Pneumatic system and method of light and superfine powder mixing machine

Abstract

The invention relates to the technical field of material mixing technological processes and control in the refractory material industry, in particular to a pneumatic system and method of a light and superfine powder mixing machine, a three-way valve in a pneumatic butterfly valve unit is connected with a second electromagnetic directional valve, and the electromagnetic directional valve is connected with a corresponding pneumatic butterfly valve; an electromagnetic directional valve in the cylinder pipeline unit is connected with the gas source storage unit, and the electromagnetic directional valve is respectively connected with a corresponding driving cylinder I; an electromagnetic directional valve in the pneumatic sealing unit is connected with the air source storage unit, and a fourth electromagnetic directional valve is connected with a corresponding second driving air cylinder through a three-way electromagnetic valve. The pneumatic system has the advantages that the pneumatic system is divided into four functional modules including the air source air storage unit, the pneumatic butterfly valve unit, the air cylinder pipeline unit and the pneumatic sealing unit, standard pneumatic connectors and unified pressure grades are adopted for all the modules, and the maintainability and expandability of the system are improved; air is centrally supplied among the modules through the branch air cylinders, and pipeline intersection and interference are reduced.

Description

Technical Field

[0001] This invention relates to the field of material mixing process and control technology in the refractory materials industry, and particularly to a pneumatic system and method for a lightweight and ultrafine powder mixer. Background Technology

[0002] With the increasing demand for high-performance refractory materials from industries such as metallurgy and chemicals, the production process of refractory bricks is developing towards finer powder, lighter materials, and more efficient mixing. Lightweight and ultrafine powder mixing equipment is a key piece of equipment in refractory material production lines, and the design and control technology of its pneumatic system directly affects mixing efficiency, product quality, and production safety.

[0003] Currently, the pneumatic systems of powder mixing equipment commonly used in the industry have the following technical problems: 1. The control unit of the pneumatic butterfly valve has a dispersed structure and poor synchronization. In existing systems, each pneumatic butterfly valve typically uses an independent air supply line and control valve, lacking a balanced air distribution design. When multiple feeding ports and discharge ports need to coordinate their operation, the difference in pipeline resistance causes inconsistent response times of each butterfly valve, affecting the accuracy of material feeding sequence and reducing mixing uniformity.

[0004] 2. The cylinder piping system has redundant structure and unreasonable layout; In existing designs, the air circuits of various drive cylinders (such as the opening and closing of the hopper cover, the drive of the vibrator, and the control of the discharge valve) are arranged in a rather messy manner, with problems such as pipe crossing and easy interference. In particular, the control circuit design of single-acting cylinders such as the vibrator cylinder is simple, lacking exhaust speed regulation and vibration isolation measures, which can easily cause system resonance.

[0005] 3. Low system integration and poor scalability; Traditional pneumatic systems typically have independently designed units (including air source, butterfly valve control, cylinder control, and sealing system), lacking an integrated layout. Non-standard air circuit interfaces and limited hose connection methods lead to difficult system maintenance and make it difficult to adapt to the adjustment requirements of different process configurations. Summary of the Invention

[0006] The purpose of this invention is to provide a pneumatic system and method for a lightweight and ultrafine powder mixer. Through a highly integrated modular system design, precise synchronous control strategy, and safety protection with vibration isolation and pressure equalization, it solves the long-standing technical bottleneck in the pneumatic control field of lightweight and ultrafine powder mixing equipment. This not only significantly improves mixing efficiency and product quality but also greatly enhances the safety of equipment operation, providing reliable core equipment technology support for high-quality, large-scale production in industries such as refractory materials.

[0007] To achieve the above objectives, the present invention provides the following technical solution: A pneumatic system for a lightweight and ultrafine powder mixer includes an air source storage unit, a pneumatic butterfly valve unit, a cylinder pipeline unit, and a pneumatic sealing unit. The pneumatic butterfly valve unit includes a solenoid directional valve group one and a three-way valve. The solenoid directional valve group one includes solenoid directional valve one and solenoid directional valve two. Port A of each three-way valve is connected to the outlet b of the air source storage unit through a pipeline. Port B of each three-way valve is connected to port II of solenoid directional valve one. Port C of each three-way valve is connected to port II of solenoid directional valve two. The working interface of solenoid directional valve one and the working interface of solenoid directional valve two are respectively connected to the corresponding pneumatic butterfly valve. The cylinder pipeline unit includes a second electromagnetic reversing valve group, which includes several third electromagnetic reversing valves. Port II of each third electromagnetic reversing valve is connected to the outlet c of the air source storage unit, and the working interface of each third electromagnetic reversing valve is connected to the corresponding drive cylinder. The pneumatic sealing unit includes a third electromagnetic reversing valve assembly and a three-way solenoid valve. The third electromagnetic reversing valve assembly includes a fourth electromagnetic reversing valve. Port II of the fourth electromagnetic reversing valve is connected to the outlet d of the air source storage unit. The working interface of the fourth electromagnetic reversing valve is connected to the corresponding drive cylinder II through the three-way solenoid valve.

[0008] Each solenoid directional valve in solenoid directional valve group one and solenoid directional valve group two is a two-position five-way solenoid directional valve, and each solenoid directional valve in solenoid directional valve group three is a two-position three-way solenoid directional valve.

