Coal gangue sintering porous brick track type tunnel kiln structure and sintering method

Abstract

The application discloses a coal gangue sintering porous brick track type tunnel kiln structure, which comprises a tunnel kiln, a kiln car structure matched with the tunnel kiln, a lower leading assembly installed on the kiln car and used for leading kiln fire downwards, and an air guide plate hingedly installed at both sides of the kiln car. The air guide plate is reset through a hinged spring structure. A pushing structure for opening and closing the air guide plate is installed at both sides of the sintering kiln section. A wind guide structure is fixedly installed on one side of the air guide plate facing a brick stack. A defective brick removing mechanism is arranged at a discharging end of a cooling kiln section. The defective brick removing mechanism comprises a detection structure for detecting defects of brick materials. A defective brick removing assembly matched with the detection structure is installed on a belt conveyor, and the defective brick removing assembly removes defective bricks from the belt conveyor. The application also discloses a sintering method of the tunnel kiln. The application realizes sintering of the bottom layer of the brick stack through leading fire downwards and realizes detection and removal of defective bricks.

Description

Technical Field

[0001] This invention belongs to the field of coal gangue sintering porous brick processing technology, and particularly relates to a track-type tunnel kiln structure and sintering method for coal gangue sintering porous bricks. Background Technology

[0002] Porous bricks, processed from materials such as coal gangue through sintering, are the most widely used building material in the construction industry, with a very large industrial demand and high requirements for the quality of the bricks, especially for large-scale building structures. The processing of porous bricks currently mainly involves sintering in tunnel kilns. Specifically, a tunnel kiln consists of three main sections: a preheating section, a sintering section, and a cooling section. The brick blanks are stacked on kiln cars, which are then pushed into the kiln one by one for processing using methods such as hydraulic jacks.

[0003] However, in actual operation, the bricks are stacked to a certain height on the kiln car, and the kiln car is mainly formed by welding steel frames. This results in the bricks at the bottom of the stack heating up slowly and cooling down too quickly (through the kiln car). Furthermore, during combustion, the kiln fires downwards, making it difficult for the flames to reach the bottom of the stack. Consequently, measurements show that the temperature difference between the top and bottom of the stack can reach nearly 100 degrees Celsius, or even higher. In addition, the bottom bricks bear a greater load on the stack.

[0004] This results in a very high scrap rate for bricks, especially at the bottom of the brick stack, during the actual processing. Consequently, there are many defective bricks at the bottom of the stack during the material cutting process, such as those that are easily broken, have surface cracks, or are not fully sintered.

[0005] This problem has plagued generations of kiln workers, and each generation of kilns has made many technical improvements to address it, such as stacking insulating bricks with lower thermal conductivity on the kiln car and sealing the sides of the kiln car, etc. However, the results have not been ideal.

[0006] The core problem is that during the kiln firing process, the high-temperature flames cannot sink to the bottom of the brick stack because it is difficult to draw the high-temperature flames down through specific mechanical structures inside the kiln. Summary of the Invention

[0008] Based on the above background, the purpose of this invention is to provide a track-type tunnel kiln structure for sintering porous bricks from coal gangue.

[0009] To achieve the above objectives, the present invention adopts the following technical solution: A track-type tunnel kiln structure for sintering porous bricks from coal gangue includes a tunnel kiln, which includes a preheating kiln section, a sintering kiln section, and a cooling kiln section; it also includes a kiln car structure that works in conjunction with the tunnel kiln, the kiln car structure including a kiln car, and a downward drawing assembly installed on the kiln car for drawing the kiln fire downward, the downward drawing assembly including air ducts hinged to both sides of the kiln car. The air-guiding plate is reset by a hinged spring structure; Several pushing structures that open and close the induced draft plates are installed on both sides of the sintering kiln section; the kiln fire ejected from the top of the tunnel kiln is guided down to the lower layer of the brick stack by opening and closing the induced draft plates. The air guide plate is fixedly installed with an air guide structure on the side facing the brick stack. The air guide structure guides the high-temperature flue gas to different positions of the brick stack. The air guide structure includes several arc-shaped air guide protrusions spaced apart, and arc-shaped air guide concave parts are formed between the arc-shaped air guide protrusions. It also includes a defect brick removal mechanism installed at the discharge end of the cooling kiln section; The defective brick removal mechanism includes a belt conveyor, on which a detection structure for detecting brick defects is installed; the detection structure is used to detect the shape, appearance, and internal damage of the brick. The belt conveyor is equipped with a defect brick removal component that works in conjunction with the detection structure. When the detection structure identifies a defect brick, the defect brick removal component removes the defect brick from the belt conveyor.

[0010] Preferably, a U-shaped hinged bracket is fixedly installed at the lower end of the side wall of the air duct, and the hinged bracket is hinged to the side wall of the kiln car. Hinged spring structures are hinged to both sides of the upper end of the side wall of the air duct, and a bracket for hinged spring structures is fixedly connected to the side wall of the kiln car.

[0011] Preferably, the hinged spring structure includes a spring telescopic rod hinged to the wind deflector plate, and the spring telescopic rod is hinged to the upper end of the bracket. The spring telescopic rod includes a push rod and a push rod sleeve that is slidably installed on the push rod. The inner end of the push rod is fixedly connected to a spring seat that slides inside the push rod sleeve. A spring is fixedly connected between the spring seat and the push rod sleeve.

