A porcelain mud slurry platform for porcelain insulators

Abstract

The application discloses a porcelain mud slurry preparation platform for porcelain insulators, which is a vertically integrated multi-layer slurry preparation platform and comprises an underground layer and a ground three-layer structure; a mixed mud slurry tank and a qualified mud slurry tank are arranged in the underground layer; a combination of a vibrating screen and a permanent magnet iron remover is arranged in the ground first layer as a mud slurry processing assembly; a new slurry tank and an old slurry tank are arranged in the ground second layer; a mud slurry stirring device is arranged in the ground third layer; the new slurry tank and the old slurry tank are respectively connected to the mixed mud slurry tank through independent gravity self-flow pipelines; the mixed mud slurry tank is connected to the mud slurry stirring device through a pumping pipeline; the discharging end of the mud slurry stirring device is connected to the mud slurry processing assembly through a gravity self-flow pipeline; and the discharging end of the mud slurry processing assembly is connected to the qualified mud slurry tank through a gravity self-flow pipeline. The key equipment and processes in the slurry preparation process are orderly integrated in a space level through the vertically integrated multi-layer structure design.

Description

Technical Field

[0001] This invention belongs to the field of porcelain insulator manufacturing technology, specifically relating to a pulping and granulation platform for producing raw porcelain clay during the raw material processing stage of porcelain insulators. Background Technology

[0002] Porcelain insulators, as core components of high-voltage transmission lines, serve the dual functions of insulation support and mechanical connection. Their manufacturing process directly affects the safety and reliability of the power grid operation. The conventional porcelain insulator manufacturing process mainly includes four key stages: raw material selection and proportioning → clay preparation and molding → glazing and firing → assembly and testing. Among these, the clay preparation stage is the core link connecting raw materials and molding, and it has a decisive influence on the mechanical strength, insulation performance, and appearance quality of the final product.

[0003] The porcelain clay preparation process typically involves wet grinding, ball milling, and sieving to remove iron. Raw materials (such as quartz, feldspar, and clay) are proportioned and initially mixed using a wet grinder, then ground into fine particles using a ball mill. Afterward, impurities and iron filings are removed by sieving to obtain a qualified slurry, which is then sent to the next stage for clay refining. The core objective of this process is to obtain porcelain clay with high uniformity and good plasticity, providing a foundation for subsequent spinning or pressing molding. If the porcelain clay contains uneven particles or air bubbles, it will lead to defects such as cracking of the insulator blank and insufficient mechanical strength, potentially causing power grid accidents in severe cases.

[0004] In existing technologies, the "new slurry mixed with old slurry" pulping process is widely considered the best solution for improving the performance of porcelain clay. Its core principle is to mix the newly prepared porcelain slurry with the recycled old slurry generated in the previous production in a certain proportion. This process has multiple advantages: it can improve resource utilization, as the unused raw materials in the old slurry can be recycled, reducing waste emissions and meeting environmental protection requirements; it makes the slurry performance more stable, as the old slurry, after pretreatment, has a more uniform particle distribution and moisture content, which can reduce the performance fluctuation of the new slurry after mixing with it; it reduces production costs and the amount of new raw materials used; and it enhances process adaptability, as the plasticity and fluidity of the mixed slurry are easier to control.

[0005] However, existing equipment adapted to the "new pulp mixed with old pulp" process generally adopts a dispersed or linear layout. These two equipment layouts have significant drawbacks in the pulping process of repeated mixing and processing: 1. Low material transfer efficiency: The linear arrangement of materials requires the long-distance transfer of new pulp and old pulp between multiple devices, and repeated handling increases energy consumption and time costs. Second, in a linear process, the mixing process is only carried out once, making it difficult to achieve full integration of new and old slurries. Repeated pipeline transportation can also lead to insufficient mixing uniformity, which may introduce impurities, reduce the product qualification rate, and affect the quality stability of porcelain clay. Third, it occupies a large space and has poor flexibility. The equipment is arranged in a straight line, which requires a large factory space and is not conducive to the compact design of the production line. If it is necessary to adjust the mixing ratio or add processing steps, the linear layout is difficult to reconfigure quickly, which restricts process optimization.