[0009] The cylinder pipeline unit also includes a solenoid directional valve group four, which includes several solenoid directional valves five. Port II of each solenoid directional valve five is connected to the outlet c of the air source storage unit, and the working interface I of the solenoid directional valve five is connected to the corresponding drive cylinder three. The three drive cylinders include the vibrator drive cylinder and the dust collection port valve drive cylinder; Five-selection two-position three-way solenoid directional valve.

[0010] The actuator of the pneumatic butterfly valve has two control ports, namely the open port and the close port. The working interface I of each solenoid directional valve in the solenoid directional valve group one is connected to the open port of the corresponding pneumatic butterfly valve, and the working interface III of each solenoid directional valve in the solenoid directional valve group one is connected to the close port of the corresponding pneumatic butterfly valve. Pneumatic butterfly valves include pneumatic butterfly valves for air exhaust filters and dust collection ports, pneumatic butterfly valves for auxiliary raw material inlets, pneumatic butterfly valves for main raw material inlets, and pneumatic butterfly valves for steam dust collection ports.

[0011] In the second electromagnetic directional valve assembly, the working interface I of each electromagnetic directional valve is connected to the rod chamber of the corresponding drive cylinder, and the working interface III of each electromagnetic directional valve in the second electromagnetic directional valve assembly is connected to the rodless chamber of the corresponding drive cylinder.

[0012] The three-way solenoid valve includes three-way solenoid valve one and three-way solenoid valve two. The driving cylinder two includes a mixing tank sealing driving cylinder and a mixing tank cover rotary sealing driving cylinder. Port C of three-way solenoid valve one and port C of three-way solenoid valve two are both connected to working interface I of solenoid directional valve four. Port A of three-way solenoid valve one is connected to the mixing tank sealing drive cylinder, and port A of three-way solenoid valve two is connected to the mixing tank cover rotary sealing drive cylinder.

[0013] The gas source storage unit includes a gas storage tank.

[0014] The drive cylinder includes a drive cylinder for controlling the opening and closing of the material bin cover and a drive cylinder for the mixture discharge valve.

[0015] A pneumatic method for a lightweight and ultrafine powder mixer, comprising: S1. Gas path initialization: Start the gas source storage unit to bring the pressure in the storage tank to the set value; The control cylinder for the mixing tank sealing drive and the mixing tank cover rotary sealing drive are in the air supply sealing state, while the cylinder for the mixture discharge valve is in the closed state. S2. Feeding control: The pneumatic butterfly valves at the main raw material inlet and the auxiliary raw material inlet are opened sequentially to feed materials into the mixing tank according to the set time. Simultaneously control the air exhaust filter and dust collection port pneumatic butterfly valve, and the steam dust collection port pneumatic butterfly valve to be in the open state; S3, Mixing process: After feeding is complete, close all pneumatic butterfly valves at the feeding ports, maintain a sealed and dust-free state, and start the mixing mechanism to mix; S4. Material preparation: After mixing is completed, the control cylinder opens the material bin cover, the control cylinder opens the dust collection port valve, and the control cylinder starts the vibrator. S5. Material Discharge Execution: The control cylinder of the mixture discharge valve opens to discharge the mixture into the hopper. After the discharge is completed, the control cylinder of the mixture discharge valve closes, the control cylinder of the vibrator stops, and the hopper cover and dust collection port valve are closed. S6. Reset and Loop: Reset all pneumatic actuators to their initial state to prepare for the next cycle.

[0016] In S2, the feeding time of the main raw material and the auxiliary raw material can be set independently, with a setting range of 0-360 seconds; In S4, the delay time from the completion of mixing to the start of discharge is 0-90 seconds; In S5, the discharge time setting range is 0-360 seconds.