[0012] Preferably, the air guiding structure includes an air guiding plate fixedly connected to the air guiding plate, and the air guiding plate is integrally formed with a first arc-shaped air guiding protrusion, a second arc-shaped air guiding protrusion and a third arc-shaped air guiding protrusion from top to bottom; A first arc-shaped air guide recess is formed between the first arc-shaped air guide protrusion and the second arc-shaped air guide protrusion, and a second arc-shaped air guide recess is formed between the second arc-shaped air guide protrusion and the third arc-shaped air guide protrusion.

[0013] Preferably, the pushing structure includes several cylinders, and the piston rod of the cylinder is fixedly mounted with a high-temperature resistant push rod that passes through the tunnel kiln. The inner end of the high-temperature resistant push rod is fixedly mounted with a pushing steel wheel for pushing the induced draft plate.

[0014] Preferably, the detection structure includes a visual inspection structure and an ultrasonic flaw detection structure disposed above the belt conveyor; The visual inspection structure includes several high-definition cameras that capture images of brick materials, and the ultrasonic flaw detection structure includes an ultrasonic probe.

[0015] Preferably, the defect brick removal assembly includes a track support structure fixedly installed on a frame on one side of the conveyor belt, and a camera bracket is installed on the top of the high-definition camera, with the camera bracket fixedly installed at the top position of the track support structure; The ultrasonic probe is fixedly mounted on the probe bracket, which is in turn fixedly mounted at the top of the track support structure.

[0016] Preferably, the track support structure includes a frame-type track support, on which a defective brick pushing structure is installed. The defective brick pushing structure includes a lead screw rotatably connected inside the frame-type track support, and a lead screw motor for driving the lead screw. A lead screw shifter is threaded onto the lead screw, and a cylinder seat is fixedly installed on the lead screw shifter. A push cylinder is installed on the cylinder seat, and a pusher seat for pushing bricks up and down from the belt conveyor is fixedly installed on the piston rod of the push cylinder.

[0017] Preferably, guide wheels are installed at the top and bottom of the lead screw shifter, and the frame-shaped track support has grooves for the guide wheels to cooperate with them.

[0018] This invention also discloses a sintering method for the above-mentioned porous brick track-type tunnel kiln structure for coal gangue sintering, characterized by comprising the following steps: (1) Kiln car entry: The bricks to be sintered are stacked on the kiln car. The kiln car is pushed into the tunnel kiln by a hydraulic jack. After the brick stack is preheated in the preheating kiln section, it enters the sintering kiln section for sintering. During the sintering process, the burners installed in the sintering kiln section spray fire downwards to sinter the brick stack. (2) Ignition sinking: The push structure pushes the air duct plate back and forth. During the process of the air duct plate from closing to opening, it generates downward airflow, which draws the sprayed combustion flame down to the bottom; The high-temperature gas generated by combustion, with the cooperation of the arc-shaped air guide protrusion and the arc-shaped air guide concave part, forms a wave-like high-temperature flue gas, which heats the interior of the brick stack along the height direction of the brick stack. (3) Defect detection: As the kiln cars continue to enter the kiln via the hydraulic jack, the sintered brick stacks are pushed into the cooling kiln section to await exiting the kiln. After exiting the kiln, the brick stacks are grabbed and fed onto the conveyor belt by a robotic arm for transfer and defect detection. First, the bricks are captured by a high-definition camera, and the captured images are uploaded to the backend. They are compared with the backend data, and bricks that do not meet the requirements in terms of shape and color are marked. If the marking is not qualified, the motor drives the screw to push the exhaust cylinder toward the defective brick, and drives the pusher to push the defective brick down from the conveyor belt. The belt conveyor continues to transport bricks. The bricks are inspected for defects by an ultrasonic probe. Unqualified bricks are marked. If the marking is not qualified, the motor drives the lead screw to push the exhaust cylinder toward the defective brick and drive the pusher to push the defective brick off the belt conveyor. The qualified bricks continue to be transported to the unloading station via belt conveyor.

[0019] The present invention has the following beneficial effects: 1. This invention ingeniously utilizes structures such as induced draft plates to guide high-temperature flames to the lower layers, improving the heating effect on the bottom of the brick stack. Specifically, during the flame-guiding and sinking process, when the kiln car enters the sintering kiln section, the nozzles on the sintering kiln section spray flames downwards to calcine the brick stack. At the same time, the pushing structure reciprocates to push the induced draft plates. During the opening and closing of the induced draft plates, downward airflow is generated, which guides the sprayed combustion flames downwards to the bottom, continuously guiding the flames downwards. This ingenious method solves the technical defect in the sintering process of brick blanks, where the high-temperature flames are difficult to sink, resulting in insufficient heating of the bottom of the brick stack, a large temperature difference with the upper layer of the brick stack, and thus an excessively high scrap rate at the bottom of the brick stack.

[0020] During the closing process of the induced draft plate, the spring is compressed, and after the thrust of the pushing structure is eliminated, the induced draft plate is reset under the elastic restoring force of the spring. This simple mechanical structure solves the technical defect that complex mechanical structures cannot drive the induced draft plate to "fan" due to the high temperature in the kiln environment.

