Fireproof material continuous forming processing device and method based on PLC control

Abstract

This invention provides a PLC-controlled continuous molding and processing device and method for fireproof materials, belonging to the field of molding and processing technology. The device utilizes a PLC-built-in multivariable coupling control algorithm to achieve closed-loop regulation of extrusion speed, conveyor belt speed, and cooling airflow intensity, preventing material accumulation or uneven cooling. It is equipped with a molding conveyor system driven by a power motor and a tensioning roller pneumatic pressure regulating mechanism, combined with a pressure-displacement dual feedback loop to regulate conveyor tension in real time, avoiding slippage and deviation. A molding hydraulic cylinder and telescopic pressure rod are used to stably press the material, and a serpentine cooling air duct rapidly cools the mold, improving molding efficiency. An integrated dust collection system effectively removes dust during the conveying process. When belt breakage or material jamming is detected, the PLC automatically reduces speed and stops the machine, providing fault protection. This invention significantly improves the automation level, production efficiency, and product quality of continuous molding of fireproof materials.

Description

Technical Field

[0001] This invention relates to the field of molding and processing technology, and more specifically, to a PLC-controlled continuous molding and processing apparatus and method for fireproof materials. Background Technology

[0002] With the increasing demands for fire safety in construction, transportation, and industry, the market demand for fire-resistant materials is growing rapidly. To meet the needs of large-scale production, continuous forming and processing equipment for fire-resistant materials has emerged. Currently, various types of equipment for continuous forming and processing of fire-resistant materials exist on the market. While these devices have achieved continuous production of fire-resistant materials to a certain extent, they still have many shortcomings in terms of production efficiency, product quality, automation level, and working environment.

[0003] Most existing continuous forming processing equipment for fire-retardant materials lacks multi-variable, closed-loop control logic. Typically, key parameters such as extrusion speed, conveyor belt speed, and cooling airflow intensity are controlled independently, without effective linkage. When the extrusion speed increases, the conveyor belt speed and cooling airflow intensity cannot be adjusted synchronously according to preset ratios. This easily leads to material accumulation problems, as the conveyor belt speed cannot keep up with the extrusion speed, causing the fire-retardant material to pile up during transport, affecting production continuity and product quality. Simultaneously, uneven cooling also frequently occurs. Because the cooling airflow intensity cannot be adjusted accordingly to the extrusion and conveyor belt speeds, some fire-retardant material may be insufficiently cooled, while other parts may be over-cooled, thus reducing the forming quality of the fire-retardant material.

[0004] Most existing continuous forming processing equipment for fireproof materials lacks a complete dust collection system. During the transportation of fireproof materials, a large amount of dust is generated. Due to the lack of effective dust collection measures, this dust permeates the workshop, not only polluting the working environment and posing a serious threat to the health of operators, but also potentially causing dust to adhere to the fireproof materials, forming impurities and reducing product quality.

[0005] Existing equipment also has shortcomings in the molding and pressing of fireproof materials. The coordination between the molding hydraulic cylinder and the telescopic pressure rod is not precise enough, making it difficult to effectively mold and press the fireproof material, failing to achieve the required shape and density, and thus unable to meet different production needs. Existing continuous molding equipment for fireproof materials is ineffective in cooling the molding die. Some units do not utilize the coordination of components such as the gas serpentine pipeline, filter tank, cold air delivery diversion connecting pipe, cold air delivery pipe, and cold air box to deliver cold air to the molding die, resulting in untimely cooling of the molding die, slow molding speed of the fireproof material, and low production efficiency. Furthermore, excessively high molding die temperatures may also affect the molding quality of the fireproof material, leading to problems such as deformation and cracking.

[0006] Most existing devices lack a dual feedback loop for pressure and displacement. They cannot monitor tension in real time using a pressure sensor mounted on the connecting arm of the adjusting pneumatic cylinder, nor can they detect changes in the position of the tensioning roller using the displacement encoder built into the pneumatic cylinder. Therefore, when the conveyor belt becomes slack or too tight, the PLC cannot dynamically adjust the output pressure of the pneumatic cylinder based on the collected data. Furthermore, in the event of a sudden belt breakage or material jam, existing devices cannot react promptly, failing to immediately reduce the extrusion motor speed and stop the conveyor, easily leading to equipment damage and increased maintenance costs and downtime. Therefore, this paper proposes a PLC-controlled continuous forming processing device and method for fire-retardant materials. Summary of the Invention

[0007] The purpose of this invention is to address the problems raised in the existing background technology. To achieve the above-mentioned objective, this invention provides the following technical solution: a PLC-controlled continuous molding and processing device for fireproof materials, including a maintenance platform. Maintenance support rods are fixed to the four corners of the bottom of the maintenance platform, and a maintenance staircase is welded to the stair section of the maintenance platform. Staircase railings are installed on both sides of the maintenance staircase. A main frame of a conveyor belt is provided between the four corners of the maintenance support rods. Adjustable pulleys for the main frame are bolted to the bottom side of the main frame, and an adjusting slide rail for the molding conveyor belt is connected below the adjusting pulleys.

[0008] As a preferred technical solution of the present invention, a conveyor belt dust collection trough housing is installed inside the middle section of the main frame of the conveyor belt, and a dust collection trough hole is provided on the upper side of the conveyor belt dust collection trough housing.

[0009] As a preferred technical solution of the present invention, the two ends of the main frame of the conveyor belt are respectively rotatably connected to conveyor belt rotating rollers, and a fireproof material forming conveyor belt is nested on the outer surface of the conveyor belt rotating rollers, wherein a fireproof material forming conveyor belt power motor is connected to one side of the conveyor belt rotating rollers.

[0010] As a preferred technical solution of the present invention, a fireproof material forming conveying and dust collection pipe is embedded in the main frame of the conveyor belt, the other end of the fireproof material forming conveying and dust collection pipe is connected to the conveyor belt dust collection fan blade, a dust collection and exhaust pipe is installed on the outside of the conveyor belt dust collection fan blade, and a bottom mounting bracket is embedded below the dust collection and exhaust pipe.

[0011] As a preferred technical solution of the present invention, a fireproof molded conveyor belt dust collection motor is installed on the top of the bottom mounting frame. The power output end of the fireproof molded conveyor belt dust collection motor is rotatably connected to a dust collection motor rotating shaft, and the dust collection motor rotating shaft is connected to the dust collection fan blades of the conveyor belt.