[0017] Compared with the prior art, the beneficial effects of the present invention are: 1. By dividing the pneumatic system into four functional modules—air source storage unit, pneumatic butterfly valve unit, cylinder pipeline unit, and pneumatic sealing unit—each module adopts standard pneumatic interfaces (such as ISO and GB / T standard interfaces) and a unified pressure level, with a reasonable layout, greatly improving the system's maintainability and scalability. Centralized air supply between modules via separate cylinders reduces pipeline crossings and interference. Through programmed control logic, the pneumatic actuators for processes such as feeding, sealing, mixing, dust removal, discharging, and rapping are coordinated in an orderly manner, significantly improving the overall smoothness and efficiency of the mixing process and solving the problem of poor process connection in traditional equipment. 2. Two-position five-way / three-way solenoid directional valves are used to directly drive each actuator. With the help of adjustable silencer exhaust valves, the pneumatic butterfly valves and cylinders can be opened and closed quickly and the speed can be adjusted. In particular, the three-way valve is used to balance the air pressure of each branch, compensate for the difference in pipeline resistance, and ensure the synchronization of the operation of multiple pneumatic butterfly valves (such as main / auxiliary feeding ports). This makes the material feeding precise and timely, and the mixing uniformity is significantly improved. 3. All pneumatic units generally use flexible hose connections (such as connecting hoses 4, 17, 29, and 34), which effectively isolates the mechanical vibration generated by the compressor and vibrator from being transmitted to pneumatic valves and pipelines, reducing joint loosening, seal failure, and sensor false alarms caused by vibration, and improving the long-term reliability of the system. 4. Multiple safety protection mechanisms are adopted: Real-time monitoring of sealing pressure is implemented, with an electrical contact pressure detection switch installed in the pneumatic sealing unit. An alarm is immediately triggered upon detecting an abnormal drop in sealing pipeline pressure, effectively preventing dust leakage and safety accidents caused by seal failure. Gas source safety protection includes a safety valve in the gas storage tank and an intermediate safety valve and intake filter in the compressor, ensuring the safety and cleanliness of the gas source from the outset. Anti-static and explosion-proof design is employed; the mixing tank, pipelines, and pneumatic actuators are all equipped with reliable grounding devices, and the actuators use anti-static sleeves. Key interfaces utilize explosion-proof electrical components, effectively dissipating static electricity generated during the ultrafine powder mixing process and reducing the risk of combustion and explosion. 5. An independent pneumatic sealing unit is adopted, with a dual-valve combination structure (i.e., a two-position three-way solenoid directional valve 24 and a three-way solenoid valve 35 combined) to provide reliable and fast sealing and unsealing for the mixing tank and tank cover, effectively preventing the escape of ultrafine powder during the mixing process and ensuring a clean working environment. 6. Adjustable silencer exhaust valves are installed at the exhaust ports of all electromagnetic reversing valves to significantly reduce exhaust noise, improve the working environment, and meet the environmental protection requirements of modern factories. 7. The air source storage unit adopts a variable frequency drive compressor, which dynamically adjusts the output according to the actual air consumption of the system to maintain the pressure of the air storage tank at the set value (such as 0.8MPa), avoiding the energy waste caused by the frequent start-up, shutdown or unloading operation of traditional air compressors. The overall energy efficiency is significantly improved. Considering that the total power of the main drive motor of the mixer is large (up to 275kW or more), the energy-saving design of the pneumatic system has a positive significance for reducing the total energy consumption of the production line. 8. The pneumatic control method is based on a programmable working block diagram. Key process parameters (such as feeding time 0-360s, mixing delay 0-90s, and discharge time 0-360s) can be flexibly set. The system can quickly adjust the pneumatic program according to the physical properties (such as flowability, density, and miscibility) of different lightweight materials and ultrafine powders, realizing "one machine for multiple uses" and greatly expanding the process applicability of the equipment. 9. Modular design makes troubleshooting and maintenance of local faults more convenient. The use of standard valves and hose fittings reduces maintenance costs. The overall system operation logic is clear and the operation is reliable, ensuring stable operation in high-load, continuous industrial production. Attached Figure Description

[0018] Figure 1 This is a diagram of a pneumatic butterfly valve system.

[0019] Figure 2 It is a plan view of the pneumatic butterfly valve and other components of the pneumatic system.

[0020] Figure 3 This is a diagram of the cylinder piping system of a pneumatic system.

[0021] Figure 4 This is a diagram of a pneumatic sealing system for a pneumatic system.

[0022] Figure 5 It is the air source storage tank and air distribution cylinder system of the pneumatic system.

[0023] Figure 6 This is a flowchart of the pneumatic control program for a pneumatic system.

[0024] In the diagram: 1. Compressor main unit; 2. Air inlet shut-off valve; 3. Check valve; 4. Connecting hose; 5. Pressure relay; 6. Air tank; 7. Pressure gauge; 8. Air tank safety valve; 9. Drain valve; 10. Distributor cylinder inlet shut-off valve; 11. Distributor cylinder; 12. Distributor cylinder inlet shut-off valve; 13. Distributor cylinder air outlet shut-off valve; 14. Air inlet shut-off valve; 15. Filter pressure reducing valve; 16. Two-position five-way solenoid directional valve; 17. Connecting hose; 18. Pneumatic butterfly valve for steam dust collection port; 19. Pneumatic butterfly valve for main raw material inlet; 20. Pneumatic butterfly valve for auxiliary raw material inlet; 21. Air exhaust filter and... 21. Pneumatic butterfly valve for dust collection port; 22. Air inlet shut-off valve; 23. Filter pressure reducing valve; 24. Two-position three-way solenoid directional valve; 25. Material bin cover opening and closing drive cylinder; 26. Vibrator drive cylinder; 27. Dust collection port valve drive cylinder; 28. Mixed material discharge valve drive cylinder; 29. ​​Connecting hose; 30. Air inlet shut-off valve; 31. Filter pressure reducing valve; 32. Electrical contact pressure detection switch; 33. Shut-off valve; 34. Connecting hose; 35. Three-way solenoid valve; 36. Mixing tank cover rotary seal drive cylinder; 37. Mixing tank seal drive cylinder; 101. Three-way valve; 102. Silencing exhaust valve. Detailed Implementation

[0025] 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.

[0026] The following embodiments are implemented based on the technical solution of the present invention, providing detailed implementation methods and specific operating procedures. 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.

[0027] Example 1 A pneumatic system for a lightweight and ultrafine powder mixer includes an air source storage unit, a pneumatic butterfly valve unit, a cylinder pipeline unit, and a pneumatic sealing unit. The air source storage unit is connected to the pneumatic butterfly valve unit, the cylinder pipeline unit, and the pneumatic sealing unit respectively to provide a working air source. 1. Gas source and storage unit, see Figure 5 ; The air source storage unit includes a compressor main unit 1, a compressed air inlet shut-off valve 2, a check valve 3, a connecting hose 4, a pressure relay 5, an air storage tank 6, a pressure gauge 7, an air tank safety valve 8, a drain valve 9, a distribution cylinder inlet shut-off valve 10, a distribution cylinder 11, a distribution cylinder inlet shut-off valve 12, a distribution cylinder air outlet shut-off valve 13, and their connecting pipelines. The compressor main unit 1 supplies compressed air to the air storage tank 6 via the compressed air inlet shut-off valve 2 and the check valve 3, and via the connecting hose 4. The air storage tank 6 supplies air to the distribution cylinder 11 via the air outlet shut-off valve 10 and the distribution cylinder inlet shut-off valve 12 (denoted as 12a). The distribution cylinder 11 is located close to each pneumatic actuator and supplies compressed air to different pneumatic subsystems via the distribution cylinder air outlet shut-off valves 13 (including 13b, 13c, and 13d) to ensure reliable operation of the actuators.

