Ultrafine powder long nozzle brick matching filling machine control method and control system

Abstract

The present application relates to superfine powder long nozzle magnesium carbon brick filling technical field, especially to a kind of superfine powder long nozzle brick cooperation filling machine control method and control system, including pre-inspection stage;Mould positioning;Layered filling;Jolt control;Demoulding control;After jolt end, lifting rotary platform drops to lower limit position;Take out the long nozzle magnesium carbon brick mould of filling completion.The present application has the advantages that: by setting stage material filling and multi-mode jolt control strategy, in combination with adjustable tamping hammer group number, hitting strength, vibration frequency, improve material filling uniformity and density, effectively discharge gas in superfine powder material, improve brick density and product service life;System has programming and parameter self-adapting function, according to different brick type, material characteristics and production batch quickly adjust process parameters, realize flexible production, compared with manual operation, shorten single filling cycle, production rhythm is stable, meet the demand of large-scale continuous production.

Description

Technical Field

[0001] This invention relates to the field of ultrafine powder long nozzle magnesia-carbon brick filling technology, and in particular to a control method and control system for ultrafine powder long nozzle bricks combined with a filling machine. Background Technology

[0002] As a key refractory material in the continuous casting process of steelmaking, the molding quality of long-nozzle magnesia-carbon bricks directly affects the stability and safety of molten steel flow. In the production of ultrafine powder magnesia-carbon bricks, the material filling and compaction processes are the core steps determining the brick's density, uniformity, and service life. Currently, the control methods for this process mainly have the following problems: 1. Traditional manual control; Operators rely on experience to add materials and manually compact them. The control process is completely open, lacking quantitative parameters and feedback mechanisms. The amount of material filling, vibration force, and rhythm cannot be precisely controlled, resulting in a loose internal structure and uneven density of the bricks, large fluctuations in product performance, and potential safety hazards caused by human operation. 2. Simple program control; The tamping and lifting actions are controlled by a fixed timing method, resulting in rigid control logic that cannot adaptively adjust according to dynamic parameters such as material type, moisture content, and air content. 3. Lack of hierarchical intelligent control; Existing control methods mostly employ one-time filling and uniform vibration, without considering the differences in the compaction characteristics of materials at different filling stages. The degassing requirements and compaction mechanisms of ultrafine powder materials differ in the initial, middle and later stages of filling. A single vibration mode cannot achieve full-process optimization, affecting the final molding quality. 4. Insufficient positioning and motion control accuracy; The positioning of the mold for magnesia-carbon bricks in Changshuikou relies heavily on mechanical limits and manual adjustments. The control system lacks high-precision position feedback and closed-loop correction mechanisms, and the positioning error often exceeds 5mm, resulting in uneven distribution of vibration force and affecting the consistency of axial density of the brick. 5. Lack of process status monitoring and feedback; Existing controls are mostly open-loop or semi-open-loop controls, lacking real-time monitoring and closed-loop adjustment of key process parameters such as material gas content, tamping zone temperature, and vibration energy transfer efficiency. The control process lacks a closed loop of "perception-decision-execution", making it difficult to achieve dynamic optimization of process status and early warning of anomalies. 6. Inadequate safety interlock control; The motion coordination between the lifting platform and the tamping hammer relies heavily on simple timing interlocks, and a multi-axis collaborative interlocking mechanism based on real-time position detection has not been established. Under high-speed or high-load conditions, mechanical interference or collision accidents are prone to occur, resulting in low equipment operation safety. Summary of the Invention

[0003] The purpose of this invention is to provide a control method and control system for ultrafine powder long nozzle bricks combined with a filling machine, which realizes layered adaptive control, improves positioning accuracy and motion coordination, provides real-time feedback of multiple parameters and full-process safety interlocking, thereby improving product quality, production efficiency and equipment safety.