[0021] 2. The design of the air guide structure allows for the flow of high-temperature hot air through a wave-like air guide structure formed by the first arc-shaped air guide protrusion, the first arc-shaped air guide concave section, the second arc-shaped air guide protrusion, the second arc-shaped air guide concave section, and the third arc-shaped air guide protrusion. This structure guides the high-temperature flue gas from different directions into the brick stack. For example, the high-temperature flue gas is guided from the upper layer of the brick stack by the air wave after passing through the first arc-shaped air guide protrusion, and then guided into the brick stack from the lower layer after passing through the third arc-shaped air guide protrusion. This ingenious method achieves the distribution of wave-like air waves along the entire height of the brick stack, thereby improving the heat treatment effect of the brick stack while reducing energy consumption.

[0022] 3. High-definition cameras are used to capture the shape of the bricks being fed into the system. Bricks with defects such as surface cracks, broken corners, or abnormal colors are automatically deemed unqualified. This visual inspection system provides an initial screening of the bricks based on their appearance. After initial screening, the bricks undergo ultrasonic testing. Ultrasonic testing is used to detect internal damage in the bricks. Bricks with internal damage are also marked as unqualified after being detected by the ultrasonic probe.

[0023] 4. The defective brick pushing and discharging structure includes a lead screw rotatably connected inside a frame-type track bracket, a lead screw motor for driving the lead screw, a lead screw shifter, a cylinder seat fixedly installed on the lead screw shifter, a push cylinder installed on the cylinder seat, and a pusher fixedly installed on the piston rod of the push cylinder to push the brick material up and down from the belt conveyor.

[0024] During the operation, after the bricks exit the kiln, the mechanical arm grabs the brick stacks and loads them onto the conveyor belt for transfer and defect detection. First, the bricks are captured by a high-definition camera, and the captured images are uploaded to the backend. They are compared with the backend data, and bricks that do not meet the requirements in terms of shape and color are marked. If the marked bricks do not meet the requirements, the motor drives the lead screw to push the exhaust cylinder toward the defective brick, and drives the pusher to push the defective brick up and down from the conveyor belt. Attached Figure Description

[0025] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of the overall structure in an embodiment of the present invention; Figure 2 This is a schematic diagram of the defective brick removal mechanism in an embodiment of the present invention; Figure 3 This is a schematic diagram of the defect brick pushing and arranging structure in an embodiment of the present invention; Figure 4 This is a schematic diagram of the defect brick removal mechanism from another perspective in an embodiment of the present invention; Figure 5 This is a schematic diagram of the structure of the air intake plate in the open state in an embodiment of the present invention; Figure 6 This is a schematic diagram of the kiln car structure in an embodiment of the present invention; Figure 7 This is a schematic diagram of the structure of the air-expelling plate in an embodiment of the present invention; Figure 8This is one of the structural schematic diagrams of the spring telescopic rod in an embodiment of the present invention; Figure 9 This is a second schematic diagram of the structure of the spring telescopic rod in an embodiment of the present invention; Figure 10 This is a schematic diagram of the kiln car structure from another perspective in an embodiment of the present invention; Figure 11 This is a schematic diagram of the structure of the ignition plate sinking in an embodiment of the present invention; Figure 12 This is a schematic diagram of the kiln car structure queuing inside the tunnel kiln in an embodiment of the present invention.

[0027] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0028] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0029] It should be noted that all directional indications (such as up, down, left, right, front, back, etc.) in the embodiments of the present invention are only used to explain the relative positional relationship and movement of each component in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indication will also change accordingly.

[0030] Furthermore, in this invention, descriptions involving "first," "second," etc., are for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of that feature. Additionally, the technical solutions of the various embodiments can be combined with each other, but only on the basis of being achievable by those skilled in the art. When the combination of technical solutions is contradictory or impossible to implement, such a combination of technical solutions should be considered non-existent and not within the scope of protection claimed by this invention.

[0031] Example 1 like Figure 1-12As shown, a track-type tunnel kiln structure for sintering porous bricks from coal gangue includes a tunnel kiln 1. The tunnel kiln 1 is a conventional tunnel for calcining brick materials, as disclosed in the prior art. It mainly consists of three parts: a preheating kiln section 11, a sintering kiln section 12, and a cooling kiln section 13 (with liftable kiln doors 14 installed at the kiln inlet and outlet of the tunnel kiln 1). Similar to the existing tunnel kiln 1, the calcined brick materials are fed into the tunnel kiln 1 via kiln cars. Therefore, a track is installed inside the tunnel kiln 1 to cooperate with the kiln cars, and track wheels 211 are installed at the bottom of the kiln cars. In the prior art, the kiln cars are pushed into the kiln one by one by a hydraulic jacking machine for sequential preheating, calcination, cooling, and exiting.

[0032] Therefore, the above structure also includes a kiln car structure 2 that works in conjunction with the tunnel kiln 1. The kiln car structure 2 includes a kiln car 21 (the main structure of the kiln car 21 is a conventional kiln car 21 disclosed in the prior art).