[0012] As a preferred technical solution of the present invention, the main frame of the conveyor belt is provided with a bottom rod, and side plates are fixed on both sides of the bottom rod. A fireproof material conveying roller is rotatably connected between the middle sections of the side plates. One side of the fireproof material conveying roller is connected to the conveying roller rotating shaft, and a power transmission belt is nested on the outer shaft of the conveying roller rotating shaft.

[0013] As a preferred technical solution of the present invention, a fireproof material conveying motor is installed on the bottom outer plate of the side plate, and the rotating shaft on the power end of the fireproof material conveying motor is connected to the power transmission belt.

[0014] As a preferred technical solution of the present invention, an inclined rod is fixed on the inner plate surface of the side plate, and an adjusting U-shaped groove is provided on the top rod of the inclined rod. A tensioning roller is connected to the adjusting U-shaped groove, and adjusting shafts are installed at both ends of the tensioning roller.

[0015] As a preferred technical solution of the present invention, a lever-adjustable air pressure cylinder is installed at the tail end of the fireproof material conveying motor. An air pressure cylinder adjusting rod is slidably connected inside the lever-adjustable air pressure cylinder, and an adjusting air pressure rod connecting arm is connected to the top rod of the air pressure cylinder adjusting rod.

[0016] As a preferred technical solution of the present invention, the other end of the adjusting air pressure rod connecting arm is connected to the connecting arm rotating shaft, and the connecting arm rotating shaft is embedded in the side plate, and the other end is connected to the fireproof material output receiving buckle rod, and the top of the fireproof material output receiving buckle rod is equipped with a buckle rod C-shaped buckle.

[0017] The upper and lower ends of the side plate are respectively connected to guide conveyor rollers, and an intermediate support platform is installed between the main frame of the conveyor belt and the bottom rod.

[0018] A forming mold is installed on the bottom plate of the inspection platform. A U-shaped air supply pipe for cold air is embedded on the side of the forming mold, and a forming hydraulic cylinder is installed on the top plate. A telescopic pressure rod is slidably connected to the forming hydraulic cylinder.

[0019] The molding die is provided with a serpentine gas delivery pipe above it. The end of the serpentine gas delivery pipe is connected to a filter tank. The other side of the filter tank is connected to a cold air delivery diversion pipe. The cold air delivery diversion pipe is connected to a cold air delivery pipe, and the cold air delivery pipe is connected to a cold air box. A connecting flange is nested on the outer pipe.

[0020] A fireproof material extrusion motor is installed on the bottom plate of the maintenance platform. A motor power transmission belt is connected to the fireproof material extrusion motor. The other end of the motor power transmission belt is connected to a spiral extrusion rotating shaft. A spiral extrusion tube is connected to one side of the spiral extrusion rotating shaft. Spiral extrusion spiral blades are provided on the outside of the spiral extrusion tube.

[0021] A method for a PLC-controlled continuous forming and processing device for fireproof materials, step 1: device foundation construction; step 11: installation of maintenance platform and related components, determine a suitable location at the device installation site, place the maintenance platform, fix maintenance support rods at the four corners of the bottom of the maintenance platform to ensure the stability of the maintenance platform; weld maintenance stairs to the stair section of the maintenance platform, and install stair railings on both sides of the maintenance stairs to ensure the safety of personnel going up and down the maintenance platform.

[0022] Step 12: Install the main frame of the conveyor belt. Install the main frame of the conveyor belt between the four corners of the maintenance support rod. Fix the adjusting pulley of the main frame to the bottom side of the main frame of the conveyor belt with bolts. Connect the adjusting pulley of the main frame to the adjusting slide rail of the forming conveyor belt so that the main frame of the conveyor belt can move on the adjusting slide rail of the forming conveyor belt, which is convenient for subsequent position adjustment.

[0023] Step 2, Conveyor Belt and Dust Collection System Installation: Step 21, Conveyor Belt Installation: Rotate and install conveyor belt rotating rollers at both ends of the main frame of the conveyor belt, and nest the fireproof material forming conveyor belt on the outer surface of the conveyor belt rotating rollers; connect the power motor of the fireproof material forming conveyor belt to one side of the conveyor belt rotating rollers to provide power to the fireproof material forming conveyor belt;

[0024] Step 22: Installation of the dust collection system. Install the dust collection trough housing inside the middle section of the main frame of the conveyor belt, and open dust collection trough holes on the dust collection trough housing; embed the fireproof molded conveyor dust collection pipe into the main frame of the conveyor belt, and connect the other end of the pipe to the conveyor belt dust collection fan blades; install the dust collection exhaust pipe outside the conveyor belt dust collection fan blades; embed a bottom mounting bracket below the dust collection exhaust pipe; install the fireproof molded conveyor belt dust collection motor on the top of the bottom mounting bracket; rotatably connect the rotating shaft of the dust collection motor to the power output end of the fireproof molded conveyor belt dust collection motor, and connect the rotating shaft of the dust collection motor to the conveyor belt dust collection fan blades to start the dust collection function;

[0025] Step 3, Installation of Fireproof Material Conveying Components: Step 31, Installation of Conveying Roller and Power Components: Install a base rod on the main frame of the conveyor belt, fix side plates on both sides of the base rod, and rotatably connect the fireproof material conveying roller between the middle sections of the side plates; connect the rotating shaft of the conveying roller to one side of the fireproof material conveying roller, and nest a power transmission belt on the outer shaft of the rotating shaft of the conveying roller; install the fireproof material conveying motor on the bottom outer plate of the side plate, and connect the rotating shaft on the power end of the fireproof material conveying motor to the power transmission belt to provide rotational power for the fireproof material conveying roller;

[0026] Step 32: Install the tensioning roller and adjusting components. Fix the inclined rod on the inner plate of the side plate. Set the adjusting U-shaped buckle groove on the top rod of the inclined rod. Connect the adjusting buckle shafts at both ends of the tensioning roller to the adjusting U-shaped buckle groove. Install the buckle adjusting air cylinder at the tail of the fireproof material conveying motor. Slidably connect the air cylinder adjusting rod inside the buckle adjusting air cylinder. Connect the top rod of the air cylinder adjusting rod to the adjusting air rod connecting arm. Embed the connecting arm shaft at the other end of the adjusting air rod connecting arm into the side plate, so that its other end is connected to the fireproof material output receiving buckle rod. Install the buckle rod C-shaped buckle on the top of the fireproof material output receiving buckle rod.

