Ash cone with combustible outer film and manufacturing device thereof

Abstract

The application discloses a burnable outer film ash cone and a manufacturing device thereof, and relates to the field of ash cones. The ash cone comprises an ash cone body and a burnable outer film covering the ash cone body. The outer film is a thin-walled shell with the same shape as the ash cone, and a forming cavity is formed in the thin-walled shell. The manufacturing device comprises a filling and arranging assembly for carrying and arranging an outer mold formed by bonding the outer film and an ash cone bottom support, a filling and pressing assembly with a lower bottom mold, a material bin, a pressing channel and a pressing mechanism for pressing coal ash material into the cavity of the outer mold, a solidification and burnable assembly with a constant-temperature furnace and a sample feeding mechanism for sequentially performing solidification and burnable heat treatment, and an automatic transfer mechanism for automatically transferring the outer mold between the assemblies. The burnable outer film protects the ash cone in the whole process, solves the problem that the traditional ash cone is easy to be damaged, ensures the shape integrity and test accuracy, and realizes automatic production.

Description

Technical Field

[0001] This invention relates to the field of coal ash cones, and more particularly to an ash cone with a burnable outer membrane and an apparatus for manufacturing the same. Background Technology

[0002] The fusibility of coal ash is a crucial indicator for power plant coal combustion, directly impacting boiler safety and economic efficiency. Abnormal ash fusibility can lead to problems such as slagging in the boiler furnace and corrosion of heating surfaces, severely affecting stable unit operation. Therefore, accurately determining the characteristic ash fusibility temperature of coal ash is a key step in coal quality analysis.

[0003] Currently, the pyramidal method is widely used as the standard test method for the ash fusion properties of coal ash in China's industrial and testing fields. The core process involves mixing coal ash powder with a particle size of less than 0.2 mm with dextrin in a specific ratio, adding an appropriate amount of water to moisten it to a plastic state, and then pressing it into a metal mold to obtain an equilateral triangular ash cone with a base length of 7 mm and a height of 20 mm. The ash cone is then carefully placed on an ash cone support plate and fed into an ash fusion tester, where it is heated to over 900 degrees Celsius at a set heating rate. The characteristic temperatures corresponding to the ash cone's deformation and softening into a hemispherical and flowing state at high temperatures are recorded through manual observation or real-time image acquisition by a camera.

[0004] However, existing ash cone preparation technologies and processes based on the pyramidal method still suffer from numerous insurmountable technical defects. Firstly, the ash cone itself lacks sufficient mechanical strength and is easily damaged. Because the ash cone is made by binding and pressing fine coal ash powder with dextrin, it is brittle and has poor structural stability. During the demolding and transfer stages of the traditional preparation process, structural defects such as cone tip chipping and edge wear are easily observed. The integrity of the ash cone's shape directly affects the observation accuracy of the deformation process at high temperatures, leading to deviations in the detection results of characteristic melting temperatures and failing to accurately reflect the true melting characteristics of the coal ash. Secondly, the preparation process relies on manual operation, resulting in low efficiency and poor stability. To avoid ash cone breakage, the demolding, transfer, and pallet placement of existing ash cones require operators with extensive experience and extremely high operational proficiency. Each step must be completed with utmost care, which not only involves high labor intensity but also leads to poor consistency and unstable pass rates in ash cone preparation, making it difficult to meet the efficiency requirements of large-scale coal quality testing. Thirdly, existing improvement schemes cannot fundamentally solve the core problems. To address the issue of easily broken ash cones, the industry has attempted improvements such as optimizing the mold structure by splitting the mold into upper and lower sections for separate demolding or spraying an anti-stick layer on the inner wall of the mold. However, these solutions only reduce frictional damage during demolding and cannot fundamentally improve the structural strength of the ash cone itself, still failing to prevent breakage during transfer and placement. Another approach is to change the shape of the ash cone to cylindrical to improve strength, but cylindrical structures do not exhibit significant deformation characteristics at high temperatures and lack corresponding national standards, making them unsuitable for existing ash fusion testing systems. Fourthly, there are limitations in the use and placement of pallets. When multiple ash cones are densely placed on an ash cone pallet, collisions easily occur between adjacent cones, leading to edge or tip damage. Furthermore, ash cones with different acidity or alkalinity require pallets made of different materials; a single pallet cannot be compatible with testing multiple acidity or alkalinity ash cones, resulting in a single test only being able to handle one type of acidity or alkalinity ash cone, further limiting testing efficiency.

[0005] In recent years, with the development of coal quality analysis technology towards automation and intelligence, the industry urgently needs a fast, reliable and low-damage ash cone preparation method to adapt to the automation transformation of the entire ash fusion test process and solve the bottleneck problems of high damage rate and low efficiency caused by manual reliance in the existing technology. Summary of the Invention

[0006] In view of this, the purpose of the present invention is to provide a burnable outer membrane for a ash cone and a device for manufacturing the same. By using a burnable outer membrane to form and protect the ash cone and then burning it off at high temperature, the structural integrity of the ash cone can be ensured during the manufacturing and transfer process, the testing accuracy can be significantly improved, and the requirements of automated production can be fully met.

