and the total water requirement w = xM. Distribute the mass of each raw material in proportion. Through the linkage control of the dry mass calculation system and the slurry storage tank flowmeter, the dry mass of each raw material added to the ball mill is guaranteed to achieve the purpose of precise batching.

[0074] The foregoing description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art will readily appreciate that various modifications and variations of the present invention are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention are intended to be within the scope of protection of the present invention.

Claims

1. A precise batching method for producing electrical porcelain, characterized in that: include: Step 1: Conduct physical and chemical tests on incoming raw materials, remove unqualified raw materials, and separate qualified raw materials into washed clay raw materials and barren raw materials; Step 2: weighing, hydrating, stirring, slurrying, screening, iron removal and moisture testing the washed clay raw material in sequence to form a standardized slurry; Step 3: pumping the standardized slurry into a slurry storage tank with a stirring device for dynamic storage, and maintaining the slurry composition uniform by stirring; Step 4: storing the lean raw material in a silo and stirring to keep its composition uniform; Step 5: Based on the dry mass calculation system, the dynamically stored clay slurry and the lean raw materials in the silo are added to the ball mill according to the formula ratio, and the water content is compensated according to the moisture content test data of each raw material to complete precise batching.

2. A precise batching method for producing electrical porcelain according to claim 1, characterized in that: In step 1, the physical and chemical testing includes testing of moisture content, impurity content and mineral composition.

3. The precise batching method for producing electrical porcelain according to claim 1, characterized in that: In step 2, the hydration is to put the washed clay raw material into a hydration tank, add water to the solid content of 50%-60%, and then stand for hydration.

4. A precise batching method for producing electrical porcelain according to claim 1, characterized in that: In step 2, the screening uses a vibrating screen to remove sand, gravel and plant residues; the iron removal is used to remove iron components in the slurry.

5. The precise batching method for producing electrical porcelain according to claim 1, characterized in that: In step three, the slurry storage tank is provided with a flow meter and a valve for controlling the amount of slurry delivered to the ball mill.

6. A precise batching method for producing electrical porcelain according to claim 1, characterized in that: In step 4, the silo is connected to the weighing chamber through a pipeline, and a valve for controlling the flow rate is set between the pipeline and the weighing chamber, and the flow rate gradually slows down according to the mass of the injected raw materials.

7. A precise batching method for producing electrical porcelain according to claim 1, characterized in that: In step 5, the dry mass calculation system is as follows: set the ball mill to produce a blank with a total dry mass m and a target moisture content x, the total slurry mass M = m / (1-x), and the total water requirement w = x·M; and distribute the dry mass of each raw material according to the formula ratio.

8. A precise batching method for producing electrical porcelain according to claim 7, characterized in that: In step 5, the calculation formula for compensating water content based on the moisture content test data of each raw material is: Z = x·m / (1-x)-Σ[m i ·x i / (1-x i )], i = 1 ~ n, where Z is the compensation water volume, m i is the dry basis mass of the i-th raw material, x i is the moisture content of the i-th raw material.

9. The precise batching method for producing electrical porcelain according to claim 1, characterized in that: In step five, the moisture content of the dynamically stored clay slurry is lower than the target moisture content of the formulation, leaving room for regulating the amount of water to be compensated.

10. The precise batching method for producing electrical porcelain according to claim 1, characterized in that: In step five, the lean raw material and clay slurry are directly added to the ball mill through a pipeline, wherein the lean raw material is weighed in a weighing room and then put in, and the clay slurry is pumped in after the volume is controlled by a flow meter in a slurry storage tank.

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