[0004] To achieve the above objectives, the present invention provides the following technical solution: A method for controlling an ultrafine powder long nozzle brick filling machine, comprising placing the long nozzle magnesia-carbon brick mold on a lifting and rotating platform, specifically including: S1, Pre-inspection phase: The compressed air source pressure is ≥0.8MPa and the compressed air inlet shut-off valve is in the closed state. The hydraulic system's oil temperature is controlled within the range of 15~45℃, and the hydraulic system's oil level is within the set range. S2, Mold positioning; The lifting and rotating platform is raised to its middle limit position, and the tamping hammer assembly is moved back to the standby position. The positioning error range of the long-sprue magnesia-carbon brick mold is ≤2mm; S3, Layered Fill; Material is injected into the magnesia-carbon brick mold in three stages: The first stage involves a material filling rate of 30% and a tamping hammer vibration frequency of 20-25Hz. The second stage involves filling 50% of the material and using a tamping hammer vibration frequency of 25-35Hz. The third stage involves a material filling rate of 20% and a tamping hammer vibration frequency of 35-45Hz. S4, Vibration control; Initial vibration: Two sets of tamping hammers strike lightly and synchronously, with each set of tamping hammers having a striking energy of 110~120J and lasting for 2.5~3s; Enhanced vibration: Alternately activate single sets of tamping hammers for heavy impact, with each set of tamping hammers having an impact energy of 290~300J, an interval of 0.5s between each set of tamping hammers, and a total duration of 10~12s; First and last vibration: Two sets of tamping hammers vibrate at a frequency of 50Hz, with an amplitude of 0.4~0.5mm, for 4~5s. S5, Demolding control; The lifting and rotating platform descends at a constant speed of 1m / min and stops after reaching the lower limit position, with a duration ranging from 3 to 8 seconds. S6. After the vibration is completed, the lifting and rotating platform is lowered to the lower limit position, and all vibration is stopped. S7. Remove the filled long nozzle magnesia-carbon brick mold.

[0005] The formula for calculating the striking energy of a tamping hammer is: (1); In formula (1): This represents the stiffness coefficient of the tamping hammer, with units of N / m; This indicates the stroke of the tamping hammer, in meters (m). This indicates the striking energy of the tamping hammer, measured in J (joules). This represents the energy conversion efficiency, with a value ranging from 0.6 to 0.85.

[0006] During the vibration process, the air content of the material inside the magnesia-carbon brick mold is detected online by differential pressure. When the air content is >8%, the corresponding tamping hammer is triggered to perform secondary vibration.

[0007] During the rapping process, an infrared thermal imager is used to monitor the temperature of the contact area between the tamping hammer and the long-sprue magnesia-carbon brick mold. When the temperature is greater than 120°C, the control system triggers an emergency shutdown.

[0008] It also includes a lifting control module, which performs the following: 1) Ascent Control: When the lifting switch is turned on and the lifting and rotating platform is in the range between the lower limit and the middle limit position, the lifting and rotating platform continues to rise; When the lifting and rotating platform is in the range between the middle limit and the upper limit, all tamping hammer groups must be in the backward limit position before it can continue to rise to the upper limit position. 2) Descent control: When the descent switch is turned on and the lifting and rotating platform is in the range between the middle limit and the lower limit, the platform continues to descend; When the lifting and rotating platform is in the range between the upper limit and the middle limit position, all tamping hammer groups are in the backward limit position before it can continue to descend to the lower limit position.

[0009] A control system for an ultrafine powder long nozzle brick and a filling machine includes a limit switch group, which includes limit switches LS1 to LS11. Limit switch LS1 is installed on the upper end of the column of the lifting and rotating platform to detect the extreme position on the lifting and rotating platform; Limit switch LS2 is installed in the middle of the column of the lifting and rotating platform to detect the middle limit position of the lifting and rotating platform; Limit switch LS3 is installed at the lower end of the column of the lifting and rotating platform to detect the lower limit position of the lifting and rotating platform; Limit switches LS4 and LS5 are respectively installed at the retraction limit position of the first set of tamping hammer drive cylinders to detect the retraction limit position of the first set of tamping hammers. Limit switches LS6 and LS7 are respectively installed at the retraction limit position of the second set of tamping hammer drive cylinders to detect the retraction limit position of the second set of tamping hammers. Limit switches LS8 and LS9 are respectively installed at the forward limit positions of the first set of tamping hammer drive cylinders to detect the forward limit positions of the first set of tamping hammers. Limit switches LS10 and LS11 are respectively installed at the forward limit positions of the second set of tamping hammer drive cylinders to detect the forward limit positions of the second set of tamping hammers.

[0010] It also includes a sensor group, which includes a compressed air pressure sensor, a hydraulic oil temperature sensor, a liquid level sensor, a tamping hammer stroke encoder, a material air content sensor, and an infrared thermal imager. The compressed air pressure detected by the compressed air pressure sensor is ≥0.8MPa; The hydraulic oil temperature sensor detects and controls the oil temperature of the hydraulic system within the range of 15~45℃; Level sensors are used to detect the fluid level in the oil tank of a hydraulic system; A tamping hammer stroke encoder is used to detect the stroke of the tamping hammer. The gas content sensor is used for differential pressure online detection of the gas content of materials in the mold of magnesia-carbon bricks with long nozzles; Infrared thermal imagers are used to monitor the temperature of the contact area between the tamping hammer and the long-nozzle magnesia-carbon brick mold.