[0033] This results in uneven heating of the brick stacks on the kiln car 21 (specifically, the upper part of the brick stack is more likely to come into contact with the high-temperature flame, while the lower part of the brick stack cannot sink to the bottom of the kiln because the high-temperature flame cannot reach the bottom of the kiln). As a result, there is a large temperature difference between the upper and lower layers of the brick stack during the calcination process, and the bricks at the bottom of the brick stack cannot be fully calcined. This technical problem is currently difficult to solve because the high-temperature environment in the kiln makes it difficult to effectively guide the high-temperature flame downwards.

[0034] In practical applications, such as traditional small blast furnaces, when the blast stops, the flame will instantly sink due to the decrease in gas pressure inside the furnace (the essence of combustion is the chemical reaction between combustibles and oxygen, releasing energy). Based on this physical phenomenon, a clever mechanical structure is used to guide the flames sprayed from the kiln downwards (in existing technology, this is done through a burner nozzle installed on the kiln). This continuously guides the high-temperature flames down to the bottom layer of the brick stack. By increasing the time that the high-temperature flames calcine the bottom layer of the brick stack, the temperature difference between the upper and lower layers of the brick stack is greatly reduced. This improves the heating effect of the bottom layer of the brick stack, reduces the amount of waste bricks, improves the calcination effect, and increases the product qualification rate.

[0035] The difficulties in solving this technical problem lie in: first, how to draw and sink the high-temperature flame downwards; and second, how the mechanical structure for drawing and sinking the high-temperature flame downwards can cope with the high-temperature kiln environment.

[0036] Based on this, the present invention makes the following improvements to overcome the above-mentioned technical difficulties and solve the bottlenecks of the prior art.

[0037] Specifically, the aforementioned kiln car 21 structure also includes a downward drawing assembly installed on the kiln car 21 for drawing the kiln fire downward. The downward drawing assembly includes air ducts 22 hinged to the left and right sides of the kiln car 21.

[0038] The induced draft plate 22 is made of high-temperature resistant thin steel plate with a thickness of 8mm. The lower end of the induced draft plate 22 is hinged to the front and rear side walls of the kiln car 21. Specifically, a U-shaped hinge bracket 221 is fixedly installed at the lower end of the side wall of the induced draft plate 22. The hinge bracket 221 is hinged to the side wall of the kiln car 21 (the hinge pin is welded to the side wall of the kiln car 21).

[0039] Meanwhile, each air intake plate 22 is reset via a hinged spring structure 24; specifically, hinged spring structures 24 are hingedly installed on the front and rear sides of the upper end of the side wall of the air intake plate 22. Correspondingly, brackets 241 for hingedly installing the hinged spring structures 24 are fixedly connected to the front and rear side walls of the kiln car 21.

[0040] The specific structure is as follows: The hinged spring structure 24 includes a spring telescopic rod that is hinged to the air duct 22. The spring telescopic rod is hinged to the upper end of the bracket (specifically, an L-shaped hinge plate 2431 is fixedly connected to the push rod below, and correspondingly, an L-shaped fixing seat that is hinged to the L-shaped hinge plate 2431 is fixedly mounted on the air duct 22, and the two are hinged by a pin).

[0041] The spring telescopic rod includes a push rod 243 (made of high-temperature resistant steel rod) and a push rod sleeve 242 (made of high-temperature resistant steel sleeve) slidably installed on the push rod 243. The inner end of the push rod 243 is fixedly connected to a spring seat that slides in the push rod sleeve 242. A spring 244 is fixedly connected between the spring seat and the push rod sleeve 242 (the spring is a high-temperature resistant spring disclosed in the prior art. In actual application, a high-temperature resistant coating can be sprayed on the surface of the spring).

[0042] Meanwhile, several pushing structures 5 that push the air intake plates 22 to open and close are installed on the left and right sides of the sintering kiln section 12; the kiln fire ejected from the top of the tunnel kiln 1 is guided down to the lower layer of the brick stack by the opening and closing of the air intake plates 22.

[0043] During the ignition and sinking process, when the kiln car 21 enters the sintering kiln section 12, the burner nozzles on the sintering kiln section 12 spray flames downwards to calcine the brick stacks. At the same time, the pushing structure 5 reciprocates to push the air duct 22. During the opening and closing of the air duct 22, the pushing structure reciprocates to push the air duct 22. During the process of the air duct 22 opening from closing, downward air is generated. The downward air draws the sprayed combustion flames downwards to the bottom, thereby continuously guiding the flames downwards (that is, the downward "pulling airflow" generated during the opening and closing of the air duct 22 pulls the flames downwards to the bottom). This ingenious method solves the technical defect that during the sintering of brick blanks, the bottom of the brick stack is not heated sufficiently due to the difficulty of the high-temperature flames sinking downwards, resulting in a large temperature difference between the bottom and the upper layers of the brick stack, which in turn leads to an excessively high scrap rate at the bottom of the brick stack.

[0044] During the closing process of the induced draft plate 22, the spring 244 is compressed, and after the thrust of the pushing structure 5 is eliminated, the induced draft plate 22 is reset under the elastic restoring force of the spring 244. This simple mechanical structure solves the technical defect that complex mechanical structures cannot drive the induced draft plate 22 to "fan" due to the influence of high temperature in the kiln environment.