[0027] Step 33: Installation of guide conveyor rollers and support platform. Connect guide conveyor rollers to the upper and lower ends of the side plate respectively. Install the intermediate support platform between the main frame of the conveyor belt and the bottom rod to provide support and guidance.

[0028] Step 4: Installation of molding die and related components:

[0029] Step 41: Installation of molding mold and hydraulic cylinder. Install the molding mold on the bottom plate of the inspection platform and embed a U-shaped air supply pipe for cold air into the side of the molding mold. Install the molding hydraulic cylinder on the top plate of the molding mold and slide a telescopic pressure rod on the molding hydraulic cylinder for molding and pressing the fireproof material.

[0030] Step 42: Install the cold air delivery system. Set up a serpentine air delivery pipe above the molding die. Connect the end of the serpentine air delivery pipe to the filter tank. Connect the other side of the filter tank to the cold air delivery diversion connection pipe. Connect the cold air delivery pipe to the cold air delivery diversion connection pipe. Connect the cold air delivery pipe to the cold air box. Nest a flange on the outer pipe to deliver cold air to cool the molding die.

[0031] Step 5: Install the fireproof material extrusion component on the bottom plate of the inspection platform and install the fireproof material extrusion motor. Connect the motor power transmission belt to the fireproof material extrusion motor. Connect the other end of the motor power transmission belt to the spiral extrusion rotating shaft. Connect one side of the spiral extrusion rotating shaft to the spiral extrusion tube. Set the spiral extrusion spiral blades on the outside of the spiral extrusion tube for extruding fireproof material.

[0032] Step 6, Debugging and Operation: Inspect all components of the entire device to ensure they are securely installed and correctly connected; connect the power and air pressure sources, and start the power motor of the fireproof material forming conveyor belt, the dust collection motor of the fireproof material forming conveyor belt, the fireproof material conveying motor, the forming hydraulic cylinder, and the fireproof material extrusion motor, and check the operation of each component; adjust the lever to adjust the air pressure cylinder, and adjust the position of the tension roller and the fireproof material output receiving lever to ensure the stability of the fireproof material conveying; turn on the cooling box and check whether the cooling conveying system is working properly and can cool the forming mold; conduct a trial run of the device.

[0033] Compared with existing technologies, the beneficial effects of this invention are as follows: The multi-variable linkage closed-loop control logic of this invention involves a PLC with a built-in multi-variable coupling control algorithm. This algorithm controls the extrusion speed of the fireproof material by the fireproof material extrusion motor, the conveyor belt speed by the fireproof material forming conveyor belt power motor, and the cooling airflow intensity by the cooling air box regulating valve. When the extrusion speed increases, the PLC automatically and synchronously increases the conveyor belt speed according to a preset ratio and increases the cooling air delivery volume to prevent material accumulation or uneven cooling.

[0034] By installing rotating rollers at both ends of the main frame of the conveyor belt and nesting them with fireproof material forming conveyor belts, and providing power from the fireproof material forming conveyor belt's motor, stable and efficient conveying of fireproof materials can be achieved, ensuring the continuity of the production process and improving production efficiency.

[0035] The installation of the dust collection system involves the coordination of components such as the conveyor belt dust collection trough housing, dust collection trough holes, fireproof material molding conveyor dust collection pipe, conveyor belt dust collection fan blades, dust collection exhaust pipe, and fireproof material molding conveyor belt dust collection motor. It can effectively remove dust generated during the conveying process, reduce dust pollution in the workshop, improve the working environment, protect the health of operators, and also help improve product quality and prevent dust from causing impurities to contaminate the fireproof materials.

[0036] The coordinated operation of the fireproof material conveying motor, power transmission belt, and conveyor roller rotation shaft provides stable rotational power to the fireproof material conveying roller, allowing for flexible adjustment of the conveying speed according to production needs and ensuring smooth conveying of the fireproof material. The tensioning roller and adjustment components, utilizing lever-adjustable pneumatic cylinders, pneumatic cylinder adjusting rods, and adjusting pneumatic rod connecting arms, facilitate easy adjustment of the tensioning roller's position, thereby adjusting the tension during fireproof material conveying, ensuring the stability of the fireproof material conveying, and reducing slippage and deviation problems during conveying. The connection of guide conveyor rollers at the upper and lower ends of the side plates and the installation of intermediate support platforms between the main conveyor frame and the bottom rod provide excellent support and guidance for the fireproof material, ensuring accurate delivery to the designated location and improving production precision and quality.

[0037] The combination of the forming hydraulic cylinder and the telescopic pressure rod effectively shapes and presses fireproof materials, achieving the required shape and density to meet diverse production needs. Through the coordination of components such as the air-supply serpentine pipe, filter tank, cold air delivery steering connection pipe, cold air delivery pipe, and cold air box, cold air is delivered to the forming mold, cooling it, accelerating the forming speed of the fireproof material, improving production efficiency, and also helping to ensure the forming quality of the fireproof material. The combination of components such as the fireproof material extrusion motor, motor power transmission belt, spiral extrusion rotating shaft, and spiral extrusion tube ensures uniform and stable extrusion of the fireproof material. A dual pressure-displacement feedback loop is established between the fireproof material conveying motor and the adjusting pneumatic cylinder: a pressure sensor installed on the adjusting pneumatic cylinder connecting arm monitors the tension force in real time; a displacement encoder built into the adjusting pneumatic cylinder detects changes in the position of the tensioning roller. The PLC determines whether the conveyor belt is too loose or too tight based on the collected data and dynamically adjusts the output pressure of the pneumatic cylinder. When a sudden belt breakage or material jamming is detected, the PLC immediately reduces the speed of the fireproof material extrusion motor and stops conveying to prevent equipment damage. Attached Figure Description

[0038] Figure 1 This is a schematic diagram of the structure provided by the present invention;

[0039] Figure 2 A schematic diagram of the spiral extrusion tube structure provided by the present invention;

[0040] Figure 3 A schematic diagram of the cold air delivery pipe structure provided by the present invention;

[0041] Figure 4 A schematic diagram of the dust extraction and exhaust pipe structure provided by the present invention;

[0042] Figure 5 This is a schematic diagram of the dust extraction channel and hole structure provided by the present invention;

[0043] Figure 6 This is a schematic diagram of the lever-adjusting pneumatic cylinder structure provided by the present invention;

[0044] Figure 7 A schematic diagram of the guide conveyor roller structure provided by the present invention;

[0045] Figure 8 A schematic diagram of the fireproof material conveying roller structure provided by the present invention;

[0046] Figure 9 A schematic diagram of the spiral extrusion blade structure provided by the present invention.