[0011] It also includes variable frequency motors, hydraulic systems, and cylinders; The variable frequency motor is equipped with a brake and is used to drive the lifting and rotating platform. The speed range is 0.5~2m / min. The hydraulic system includes a hydraulic pump station for driving the lifting and rotating platform; The cylinder is a double-acting cylinder used to drive the tamping hammer, and its stroke is adjustable.

[0012] The limit switch assembly adopts a dual redundancy design: Limit switches LS1~LS3 adopt a combination of mechanical limit and electrical switch; LS4~LS11 are equipped with magnetic proximity switches.

[0013] Compared with the prior art, the beneficial effects of the present invention are: 1. By setting a phased material filling and multi-mode vibration control strategy, combined with the adjustable number of tamping hammers, striking force, and vibration frequency, the uniformity and density of material filling are significantly improved, the gas in the ultrafine powder material is effectively discharged, and the density of the brick and the service life of the product are increased. 2. The system has programming and parameter self-adaptation functions, which can quickly adjust process parameters according to different brick types, material characteristics and production batches to achieve flexible production. Compared with manual operation, it shortens the single filling cycle, and the production cycle is stable and predictable, meeting the needs of large-scale continuous production. 3. Through multi-level position interlock control between the lifting platform and the tamping hammer, combined with real-time status monitoring and emergency shutdown mechanism of the air source, hydraulic and electrical systems, safety accidents such as mechanical interference, collision and overheating are effectively prevented, and the system failure rate is reduced. 4. The system integrates multiple parameter sensing systems such as online gas content detection and infrared temperature monitoring to achieve visualization and controllability of the process, effectively prevent quality defects, and improve product consistency and pass rate; the automated control system realizes unmanned operation of the entire process from mold loading, filling, vibration to demolding, significantly reducing manual intervention, reducing labor intensity and human error, and improving the overall automation level of the production line. Attached Figure Description

[0014] Figure 1 This is a flowchart of the control process for the filling of ultrafine powder long nozzle bricks.

[0015] Figure 2 This is a schematic diagram of the structure of the ultrafine powder long nozzle brick and the filling control system.

[0016] Figure 3 This is a top view of the structure of the ultrafine powder long nozzle brick and filling control system.

[0017] Figure 4 This is a top view of the structure of the ultrafine powder long nozzle brick and filling control system.

[0018] In the diagram: 1. A set of tamping hammers; 2. A set of drive cylinders; 3. A lifting and rotating platform; 4. A set of tamping hammer drive mechanisms; 5. Compressed air system; 6. Shut-off valve; 7. Connecting bus junction box for filling machine; 8. Air source pipeline; 9. Hydraulic system; 10. Hydraulic system junction box; 11. Two sets of tamping hammers; 12. Two sets of drive cylinders. Detailed Implementation

[0019] The present invention will now be described in detail with reference to the accompanying drawings, but it should be noted that the implementation of the present invention is not limited to the following embodiments.

[0020] The following embodiments are implemented based on the technical solution of the present invention, providing detailed implementation methods and specific operation processes. However, the scope of protection of the present invention is not limited to the following embodiments. Unless otherwise specified, the methods used in the following embodiments are conventional methods.

[0021] Example 1 To address the problems of low filling coefficient, unstable quality, poor venting efficiency, and uncontrollable production efficiency associated with traditional manual filling of ultrafine powder long nozzle magnesia-carbon bricks, this invention provides a filling control method for ultrafine powder long nozzle bricks, comprising one set of tamping hammers 1 and two sets of tamping hammers 11, see [link to relevant documentation]. Figures 2-4 A set of tamping hammers 1 is driven by a set of tamping hammer drive mechanisms 4, which are equipped with a set of drive cylinders 2; two sets of tamping hammers 11 are driven by two sets of tamping hammer drive mechanisms, which are equipped with two sets of drive cylinders 12; a compressed air system 5 provides air to the first set of cylinders 2 and the second set of cylinders 12; a hydraulic system 9 provides power to the tamping hammers. For details on the ultrafine powder long nozzle brick filling device, see publication number CN120921493A, patent title "An ultrafine powder long nozzle magnesia-carbon brick filling device and method". This invention achieves high-precision, high-efficiency, and high-stability automated filling operations by integrating lifting control, vibration control, hydraulic and pneumatic coordinated control, and intelligent monitoring functions. Figure 1 Specifically, it includes the following steps: S1, Pre-inspection phase: The compressed air source pressure is ≥0.8MPa and the compressed air inlet shut-off valve 6 is in the closed state. Check if the hydraulic system oil temperature is within the range of 15~45℃ and confirm that the oil level is within the set range.