[0006] In summary, the porcelain clay preparation process is a crucial step in the production of porcelain insulators. While the "new clay mixed with old clay" process can improve performance and economy, existing linear arrangement equipment cannot meet its high-efficiency and stable production requirements. Therefore, a new type of clay preparation platform is urgently needed to optimize equipment layout and material flow, thereby addressing the aforementioned technical shortcomings. Summary of the Invention

[0007] The technical problem solved by this invention is to provide a porcelain clay preparation platform for porcelain insulators, which aims to solve the problem of low efficiency caused by unreasonable equipment layout in the existing clay preparation process. Through the spatial layout of the platform structure, the entire process of porcelain clay preparation is efficiently connected, improving the stability and resource utilization of porcelain clay preparation, thereby solving the defects in the above-mentioned technical background.

[0008] The technical problem solved by this invention is achieved by the following technical solution: A porcelain clay preparation platform for porcelain insulators is a vertically integrated multi-layer platform, comprising a basement level and a three-layer surface level structure. The underground space is equipped with a mixing mud tank and a qualified mud tank. A mud processing assembly is installed in the space of the ground floor. The mud processing assembly is a combination of a vibrating screen and a permanent magnet separator, with the vibrating screen in front and the permanent magnet separator behind. The space on the second floor of the ground is equipped with a new slurry tank and an old slurry tank. A mud mixing device is installed in the space of the three ground floors; The new slurry tank and the old slurry tank are each connected to the mixing slurry tank via independent gravity flow pipelines. The mixing slurry tank is connected to the slurry mixing device via a pumping pipeline. The discharge end of the slurry mixing device is connected to the slurry processing component via a gravity flow pipeline. The discharge end of the slurry processing component is connected to the qualified slurry tank via a gravity flow pipeline.

[0009] As a further limitation, the gravity flow pipelines connected to the new slurry tank, old slurry tank, slurry mixing device, and slurry processing components are all equipped with flow meters and electrically controlled valves.

[0010] As a further limitation, vibrating screens are installed on both the gravity flow pipelines connecting to the new slurry tank and the gravity flow pipelines connecting to the old slurry tank.

[0011] As a further limitation, the vibrating screen in the mud processing assembly is preferably a multi-stage vibrating screen.

[0012] As a further limitation, each of the new mud tank, old mud tank, mixed mud tank, and qualified mud tank is equipped with an independent agitation device to prevent mud sedimentation through continuous agitation.

[0013] As a further limitation, the front end of the new pulp tank is connected to a ball mill pulping device.

[0014] As a further limitation, the old pulp tank is equipped with a dynamic moisture content monitoring device to monitor the moisture content of the old pulp in the old pulp tank in real time; the old pulp tank is also equipped with a return wheel residual material powder supply device and a water supply pipe, so that if the moisture content of the old pulp measured by the dynamic moisture content monitoring device is too high or too low, an appropriate amount of residual material powder can be added through the return wheel residual material powder supply device or water can be added through the water supply pipe to accurately control the moisture content of the old pulp to the range required by the process.

[0015] Beneficial Effects: This invention provides a porcelain clay slurry preparation platform for porcelain insulators. This platform, through a vertically integrated multi-layered structural design, systematically integrates key equipment and processes throughout the slurry preparation process. This multi-layered layout significantly shortens material transport distances, thereby effectively reducing the overall slurry preparation cycle time. Furthermore, this multi-layered layout can be combined with gravity-flow pipelines to reduce the use of pumping devices. While reducing energy consumption, the combined gravity flow and pumping transport method reduces raw material loss due to pipeline residue, improving resource utilization and reducing raw material consumption. In addition, this spatial layout facilitates integrated control through a control system, enabling automation of the entire process, including batching, mixing, conveying, and testing. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the platform structure of a preferred embodiment of the present invention.

[0017] The components include: 1. Pumping pipeline; 2. Bearing plate; 3. First gravity flow pipeline; 4. Plunger pump; 5. Foundation; 6. Third gravity flow pipeline; 7. Second gravity flow pipeline; 8. Mud mixing device; 9. New mud tank; 10. Old mud tank; 11. Vibrating screen I; 12. Vibrating screen II; 13. Permanent magnet iron separator; 14. Mixing mud tank; 15. Qualified mud tank. Detailed Implementation

[0018] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below with reference to specific illustrations.

[0019] In the following embodiments, those skilled in the art will understand that, unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains. It should also be understood that terms such as those defined in general dictionaries should be understood to have a meaning consistent with their meaning in the context of the prior art, and should not be interpreted in an idealized or overly formal sense unless defined as herein.