[0045] Example 2 like Figure 1-12 As shown, this embodiment, based on the structure of embodiment 1, includes a plurality of cylinders 51 mounted on the outer wall of the tunnel kiln 1 (a cylinder series support is fixedly installed between the cylinder barrels of the cylinders 51, and the cylinder series support is fixedly installed on the outer wall of the tunnel kiln 1). A high-temperature resistant push rod is fixedly installed on the piston rod of the cylinder 51, passing through the tunnel kiln 1. A pushing steel wheel 52 for pushing the induced draft plate 22 is fixedly installed on the inner end of the high-temperature resistant push rod. The high-temperature environment inside the kiln is coped with by pushing the steel wheel 52 and the high-temperature resistant push rod. During the rapid retraction of the cylinder 51, the induced draft plate is instantly moved towards the side wall of the furnace cavity and opened under the cooperation of the spring, generating an instantaneous negative pressure suction force, which instantly pulls the high-temperature flame on the top of the furnace down to the bottom of the brick stack.

[0046] In actual operation, in order to increase the sealing performance, several high-temperature resistant steel sleeves that cooperate with the sliding of the high-temperature resistant push rod are driven into the tunnel kiln 1 in the existing way, so that the high-temperature resistant push rod is slidably connected to the high-temperature resistant steel sleeve, thereby increasing the sealing performance.

[0047] During operation, the cylinder pushes the steel wheel 52 to rotate the air-guiding plate 22. When the cylinder 51 drives the high-temperature push rod to retract, the spring-loaded extension rod drives the air-guiding plate 22 to return to its original position. This ingenious method achieves the opening and closing of the air-guiding plate 22.

[0048] Example 3 like Figure 1-12 As shown, in this embodiment, based on the structure of embodiment 2, in order to further enhance the heating effect on the bottom of the brick stack by igniting the high-temperature flame during the opening and closing of the air-guiding plate 22, an air-guiding structure is fixedly installed on the side of the air-guiding plate 22 facing the brick stack. The air-guiding structure 23 enables the high-temperature hot air wave generated during the fanning process of the air-guiding plate 22 to be introduced into the inner layer of the brick stack, thereby further improving the heat treatment effect of the brick stack.

[0049] Specifically, the air guiding structure 23 includes an air guiding plate (made of high-temperature resistant ceramic fiber board) fixedly connected to the air guiding plate 22. The air guiding plate is integrally formed with a first arc-shaped air guiding protrusion 231, a second arc-shaped air guiding protrusion 232 and a third arc-shaped air guiding protrusion 233 from top to bottom. A first arc-shaped air guide recess is formed between the first arc-shaped air guide protrusion 231 and the second arc-shaped air guide protrusion 232, and a second arc-shaped air guide recess is formed between the second arc-shaped air guide protrusion 232 and the third arc-shaped air guide protrusion 233.

[0050] During the fanning process of the exhaust plate 22, the high-temperature hot airflow is guided into the brick stack from different directions by the wave-shaped air guiding structure 23 formed by the first arc-shaped air guiding protrusion 231-first arc-shaped air guiding protrusion 231-second arc-shaped air guiding protrusion 232; second arc-shaped air guiding protrusion 232-second arc-shaped air guiding recess-third arc-shaped air guiding protrusion 233. For example, the high-temperature flue gas is guided from the upper layer of the brick stack by the air wave after passing through the first arc-shaped air guiding protrusion 231, and after passing through the third arc-shaped air guiding protrusion 233, the high-temperature flue gas is guided into the brick stack from the lower layer. In this ingenious way, the wave-shaped air wave is guided along the entire height of the brick stack, thereby improving the heat treatment effect of the brick stack while reducing energy consumption.

[0051] Example 4 like Figure 1-12 As shown, in this embodiment, based on the structure of embodiment 3, after the brick stacks on the kiln car 21 have been calcined, the kiln car 21 is pushed into the cooling kiln section 13 with the help of the hydraulic jacking machine, and then exits the kiln from the tail end of the kiln to wait for feeding.

[0052] Therefore, a parking platform 6 for placing kiln cars 21 is fixedly installed at the kiln tail position of the tunnel kiln 1 in the existing manner. In order to realize automatic brick feeding, a mechanical arm 3 for feeding bricks is installed at the edge of the parking platform 6. Specifically, the mechanical arm 3 is a conventional mechanical arm for feeding bricks disclosed in the prior art. Its main structure includes a mechanical arm body and a clamp for holding bricks installed on the mechanical arm body.

[0053] This method enables automated unloading of bricks.

[0054] Example 5 like Figure 1-12 As shown, this embodiment is based on the structure of embodiment 4. In the actual production process, the scrap rate of bricks processed by the kiln, especially the bricks at the bottom of the brick stack, is high. Therefore, a large number of unqualified bricks are mixed in with qualified finished bricks. In particular, if bricks with qualified surfaces but internal structural defects are not removed in time, they will not only pose a certain threat to the safety of the building structure in subsequent use, especially when applied to key positions such as load-bearing and load-bearing structures.

[0055] Timely sorting of kiln bricks after calcination will fundamentally solve this problem and ensure that all delivered bricks are of qualified quality.

[0056] To address this, the present invention adds an automated production line for unloading, inspection, and transfer to the traditional kiln production line, so as to inspect the bricks during the unloading process.