[0022] S2, Mold positioning; The lifting and rotating platform is raised to the middle limit position (detected by limit switch LS2); Control all tamping hammer groups to return to the standby position (detected by limit switches LS4~LS7); The mold position is corrected by a vision positioning system or mechanical positioning pin installed on the platform, and the position of the long nozzle magnesia-carbon brick mold is adjusted along the X and Y directions by a servo motor driven fine adjustment mechanism to ensure that the positioning error range of the long nozzle magnesia-carbon brick mold is ≤2mm.

[0023] S3, Layered Fill; Material is injected into the magnesia-carbon brick mold in three stages: The first stage involves a material filling rate of 30% and a tamping hammer vibration frequency of 20-25Hz. The second stage involves filling 50% of the material and using a tamping hammer vibration frequency of 25-35Hz. The third stage involves a material filling rate of 20% and a tamping hammer vibration frequency of 35-45Hz.

[0024] S4, Vibration control; Initial vibration: Two sets of tamping hammers strike lightly and synchronously, with each set of tamping hammers having a striking energy of 110~120J and a duration of 2.5~3s; Enhanced vibration: Alternately activate single groups of tamping hammers for heavy impact, with each group of tamping hammers having an impact energy of 290~300J, an interval of 0.5s between each group of tamping hammers, and a total duration of 10~12s; First and last vibration: Two sets of tamping hammers vibrate at a frequency of 50Hz, with an amplitude of 0.4~0.5mm, for a duration of 4~5s.

[0025] The formula for calculating the striking energy of a tamping hammer is: (1); In formula (1): This represents the stiffness coefficient of the tamping hammer, with units of N / m; This indicates the stroke of the tamping hammer, in meters (m). This indicates the striking energy of the tamping hammer, measured in J (joules). This represents the energy conversion efficiency, with a value ranging from 0.6 to 0.85.

[0026] S5, Demolding control; The lifting and rotating platform is controlled to descend at a constant speed of 1m / min, and stops after reaching the lower limit position (detected by limit switch LS3), and remains there for 3~8 seconds.

[0027] S6, Lifting Control: 1) Ascent Control: When the lifting switch is turned on and the lifting and rotating platform is in the range between the lower limit and the middle limit position, the lifting and rotating platform continues to rise; When the lifting and rotating platform is in the range between the middle limit and the upper limit position, all tamping hammer groups are in the backward limit position before it can continue to rise to the upper limit position (detected by limit switch LS1). 2) Descent control: When the descent switch is turned on and the lifting and rotating platform is in the range between the middle limit and the lower limit, the platform continues to descend; When the lifting and rotating platform is in the range between the upper limit and the middle limit position, all tamping hammer groups are in the backward limit position before it can continue to descend to the lower limit position (detected by limit switch LS3).

[0028] S7. Emergency Control: During the vibration process, the air content of the material in the long-sprue magnesia-carbon brick mold is monitored online by a differential pressure sensor. When the air content is >8%, the corresponding tamping hammer is triggered to perform secondary vibration. The temperature of the contact area between the tamping hammer and the long-sprue magnesia-carbon brick mold is monitored by an infrared thermal imager. When the temperature is greater than 120°C, the control system immediately triggers an emergency shutdown.

[0029] S8, End Phase: After the vibration is completed, control the lifting and rotating platform to descend to the lower limit position and stop all vibration.

[0030] S9. Remove the long-nozzle magnesia-carbon brick mold: Remove the filled magnesia-carbon brick mold from the lifting and rotating platform.

[0031] This method achieves uniform filling and efficient compaction of ultrafine powder materials through a structured and parameterized control process, significantly improving the density, uniformity and service life of bricks. It is suitable for the automated molding and production of various ultrafine powder refractory materials.

[0032] Example 2 A control system for an ultrafine powder elongated nozzle brick and a filling machine, see [link / reference]. Figures 2-4 This includes limit switch groups and sensor groups; 1. Limit switch assembly: The limit switch group includes limit switches LS1 to LS11: Limit switch LS1 is installed on the upper end of the column of the lifting and rotating platform to detect the extreme position on the lifting and rotating platform; Limit switch LS2 is installed in the middle of the column of the lifting and rotating platform to detect the middle limit position of the lifting and rotating platform; Limit switch LS3 is installed at the lower end of the column of the lifting and rotating platform to detect the lower limit position of the lifting and rotating platform; Limit switches LS4 and LS5 adopt a dual-redundancy design and are respectively installed at the retraction limit position of the first set of tamping hammer drive cylinders to detect the retraction limit position of the first set of tamping hammers. Limit switches LS6 and LS7 adopt a dual redundancy design and are respectively installed at the retraction limit position of the second set of tamping hammer drive cylinders to detect the retraction limit position of the second set of tamping hammers. Limit switches LS8 and LS9 adopt a dual-redundancy design and are respectively installed at the forward limit position of the first set of tamping hammer drive cylinders to detect the forward limit position of the first set of tamping hammers. Limit switches LS10 and LS11 adopt a dual-redundancy design and are respectively installed at the forward limit position of the second set of tamping hammer drive cylinders to detect the forward limit position of the second set of tamping hammers.