[0028] The compressor unit 1 is driven by a frequency converter, which can adjust the discharge volume according to the air consumption of the pneumatic system: when the air consumption decreases, the discharge volume is reduced to maintain the air tank pressure below the set value (pressure relay 5 is set to 0.8MPa); when the air tank pressure is lower than the set value, the discharge volume is increased to avoid energy waste caused by frequent start-stop of the motor. The compressor unit 1 is equipped with an intercooler and an intake filter; the former is used for heat dissipation, and the latter is used to ensure the cleanliness and safety of the intake air. The compressor unit 1 is also equipped with an intermediate safety valve to ensure stable and safe output air pressure and flow. The one-way valve 3 allows compressed air to flow only from the compressor to the air tank, preventing backflow. The connecting hose 4 is used to isolate compressor vibration and prevent vibration from being transmitted to the air tank and subsequent pipelines. The air tank 6 is equipped with an air tank safety valve 8 for overpressure protection; and a drain valve 9 for periodically removing water accumulated in the tank. The air source storage unit can provide stable, clean, and pressure-controllable compressed air for the subsequent pneumatic butterfly valve unit, cylinder pipeline unit, and pneumatic sealing unit, and has the advantages of energy saving, safety, and low vibration.

[0029] 2. Pneumatic butterfly valve unit, see Figure 1 ,See Figure 2 ; The pneumatic butterfly valve unit includes an air inlet shut-off valve 14, a filter pressure reducing valve 15, two three-way valves 101, four two-position five-way solenoid directional valves 16, a connecting hose 17, and corresponding pneumatic butterfly valves and connecting pipelines. The pneumatic butterfly valves include an air exhaust filter and dust collection port pneumatic butterfly valve 21, a secondary raw material inlet pneumatic butterfly valve 20, a main raw material inlet pneumatic butterfly valve 19, and a steam dust collection port pneumatic butterfly valve 18.

[0030] The air inlet II of each two-position five-way solenoid directional valve 16 is connected to the outlet of the filter pressure reducing valve 15; the actuator of each pneumatic butterfly valve is provided with two control ports, namely an open port and a closed port; the working interface I of each two-position five-way solenoid directional valve 16 is connected to the open port of the corresponding pneumatic butterfly valve, and the working interface III of each two-position five-way solenoid directional valve 16 is connected to the closed port of the corresponding pneumatic butterfly valve; the exhaust port of each two-position five-way solenoid directional valve 16 is provided with an adjustable silencer exhaust valve 102, which is used to adjust the butterfly valve's operating speed and reduce exhaust noise.

[0031] Port A of each three-way valve 101 is connected to the outlet b of the air source storage unit. Ports B and C of each three-way valve 101 are respectively connected to the inlet II of different two-position five-way solenoid directional valves 16 via pipelines. The three-way valve 101 is a balanced distribution type three-way valve, and the valve body is equipped with an adjustable throttling element. By adjusting the opening of the throttling element, the flow rate and pressure of compressed air flowing from port A to ports B and C are adjusted, so that the pressure distributed to different branches remains balanced within a set range. When the system is working, compressed air is distributed from the air source storage unit to each branch through the three-way valve 101. The pressure of each branch is dynamically balanced through the throttling adjustment of the three-way valve 101, thereby compensating for the uneven resistance caused by differences in pipeline length, number of bends, and installation. The equalizing pressure is precisely transmitted to the actuator of the corresponding pneumatic butterfly valve through the corresponding two-position five-way solenoid directional valve 16, ensuring that multiple pneumatic butterfly valves can obtain basically consistent air pressure supply when they receive control signals, thereby achieving synchronization of actions and avoiding valve opening and closing timing deviations caused by air pressure differences.

[0032] The pneumatic butterfly valve unit is used to control the opening and closing of the main and auxiliary raw material feeding ports, as well as process interfaces such as air exhaust filters, dust collection ports, and steam dust collection ports in the mixer. Connecting hose 17 connects the corresponding solenoid directional valve to the pneumatic butterfly valve, which facilitates installation in multi-pipe environments and effectively isolates airflow vibrations, preventing vibration transmission to the main equipment structure.

[0033] The pneumatic butterfly valve unit achieves rapid, stable, and coordinated operation of the pneumatic butterfly valve in the ultrafine powder mixing process through measures such as independent control, balanced air pressure distribution, adjustable speed, and vibration isolation, thereby improving the reliability and environmental friendliness of the mixing process.

[0034] 3. Cylinder piping unit, see Figure 3 ; The cylinder piping unit includes an air inlet shut-off valve 22, a filter pressure reducing valve 23, two two-position five-way solenoid directional valves 16, two two-position three-way solenoid directional valves 24, a connecting hose 29, and a drive cylinder and connecting piping.

[0035] The cylinder piping unit contains two control subsystems: First subsystem (double-acting cylinder control): The system is controlled by a two-position five-way solenoid valve 16. The drive cylinders include: a material bin cover opening and closing drive cylinder 25 and a mixture discharge valve drive cylinder 28. The air inlet II of each two-position five-way solenoid valve 16 is connected to the outlet of the filter pressure reducing valve 23. The working port I and working port III of each two-position five-way solenoid valve 16 are respectively connected to the rod chamber and rodless chamber of the corresponding drive cylinder through a connecting hose 29.