[0020] See Figure 1 A porcelain clay preparation platform for porcelain insulators is provided in this embodiment. The porcelain clay preparation platform is a vertically integrated multi-layer platform. The platform is constructed with a steel frame structure, which has a spatial layout of 1 underground floor and 3 above-ground floors. The steel frame platform is used as the load-bearing layer 2. The equipment area adopts non-slip and wear-resistant floor and stainless steel guardrails to meet the safety standards of industrial production and realize efficient connection, quality control and environmentally friendly operation of the entire porcelain clay preparation process.

[0021] In this embodiment, the underground floor is a sunken space below the foundation 5. The space is equipped with a mixing mud tank 14 and a qualified mud tank 15. The surface of the underground floor corresponding to the foundation 5 is sealed with a bearing plate and is responsible for the functions of mud mixing and homogenization and qualified product storage.

[0022] The ground floor serves as the core processing area, where mud filtration, iron removal, and high-pressure conveying are achieved. This space houses a mud processing assembly, employing a combined layout of a vibrating screen II 12 and a permanent magnet separator 13. The vibrating screen II 12, a three-stage vibrating screen, acts as the front-end processing unit, using a multi-stage screen structure to classify and screen the mud by particle size, effectively intercepting impurities exceeding the size limit. The permanent magnet separator 13, connected at the rear, utilizes strong magnetic adsorption to efficiently separate residual ferromagnetic particles from the mud. This series-connected processing mode ensures both uniform mud particle size and thorough removal of ferromagnetic impurities, providing high-quality mud that meets process standards for subsequent processes.

[0023] In addition, the ground floor of this embodiment also has reserved space for the assembly of the plunger pump 4.

[0024] The second floor is the raw material fine processing and storage area, which is equipped with a new pulp tank 9 and an old pulp tank 10. The new pulp tank 9 is used to receive the new pulp produced by the ball mill pulping equipment, while the old pulp tank 10 is used to collect the recycled old pulp from the previous production.

[0025] In this embodiment, the new mud tank 9, the old mud tank 10, the mixed mud tank 14, and the qualified mud tank 15 are all designed with a sealed structure and equipped with an independent stirring device to prevent mud sedimentation and clumping.

[0026] The ground floor is a high-efficiency mixing zone, which is equipped with a mud mixing device 8. In this embodiment, the mud mixing device 8 is a stainless steel mixing tank, which uses a combination of a high-torque mixing paddle and a variable frequency speed control motor. It can flexibly adjust the mixing intensity and time according to the ratio requirements of new mud and old mud to ensure that the two muds are fully mixed in the mixing mud tank 14.

[0027] In this embodiment, the new slurry tank 9 uses a ball mill to produce new slurry. After the slurry is prepared, it is put into the ball mill. Once the fineness of the slurry reaches the required level, it is pumped into the new slurry tank 9. The old slurry tank 10 is used to recycle the slurry returned from the molding process. Considering that the moisture content of the slurry may fluctuate due to differences in the production process, the old slurry tank 10 is used to receive the old slurry from the slurry tank. The moisture content of the slurry tank is controlled by the following method: first, excess water is added to the old slurry tank 10, and then some residual powder is added back. The mixture is stirred evenly until the moisture content of the slurry in the old slurry tank 10 is qualified, and then it is pumped into the old slurry tank 10.

[0028] In other implementation cases, the old pulp tank 10 can be equipped with a return feed powder supply device and a water supply pipe, as well as a dynamic moisture content monitoring device to accurately grasp the moisture content of the old pulp through real-time data feedback. When the dynamic moisture content monitoring device detects that the moisture content of the old pulp exceeds the process requirements, the system will automatically start the adjustment program: if the moisture content is too high, water will be added through the water supply pipe according to a preset ratio, and the stirring device in the old pulp tank will be started to accelerate mixing; if the moisture content is too low, dried feed powder will be added quantitatively through the return feed powder supply device, and multi-stage stirring will be used to ensure that the powder and pulp are fully integrated. This closed-loop control system can also correct the old pulp parameters in the old pulp tank 10 in real time, so that its moisture content is stabilized within the process allowable deviation range, providing a stable raw material guarantee for the subsequent mixing of new and old pulp.

[0029] The new slurry tank 9 and the old slurry tank 10 are connected to the mixing slurry tank 14 on the first basement floor via independent first gravity flow pipe 3 and second gravity flow pipe 7, respectively. The new and old slurries in the new slurry tank 9 and the old slurry tank 10 are mixed in a specific ratio during use, precisely controlled by a mass flow meter and a proportional valve. The slurries then flow by gravity through the first gravity flow pipe 3 and the second gravity flow pipe 7 into their respective vibrating screens I 11 for screening. The screened, proportioned slurry is then sent to the slurry mixing tank 14.