[0033] Limit switches LS1~LS3 adopt mechanical limit + electrical switch, with announcement number CN202384189U, patent name is a new type of limit switch, and other models can also be used; LS4~LS11 are equipped with magnetic induction proximity switches.

[0034] 2. Sensor group The sensor group includes a compressed air pressure sensor, a hydraulic oil temperature sensor, a liquid level sensor, a tamping hammer stroke encoder, a material air content sensor, and an infrared thermal imager. The compressed air pressure sensor is used to detect whether the air source pressure is ≥0.8MPa; Hydraulic oil temperature sensors are used to detect whether the oil temperature in the hydraulic system is within the range of 15~45℃; Level sensors are used to detect the fluid level in the oil tank of a hydraulic system; A tamping hammer stroke encoder is used to detect the stroke of the tamping hammer. The material gas content sensor adopts a differential pressure sensor to monitor the gas content of the material in the long-nozzle magnesia-carbon brick mold online; Infrared thermal imagers are used to monitor the temperature of the contact area between the tamping hammer and the long-nozzle magnesia-carbon brick mold.

[0035] 3. Implementing agency The actuators include a variable frequency motor, a hydraulic system, and cylinders; The variable frequency motor is equipped with a brake and is used to drive the lifting and rotating platform. The speed range is 0.5~2m / min. The hydraulic system includes a hydraulic pump station for driving the lifting and rotating platform; The cylinder is a double-acting cylinder, consisting of four groups of eight cylinders, used to drive the tamping hammer, and the stroke is adjustable.

[0036] 4. Control program framework: The system control program includes a basic condition preparation module, a basic logic control module for lifting / lowering operation, a hydraulic system control module, a module for selecting the number of tamping hammer groups, a module for selecting the tamping hammer striking force, a module for selecting and interlocking the tamping hammer position, a module for selecting the rotary table rotation start, and a module for selecting the rotary lifting table speed. The Operation Preparation Basic Conditions module is used to perform system self-checks and initialization in the S1 pre-check phase, including checking the air source pressure, hydraulic oil temperature and level, and the status of valves in each system to ensure that the system starts up and runs under safe conditions. The basic logic control module for lifting / lowering operation is used to execute the lifting control process in steps S2, S5, and S6, to complete the lifting and rotating platform to rise and fall according to the position range, and to interlock with the position of the tamping hammer to ensure safe operation. The hydraulic system control module is used to execute the hydraulic drive control of the lifting and rotating platform and the rotation action of the turntable in step S6, providing stable and reliable power output to ensure the accuracy and smoothness of the platform lifting and rotation; The tamping hammer group number selection module is used to select the tamping hammer group in S4 vibration control. It can be flexibly configured into two groups of four hammers or one group of two hammers working mode according to brick type and process requirements. The tamping hammer impact force selection module is used to dynamically adjust the impact force in the S4 vibration control, and supports switching and adaptation between two working conditions: light impact (110~120J) and heavy impact (290~300J). The tamping hammer position selection and interlocking module is used to monitor and interlock the position of the tamping hammer in S2, S4 and S6, ensuring that it is always in a safe position during the lifting and rotating platform to prevent equipment interference and collision. The rotary table rotation start selection module is used to control the rotation of the rotary table during the S3 layered filling and S4 vibration control processes, so as to complete the multi-directional uniform filling and compaction of the long nozzle magnesia-carbon brick mold. The lifting and rotating platform speed selection module is used to set and adjust the lifting speed (e.g., 1m / min) of the lifting and rotating platform in the S5 demolding control to adapt to the operating requirements of different materials and process stages, and to ensure smooth operation and accurate positioning.