[0047] The image shows:

[0048] 1. Inspection platform; 2. Inspection support rod; 3. Inspection staircase; 4. Staircase railing; 5. Main frame of conveyor belt; 6. Adjustable pulley of main frame; 7. Adjustable slide rail of forming conveyor belt; 8. Dust extraction trough housing of conveyor belt; 9. Dust extraction trough holes; 10. Rotating roller of conveyor belt; 11. Fireproof material forming conveyor belt; 12. Power motor of fireproof material forming conveyor belt; 13. Dust extraction pipe of fireproof material forming conveyor belt; 14. Dust extraction fan blade of conveyor belt; 15. Dust extraction and exhaust pipe; 16. Bottom mounting frame; 17. Dust extraction motor of fireproof material forming conveyor belt; 18. Rotating shaft of dust extraction motor; 19. Base rod; 20. Side plate; 21. Fireproof material conveying roller; 22. Rotating shaft of conveying roller; 23. Power transmission belt; 24. Fireproof material conveying motor; 25. Diagonal rod; 26. Adjusting U-shaped groove; 27. Tensioning roller; 28. Adjusting buckle shaft; 29. ​​Buckle rod adjusting pneumatic cylinder; 30. Pneumatic cylinder adjusting air rod; 31. Adjusting pneumatic rod connecting arm; 32. Connecting arm rotating shaft; 33. Fireproof material output receiving buckle rod; 34. Buckle rod C-shaped buckle; 35. Guide conveyor roller; 36. Intermediate section support platform; 37. Forming mold; 38. Cold air U-shaped air supply pipe; 39. Forming hydraulic cylinder; 40. Telescopic pressure rod; 41. Air supply serpentine pipe; 42. Filter tank; 43. Cold air supply turning connecting pipe; 44. Cold air supply pipe; 45. Cold air box; 46. Connecting flange; 47. Fireproof material extrusion motor; 48. Motor power transmission belt; 49. Spiral extrusion rotating shaft; 50. Spiral extrusion pipe; 51. Spiral extrusion spiral blade. Detailed Implementation

[0049] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments.

[0050] Therefore, the following detailed description of the embodiments of the present invention is not intended to limit the scope of the claimed invention, but merely illustrates some embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention. It should be noted that, in the absence of conflict, the embodiments and features and technical solutions in the embodiments of the present invention can be combined with each other. It should be noted that similar reference numerals and letters in the following figures indicate similar items; therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0051] Example 1: Please refer to Figure 1A PLC-controlled continuous molding and processing device for fireproof materials includes a maintenance platform 1. Maintenance support rods 2 are fixed at the four corners of the bottom of the maintenance platform 1. Maintenance stairs 3 are welded to the stair section of the maintenance platform 1. Stair railings 4 are installed on both sides of the maintenance stairs 3. A conveyor belt main frame 5 is provided between the four corners of the maintenance support rods 2. Adjustable pulleys 6 are bolted to the bottom side of the conveyor belt main frame 5. Adjustable slide rails 7 of the molding conveyor belt are connected below the main frame adjusting pulleys 6.

[0052] Please refer to Figure 5 The conveyor belt main frame 5 has a conveyor belt dust collection trough housing 8 installed inside the middle section, and the upper side of the conveyor belt dust collection trough housing 8 is provided with dust collection trough holes 9.

[0053] The main frame 5 of the conveyor belt is rotatably connected to two ends of the conveyor belt rotating roller 10, and the outer surface of the conveyor belt rotating roller 10 is nested with a fireproof material forming conveyor belt 11. The fireproof material forming conveyor belt power motor 12 is connected to one side of the conveyor belt rotating roller 10.

[0054] Please refer to Figure 4 Fireproof material molded conveyor dust suction pipe 13 is embedded on the main frame 5 of the conveyor belt. The other end of the fireproof material molded conveyor dust suction pipe 13 is connected to the conveyor belt dust suction fan blade 14. A dust suction exhaust pipe 15 is installed on the outside of the conveyor belt dust suction fan blade 14, and a bottom mounting bracket 16 is embedded below the dust suction exhaust pipe 15.

[0055] The bottom mounting bracket 16 is equipped with a fireproof molded conveyor belt dust collection motor 17. The power output end of the fireproof molded conveyor belt dust collection motor 17 is rotatably connected to the dust collection motor rotating shaft 18, and the dust collection motor rotating shaft 18 is connected to the conveyor belt dust collection fan blade 14.

[0056] Please refer to Figure 8 The main frame 5 of the conveyor belt is equipped with a bottom rod 19, and side plates 20 are fixed on both sides of the bottom rod 19. A fireproof material conveying roller 21 is rotatably connected between the middle sections of the side plates 20. One side of the fireproof material conveying roller 21 is connected to a conveying roller rotating shaft 22, and a power transmission belt 23 is nested on the outer shaft of the conveying roller rotating shaft 22. A fireproof material conveying motor 24 is installed on the bottom outer plate of the side plate 20, and the rotating shaft on the power end of the fireproof material conveying motor 24 is connected to the power transmission belt 23.

[0057] Please refer to Figure 7 An inclined rod 25 is fixed on the inner plate surface of the side plate 20. An adjusting U-shaped groove 26 is provided on the top rod of the inclined rod 25. A tensioning roller 27 is connected to the adjusting U-shaped groove 26, and adjusting shafts 28 are installed at both ends of the tensioning roller 27.

[0058] Please refer to Figure 6The tail of the fireproof material conveying motor 24 is equipped with a lever-adjusting pneumatic cylinder 29. The lever-adjusting pneumatic cylinder 29 is slidably connected to a pneumatic cylinder adjusting rod 30. The top rod of the pneumatic cylinder adjusting rod 30 is connected to the adjusting pneumatic rod connecting arm 31.