[0030] The mud in the mud mixing tank 14 is connected to the plunger pump 4 via the pumping pipeline 1, and is transported to the mud mixing device 8 on the third floor under the high pressure drive of the plunger pump 4. The mud mixing device 8 uses the rotation of the high-torque stirring paddle to fully mix the new and old mud. During the mixing process, the mixing speed and time can be adjusted according to the process requirements to ensure that the uniformity of the mud reaches the optimal state.

[0031] The mixed slurry is transported to the slurry processing assembly on the ground floor via a third gravity-fed pipeline 6 connected to the bottom of the slurry mixing device 8. First, it enters the vibrating screen II 12 for multi-stage particle size screening, effectively intercepting large particles of impurities. Then, it flows into the permanent magnet separator 13, where a strong magnetic field removes residual ferromagnetic particles. The qualified slurry, after filtration and iron removal, is finally transported via pipeline to the qualified slurry tank 15 on the underground floor for storage, awaiting the next processing step.

[0032] In this embodiment, the slurry in the qualified slurry tank 15 is pumped to the spray granulation tower by a plunger pump, where it is granulated. After being screened by a vibrating screen, the finished particles are lifted to the silo by a conveyor belt.

[0033] In this embodiment, the entire pulping process employs a combined gravity flow and pumping transport method, along with a multi-layered spatial layout design, achieving high efficiency and energy saving in material flow. Simultaneously, the sealed tank design and closed-loop control system ensure the stability of the slurry quality and the precise controllability of process parameters. Furthermore, the coordination between the gravity flow design and the pumping pipeline structure effectively reduces pumping energy consumption and minimizes raw material loss due to pipeline residue.

[0034] Through the above structural design and equipment configuration, this invention achieves vertical integration and automated control of the entire porcelain clay preparation process, significantly improving pulping efficiency and product quality stability.

[0035] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of this invention is defined by the appended claims and their equivalents.

Claims

1. A porcelain clay preparation platform for porcelain insulators, characterized in that, It includes a basement level and three ground-level floors: The underground space is equipped with a mixing mud tank and a qualified mud tank. The three-layer ground structure has a mud processing component installed in the space of the ground floor. The mud processing component is a combination of a vibrating screen and a permanent magnet separator, with the vibrating screen in front and the permanent magnet separator behind. The new slurry pool and the old slurry pool are set in the space of the second floor of the three-layer ground structure. A mud mixing device is installed in the space of the three ground-level layers of the three-layer ground structure. The new slurry tank and the old slurry tank are each connected to the mixing slurry tank via independent gravity flow pipelines. The mixing slurry tank is connected to the slurry mixing device via a pumping pipeline. The discharge end of the slurry mixing device is connected to the slurry processing component via a gravity flow pipeline. The discharge end of the slurry processing component is connected to the qualified slurry tank via a gravity flow pipeline.

2. The porcelain clay slurry preparation platform for porcelain insulators according to claim 1, characterized in that, The gravity flow pipelines connected to the new slurry tank, old slurry tank, slurry mixing device, and slurry processing components are all equipped with flow meters and electrically controlled valves.

3. The porcelain clay slurry preparation platform for porcelain insulators according to claim 1, characterized in that, Vibrating screens are installed on both the gravity flow pipelines connecting to the new slurry tank and the gravity flow pipelines connecting to the old slurry tank.

4. The porcelain clay slurry preparation platform for porcelain insulators according to claim 1, characterized in that, The vibrating screen in the mud processing assembly is a multi-stage vibrating screen.

5. The porcelain clay slurry preparation platform for porcelain insulators according to claim 1, characterized in that, Each of the new mud tank, old mud tank, mixed mud tank, and qualified mud tank is equipped with an independent mixing device.

6. The porcelain clay slurry preparation platform for porcelain insulators according to claim 1, characterized in that, The new slurry tank is connected to a ball mill pulping device at its front end.

7. The porcelain clay slurry preparation platform for porcelain insulators according to claim 1, characterized in that, The old pulp tank is equipped with a dynamic moisture content monitoring device, a return wheel residual material powder supply device, and a water supply pipe. When the moisture content of the old pulp measured by the dynamic moisture content monitoring device is too high or too low, an appropriate amount of residual material powder is added through the return wheel residual material powder supply device or water is added through the water supply pipe to accurately control the moisture content of the old pulp to the range required by the process.

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