[0036] The exhaust port of the corresponding drive cylinder is equipped with an adjustable fast-acting muffler exhaust valve 102, which is used to adjust the cylinder action speed and reduce noise.

[0037] Second subsystem (single-acting cylinder control): The control is achieved by a two-position three-way solenoid valve 24 (the two-position three-way solenoid valve is normally open and has a single electromagnet). The drive cylinders include: a vibrator drive cylinder 26 and a dust collection port valve drive cylinder 27. The air inlet II of each two-position three-way solenoid valve 24 is connected to the outlet of the filter pressure reducing valve 23, and the working port I of the two-position three-way solenoid valve 24 is connected to the air inlet of the corresponding single-acting cylinder through a connecting hose 29.

[0038] The cylinder piping unit operation includes: Material bin cover control: The material bin cover opening and closing drive cylinder 25 is controlled by a two-position five-way solenoid reversing valve 16 to achieve precise opening and closing of the material bin cover; Discharge valve control: The discharge valve is controlled by a two-position five-way solenoid directional valve 16 to drive the cylinder 28, thereby achieving reliable opening and closing of the discharge gate; Vibration auxiliary control: The vibrator drive cylinder 26 is controlled by the two-position three-way solenoid valve 24 to start the vibration action during the material discharge process, so as to promote the smooth discharge of materials from the chute and prevent material blockage or "bulging" phenomenon. Dust collection port control: The dust collection port valve is controlled by a two-position three-way solenoid valve 24 to drive the cylinder 27, thereby realizing the opening and closing control of the dust collection port.

[0039] The cylinder piping unit isolates air path vibration by using a hose connection, controls cylinder speed by adjusting exhaust throttling, and achieves coordinated control of various pneumatic actuators in the mixer through the reasonable configuration of double-acting and single-acting cylinders, ensuring the smoothness and reliability of the discharge process.

[0040] 4. Pneumatic sealing unit, see Figure 4 ; The pneumatic sealing unit includes an air inlet shut-off valve 30, a filter pressure reducing valve 31, a two-position three-way solenoid directional valve 24, a shut-off valve 33, two three-way solenoid valves 35, a connecting hose 34, and corresponding drive cylinders; the drive cylinders include: a mixing tank sealing drive cylinder 37 and a mixing tank cover rotary sealing drive cylinder 36.

[0041] The air inlet II of the two-position three-way solenoid directional valve 24 is connected to the air source through the filter pressure reducing valve 31. The two-position three-way solenoid directional valve 24 is normally open. When the power is off, the spring returns to the original position and supplies air. When the power is on, the air supply stops and the cylinder exhausts air.

[0042] The working port I of the two-position three-way solenoid directional valve 24 is connected to the C port of the two three-way solenoid valves 35 respectively through the connecting hose 34; the B port of the two three-way solenoid valves 35 is connected to the air source through the filter pressure reducing valve 31; the A port of the three-way solenoid valve 35-1 is connected to the mixing tank sealing drive cylinder 37; the A port of the three-way solenoid valve 35-2 is connected to the mixing tank cover rotary sealing drive cylinder 36.

[0043] The outlet of the filter pressure reducing valve 31 is equipped with an electrical contact pressure detection switch 32 for real-time monitoring of pipeline pressure. When the pressure is detected to be lower than the set value, an alarm signal is issued. There are shut-off valves 33 between the three-way solenoid valve 35-1 and the filter pressure reducing valve 31, and between the three-way solenoid valve 35-2 and the filter pressure reducing valve 31, for cutting off the gas supply during maintenance.

[0044] Work style: Sealing state establishment: When the two-position three-way solenoid directional valve 24 is de-energized, compressed air is supplied to the two three-way solenoid valves 35 through the valve, which in turn drives the mixing tank sealing drive cylinder 37 and the mixing tank cover rotation sealing drive cylinder 36 to operate, thereby achieving a reliable seal of the mixing tank.

[0045] Release of seal: When the two-position three-way solenoid directional valve 24 is energized, the valve cuts off the gas source and connects the cylinder pipeline to the atmosphere. The mixing tank sealing drive cylinder 37 and the mixing tank cover rotation sealing drive cylinder 36 are reset and exhaust under the action of the spring, and the seal is released.

[0046] Safety monitoring: The electrical contact pressure detection switch continuously monitors the pressure of the sealed pipeline. When an abnormal drop in pressure is detected, an audible and visual alarm is immediately issued to remind the operator to check the sealing system and prevent dust leakage or safety accidents caused by seal failure.

[0047] The pneumatic sealing unit achieves reliable control and safety assurance of key sealing parts of the mixer through a dual valve control design (a combination of a two-position three-way solenoid directional valve and a three-way solenoid valve) and real-time pressure monitoring. It is particularly suitable for working conditions with strict sealing performance requirements during the mixing of ultrafine powders.