[0057] Therefore, the above structure also includes a defect brick removal mechanism 4 located at the discharge end of the cooling kiln section 13.

[0058] Specifically, the defective brick removal mechanism 4 includes a belt conveyor 41, which is a conventional belt conveyor disclosed in the prior art. The main structure includes a frame and belt drums installed at both ends of the frame (the two are driven by belts), and the belt drum at the discharge end is driven by a transmission mechanism. Multiple idlers supporting the belt are also installed on the frame.

[0059] The robotic arm is located between the tunnel kiln 1 and the belt conveyor 41, grabbing bricks from the brick stack and feeding them onto the belt conveyor 41.

[0060] Therefore, the belt conveyor 41 is equipped with a detection structure for detecting defects in the brick material; the detection structure is used to detect the shape, appearance and internal damage of the brick material.

[0061] Specifically, the detection structure includes a visual inspection structure and an ultrasonic flaw detection structure located above the belt conveyor 41.

[0062] The visual inspection structure includes several high-definition cameras 451 for capturing images of brick materials. The high-definition cameras 451 are used to capture the shape of the brick materials being fed. Brick materials with shape defects, such as cracks on the surface, broken corners, or abnormal colors, are necessarily unqualified. In other words, the high-definition camera 451 structure enables preliminary screening of the brick materials from their appearance.

[0063] After initial screening, the bricks undergo ultrasonic testing (specifically, the ultrasonic testing structure includes an ultrasonic probe 461). The ultrasonic testing structure is used to detect the interior of the bricks using ultrasonic waves. Bricks with internal damage are also marked as unqualified bricks after being detected by the ultrasonic probe 461.

[0064] The above-mentioned use of ultrasonic probe 461 to detect internal defects in materials is a conventional technical means disclosed in the prior art. For example, ultrasonic probe 461 adopts ultrasonic flaw detection sensors commonly used in existing industrial production.

[0065] The above two methods are used to detect defective bricks, and the defective bricks are removed by the defective brick removal component. The remaining bricks transported on the belt conveyor 41 are qualified bricks. This method achieves automated screening of defective and unqualified brick materials.

[0066] Example 6 like Figure 1-12As shown, in this embodiment, based on the structure of embodiment 5, a defect brick removal component that cooperates with the detection structure is installed on the belt conveyor 41. When the detection structure identifies a defect brick, the defect brick removal component removes the defect brick from the belt conveyor 41.

[0067] Specifically, the defect brick removal assembly includes a track support structure 42 fixedly installed on the left side frame 411 of the belt conveyor 41, a camera bracket 45 mounted on top of the high-definition camera 451, and the camera bracket 45 fixedly installed at the top position of the track support structure 42. The aforementioned ultrasonic probe 461 is fixedly installed on a probe bracket 46, which is also fixedly installed at the top position of the track support structure 42.

[0068] The track support structure 42 includes a frame-type track support, the bottom of which is welded and fixed to the top of the frame of the belt conveyor 41 via a connecting beam frame.

[0069] A defective brick pushing structure 43 is installed on the frame-type track support. The defective brick pushing structure 43 includes a lead screw 432 rotatably connected inside the frame-type track support, and a lead screw motor 431 that drives the lead screw 432 (bearings are installed at both ends of the frame-type track support, the lead screw 432 is rotatably connected to the bearings, and the lead screw motor 431 is fixedly installed on the frame-type track support). A lead screw shift seat 435 is threadedly connected to the lead screw 432. A cylinder seat is fixedly installed on the lead screw shift seat 435. A push cylinder 433 is installed on the cylinder seat. A push seat 434 that pushes bricks up and down from the belt conveyor 41 is fixedly installed on the piston rod of the push cylinder 433.

[0070] During operation, after the bricks exit the kiln, the mechanical arm grabs the brick stacks and loads them onto the conveyor belt 41 for transfer and defect detection. First, the brick material is captured by a high-definition camera 451, which is the same as the existing product inspection method. The captured image is uploaded to the background and compared with the background data. Bricks that do not meet the requirements in terms of shape and color are marked. If the marking is not qualified, the screw motor 431 drives the screw 432 to push the exhaust cylinder 433 toward the defective brick, and drives the pusher 434 to push the defective brick down from the conveyor belt 41.

[0071] Meanwhile, the belt conveyor 41 continues to transport bricks. The bricks are inspected for defects by the ultrasonic probe 461. Unqualified bricks are marked. If the marking is not qualified, the motor drives the lead screw 432 to push the exhaust cylinder 433 toward the defective brick and drive the pusher 434 to push the defective brick off the belt conveyor 41. Qualified bricks continue to be transported to the unloading station via the belt conveyor 41.

[0072] In actual operation, in order to help push the bricks off the belt conveyor 41, a guide plate 47 is installed on the right frame 411 of the belt conveyor 41 in the existing manner, and the bricks slide down along the guide plate 47.

[0073] In other words, during the working process, the above-mentioned structure is used to push and remove the detected defective bricks from the belt conveyor 41. This ingenious method solves the technical defect that a large number of defective bricks are mixed with qualified bricks during the production process, making it difficult to manually detect and remove them.

[0074] Specifically, in actual operation, there are at least a dozen defective bricks in the brick stack of car 21 of a kiln. If these defective bricks are not accurately removed, they will pose a safety hazard in subsequent application.