[0059] The other end of the adjusting air pressure rod connecting arm 31 is connected to the connecting arm pivot 32, and the connecting arm pivot 32 is embedded in the side plate 20. The other end is connected to the fireproof material output receiving rod 33, and a rod C-shaped buckle 34 is installed on the top of the fireproof material output receiving rod 33.

[0060] The upper and lower ends of the side plate 20 are respectively connected to the guide conveyor rollers 35, and the intermediate section support platform 36 is installed between the main frame of the conveyor belt 5 and the bottom rod 19.

[0061] Please refer to Figure 2 A forming mold 37 is installed on the bottom plate of the inspection platform 1. A U-shaped air supply pipe 38 for cold air is embedded on the side of the forming mold 37, and a forming hydraulic cylinder 39 is installed on the top plate. A telescopic pressure rod 40 is slidably connected to the forming hydraulic cylinder 39.

[0062] Please refer to Figure 3 A gas delivery serpentine pipe 41 is provided above the molding die 37. The end of the gas delivery serpentine pipe 41 is connected to a filter tank 42. The other side of the filter tank 42 is connected to a cold air delivery diversion pipe 43. A cold air delivery pipe 44 is connected to the cold air delivery pipe 43, and a cold air box 45 is connected to the cold air delivery pipe 44. A connecting flange 46 is nested on the outer pipe.

[0063] Please refer to Figure 9 A fireproof material extrusion motor 47 is installed on the bottom plate of the inspection platform 1. A motor power transmission belt 48 is connected to the fireproof material extrusion motor 47. The other end of the motor power transmission belt 48 is connected to the spiral extrusion rotating shaft 49. A spiral extrusion tube 50 is connected to one side of the spiral extrusion rotating shaft 49. Spiral extrusion spiral blades 51 are provided on the outside of the spiral extrusion tube 50.

[0064] Example 2: Method for continuous molding and processing device of fireproof material based on PLC control, Step 1, device foundation construction: Step 11, installation of inspection platform and related components, determine a suitable location at the device installation site, place the inspection platform 1, fix the inspection support rods 2 at the four corners of the bottom of the inspection platform 1 to ensure the stability of the inspection platform 1; weld the inspection staircase 3 to the stair section of the inspection platform 1, and install the stair railings 4 on both sides of the inspection staircase 3 to ensure the safety of personnel going up and down the inspection platform;

[0065] Step 12: Install the main frame of the conveyor belt. Install the main frame of the conveyor belt 5 between the four corners of the maintenance support rod 2. Fix the main frame adjusting pulley 6 to the bottom side of the main frame of the conveyor belt 5 with bolts. Connect the main frame adjusting pulley 6 to the forming conveyor belt adjusting slide rail 7 so that the main frame of the conveyor belt 5 can move on the forming conveyor belt adjusting slide rail 7, which is convenient for subsequent position adjustment.

[0066] Step 2, Installation of Conveyor Belt and Dust Collection System: Step 21, Installation of Conveyor Belt: Rotate and install conveyor belt rotating rollers 10 at both ends of the main frame 5 of the conveyor belt, and nest the fireproof material forming conveyor belt 11 on the outer surface of the conveyor belt rotating rollers 10; connect the fireproof material forming conveyor belt power motor 12 to one side of the conveyor belt rotating rollers 10 to provide power to the fireproof material forming conveyor belt 11;

[0067] Step 22: Installation of the dust collection system. A dust collection trough housing 8 is installed inside the middle section of the main frame 5 of the conveyor belt, and dust collection trough holes 9 are opened on the housing 8. A fire-retardant molded conveyor dust collection pipe 13 is embedded into the main frame 5 of the conveyor belt, with its other end connected to a conveyor belt dust collection fan blade 14. A dust collection exhaust pipe 15 is installed outside the conveyor belt dust collection fan blade 14. A bottom mounting bracket 16 is embedded below the dust collection exhaust pipe 15. A fire-retardant molded conveyor belt dust collection motor 17 is installed on top of the bottom mounting bracket 16. The rotating shaft 18 of the dust collection motor is rotatably connected to the power output end of the fire-retardant molded conveyor belt dust collection motor 17, and the rotating shaft 18 of the dust collection motor is connected to the conveyor belt dust collection fan blade 14 to activate the dust collection function.

[0068] Step 3, Installation of fireproof material conveying components: Step 31, Installation of conveying rollers and power components: Install a base rod 19 on the main frame 5 of the conveyor belt, fix side plates 20 on both sides of the base rod 19, and rotatably connect the fireproof material conveying roller 21 between the middle sections of the side plates 20; connect the conveying roller rotating shaft 22 to one side of the fireproof material conveying roller 21, and nest the power transmission belt 23 on the outer shaft of the conveying roller rotating shaft 22; install the fireproof material conveying motor 24 on the bottom outer plate of the side plate 20, and connect the rotating shaft on the power end of the fireproof material conveying motor 24 to the power transmission belt 23 to provide rotational power for the fireproof material conveying roller 21;

[0069] Step 32: Installation of tensioning roller and adjusting components. Fix the inclined rod 25 on the inner plate surface of the side plate 20. Set the adjusting U-shaped buckle groove 26 on the top rod of the inclined rod 25. Connect the adjusting buckle shafts 28 at both ends of the tensioning roller 27 to the adjusting U-shaped buckle groove 26. Install the buckle adjusting air cylinder 29 at the tail of the fireproof material conveying motor 24. Slidably connect the air cylinder adjusting rod 30 inside the buckle adjusting air cylinder 29. Connect the top rod of the air cylinder adjusting rod 30 to the adjusting air rod connecting arm 31. Embed the connecting arm rotating shaft 32 at the other end of the adjusting air rod connecting arm 31 into the side plate 20, so that its other end is connected to the fireproof material output receiving buckle 33. Install the buckle C-shaped buckle 34 on the top of the fireproof material output receiving buckle 33.

[0070] Step 33: Installation of guide conveyor rollers and support platform. Guide conveyor rollers 35 are connected to the upper and lower ends of the side plate 20 respectively. The middle section support platform 36 is installed between the main frame of the conveyor belt 5 and the bottom rod 19 to provide support and guidance.