[0048] A pneumatic method for a lightweight and ultrafine powder mixer, see Figure 6 ,include: S1. Gas path initialization: Start the gas source storage unit to bring the pressure in the storage tank to the set value; The control cylinder for the mixing tank sealing drive and the mixing tank cover rotary sealing drive are in the air supply sealing state, while the cylinder for the mixture discharge valve is in the closed state. S2. Feeding control: The pneumatic butterfly valves at the main raw material inlet and the auxiliary raw material inlet are opened sequentially to feed materials into the mixing tank according to the set time. Simultaneously control the air exhaust filter and dust collection port pneumatic butterfly valve, and the steam dust collection port pneumatic butterfly valve to be in the open state; S3, Mixing process: After feeding is complete, close all pneumatic butterfly valves at the feeding ports, maintain a sealed and dust-free state, and start the mixing mechanism to mix; S4. Material preparation: After mixing is completed, the control cylinder opens the material bin cover, the control cylinder opens the dust collection port valve, and the control cylinder starts the vibrator. S5. Material Discharge Execution: The control cylinder of the mixture discharge valve opens to discharge the mixture into the hopper. After the discharge is completed, the control cylinder of the mixture discharge valve closes, the control cylinder of the vibrator stops, and the hopper cover and dust collection port valve are closed. S6. Reset and Loop: Reset all pneumatic actuators to their initial state to prepare for the next cycle.

[0049] The feeding time of the main raw material and the auxiliary raw material can be set independently, with a setting range of 0-360 seconds; In S4, the delay time from the completion of mixing to the start of discharge is 0-90 seconds; In S5, the discharge time setting range is 0-360 seconds.

[0050] Example 2 In this embodiment, the pneumatic system of a lightweight and ultrafine powder mixer is the same as that in Embodiment 1, with the addition of a working process.

[0051] The pneumatic system of the lightweight and ultrafine powder mixer is based on the principle of unit-based collaborative control. Following a preset process procedure, it sequentially completes three major stages: mixing preparation, material feeding and mixing, and material discharge. The specific working process is as follows: Phase 1: System initialization and hybridization preparation; 1. Gas source establishment: Start the compressor host (1) and stabilize the pressure of the air tank (6) at 0.8MPa through frequency conversion speed regulation; the compressed air is distributed to the air source inlet of each subsystem through the air distribution cylinder (11).

[0052] 2. Seal establishment: When the two-position three-way solenoid valve (24) of the pneumatic sealing unit is de-energized, compressed air enters the mixing tank sealing drive cylinder (37) and the mixing tank cover rotation sealing drive cylinder (36) through the three-way solenoid valve (35), pushing the piston to make the mixing tank reach a completely sealed state.

[0053] The electrical contact pressure detection switch monitors the pressure in the sealed pipeline in real time to confirm that the seal is reliable.

[0054] 3. Discharge valve pre-closed: The two-position five-way solenoid directional valve (16) of the cylinder pipeline unit controls the mixture discharge valve to drive the cylinder (28) to the closed position, ensuring that the bottom of the mixing tank is sealed.

[0055] 4. Dust removal preparation: The pneumatic butterfly valve unit controls the opening of the air exhaust filter and the pneumatic butterfly valve (21) at the dust collection port, and the pneumatic butterfly valve (18) at the steam dust collection port, to establish a negative pressure dust removal environment for the mixing process.

[0056] Second stage: Material feeding and mixing process; 1. Input of main raw materials: When the two-position five-way solenoid directional valve (16) corresponding to the main raw material input pneumatic butterfly valve (19) of the pneumatic butterfly valve unit is energized, compressed air enters the "open" chamber of the butterfly valve actuator through the evenly distributed three-way valve (101), and the valve opens. After the raw materials are added according to the set time (adjustable from 0-360s), the solenoid valve reverses and the butterfly valve closes.

[0057] 2. Input of by-products: The auxiliary raw material inlet pneumatic butterfly valve (20) is fed in according to the same principle, and its feeding time can be set independently; By adjusting the flow through the three-way valve (101), the main and auxiliary feeding butterfly valves are ensured to obtain balanced air pressure, thereby achieving synchronous opening and closing of the valves.

[0058] 3. Mixing process: After all the feeding ports are closed, the mixer drive motor starts and the mixing process begins; The sealing system maintains working pressure, and the dust removal butterfly valve remains open. The pneumatic system is in standby mode, maintaining only sealing and dust removal functions.

[0059] Third stage: End of mixing and discharge; 1. Material preparation: After mixing is complete, the system delay is 0-90 seconds (adjustable). The cylinder pipeline unit controls the opening and closing of the material box cover, driving the cylinder (25) to open the material box cover; Two-position three-way solenoid reversing valve (24) controls the dust collection port valve to drive cylinder (27) to open the dust collection port.

[0060] 2. Vibration start-up: Two-position three-way solenoid directional valve (24) controls the start of vibrator drive cylinder (26) to vibrate the discharge chute at a predetermined frequency to prevent material accumulation.

[0061] 3. Material Dispatch Execution: Two-position five-way solenoid directional valve (16) controls the mixture discharge valve drive cylinder (28) to open the discharge gate; The mixture is discharged into the hopper under gravity and vibration, and the discharge time is adjustable from 0 to 360 seconds. During the discharge process, the silencer valve 102 at the exhaust port adjusts the cylinder speed to ensure the smooth operation of the discharge gate.

[0062] 4. Material discharge completed: After the material discharge is completed, the mixture discharge valve drive cylinder (28) closes; The vibrator drive cylinder (26) stops; The hopper cover and dust collection port are closed in sequence.

[0063] Phase 4: System reset; 1. Seal release: The two-position three-way solenoid reversing valve (24) is energized, and the mixing tank sealing drive cylinder (37) and the mixing tank cover rotation sealing drive cylinder (36) exhaust gas, thus releasing the seal.

[0064] 2. Gas source adjustment: When the system detects a decrease in gas consumption, the compressor automatically reduces its output frequency to maintain the pressure in the gas tank within the set range.