[0007] The technical solution adopted by this invention to solve its technical problem is: A burnable outer membrane is provided, and an apparatus for manufacturing the same thereto is provided. The burnable outer membrane includes a burnable outer membrane and a thin-walled shell with the same shape as the burnable outer membrane. A cavity is formed inside the shell to accommodate the burnable outer membrane, and the burnable outer membrane is disposed in the cavity.

[0008] Preferably, the burnable outer membrane is a triangular pyramidal thin-walled shell with a wall thickness of 0.2 mm to 1 mm.

[0009] Preferably, the burnable outer film is provided with a feed port and a through port communicating with the cavity. The feed port is located on the conical side of the burnable outer film, and the through port is located at the bottom of the burnable outer film and communicates with the concave surface of the ash cone base. The burnable outer film can be bonded to the ash cone base to form an outer mold for making the ash cone.

[0010] Preferably, the material of the burnable outer membrane is one of plant fiber paper, polyester material, paraffin paper, or engineering plastic.

[0011] A device for manufacturing ash cones with a burnable outer membrane includes: a filling and arranging assembly, a filling and pressing assembly, a curing and burnable assembly, and an automatic mechanism. The filling and arranging assembly includes an outer mold and an ash cone support plate. The outer mold is formed by bonding a burnable outer membrane to an ash cone base. The ash cone support plate is used to support and arrange multiple outer molds. The filling and pressing assembly includes a lower ash cone mold, a hopper, a pressing channel, an ash cone pressing mechanism, and a mold pressing mechanism. The lower ash cone mold is used to receive and position the outer molds transferred by the automatic mechanism. The hopper is used to store coal ash material. The pressing channel connects the hopper to the lower ash cone mold. The outer mold has a feed inlet, and the ash cone pressing mechanism is used to press the coal ash material in the hopper into the cavity of the outer mold through the pressing channel. The mold pressing mechanism is used to press the lower bottom mold of the ash cone during the pressing process. The curing and burn-off assembly includes a constant temperature furnace, a sample feeding rod, and a temperature measurement and control unit. The constant temperature furnace is used to perform sequential curing heat treatment and burn-off heat treatment on the ash cone support plate carrying the outer mold. The sample feeding rod is used to send the ash cone support plate into or out of the constant temperature furnace. The temperature measurement and control unit is used to monitor and adjust the temperature inside the constant temperature furnace. The automatic mechanism is used to transfer the outer mold from the ash cone support plate to the lower bottom mold of the ash cone.

[0012] Preferably, the bottom of the ash cone base is integrally formed with a positioning surface, and its side is provided with a clamping surface. The positioning surface is fixed in conjunction with the positioning groove of the ash cone support plate. The gripper of the automatic mechanism is horizontally oriented towards the clamping surface and fits and conforms to the clamping surface to form a stable clamping.

[0013] Preferably, a return spring and a guide spring pin are provided on the lower side of the mold base of the lower mold of the ash cone. The return spring and the guide spring pin are both vertically installed in the spring mounting seat. The guide spring pin is located in the center hole of the return spring. The two are coaxially arranged and elastically abut against the lower mold of the ash cone. The lower mold of the ash cone is connected to the mold pressing mechanism through a transition plate. The transition plate is provided with a positioning groove corresponding to the mold base. The lower end of the positioning groove is provided with a mating inclined surface on both sides of the mold base. The telescopic mechanism of the ash cone pressing mechanism is horizontally fixed to the outside of the hopper through a mounting plate. Its output end is coaxially connected to the punch. The punch moves in a reciprocating linear motion along the axial direction of the pressing channel to continuously press the plastic coal ash into the cavity and compact it.

[0014] Preferably, the mold clamping mechanism includes a pressure head, a linkage mechanism, and an actuator. The actuator is disposed on one side of the mold clamping mechanism. One end of the linkage mechanism is hinged to the output end of the actuator, and the other end extends vertically upward and is fixedly connected to the pressure head. The actuator drives the linkage mechanism to extend and retract, thereby moving the pressure head to apply a stable clamping force to the lower mold of the gray cone.

[0015] Preferably, a quick-closing furnace door is hinged at the front opening of the constant temperature furnace. The linear mechanism is horizontally fixed to the outer wall of the constant temperature furnace, and its output end is connected to the side of the quick-closing furnace door via a connecting rod to control the quick-closing furnace door to flip along the hinge axis to achieve opening and closing. The temperature measuring instrument is a sheathed thermocouple, and its probe extends vertically downward into the middle of the heating cavity of the constant temperature furnace, which can monitor the average temperature inside the cavity in real time and feed it back to the temperature control unit for adjustment.