[0071] Step 4: Installation of molding die and related components:

[0072] Step 41: Installation of molding mold and hydraulic cylinder. Install molding mold 37 on the bottom plate of inspection platform 1, and embed cold air U-shaped gas pipe 38 on the side of molding mold 37; install molding hydraulic cylinder 39 on the top plate of molding mold 37, and slide telescopic pressure rod 40 on molding hydraulic cylinder 39 for molding and pressing fireproof material.

[0073] Step 42: Installation of the cold air delivery system. A serpentine air delivery pipe 41 is installed above the molding die 37. The end of the serpentine air delivery pipe 41 is connected to the filter tank 42. The other side of the filter tank 42 is connected to the cold air delivery diversion connecting pipe 43. A cold air delivery pipe 44 is connected to the cold air delivery diversion connecting pipe 43. The cold air delivery pipe 44 is connected to the cold air box 45. A flange 46 is nested on the outer pipe for delivering cold air to cool the molding die.

[0074] Step 5: Fireproof material extrusion component is installed on the bottom plate of inspection platform 1. Fireproof material extrusion motor 47 is installed, and motor power transmission belt 48 is connected to fireproof material extrusion motor 47. The other end of motor power transmission belt 48 is connected to spiral extrusion rotating shaft 49. One side of spiral extrusion rotating shaft 49 is connected to spiral extrusion tube 50. Spiral extrusion spiral blades 51 are set outside spiral extrusion tube 50 for extruding fireproof material.

[0075] Step 6, Debugging and Operation: Inspect all components of the entire device to ensure they are securely installed and correctly connected; connect the power and air pressure sources, and start the fireproof material forming conveyor belt motor 12, the fireproof material forming conveyor belt dust extraction motor 17, the fireproof material conveying motor 24, the forming hydraulic cylinder 39, and the fireproof material extrusion motor 47, and check the operation of each component; adjust the lever to adjust the air pressure cylinder 29, and adjust the position of the tension roller 27 and the fireproof material output receiving lever 33 to ensure the stability of the fireproof material conveying; turn on the cooling box 45 and check whether the cooling conveying system is working properly and can cool the forming mold; conduct a trial run of the device.

[0076] Example 3: A PLC-controlled continuous forming and processing device for fire-retardant materials, with multi-variable linkage closed-loop control logic: The PLC has a built-in multi-variable coupling control algorithm, which links the extrusion speed of the fire-retardant material to the extrusion motor 47, the conveyor belt speed to the forming conveyor belt power motor 12, and the cooling airflow intensity to the regulating valve of the cooling air box 45. When the extrusion speed increases, the PLC automatically and synchronously increases the conveyor belt speed according to a preset ratio and increases the cooling air delivery volume to prevent material accumulation or uneven cooling.

[0077] A dual pressure-displacement feedback loop is established between the fireproof material conveying motor 24 and the adjusting pneumatic cylinder 29: a pressure sensor installed on the adjusting pneumatic cylinder connecting arm 31 monitors the tension force in real time; a displacement encoder built into the adjusting pneumatic cylinder rod 30 detects changes in the position of the tensioning roller 27. The PLC determines whether the fireproof material forming conveyor belt 11 is too loose or too tight based on the collected data and dynamically adjusts the output pressure of the pneumatic cylinder. When a sudden belt breakage or material jamming is detected, the PLC immediately reduces the speed of the fireproof material extrusion motor 47 and stops conveying to prevent equipment damage.

[0078] The pneumatic tensioning mechanism is deeply integrated with PLC feedback control to achieve real-time sensing and active compensation of the tension status, which is superior to traditional fixed or manual adjustment methods. Intelligent mold temperature prediction and cooling air regulation algorithm: A multi-point temperature sensor array is arranged inside the molding mold 37 to collect the temperature distribution of different areas of the mold in real time; the PLC runs a built-in heat conduction prediction model, combined with the extrusion rate and material type, to predict the mold's heating trend; the opening of the electric valve on the cooling air delivery diversion connecting pipe 43 is automatically adjusted to dynamically control the cooling intensity of the U-shaped cooling air delivery pipe 38; it supports a "segmented cooling" mode: high cooling speed at the front end for rapid shaping, and slow cooling at the rear end to reduce internal stress. Breaking through the limitations of traditional constant temperature control, a predictive temperature control algorithm is introduced, balancing cooling effect and energy consumption optimization.

[0079] The PLC system integrates a fault knowledge base for fault self-diagnosis and remote operation and maintenance interfaces, which can identify common abnormal modes such as motor overload, insufficient air pressure, and blockage warnings. When an abnormality occurs, it automatically pops up fault codes and handling suggestions, such as: "E203 – Fireproof material molding conveyor belt dust suction motor 17 stalled, please check conveyor belt dust suction fan blade 14". It supports uploading operating data to the cloud platform via industrial Ethernet or 4G module to realize remote monitoring, parameter adjustment and firmware upgrade. It can connect to MES / ERP systems to realize automatic archiving of production data and production scheduling.

[0080] The PLC is equipped with a touchscreen human-machine interface (HMI), allowing operators to select different material types such as calcium silicate board and magnesium oxide fireproof board. Each material corresponds to a set of process formulas, including: extrusion speed settings corresponding to the extrusion motor frequency of the fireproof material (47); molding pressure and hydraulic cylinder pressure threshold (39); cooling time and air flow rate; and conveyor belt speed curve. The system can store ≥50 sets of formulas, which can be recalled with a single click when switching products without resetting. This enables flexible "one machine, multiple materials" production, significantly improving the equipment's applicability and changeover efficiency.

[0081] The PLC establishes multiple safety interlocking logics: if the guardrail door of the inspection platform 1 is not closed, the fireproof material extrusion motor 47 and the conveying system are prohibited from starting; if the dust collection motor 17 of the fireproof material forming conveyor belt stops for more than 10 seconds, an automatic alarm is triggered and a risk of dust accumulation is indicated; during the downward movement of the forming hydraulic cylinder 39, if the telescopic pressure rod 40 does not reach the predetermined position, it is determined to be a mold jam, and the system immediately stops and reverses; if the C-type buckle 34 is not returned to its original position, the next batch of output is prohibited. This deeply integrates mechanical safety with electrical control, constructing a full-chain safety protection system that complies with ISO 13849 standards.