[0037] 5. Electrical control circuitry: The electrical control circuit includes the bus junction box 7 (TB-1) for the filling machine, the lifting control circuit, the hydraulic drive circuit, the pneumatic control circuit, and the tamping hammer control circuit. The bus junction box 7 (TB-1) of the filling machine is used to supply power to each junction box and actuator. The actuator includes the lifting drive motor M2, the hydraulic pump motor M1, the pneumatic solenoid valve, the hydraulic solenoid valve, each limit switch and related sensors. The lifting control circuit is used to connect limit switches LS1, LS2, LS3 and the lifting and rotating platform drive motor M2 through a junction box and converter (such as a terminal block or signal distribution module) to complete the position detection and drive control of the lifting and rotating platform. The hydraulic drive circuit is used to provide power and control signals to the hydraulic pump motor M1 and the corresponding hydraulic solenoid directional valve, relief valve and oil control valve through the hydraulic system junction box 10 (TB-2). The pneumatic control circuit is used to provide control power to pneumatic components such as pneumatic solenoid valves, inlet shut-off valves 6, pressure switches and pressure reducing valves in the compressed air system through junction box PB-3; The tamping hammer control circuit is used to provide control power to the limit switches LS4~LS11 of each tamping hammer through the junction box PB-2 and converters (such as signal distribution and isolation modules), and to receive their position feedback signals to complete the monitoring and interlocking control of the tamping hammer's forward and backward movements.

[0038] Example 3 A filling control system for ultrafine powder long nozzle bricks is developed. Based on the integrated design of the basic control program flowchart and electrical control circuit, it realizes fully automatic, high-precision, and flexibly adjustable filling and vibration control.

[0039] I. Basic Flowchart of System Control This basic control flowchart forms the core control framework of the system. It is programmable and adaptable to different material properties, brick sizes, and production batch requirements. The system features rapid response, large adjustment margin, and wide applicability, and mainly includes the following modules: 1. Basic Conditions for Operation Preparation Module: With the power supply on, the air source pressure is checked to be ≥0.8MPa, and the air circuit on / off status is checked via the compressed air inlet shut-off valve 6 (LSo). If the air source pressure is insufficient or LSO is not connected, the system will prevent the tamping hammer from operating.

[0040] 2. Basic logic control module for the upward operation of the rotating lifting platform: Once the ascent switch is turned on, the platform begins to rise; Real-time platform location detection via inverter: If it is within the range of "lower limit LS3 - middle LS2", it will continue to rise; If the range is between "LS2 (middle) and LS1 (upper limit), all tamping hammers must be in the backward limit position (LS4~LS7) before they can continue to rise to LS1 and stop.

[0041] 3. Basic logic control module for the descent of the rotating lifting platform: Once the descent switch is turned on, the platform begins to descend; Real-time platform location detection via inverter: If it is within the range of "intermediate LS2 - lower limit LS3", it will continue to decline; If the range is between "upper limit LS1 - middle LS2", all tamping hammers must be in the backward limit position (LS4~LS7) before they can continue to descend to LS3 and stop.

[0042] 4. Hydraulic system control module: The system is powered by a hydraulic pump driven by a motor M1 (3.7kW), with a system pressure of 70kg / cm², a flow rate of 20L / min, and an oil tank capacity of 60L. The system is equipped with an oil inlet filter, a suction filter, a return filter, and a contamination alarm. The hydraulic motor speed, torque, and direction are adjusted via a three-position five-way dual solenoid directional valve, dual one-way throttle valves, and an overflow valve to achieve precise drive of the rotating platform. 5. Tamping hammer group selection module: It supports two working modes: "two groups of four" or "one group of two". The mode can be flexibly selected according to the brick size and the vibration position to meet different production needs.

[0043] 6. Tamping hammer impact force selection module: It offers two working conditions: "heavy impact" and "light impact," which can be selected based on the brick diameter and material characteristics; for example, heavy impact is used for large-diameter bricks, and light impact is used for small-diameter bricks.

[0044] 7. Tamping hammer position selection and interlocking module: The forward and backward limits of two groups of eight cylinders are monitored by limit switches LS4~LS11 and interlocked with the operating status of the lifting platform to prevent equipment interference. in: LS4 and LS5 are the first setback limits; LS6 and LS7 are the second set of backoff limits; LS8 and LS9 are the first group of forward limits; LS10 and LS11 are the advance limits for the second group.

[0045] 8. Turntable rotation start selection module: The hydraulic system drives a hydraulic motor, which in turn rotates the rotary table via gear transmission. The control system can adjust the output torque and speed of the hydraulic motor, achieving stepless adjustment of the rotation speed to adapt to different rapping process requirements.

[0046] 9. Rotary lifting platform speed selection module: The lifting speed is controlled by a variable frequency drive motor reducer with a brake. The operating speed is set according to the brick size, material type and ratio to ensure accurate positioning during lifting and avoid position deviation caused by brake failure.

[0047] II. Electrical Control Circuit Structure The electrical control circuit provides stable power supply and signal transmission for the system. It features a clear structure, good scalability, and convenient maintenance, and mainly includes the following parts: 1. Compatible with filling machine bus junction box 7 (TB-1): As the main power distribution hub, it provides power to various distribution boxes, actuators, and sensors.