[0016] Preferably, the sample feeding rod drives the gray cone support plate carrying the outer mold to move up and down smoothly along the guide rail of the constant temperature furnace; the feed port of the burnable outer film can be set on one or more sides of the cone, or on the top of the burnable outer film.

[0017] The beneficial effects of this invention are: This invention provides a burnable outer membrane for ash cones and its manufacturing apparatus. By introducing a burnable outer membrane to fully encapsulate and protect the ash cones throughout the entire process, it fundamentally solves the key technical problem of ash cones being easily damaged due to their brittle texture during demolding, transfer, and operation. This ensures the integrity and regularity of the geometric shape of each ash cone, significantly improving the accuracy and reliability of ash fusion characteristic temperature testing. Simultaneously, it simplifies the ash cone manufacturing process, eliminating reliance on operator experience and skills, reducing labor intensity, and increasing production efficiency. It is compatible with automated equipment such as automatic pressing molds and automatic transfer fixtures, meeting the industry's demand for automated and intelligent coal quality analysis. Furthermore, it is compatible with testing scenarios for different acid and alkaline ash cones, breaking through the limitation of traditional single-plate testing of only one type of acid and alkaline ash cone, further improving the overall efficiency and applicability of ash fusion testing. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the structure of a gray cone with a burnable outer membrane according to Embodiment 1 of the present invention.

[0019] Figure 2 This is a schematic diagram of the overall structure of a gray cone manufacturing device with a burnable outer membrane according to Embodiment 2 of the present invention.

[0020] Figure 3 This is a schematic diagram of the empty membrane array of the ash cone before filling in a ash cone fabrication device with a burnable outer membrane according to Embodiment 2 of the present invention.

[0021] Figure 4 This is a schematic diagram of the filling and pressing component of Embodiment 2 of the present invention.

[0022] Figure 5 This is a cross-sectional view of the filling and pressing component of Embodiment 2 of the present invention.

[0023] Figure 6 This is a partial structural diagram of the filling and pressing component of Embodiment 2 of the present invention.

[0024] Figure 7 This is a structural diagram of the constant temperature furnace sample delivery system in Embodiment 2 of the present invention.

[0025] Figure 8 This is a flowchart illustrating the usage of Embodiment 2 of the present invention.

[0026] Figure 9 This is a physical diagram of the ash cone with a burnable outer membrane according to the present invention.

[0027] Figure 10 A three-dimensional structural reference diagram of a device for manufacturing a burnable outer membrane ash cone.

[0028] In the diagram: 1. Filling and arranging assembly; 11. Burnable outer membrane; 111. Feed inlet; 112. Through port; 12. Ash cone bottom support; 121. Positioning surface; 122. Clamping surface; 123. Concave surface; 13. Ash cone body; 14. Outer mold; 15. Ash cone support plate; 151. Positioning groove; 2. Filling and pressing assembly; 21. Ash cone clamping mechanism; 211. Punch; 212. Telescopic mechanism; 213. Mounting plate; 22. Ash cone lower mold; 221. Clamping channel; 222. Material 223. Mold base; 224. Positioning groove; 225. Return spring; 226. Spring mounting seat; 227. Guide spring pin; 228. Adapter plate; 229. Mating inclined surface; 23. Mold clamping mechanism; 231. Press head; 232. Linkage mechanism; 233. Actuator; 3. Curing burn-off assembly; 31. Constant temperature oven; 32. Thermometer; 33. Guide rail; 34. Quick-closing oven door; 35. Linear mechanism; 36. Sample feeding rod; 4. Automatic mechanism; 41. Gripper.

[0029] It should be noted that these accompanying drawings and textual descriptions are not intended to limit the scope of the invention in any way, but rather to illustrate the concept of the invention to those skilled in the art by referring to specific embodiments. Detailed Implementation

[0030] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0031] Example 1 like Figure 1 and Figure 9 As shown, a burnable outer membrane ash cone includes: an ash cone body 13 and a burnable outer membrane 11. The burnable outer membrane 11 is a thin-walled shell with the same shape as the ash cone body 13, and a cavity is formed inside it for accommodating the ash cone body 13. The ash cone body 13 is disposed in the cavity.

[0032] It should be noted that the ash cone body 13, as the core component for determining ash fusibility in coal quality analysis, must meet the observation requirements of subsequent high-temperature testing. The burnable outer membrane 11, as a thin-walled shell with the same shape as the ash cone body 13, can form a physical covering structure, providing protection for the molding and transportation of the ash cone body 13 and preventing damage to the ash cone body 13 due to its own structural characteristics. The cavity formed inside the outer membrane is the molding space of the ash cone body 13, which can limit the accumulation shape of coal ash material and ensure that the ash cone body 13 forms a regular shape that meets the testing requirements. The ash cone body 13 is set in the cavity, which can achieve precise molding by means of the cavity contour, and can also isolate external collisions and friction through the covering effect of the outer membrane, ensuring the structural integrity of the ash cone body 13 before manufacturing and transfer to the testing stage. Moreover, the outer membrane can disappear in the high-temperature environment afterward and will not interfere with the fusibility test of the ash cone body 13.