[0082] The PLC monitors the power consumption of each motor in real time and adopts a frequency conversion energy-saving strategy: during periods of no material and no load, the speed of the power motor 12 of the fireproof material forming conveyor belt is automatically reduced to standby mode; the dust collection motor 17 of the fireproof material forming conveyor belt is only started when the material passes through the dust collection area, and is in sleep mode at other times.

[0083] The above embodiments are only used to illustrate the present invention and are not intended to limit the technical solutions described herein. Although the present invention has been described in detail with reference to the above embodiments, the present invention is not limited to the specific embodiments described above. Therefore, any modifications or substitutions to the present invention, as well as all technical solutions and improvements that do not depart from the spirit and scope of the invention, are covered within the scope of the claims of the present invention.

Claims

1. A PLC-controlled continuous forming and processing device for fireproof materials, comprising a maintenance table (1), characterized in that, The inspection platform (1) has four corners at the bottom, each fixed with an inspection support rod (2). The inspection platform (1) has a staircase (3) welded to its stair section. The inspection staircase (3) has railings (4) installed on both sides. The inspection support rod (2) has a conveyor belt main frame (5) between its four corners. The conveyor belt main frame (5) has a main frame adjusting pulley (6) bolted to its bottom side. The main frame adjusting pulley (6) is connected to a forming conveyor belt adjusting slide rail (7). The conveyor belt main frame (5) has a conveyor belt dust collection groove housing (8) installed inside its middle section. The conveyor belt dust collection groove housing (8) has a dust collection groove hole (9) on its upper side. The two ends of the conveyor belt main frame (5) are rotatably connected to a conveyor belt rotating roller (10). The outer surface of the conveyor belt rotating roller (10) is nested with a fireproof material forming conveyor belt (11). The fireproof material forming conveyor belt power motor (12) is connected to one side of the conveyor belt rotating roller (10). A fireproof material molding conveyor dust collection pipe (13) is embedded in the main frame (5) of the conveyor belt. The other end of the fireproof material molding conveyor dust collection pipe (13) is connected to the conveyor belt dust collection fan blade (14). A dust collection exhaust pipe (15) is installed on the outside of the conveyor belt dust collection fan blade (14). A bottom mounting bracket (16) is embedded below the dust collection exhaust pipe (15). A fireproof material molding conveyor belt dust collection motor (17) is installed on the top of the bottom mounting bracket (16). The power output end of the fireproof material molding conveyor belt dust collection motor (17) is... A vacuum motor rotating shaft (18) is rotatably connected, and the vacuum motor rotating shaft (18) is connected to the vacuum fan blades (14) of the conveyor belt. A bottom rod (19) is provided on the main frame (5) of the conveyor belt. Side plates (20) are fixed on both sides of the bottom rod (19). A fireproof material conveying roller (21) is rotatably connected between the middle sections of the side plates (20). A conveying roller rotating shaft (22) is connected to one side of the fireproof material conveying roller (21). A power transmission belt (23) is nested on the outer shaft of the conveying roller rotating shaft (22). A fireproof material conveying motor (24) is installed on the bottom outer plate of the side plate (20), and the rotating shaft on the power end of the fireproof material conveying motor (24) is connected to the power transmission belt (23); An inclined rod (25) is fixed on the inner plate surface of the side plate (20). An adjusting U-shaped groove (26) is provided on the top rod of the inclined rod (25). A tensioning roller (27) is connected to the adjusting U-shaped groove (26). Adjusting shafts (28) are installed at both ends of the tensioning roller (27). The fireproof material conveying motor (24) is equipped with a lever-adjusting pneumatic cylinder (29) at its tail. The lever-adjusting pneumatic cylinder (29) is slidably connected to a pneumatic cylinder adjusting rod (30). The top rod of the pneumatic cylinder adjusting rod (30) is connected to an adjusting pneumatic rod connecting arm (31). The other end of the regulating air pressure rod connecting arm (31) is connected to the connecting arm pivot (32), and the connecting arm pivot (32) is embedded in the side plate (20). The other end is connected to the fireproof material output receiving buckle (33), and the top of the fireproof material output receiving buckle (33) is equipped with a buckle C-shaped buckle (34).

2. The PLC-controlled continuous forming and processing device for fireproof materials according to claim 1, characterized in that, The upper and lower ends of the side plate (20) are respectively connected to guide conveyor rollers (35), and an intermediate support platform (36) is installed between the main frame of the conveyor belt (5) and the bottom rod (19).

3. The PLC-controlled continuous forming and processing device for fireproof materials according to claim 2, characterized in that, The inspection platform (1) has a forming mold (37) installed on its base plate. A U-shaped air supply pipe (38) for cold air is embedded on the side of the forming mold (37). A forming hydraulic cylinder (39) is installed on the top plate of the forming mold (37). A telescopic pressure rod (40) is slidably connected to the forming hydraulic cylinder (39).

4. The PLC-controlled continuous forming and processing device for fireproof materials according to claim 3, characterized in that, The molding die (37) is provided with a gas delivery serpentine pipe (41) above it. The end of the gas delivery serpentine pipe (41) is connected to a filter tank (42). The other side of the filter tank (42) is connected to a cold air delivery diversion pipe (43). The cold air delivery diversion pipe (43) is connected to a cold air delivery pipe (44), and the cold air delivery pipe (44) is connected to a cold air box (45). A connecting flange (46) is nested on the outer pipe.

5. The PLC-controlled continuous forming and processing device for fireproof materials according to claim 4, characterized in that, The inspection platform (1) is equipped with a fireproof material extrusion motor (47), and the fireproof material extrusion motor (47) is connected to a motor power transmission belt (48). The other end of the motor power transmission belt (48) is connected to a spiral extrusion rotating shaft (49). A spiral extrusion tube (50) is connected to one side of the spiral extrusion rotating shaft (49). Spiral extrusion spiral blades (51) are provided on the outside of the spiral extrusion tube (50).