[0048] 2. Electrical circuit control for rotary lifting platform: The TB-1 is connected to the variable frequency drive motor reducer M2 via converter JB-1; TB-1 is connected to intermediate position limit switch LS2 via junction box PB-1 and converter JB-2; TB-1 is connected to the upper limit switch LS1 via junction box PB-1, converters JB-2 and JB-3; It is connected from TB-1 to the lower limit switch LS3 via junction box PB-1 and converter JB-4.

[0049] 3. Rotary table rotation hydraulic drive circuit control: The hydraulic pump motor M1 is powered by TB-1 and hydraulic system junction box 10 (TB-2); The TB-2 provides power to the hydraulic system's solenoid directional valves, electrically controlled relief valves, electronic level gauges, oil temperature control equipment, pressure monitoring components, and pollution alarm devices.

[0050] 4. Pneumatic system circuit control: The control power supply for the pneumatic solenoid valve, pressure monitoring switch and shut-off valve 6 is provided by TB-1 through junction box PB-3.

[0051] 5. Circuit control of the tamping hammer drive cylinder: A set of tamping hammers: LS4, LS5 (backward limit) and LS8, LS10 (forward limit) are powered by TB-1 via PB-2, converters JB-5 and JB-6; Two sets of tamping hammers: LS6, LS7 (backward limit) and LS9, LS11 (forward limit) are powered by TB-1 via PB-2, converters JB-7 and JB-8.

[0052] This system achieves automated, high-precision, and high-reliability operation of the ultrafine powder long nozzle brick filling process through the coordination of program control and electrical hardware, making it suitable for large-scale and flexible production needs.

[0053] This invention significantly improves the uniformity and density of material filling by setting a phased material filling and multi-mode vibration control strategy, combined with adjustable tamping hammer sets, striking force, and vibration frequency. It effectively removes gas from ultrafine powder materials, increasing brick density and product lifespan. The system features programming and parameter self-adaptation functions, allowing for rapid adjustment of process parameters based on different brick types, material characteristics, and production batches, achieving flexible production. Compared to manual operation, it shortens the single filling cycle, ensuring stable and predictable production rhythm and meeting the needs of large-scale continuous production. Through multi-level position interlocking control between the lifting platform and the tamping hammer, combined with real-time status monitoring and emergency shutdown mechanisms for the air source, hydraulic, and electrical systems, it effectively prevents safety accidents such as mechanical interference, collisions, and overheating, reducing system failure rates. Integrating multi-parameter sensing systems such as online gas content detection and infrared temperature monitoring enables visualization and controllability of the process, effectively preventing quality defects and improving product consistency and pass rate. The automated control system achieves unmanned operation throughout the entire process from mold loading, filling, vibration to demolding, significantly reducing manual intervention, labor intensity, and human error, and improving the overall automation level of the production line.

Claims

1. A control method for a super fine powder shroud brick mixing and filling machine, characterized by, The long-sprue magnesia-carbon brick mold is placed on a lifting and rotating platform, specifically including: S1, Pre-inspection phase: The compressed air source pressure is ≥0.8MPa and the compressed air inlet shut-off valve is in the closed state. The hydraulic system's oil temperature is controlled within the range of 15~45℃, and the hydraulic system's oil level is within the set range. S2, Mold positioning; The lifting and rotating platform is raised to its middle limit position, and the tamping hammer assembly is moved back to the standby position. The positioning error range of the long-sprue magnesia-carbon brick mold is ≤2mm; S3, Layered Fill; Material is injected into the magnesia-carbon brick mold in three stages: The first stage involves a material filling rate of 30% and a tamping hammer vibration frequency of 20-25Hz. The second stage involves filling 50% of the material and using a tamping hammer vibration frequency of 25-35Hz. The third stage involves a material filling rate of 20% and a tamping hammer vibration frequency of 35-45Hz. S4, Vibration control; Initial vibration: Two sets of tamping hammers strike lightly and synchronously, with each set of tamping hammers having a striking energy of 110~120J and lasting for 2.5~3s; Enhanced vibration: Alternately activate single sets of tamping hammers for heavy impact, with each set of tamping hammers having an impact energy of 290~300J, an interval of 0.5s between each set of tamping hammers, and a total duration of 10~12s; First and last vibration: Two sets of tamping hammers vibrate at a frequency of 50Hz, with an amplitude of 0.4~0.5mm, for 4~5s. S5, Demolding control; The lifting and rotating platform descends at a constant speed of 1m / min and stops after reaching the lower limit position, with a duration ranging from 3 to 8 seconds. S6. After the vibration is completed, the lifting and rotating platform is lowered to the lower limit position, and all vibration is stopped. S7. Remove the long nozzle magnesia-carbon brick mold after filling; It also includes a lifting control module, which performs the following: 1) Ascent Control: When the lifting switch is turned on and the lifting and rotating platform is in the range between the lower limit and the middle limit position, the lifting and rotating platform continues to rise; When the lifting and rotating platform is in the range between the middle limit and the upper limit, all tamping hammer groups must be in the backward limit position before it can continue to rise to the upper limit position. 2) Descent control: When the descent switch is turned on and the lifting and rotating platform is in the range between the middle limit and the lower limit, the platform continues to descend; When the lifting and rotating platform is in the range between the upper limit and the middle limit position, all tamping hammer groups are in the backward limit position before it can continue to descend to the lower limit position.