[0033] Furthermore, the burnable outer membrane 11 is a triangular pyramidal thin-walled shell with a wall thickness of 0.2 mm to 1 mm.

[0034] It should be noted that the burnable outer membrane 11 adopts a triangular pyramidal structure adapted to the requirements of ash fusion test. This shape allows the ash cone body 13 to exhibit clear and observable deformation characteristics during high-temperature testing, which meets the requirements of the standard test method for the shape of the ash cone and ensures the effectiveness of subsequent melting temperature detection. The thin-walled shell design can provide uniform coverage and support for the internally formed ash cone body 13, avoiding structural defects in the ash cone during manufacturing and transportation, and can also reduce the amount of material used to ensure rapid burn-off under subsequent high-temperature environment, without interfering with the shape and performance of the ash cone body 13.

[0035] Furthermore, the burnable outer membrane 11 is provided with a feed port 111 and a through port 112 communicating with the cavity. The feed port 111 is located on the conical side of the burnable outer membrane 11, and the through port 112 is located at the bottom of the burnable outer membrane 11 and communicates with the concave surface 123 of the ash cone base 12. The burnable outer membrane 11 can be bonded to the ash cone base 12 to form an outer mold 14 for making ash cones.

[0036] It should be noted that the feed port 111 on the burnable outer membrane 11 serves as a channel for the coal ash material to enter the cavity. Its connection design with the cavity ensures smooth material injection and provides a raw material conveying path for the molding of the ash cone body 13. The feed port 111 is located on the side of the cone, which facilitates precise docking with the pressing channel 221 of the manufacturing device and allows the material to fill the cavity evenly under pressure, avoiding voids or uneven density inside the ash cone body 13 due to improper feeding position. The through-hole 112 is connected to the cavity and located at the bottom of the burnable outer film 11. It can expel air from the cavity during the material filling process, ensuring that the material adheres tightly to the inner wall of the cavity and improving the molding quality of the ash cone body 13. Its design, which is connected to the concave surface 123 of the ash cone base 12, allows the outer film and the ash cone base 12 to form a cooperative support structure. This not only enhances the overall stability of the outer mold 14, but also prevents the ash cone body 13 from being damaged due to uneven stress at the bottom during manufacturing and transportation through the load-bearing function of the ash cone base 12, thus providing a reliable guarantee for the subsequent pressing and curing process.

[0037] Furthermore, the material of the burnable outer membrane 11 is one of plant fiber paper, polyester material, paraffin paper, or engineering plastic.

[0038] It should be noted that these materials possess sufficient structural stability during room temperature and the pressing and transporting of the ash cone, enabling them to form a thin-walled shell with a fixed shape. This shell provides uniform coverage and support for the internally formed ash cone body 13, resisting the pressure during pressing and the friction and collision during transport, thus preventing damage to the ash cone body 13. Simultaneously, these materials exhibit high-temperature response characteristics, allowing them to quickly and completely disappear at a set temperature through sublimation, decomposition, or combustion during subsequent heat treatment of burn-off, without producing any residual substances that could affect the ash cone body 13 or test results. This ensures the structural integrity of the ash cone body 13 during the manufacturing stage and allows it to be completely removed before testing, without interfering with the observation of the ash cone's melting deformation and the detection of its characteristic temperature, thus ensuring the accuracy of the test.

[0039] The working principle and usage method of a burnable outer membrane ash cone according to this embodiment: This embodiment provides a burnable outer film ash cone. The burnable outer film 11 is bonded to the ash cone base 12 to form a stable outer mold 14, which defines the shape of the ash cone body 13 through the cavity, and at the same time, uses its own structural strength to provide all-round coverage and support for the ash cone body 13 under normal temperature conditions. When filling material, the feed port 111 serves as a conveying channel to achieve precise injection of plastic coal ash, and the through port 112 simultaneously discharges air from the cavity, ensuring that the material tightly adheres to the inner wall of the cavity to form a structurally uniform ash cone body 13; the ash cone base 12... The concave surface 123 cooperates with the through-hole 112 to provide bottom support for the outer mold 14, enhance overall stability, and avoid damage caused by uneven force on the bottom during transportation and pressing. The material selected for the burnable outer film 11 takes into account both room temperature support and high temperature burn-off properties, maintains morphological stability during the molding and transportation stages of the ash cone body 13, resists external impact, and completely disappears at the set temperature before entering the high temperature testing stage, leaving no impurities and not affecting the melting deformation law of the ash cone body 13, ultimately ensuring the accuracy of the ash melting characteristic temperature test.