[0065] 3. Standby state: All pneumatic components are reset, ready for the next work cycle.

[0066] The manifestation of system characteristics during operation: Synchronization Guarantee: The throttling regulation of the three-way valve (101) ensures that multiple butterfly valves operate synchronously, avoiding material input timing errors; Vibration isolation: Each unit is connected by flexible hoses to effectively isolate the vibration generated by the compressor and rapper; Speed ​​controllable: All exhaust ports are equipped with silencer exhaust valves 102 to achieve precise adjustment of cylinder / butterfly valve operating speed; Safety monitoring: Real-time monitoring of sealing pressure; alarm and shutdown immediately in case of abnormality; Energy-saving operation: The compressor uses frequency conversion regulation to avoid frequent start-stop and reduce energy consumption.

[0067] Efficient, stable, and safe mixed production is achieved through precise timing control, balanced pressure distribution, and vibration isolation design.

[0068] This invention divides the pneumatic system into four functional modules: an air source and storage unit, a pneumatic butterfly valve unit, a cylinder pipeline unit, and a pneumatic sealing unit. Each module uses standard pneumatic interfaces (such as ISO and GB / T standard interfaces) and a unified pressure rating, resulting in a rational layout that greatly improves the system's maintainability and scalability. Centralized air supply between modules via distributed cylinders reduces pipeline crossings and interference. Through programmed control logic, the pneumatic actuators for processes such as feeding, sealing, mixing, dust removal, discharging, and vibration are coordinated in an orderly manner, significantly improving the overall smoothness and efficiency of the mixing process and solving the problems associated with traditional equipment process connections. To address the issue of poor airflow, a two-position five-way / three-way solenoid directional valve is used to directly drive each actuator. Combined with an adjustable silencer exhaust valve 102, this enables rapid opening and closing of the pneumatic butterfly valves and cylinders, with adjustable speed. Specifically, the three-way valve balances the air pressure in each branch, compensating for differences in pipeline resistance and ensuring the synchronous operation of multiple pneumatic butterfly valves (such as the main / auxiliary feeding ports). This allows for precise and timely material input, significantly improving mixing uniformity. All pneumatic units utilize flexible hose connections (such as connecting hoses 4, 17, 29, and 34), effectively isolating the mechanical vibrations generated by the compressor and vibrator from being transmitted to the pneumatic valves and pipelines, reducing the impact of mechanical vibrations. Vibration-induced joint loosening, seal failure, and sensor false alarms improve the long-term reliability of the system; multiple safety protection mechanisms are adopted, the sealing pressure is monitored in real time, and the pneumatic sealing unit is equipped with an electrical contact pressure detection switch. Once an abnormal decrease in the pressure of the sealing pipeline is detected, an alarm is immediately triggered, effectively preventing dust leakage and safety accidents caused by seal failure; through air source safety protection, a safety valve (8) is installed in the air storage tank, and an intermediate safety valve and suction filter are installed in the compressor to ensure the safety and cleanliness of the air source from the source; through anti-static and explosion-proof design, the static discharge measures for ultrafine powder mixing are considered in the system design to reduce static electricity. Low safety hazards; employs an independent pneumatic sealing unit with a dual-valve combination structure (i.e., a two-position three-way solenoid directional valve 24 combined with a three-way solenoid valve 35), providing reliable and rapid sealing and unsealing for the mixing tank and tank cover, effectively preventing the escape of ultrafine powder during the mixing process and ensuring a clean working environment; adjustable silencer exhaust valves 102 are installed at the exhaust ports of all solenoid directional valves, significantly reducing exhaust noise, improving the working environment, and meeting the environmental protection requirements of modern factories; the gas source storage unit uses a variable frequency drive compressor, dynamically adjusting the output according to the actual gas consumption of the system to maintain the pressure of the gas storage tank at the set value (e.g., 0).The system operates at 8MPa, avoiding the energy waste caused by frequent start-stop or unloading operations of traditional air compressors, resulting in a significant improvement in overall energy efficiency. Considering the large total power of the main drive motor of the mixer (up to 275kW or more), the energy-saving design of the pneumatic system is of positive significance for reducing the total energy consumption of the production line. The pneumatic control method is based on a programmable block diagram, and key process parameters (such as feeding time 0-360s, mixing delay 0-90s, and discharge time 0-360s) can be flexibly set. The system can quickly adjust the pneumatic program according to the physical properties (such as flowability, density, and miscibility) of different lightweight materials and ultrafine powders, achieving "one machine for multiple uses" and greatly expanding the process applicability of the equipment. The modular design makes troubleshooting and maintenance of local faults more convenient, and the use of standard valves and hose connectors reduces maintenance costs. The overall system operation logic is clear, the operation is reliable, and stable operation is guaranteed in high-load, continuous industrial production.