2. The method for controlling an ultrafine powder long nozzle brick in conjunction with a filling machine according to claim 1, characterized in that, The formula for calculating the striking energy of the tamping hammer is as follows: (1)； In formula (1): This represents the stiffness coefficient of the tamping hammer, with units of N / m; This indicates the stroke of the tamping hammer, in meters (m). This indicates the striking energy of the tamping hammer, measured in J (joules). This represents the energy conversion efficiency, with a value ranging from 0.6 to 0.

85.

3. The method for controlling an ultrafine powder long nozzle brick in conjunction with a filling machine according to claim 1, characterized in that, During the vibration process, the air content of the material inside the magnesia-carbon brick mold is detected online by differential pressure. When the air content is >8%, the corresponding tamping hammer is triggered to perform secondary vibration.

4. The method for controlling an ultrafine powder long nozzle brick in conjunction with a filling machine according to claim 1, characterized in that, During the rapping process, an infrared thermal imager is used to monitor the temperature of the contact area between the tamping hammer and the long-sprue magnesia-carbon brick mold. When the temperature is greater than 120°C, the control system triggers an emergency shutdown.

5. A control system for an ultrafine powder long nozzle brick and a filling machine that implements the method described in any one of claims 1-4, characterized in that, It includes a limit switch group, which includes limit switches LS1 to LS11; Limit switch LS1 is installed on the upper end of the column of the lifting and rotating platform to detect the extreme position on the lifting and rotating platform; Limit switch LS2 is installed in the middle of the column of the lifting and rotating platform to detect the middle limit position of the lifting and rotating platform; Limit switch LS3 is installed at the lower end of the column of the lifting and rotating platform to detect the lower limit position of the lifting and rotating platform; Limit switches LS4 and LS5 are respectively installed at the retraction limit position of the first set of tamping hammer drive cylinders to detect the retraction limit position of the first set of tamping hammers. Limit switches LS6 and LS7 are respectively installed at the retraction limit position of the second set of tamping hammer drive cylinders to detect the retraction limit position of the second set of tamping hammers. Limit switches LS8 and LS9 are respectively installed at the forward limit positions of the first set of tamping hammer drive cylinders to detect the forward limit positions of the first set of tamping hammers. Limit switches LS10 and LS11 are respectively installed at the forward limit positions of the second set of tamping hammer drive cylinders to detect the forward limit positions of the second set of tamping hammers.

6. The control system for an ultrafine powder long nozzle brick and a filling machine according to claim 5, characterized in that, It also includes a sensor group, which includes a compressed air pressure sensor, a hydraulic oil temperature sensor, a liquid level sensor, a tamping hammer stroke encoder, a material air content sensor, and an infrared thermal imager. The compressed air pressure detected by the compressed air pressure sensor is ≥0.8MPa; The hydraulic oil temperature sensor detects and controls the oil temperature of the hydraulic system within the range of 15~45℃; Level sensors are used to detect the fluid level in the oil tank of a hydraulic system; A tamping hammer stroke encoder is used to detect the stroke of the tamping hammer. The gas content sensor is used for differential pressure online detection of the gas content of materials in the mold of magnesia-carbon bricks with long nozzles; Infrared thermal imagers are used to monitor the temperature of the contact area between the tamping hammer and the long-nozzle magnesia-carbon brick mold.

7. The control system for an ultrafine powder long nozzle brick and a filling machine according to claim 5, characterized in that, It also includes variable frequency motors, hydraulic systems, and cylinders; The variable frequency motor is equipped with a brake and is used to drive the lifting and rotating platform. The speed range is 0.5~2m / min. The hydraulic system includes a hydraulic pump station for driving the lifting and rotating platform; The cylinder is a double-acting cylinder used to drive the tamping hammer, and its stroke is adjustable.

8. The control system for an ultrafine powder long nozzle brick and a filling machine according to claim 5, characterized in that, The limit switch assembly adopts a dual redundancy design: Limit switches LS1~LS3 adopt a combination of mechanical limit and electrical switch; LS4~LS11 are equipped with magnetic proximity switches.

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