[0040] In use, the burnable outer membrane 11 is first bonded and fixed to the ash cone base 12 to form a complete outer mold 14, ensuring that the through-hole 112 and the concave surface 123 of the ash cone base 12 are completely fitted and connected; the prepared plastic coal ash is injected into the cavity through the feed port 111 on the side of the burnable outer membrane 11 cone, and the internal air is discharged through the through-hole 112 during the injection process to ensure that the material is fully filled without gaps; after the material is filled, the ash cone body 13 is subjected to preliminary curing treatment to give it basic structural strength; the ash cone base 12 provides support. The outer mold 14, together with the inner ash cone body 13, is transferred. During the transfer, the burnable outer film 11 and the ash cone base 12 jointly resist external forces such as collision and friction, protecting the integrity of the ash cone body 13. The outer mold 14 carrying the ash cone body 13 is placed in a constant temperature furnace 31. First, a curing heat treatment is performed to enhance the strength of the ash cone body 13. Then, the temperature is raised to perform a burnable heat treatment, so that the burnable outer film 11 completely disappears. The remaining ash cone body 13 is removed and placed in an ash fusion tester to determine its ash fusion characteristic temperature according to the standard test procedure.

[0041] Example 2 like Figure 2 and Figure 10 As shown, this embodiment of an ash cone manufacturing device with a burnable outer membrane includes: a filling and arranging assembly 1, a filling and pressing assembly 2, a curing and burnable assembly 3, and an automatic mechanism 4. The filling and arranging assembly 1 includes an outer mold 14 and an ash cone support plate 15. The outer mold 14 is formed by bonding a burnable outer membrane 11 to an ash cone base 12. The ash cone support plate 15 is used to support and arrange multiple outer molds 14. The filling and pressing assembly 2 includes an ash cone bottom mold 22, a hopper 222, a pressing channel 221, an ash cone pressing mechanism 21, and a mold pressing mechanism 23. The ash cone bottom mold 22 is used to receive and position the outer molds 14 transferred by the automatic mechanism 4. The hopper 222 is used to store coal ash material. The pressing channel 221 connects the hopper 222 to the ash cone base 12. The feed inlet 111 of the outer mold 14 in the cone bottom mold 22; the ash cone pressing mechanism 21 is used to press the coal ash material in the hopper 222 into the cavity of the outer mold 14 through the pressing channel 221; the mold pressing mechanism 23 is used to press the ash cone bottom mold 22 during the pressing process; the curing and burn-off assembly 3 includes a constant temperature furnace 31, a sample feeding rod 36 and a temperature measurement and control unit; the constant temperature furnace 31 is used to perform sequential curing heat treatment and burn-off heat treatment on the ash cone support plate 15 carrying the outer mold 14; the sample feeding rod 36 is used to feed the ash cone support plate 15 into or out of the constant temperature furnace 31; the temperature measurement and control unit is used to monitor and adjust the temperature inside the constant temperature furnace 31; the automatic mechanism 4 is used to transfer the outer mold 14 from the ash cone support plate 15 to the ash cone bottom mold 22.

[0042] It should be noted that in the filling and arranging assembly 1, the outer mold 14 is composed of a burnable outer film 11 bonded to the ash cone base 12, which not only provides a forming cavity for the ash cone body 13, but also enhances the structural stability with the help of the ash cone base. The ash cone support plate 15 supports and arranges multiple outer molds 14 to achieve the basic layout for batch production and improve production efficiency. In the filling and pressing assembly 2, the lower ash cone mold 22 is used to accurately receive and position the outer mold 14 transferred by the automatic mechanism 4 to ensure the alignment of the feeding position. The hopper 222 stores coal ash material to provide raw materials for molding. The pressing channel 221 establishes the conveying path between the hopper 222 and the feeding port 111 of the outer mold 14. The ash cone pressing mechanism 21 uses pressure to press the material into the cavity through the channel, so that the material is compacted and formed. The mold clamping mechanism 23 clamps the lower mold 22 of the ash cone during pressing to prevent mold displacement from affecting molding accuracy. In the curing and burn-off assembly 3, the constant temperature furnace 31 sequentially completes the curing heat treatment and burn-off heat treatment. The curing process enhances the structural strength of the ash cone body 13, and the burn-off process causes the outer film to completely disappear. The sample feeding rod 36 realizes the smooth transfer of the ash cone support plate 15 into and out of the constant temperature furnace 31. The temperature measurement and control unit monitors and adjusts the furnace temperature in real time to ensure stable curing and burn-off effects. The automatic mechanism 4 undertakes the transfer of the outer mold 14 from the ash cone support plate 15 to the lower mold 22 of the ash cone, replacing manual operation. This reduces labor intensity and avoids damage to the outer film or ash cone caused by manual transfer, realizing automated connection of the production process and ensuring efficient and orderly progress of each link.