Claims

1. A pneumatic system for a lightweight and ultrafine powder mixer, characterized in that, It includes an air source storage unit, a pneumatic butterfly valve unit, a cylinder pipeline unit, and a pneumatic sealing unit; The pneumatic butterfly valve unit includes a solenoid directional valve group one and a three-way valve. The solenoid directional valve group one includes solenoid directional valve one and solenoid directional valve two. Port A of each three-way valve is connected to the outlet b of the air source storage unit through a pipeline. Port B of each three-way valve is connected to port II of solenoid directional valve one. Port C of each three-way valve is connected to port II of solenoid directional valve two. The working interface of solenoid directional valve one and the working interface of solenoid directional valve two are respectively connected to the corresponding pneumatic butterfly valve. The cylinder pipeline unit includes a second electromagnetic reversing valve group, which includes several third electromagnetic reversing valves. Port II of each third electromagnetic reversing valve is connected to the outlet c of the air source storage unit, and the working interface of each third electromagnetic reversing valve is connected to the corresponding drive cylinder. The pneumatic sealing unit includes a third electromagnetic reversing valve assembly and a three-way solenoid valve. The third electromagnetic reversing valve assembly includes a fourth electromagnetic reversing valve. Port II of the fourth electromagnetic reversing valve is connected to the outlet d of the air source storage unit. The working interface of the fourth electromagnetic reversing valve is connected to the corresponding drive cylinder II through the three-way solenoid valve.

2. The pneumatic system of a lightweight and ultrafine powder mixer according to claim 1, characterized in that, Each electromagnetic directional valve in electromagnetic directional valve group one and electromagnetic directional valve group two is a two-position five-way electromagnetic directional valve, and each electromagnetic directional valve in electromagnetic directional valve group three is a two-position three-way electromagnetic directional valve.

3. The pneumatic system of a lightweight and ultrafine powder mixer according to claim 1, characterized in that, The cylinder pipeline unit also includes a solenoid reversing valve group four, which includes several solenoid reversing valves five. The II port of each solenoid reversing valve five is connected to the outlet c of the air source storage unit, and the working interface I of the solenoid reversing valve five is connected to the corresponding drive cylinder three. The three drive cylinders include the vibrator drive cylinder and the dust collection port valve drive cylinder; Five-selection two-position three-way solenoid directional valve.

4. The pneumatic system of a lightweight and ultrafine powder mixer according to claim 1, characterized in that, The actuator of the pneumatic butterfly valve is provided with two control ports, namely an open port and a close port. The working interface I of each solenoid directional valve in the solenoid directional valve group I is connected to the open port of the corresponding pneumatic butterfly valve, and the working interface III of each solenoid directional valve in the solenoid directional valve group I is connected to the close port of the corresponding pneumatic butterfly valve. Pneumatic butterfly valves include pneumatic butterfly valves for air exhaust filters and dust collection ports, pneumatic butterfly valves for auxiliary raw material inlets, pneumatic butterfly valves for main raw material inlets, and pneumatic butterfly valves for steam dust collection ports.

5. The pneumatic system of a lightweight and ultrafine powder mixer according to claim 1, characterized in that, In the second electromagnetic directional valve assembly, the working interface I of each electromagnetic directional valve is connected to the rod chamber of the corresponding drive cylinder, and the working interface III of each electromagnetic directional valve is connected to the rodless chamber of the corresponding drive cylinder.

6. The pneumatic system of a lightweight and ultrafine powder mixer according to claim 1, characterized in that, The three-way solenoid valve includes a first three-way solenoid valve and a second three-way solenoid valve. The second drive cylinder includes a mixing tank sealing drive cylinder and a mixing tank cover rotary sealing drive cylinder. Port C of three-way solenoid valve one and port C of three-way solenoid valve two are both connected to working interface I of solenoid directional valve four. Port A of three-way solenoid valve one is connected to the mixing tank sealing drive cylinder, and port A of three-way solenoid valve two is connected to the mixing tank cover rotary sealing drive cylinder.

7. The pneumatic system of a lightweight and ultrafine powder mixer according to claim 1, characterized in that, The gas source storage unit includes a gas storage tank.

8. The pneumatic system of a lightweight and ultrafine powder mixer according to claim 1, characterized in that, The aforementioned drive cylinder includes a drive cylinder for controlling the opening and closing of the material bin cover and a drive cylinder for the mixture discharge valve.

9. A pneumatic method for a lightweight and ultrafine powder mixer using the system described in any one of claims 1-8, characterized in that, include: S1. Gas path initialization: Start the gas source storage unit to bring the pressure in the storage tank to the set value; The control cylinder for the mixing tank sealing drive and the mixing tank cover rotary sealing drive are in the air supply sealing state, while the cylinder for the mixture discharge valve is in the closed state. S2. Feeding control: The pneumatic butterfly valves at the main raw material inlet and the auxiliary raw material inlet are opened sequentially to feed materials into the mixing tank according to the set time. Simultaneously control the air exhaust filter and dust collection port pneumatic butterfly valve, and the steam dust collection port pneumatic butterfly valve to be in the open state; S3, Mixing process: After feeding is complete, close all pneumatic butterfly valves at the feeding ports, maintain a sealed and dust-free state, and start the mixing mechanism to mix; S4. Material preparation: After mixing is completed, the control cylinder opens the material bin cover, the control cylinder opens the dust collection port valve, and the control cylinder starts the vibrator. S5. Material Discharge Execution: The control cylinder of the mixture discharge valve opens to discharge the mixture into the hopper. After the discharge is completed, the control cylinder of the mixture discharge valve closes, the control cylinder of the vibrator stops, and the hopper cover and dust collection port valve are closed. S6. Reset and Loop: Reset all pneumatic actuators to their initial state to prepare for the next cycle.

10. The pneumatic method for a lightweight and ultrafine powder mixer according to claim 1, characterized in that, In S2, the feeding time of the main raw material and the auxiliary raw material can be set independently, with a setting range of 0-360 seconds; In S4, the delay time from the completion of mixing to the start of discharge is 0-90 seconds; In S5, the discharge time setting range is 0-360 seconds.

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