[0075] During operation, driven by the lead screw motor 431, the lead screw shifter 435-cylinder seat moves back and forth along the lead screw 432 and the frame-type track bracket, pushing the detected defective product bricks off the conveyor belt 41.

[0076] Example 7 like Figure 1-12 As shown, this embodiment is based on the structure of embodiment 6. It should be noted that the lead screw motor 431, high-definition camera 451, ultrasonic probe 461, and push-out cylinder 433 are all controlled by a PLC in accordance with existing methods. PLC control of the above-mentioned equipment is a conventional method disclosed in the prior art. Those skilled in the art can consult technical manuals, dictionaries, and other existing technologies to understand the specific structure and principle of how a PLC controls the above-mentioned components to work together to push out defective products from the production line in industrial applications.

[0077] Example 8 like Figure 1-12 As shown, in this embodiment, based on the structure of embodiment 7, in order to improve the flexibility of movement during the movement of the lead screw shifter 435, guide wheels 436 are respectively installed on the top and bottom of the lead screw shifter 435, and the frame-type track support is provided with a wheel groove 421 that cooperates with the guide wheel 436.

[0078] Example 9 like Figure 1-12 As shown, this embodiment, based on the structure of embodiment 8, also discloses a sintering method for the above-mentioned coal gangue sintering porous brick track-type tunnel kiln 1 structure, characterized by including the following steps: (1) Kiln car 21 enters the furnace: The bricks to be sintered are stacked on the kiln car 21. The kiln car 21 is pushed into the tunnel kiln 1 by the hydraulic jack. After the brick stack is preheated by the preheating kiln section 11, it enters the sintering kiln section 12 for sintering. During the sintering process, the burner nozzles installed in the sintering kiln section 12 spray fire downwards to sinter the brick stack. (2) Ignition sinking: The push structure 5 pushes the air induced plate 22 back and forth. During the process of the air induced plate 22 opening from closing, a downward airflow is formed, which sinks the high temperature flame into the lower end of the brick stack to sinter the bottom layer of the brick stack. The high-temperature gas generated by combustion, with the cooperation of the arc-shaped air guide protrusion and the arc-shaped air guide concave part, forms a wave-like high-temperature flue gas, which heats the interior of the brick stack along the height direction of the brick stack. (3) Defect detection: As the kiln car 21 continues to enter the kiln via the hydraulic jack, the sintered brick stacks are pushed into the cooling kiln section 13 to await exiting the kiln. After exiting the kiln, the brick stack is grabbed and fed onto the conveyor belt 41 by a robotic arm for transfer and defect detection. First, the brick material is captured by a high-definition camera 451. The captured image is uploaded to the background and compared with the background data. Brick materials that do not meet the requirements in terms of shape and color are marked. If the marking is not qualified, the motor drives the lead screw 432 to drive the exhaust cylinder 433 to face the defective brick and drive the pusher 434 to push the defective brick down from the conveyor belt 41. The belt conveyor 41 continues to transport bricks. The bricks are inspected for defects by the ultrasonic probe 461. Unqualified bricks are marked. If the marking is not qualified, the motor drives the lead screw 432 to push the exhaust cylinder 433 toward the defective brick and drives the pusher 434 to push the defective brick off the belt conveyor 41. The qualified bricks continue to be transported to the unloading station via belt conveyor 41.

[0079] Of course, the above description is not intended to limit the present invention, and the present invention is not limited to the examples given above. Any changes, modifications, additions or substitutions made by those skilled in the art within the scope of the present invention should also fall within the protection scope of the present invention.

Claims

1. A track-type tunnel kiln structure for sintering porous bricks from coal gangue, comprising a tunnel kiln, the tunnel kiln including a preheating kiln section, a sintering kiln section, and a cooling kiln section; characterized in that, It also includes a kiln car structure that works in conjunction with a tunnel kiln. The kiln car structure includes a kiln car and a lowering assembly installed on the kiln car for drawing the kiln fire downwards. The lowering assembly includes air ducts hinged to both sides of the kiln car. The air-guiding plate is reset by a hinged spring structure; Several pushing structures that open and close the induced draft plates are installed on both sides of the sintering kiln section; the kiln fire ejected from the top of the tunnel kiln is guided down to the lower layer of the brick stack by opening and closing the induced draft plates. The air guide plate is fixedly installed with an air guide structure on the side facing the brick stack. The air guide structure guides the high-temperature flue gas to different positions of the brick stack. The air guide structure includes several arc-shaped air guide protrusions spaced apart, and arc-shaped air guide concave parts are formed between the arc-shaped air guide protrusions. It also includes a defect brick removal mechanism installed at the discharge end of the cooling kiln section; The defective brick removal mechanism includes a belt conveyor, on which a detection structure for detecting brick defects is installed; the detection structure is used to detect the shape, appearance, and internal damage of the brick. The belt conveyor is equipped with a defect brick removal component that works in conjunction with the detection structure. When the detection structure identifies a defect brick, the defect brick removal component removes the defect brick from the belt conveyor.