[0043] Furthermore, such as Figure 3 As shown, the bottom of the ash cone base 12 is integrally formed with a positioning surface 121, and its side is provided with a clamping surface 122. The positioning surface 121 is fixed in cooperation with the positioning groove 151 of the ash cone support plate 15. The gripper 41 of the automatic mechanism 4 is horizontally oriented towards the clamping surface 122 and is adapted to fit the clamping surface 122 to form a stable clamping.

[0044] It should be noted that the positioning surface 121 integrally formed at the bottom of the cone base 12 is structurally designed to fit the positioning groove 151 of the cone support plate 15. This transitional fit ensures a stable connection between the two, preventing displacement or wobbling of the outer mold 14 on the support plate while guaranteeing convenient loading and unloading. This provides a precise positioning basis for batch arrangement of the outer mold 14. The circumferentially arranged clamping surface 122 on the side of the cone base 12 increases the contact area with the gripper 41 of the automatic mechanism 4, providing structural support for stable clamping and preventing clamping. During the removal process, the concentrated force may cause damage to the bottom support or outer membrane of the ash cone. The gripper 41 of the automatic mechanism 4 is horizontally oriented towards the gripping surface 122. The adaptive and fitting design allows the gripper 41 to form a tight contact with the gripping surface 122, ensuring that the gripping force is evenly transmitted. This not only firmly grips the bottom support 12 of the ash cone to drive the outer mold 14 to move, but also maintains the horizontal posture of the outer mold 14 during the transfer process, avoiding material leakage or damage to the outer membrane due to tilting. This achieves a smooth and accurate transfer of the outer mold 14 from the ash cone support plate 15 to the lower bottom mold 22 of the ash cone.

[0045] Furthermore, such as Figures 4-6 As shown, a return spring 225 and a guide spring pin 227 are provided on the lower side of the mold base 223 of the lower mold of the ash cone 22. The return spring 225 and the guide spring pin 227 are both vertically installed in the spring mounting seat 226. The guide spring pin 227 is located in the center hole of the return spring 225. The two are coaxially arranged and elastically abut against the lower mold of the ash cone 22. The lower mold of the ash cone 22 is connected to the mold clamping mechanism 23 through the adapter plate 228. A positioning groove 224 is provided on the mold base 223 on the 228. A mating inclined surface 229 is provided on both sides of the lower end of the positioning groove 224 corresponding to the mold base 223. The telescopic mechanism 212 of the ash cone pressing mechanism 21 is horizontally fixed to the outside of the hopper 222 through the mounting plate 213. Its output end is coaxially connected to the punch 211. The punch 211 moves in a reciprocating linear motion along the axial direction of the pressing channel 221 to continuously press the plastic coal ash into the cavity and compact it.

[0046] It should be noted that the spring mounting seat 226 on the lower side of the bottom mold 22 of the ash cone provides a stable mounting base for the return spring 225 and the guide spring pin 227. The two are coaxially arranged and the guide spring pin 227 is located in the center hole of the return spring 225. This not only provides precise guidance for the extension and retraction of the return spring 225, preventing it from deviating or twisting, but also forms an elastic support structure that elastically resists the bottom mold 22 of the ash cone. When the mold clamping mechanism 23 applies clamping force, it stores elastic potential energy. After the clamping is completed, it releases the potential energy to push the bottom mold 22 of the ash cone to automatically reset. The adapter plate 228 serves as a connecting component to achieve a stable connection between the bottom mold 22 of the ash cone and the mold clamping mechanism 23, ensuring smooth transmission of clamping force and stable and controllable reset action. The telescopic mechanism 212 of the ash cone pressing mechanism 21 is horizontally fixed to the outside of the hopper 222. Its installation position is consistent with the axial direction of the pressing channel 221, which can provide precise horizontal driving force. The output end is coaxially connected to the punch 211 to ensure efficient transmission of driving force along the direction of the pressing channel 221. The punch 211 makes reciprocating linear motion along the axial direction of the pressing channel 221, which can continuously push the plastic coal ash in the hopper 222 to the cavity of the outer mold 14, and can also eliminate the voids in the material through reciprocating compaction action, ensuring that the density of the ash cone body 13 is uniform and the structure is stable after molding.

[0047] Furthermore, such as Figure 5 As shown, the mold clamping mechanism 23 includes a pressure head 231, a linkage mechanism 232, and an execution mechanism 233. The execution mechanism 233 is located on one side of the mold clamping mechanism 23. One end of the linkage mechanism 232 is hinged to the output end of the execution mechanism 233, and the other end extends vertically upward and is fixedly connected to the pressure head 231. The execution mechanism 233 drives the linkage mechanism 232 to extend and retract, thereby moving the pressure head 231 to apply a stable clamping force to the lower mold 22 of the gray cone.