6. The processing method of the PLC-controlled continuous forming processing device for fireproof materials according to claim 5, characterized in that, Step 1: Equipment foundation construction: Step 11: Installation of the maintenance platform and related components. Determine a suitable location at the installation site and place the maintenance platform (1). Fix maintenance support rods (2) at the four corners of the bottom of the maintenance platform (1) to ensure the stability of the maintenance platform (1). Weld maintenance stairs (3) to the stair section of the maintenance platform (1) and install stair railings (4) on both sides of the maintenance stairs (3) to ensure the safety of personnel going up and down the maintenance platform. Step 12: Install the main frame of the conveyor belt. Install the main frame of the conveyor belt (5) between the four corners of the maintenance support rod (2). Fix the main frame adjusting pulley (6) to the bottom side of the main frame of the conveyor belt (5) with bolts. Connect the main frame adjusting pulley (6) to the forming conveyor belt adjusting slide rail (7) so that the main frame of the conveyor belt (5) can move on the forming conveyor belt adjusting slide rail (7) for easy adjustment of position later. Step 2, Installation of conveyor belt and dust collection system: Step 21: Install the conveyor belt. Rotate and install the conveyor belt rotating rollers (10) at both ends of the main frame (5) of the conveyor belt. Nest the fireproof material forming conveyor belt (11) on the outer surface of the conveyor belt rotating rollers (10). Connect the fireproof material forming conveyor belt power motor (12) to one side of the conveyor belt rotating rollers (10) to provide power to the fireproof material forming conveyor belt (11). Step 22: Install the dust collection system. Install the dust collection trough housing (8) inside the middle section of the main frame (5) of the conveyor belt, and open the dust collection trough holes (9) on the dust collection trough housing (8). Embed the fireproof material molded conveyor dust collection pipe (13) into the main frame (5) of the conveyor belt, and connect the other end of it to the conveyor belt dust collection fan blade (14). Install the dust collection exhaust pipe (15) outside the conveyor belt dust collection fan blade (14). Embed the bottom mounting bracket (16) below the dust collection exhaust pipe (15). Install the fireproof material molded conveyor belt dust collection motor (17) on the top of the bottom mounting bracket (16). Rotate the dust collection motor rotating shaft (18) to the power output end of the fireproof material molded conveyor belt dust collection motor (17), and connect the dust collection motor rotating shaft (18) to the conveyor belt dust collection fan blade (14) to start the dust collection function. Step 3: Installation of fireproof material conveying components: Step 31: Installation of conveyor rollers and power components. Install a bottom rod (19) on the main frame (5) of the conveyor belt, fix side plates (20) on both sides of the bottom rod (19), and rotatably connect the fireproof material conveyor roller (21) between the middle sections of the side plates (20); connect the conveyor roller rotating shaft (22) to one side of the fireproof material conveyor roller (21), and nest the power transmission belt (23) on the outer shaft of the conveyor roller rotating shaft (22); install the fireproof material conveying motor (24) on the bottom outer plate of the side plate (20), and connect the rotating shaft on the power end of the fireproof material conveying motor (24) to the power transmission belt (23) to provide rotational power for the fireproof material conveyor roller (21); Step 32: Installation of tensioning roller and adjusting components. Fix the inclined rod (25) on the inner plate of the side plate (20). Set the adjusting U-shaped buckle groove (26) on the top rod of the inclined rod (25). Connect the adjusting buckle shafts (28) at both ends of the tensioning roller (27) to the adjusting U-shaped buckle groove (26). Install the buckle adjusting air cylinder (29) at the tail of the fireproof material conveying motor (24). Slide the air cylinder adjusting air rod (30) inside the buckle adjusting air cylinder (29). Connect the top rod of the air cylinder adjusting air rod (30) to the adjusting air rod connecting arm (31). Embed the connecting arm rotating shaft (32) at the other end of the adjusting air rod connecting arm (31) into the side plate (20) so that its other end is connected to the fireproof material output receiving buckle rod (33). Install the buckle C-shaped buckle (34) on the top of the fireproof material output receiving buckle rod (33). Step 33: Installation of guide conveyor rollers and support platform. Connect guide conveyor rollers (35) to the upper and lower ends of the side plate (20) respectively. Install the intermediate support platform (36) between the main frame of the conveyor belt (5) and the bottom rod (19) to provide support and guidance. Step 4: Installation of molding die and related components: Step 41: Installation of molding mold and hydraulic cylinder. Install molding mold (37) on the bottom plate of inspection platform (1), and embed cold air U-shaped gas pipe (38) on the side of molding mold (37); install molding hydraulic cylinder (39) on the top plate of molding mold (37), and slide telescopic pressure rod (40) on molding hydraulic cylinder (39) for molding and pressing fireproof material; Step 42: Install the cold air delivery system. Set up a serpentine gas delivery pipe (41) above the molding die (37). Connect the end of the serpentine gas delivery pipe (41) to the filter tank (42). Connect the other side of the filter tank (42) to the cold air delivery diversion connecting pipe (43). Connect the cold air delivery pipe (44) to the cold air delivery diversion connecting pipe (43). Connect the cold air delivery pipe (44) to the cold air box (45). Nest the connecting flange (46) on the outer pipe. The PLC has a built-in multivariable coupling control algorithm. The extrusion speed of the fireproof material is controlled by the fireproof material extrusion motor (47). The running speed of the conveyor belt is controlled by the fireproof material molding conveyor belt power motor (12). The cooling airflow intensity is controlled by the regulating valve of the cold air box (45). When the extrusion speed increases, the PLC automatically increases the linear speed of the conveyor belt according to the preset ratio and increases the cold air delivery volume. The cold air is delivered to cool the molding die. Step 5: Fireproof material extrusion component is installed on the bottom plate of the inspection platform (1). Fireproof material extrusion motor (47) is installed, and the motor power transmission belt (48) is connected to the fireproof material extrusion motor (47). The other end of the motor power transmission belt (48) is connected to the spiral extrusion rotating shaft (49). One side of the spiral extrusion rotating shaft (49) is connected to the spiral extrusion tube (50). Spiral extrusion spiral blades (51) are set on the outside of the spiral extrusion tube (50) for extruding fireproof material. Step 6, Debugging and Operation: Inspect all components of the entire device to ensure that they are firmly installed and correctly connected; connect the power supply and air pressure source, start the fireproof material forming conveyor belt power motor (12), fireproof material forming conveyor belt dust suction motor (17), fireproof material conveying motor (24), forming hydraulic cylinder (39), and fireproof material extrusion motor (47) equipment, and check the operation of each component; adjust the lever to adjust the air pressure cylinder (29), adjust the position of the tension roller (27) and the fireproof material output receiving lever (33) to ensure the stability of fireproof material conveying; turn on the cold air box (45) to check whether the cold air conveying system is working properly and whether it can cool the forming mold; conduct a trial run of the device.

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