2. The track-type tunnel kiln structure for coal gangue sintering porous bricks according to claim 1, characterized in that, A U-shaped hinged bracket is fixedly installed at the lower end of the side wall of the air duct, and the hinged bracket is hinged to the side wall of the kiln car. Hinged spring structures are hinged to both sides of the upper end of the side wall of the air duct, and a bracket for hinged spring structures is fixedly connected to the side wall of the kiln car.

3. The track-type tunnel kiln structure for coal gangue sintering porous bricks according to claim 2, characterized in that, The hinged spring structure includes a spring telescopic rod hinged to the air guide plate, and the spring telescopic rod is hinged to the upper end of the bracket. The spring telescopic rod includes a push rod and a push rod sleeve that is slidably installed on the push rod. The inner end of the push rod is fixedly connected to a spring seat that slides inside the push rod sleeve. A spring is fixedly connected between the spring seat and the push rod sleeve.

4. The track-type tunnel kiln structure for coal gangue sintering porous bricks according to claim 1, characterized in that, The air guiding structure includes an air guiding plate fixedly connected to the air guiding plate, and the air guiding plate has a first arc-shaped air guiding protrusion, a second arc-shaped air guiding protrusion and a third arc-shaped air guiding protrusion integrally formed from top to bottom. A first arc-shaped air guide recess is formed between the first arc-shaped air guide protrusion and the second arc-shaped air guide protrusion, and a second arc-shaped air guide recess is formed between the second arc-shaped air guide protrusion and the third arc-shaped air guide protrusion.

5. The track-type tunnel kiln structure for sintering porous bricks from coal gangue according to claim 1, characterized in that, The pushing structure includes several cylinders, and the piston rods of the cylinders are fixedly mounted with high-temperature resistant push rods that pass through the tunnel kiln. The inner end of the high-temperature resistant push rods is fixedly mounted with a pushing steel wheel for pushing the induced draft plate.

6. The track-type tunnel kiln structure for sintering porous bricks from coal gangue according to claim 1, characterized in that, The detection structure includes a visual inspection structure and an ultrasonic flaw detection structure installed above the belt conveyor. The visual inspection structure includes several high-definition cameras that capture images of brick materials, and the ultrasonic flaw detection structure includes an ultrasonic probe.

7. The track-type tunnel kiln structure for coal gangue sintering porous bricks according to claim 6, characterized in that, The defect brick removal assembly includes a track support structure fixedly installed on a frame on one side of the conveyor belt, and a camera bracket is installed on the top of the high-definition camera. The camera bracket is fixedly installed at the top position of the track support structure. The ultrasonic probe is fixedly mounted on the probe bracket, which is in turn fixedly mounted at the top of the track support structure.

8. The track-type tunnel kiln structure for coal gangue sintering porous bricks according to claim 7, characterized in that, The track support structure includes a frame-type track support, on which a defective brick pushing and discharging structure is installed. The defective brick pushing and discharging structure includes a lead screw rotatably connected inside the frame-type track support, and a lead screw motor that drives the lead screw. A lead screw shifter is threaded onto the lead screw, and a cylinder seat is fixedly installed on the lead screw shifter. A push cylinder is installed on the cylinder seat, and a pusher seat that pushes bricks up and down from the belt conveyor is fixedly installed on the piston rod of the push cylinder.

9. The track-type tunnel kiln structure for coal gangue sintering porous bricks according to claim 8, characterized in that, The top and bottom of the lead screw shifter are respectively equipped with guide wheels, and the frame-type track support is provided with wheel grooves that cooperate with the guide wheels.

10. A sintering method employing the track-type tunnel kiln structure for porous brick sintering of coal gangue as described in any one of claims 8-9, characterized in that, Includes the following steps: (1) Kiln car entry: The bricks to be sintered are stacked on the kiln car. The kiln car is pushed into the tunnel kiln by a hydraulic jack. After the brick stack is preheated in the preheating kiln section, it enters the sintering kiln section for sintering. During the sintering process, the burners installed in the sintering kiln section spray fire downwards to sinter the brick stack. (2) Ignition sinking: The push structure pushes the air duct plate back and forth. During the process of the air duct plate from closing to opening, it generates downward airflow, which draws the sprayed combustion flame down to the bottom; The high-temperature gas generated by combustion, with the cooperation of the arc-shaped air guide protrusion and the arc-shaped air guide concave part, forms a wave-like high-temperature flue gas, which heats the interior of the brick stack along the height direction of the brick stack. (3) Defect detection: As the kiln cars continue to enter the kiln via the hydraulic jack, the sintered brick stacks are pushed into the cooling kiln section to await exiting the kiln. After exiting the kiln, the brick stacks are grabbed and fed onto the conveyor belt by a robotic arm for transfer and defect detection. First, the bricks are captured by a high-definition camera, and the captured images are uploaded to the backend. They are compared with the backend data, and bricks that do not meet the requirements in terms of shape and color are marked. If the marking is not qualified, the motor drives the screw to push the exhaust cylinder toward the defective brick, and drives the pusher to push the defective brick down from the conveyor belt. The belt conveyor continues to transport bricks. The bricks are inspected for defects by an ultrasonic probe. Unqualified bricks are marked. If the marking is not qualified, the motor drives the lead screw to push the exhaust cylinder toward the defective brick and drive the pusher to push the defective brick off the belt conveyor. The qualified bricks continue to be transported to the unloading station via belt conveyor.

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