[0048] It should be noted that the actuator 233 of the mold clamping mechanism 23 is installed on one side of the mold clamping mechanism 23, which can provide a stable and controllable driving force, providing the power basis for the entire clamping action; one end of the linkage mechanism 232 is hinged to the output end of the actuator 233, and the other end is fixedly connected to the pressure head 231. Its hinge design can realize flexible conversion of the direction of movement, converting the output of the actuator 233 into the clamping force required by the pressure head 231; the pressure head 231, as a component that directly acts on the bottom mold 22 of the ash cone, converts the force transmitted by the linkage mechanism 232 into a uniform clamping force through close contact with the bottom mold 22 of the ash cone; when the actuator 233 drives the linkage mechanism 232 to extend and retract, the pressure head 231 is driven to move precisely in the vertical direction through the transmission of the linkage, applying a stable and continuous clamping force to the bottom mold 22 of the ash cone, avoiding displacement or shaking of the bottom mold 22 of the ash cone during the ash cone pressing process, and ensuring the forming accuracy and structural stability when the coal ash material is pressed into the cavity.

[0049] Furthermore, such as Figure 7 As shown, a quick-closing furnace door 34 is hinged at the front opening of the constant temperature furnace 31. The linear mechanism 35 is horizontally fixed to the outer wall of the constant temperature furnace 31, and its output end is connected to the side of the quick-closing furnace door 34 through a connecting rod. It is used to control the quick-closing furnace door 34 to flip along the hinge axis to realize opening and closing. The temperature measuring instrument 32 is a sheathed thermocouple. Its probe end extends vertically downward into the middle of the heating cavity of the constant temperature furnace 31. It can monitor the average temperature in the cavity in real time and feed it back to the temperature control unit for adjustment.

[0050] It should be noted that the quick-closing furnace door 34, hinged at the front of the constant temperature furnace 31, opens and closes the furnace body through a flipping action. When closed, it seals the heating chamber, reducing heat loss and providing a stable temperature environment for the curing of the ash cone and the burning off of the outer film. The linear mechanism 35 is horizontally fixed to the outer wall of the constant temperature furnace 31 and can output a stable horizontal driving force. It is connected to the side of the quick-closing furnace door 34 through a connecting rod, converting the horizontal movement into the flipping movement of the furnace door, realizing the rapid and accurate opening and closing of the furnace door, and avoiding large fluctuations in the furnace temperature due to excessively long opening and closing processes. The temperature measuring instrument 32 is armored. A thermocouple is installed, with its probe extending vertically downwards into the middle of the heating chamber of the constant temperature furnace 31. This allows for accurate capture of the average temperature within the chamber, avoiding detection errors caused by localized temperature deviations. The temperature measuring instrument 32 feeds back the real-time monitored temperature signal to the temperature control unit. The control unit adjusts the heating power of the constant temperature furnace 31 according to the preset curing and burn-off temperature requirements, ensuring that the temperature inside the furnace remains within the set range. This guarantees that the gray cone body 13 has sufficient strength after curing, while also achieving complete burn-off of the burnable outer film 11, preventing abnormal temperatures from affecting the manufacturing effect and subsequent testing accuracy.

[0051] Furthermore, the sample feeding rod 36 drives the gray cone support plate 15 carrying the outer mold 14 to rise and fall smoothly along the guide rail 33 of the constant temperature furnace 31; the feed port 111 of the burnable outer film 11 can be set on one or more sides of the cone, or set on the top of the burnable outer film 11.

[0052] It should be noted that the guide rail 33 of the constant temperature furnace 31 provides stable guidance for the lifting and lowering of the ash cone support plate 15, limiting the movement trajectory of the support plate and avoiding tilting or shaking during the transfer process. The sample delivery rod 36 works in conjunction with the guide rail 33 to drive the ash cone support plate 15, which carries the outer mold 14, to rise and fall smoothly. This not only protects the outer film and the inner ash cone body 13 from collision and friction damage, but also ensures that the support plate accurately enters and exits the heating chamber of the constant temperature furnace 31, ensuring a smooth connection between the curing and burn-off processes. The feed port 111 of the burn-off outer film 11 has a flexible and diverse location. Whether it is one or more sides of the cone or the top, its core purpose is to adapt to different filling scenarios and material conveying directions, ensuring that the plastic coal ash can be smoothly and evenly injected into the cavity, avoiding problems such as incomplete filling and uneven density caused by limitations in the feed angle or position.

[0053] The working principle and usage of the ash cone manufacturing device with a burnable outer membrane in this embodiment are as follows: This embodiment provides a device for manufacturing ash cones with a burnable outer membrane. Through the coordinated operation of four major components, it achieves automated, low-damage, batch production of ash cones. In the filling and arranging assembly 1, the outer mold 14 is formed by bonding the burnable outer membrane 11 to the ash cone base 12. It not only defines the shape of the ash cone through the cavity but also enhances the structural stability with the help of the ash cone base. The ash cone support plate 15 cooperates with the positioning surface 121 of the ash cone base through the positioning groove 151 to achieve precise array arrangement of the outer mold 14. The automatic mechanism 4 uses the gripper 41 to fit and conform to the clamping surface 122 of the ash cone base, smoothly transferring the outer mold 14 from the support plate to the lower mold 22 of the ash cone, replacing manual labor and avoiding damage. In the filling and pressing assembly, the lower mold 22 of the ash cone precisely positions the outer mold 14 through the mold cooperation inclined surface 229. The hopper 222 stores plastic coal ash. The telescopic mechanism 212 of the ash cone pressing mechanism 21 drives the punch 211 along the pressing channel 22. 1. The reciprocating motion presses the material into the cavity and compacts it. At the same time, the mold clamping mechanism 23 drives the press head 231 to clamp the lower mold through the actuator 233 and the linkage mechanism 232 to prevent displacement. The return spring 225 of the lower mold and the guide spring pin 227 work together to achieve automatic reset after clamping. In the curing burn-off assembly, the sample feeding rod 36 drives the tray to move smoothly in and out along the guide rail 33 of the constant temperature furnace 31. The quick-closing furnace door 34 quickly opens and closes through the linear mechanism 35 to ensure the temperature inside the furnace is stable. The temperature measurement and control unit adjusts the temperature in real time with the help of the armored thermocouple. First, the gray cone body 13 is cured to enhance its strength. Then, the temperature is raised to completely burn off the burn-off outer film 11. Finally, a gray cone with a complete shape can be directly used for testing. The whole process takes into account both automation efficiency and molding accuracy.

[0054] In use, the burnable outer membrane 11 is first bonded and fixed to the ash cone base 12 to form an outer mold 14, ensuring that the through-hole 112 is in contact with the concave surface 123 of the ash cone base. Then, multiple outer molds 14 are arranged in an array on the base plate through the transition fit between the positioning surface 121 of the ash cone base and the positioning groove 151 of the ash cone support plate 15. The automatic mechanism 4 is started, and its gripper 41 is horizontally attached to the gripping surface 122 of the ash cone base, and the outer molds 14 are smoothly transferred one by one to the lower mold 22 of the ash cone and accurately positioned by the mold fitting inclined surface 229. The prepared plastic coal ash is added into the hopper 222, and the filling and pressing program is started. The mold pressing mechanism 23 drives the press head 231 to press the lower mold 22 of the ash cone, and the telescopic mechanism 212 of the ash cone pressing mechanism 21 drives the punch 211 to reciprocate along the pressing channel 221. The coal ash in the hopper 222 is pressed into the outer mold cavity through the feed inlet 111, while air is discharged through the through-hole 112 to ensure full filling. After pressing, the mold clamping mechanism 23 is released, and the bottom mold 22 of the ash cone is automatically reset under the action of the return spring 225 and the guide spring pin 227. The automatic mechanism 4 moves the outer mold 14 that carries the shaped ash cone back to the ash cone support plate 15. The sample feeding rod 36 drives the support plate to enter the furnace along the guide rail 33 of the constant temperature furnace 31. The quick-closing furnace door 34 is closed, and the temperature measurement and control unit controls the constant temperature furnace 31 to first perform solidification heat treatment, and then heat up to perform burn-off heat treatment, so that the burn-off outer film 11 completely disappears. After the treatment is completed, the sample feeding rod 36 drives the support plate to move out of the constant temperature furnace 31, and the ash cone body 13 on the support plate is taken out, which can then be used for subsequent ash melting characteristic temperature testing.

[0055] Finally, it should be noted that the above description is merely a preferred embodiment of the present invention and is only used to illustrate the technical solution of the present invention, and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention are included within the scope of protection of the present invention.

[0056] In the description of this invention, it should be understood that the terms "upper", "lower", "upper end", "lower end", "upper surface", "lower surface", etc., indicate the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention.

[0057] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "setting" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal communication between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

Claims

1. A ash cone with a burnable outer film, characterized in that, include: The ash cone body (13) and the burnable outer membrane (11) are thin-walled shells with the same shape as the ash cone body (13), and a cavity is formed inside the ash cone body (13) for accommodating the ash cone body (13). The ash cone body (13) is disposed in the cavity.

2. The ash cone with a burnable outer film as described in claim 1, characterized in that: The burnable outer membrane (11) is a triangular pyramidal thin-walled shell with a wall thickness of 0.2 mm to 1 mm.

3. The ash cone with a burnable outer film as described in claim 2, characterized in that: The burnable outer membrane (11) is provided with a feed port (111) and a through port (112) communicating with the cavity. The feed port (111) is located on the conical side of the burnable outer membrane (11), and the through port (112) is located at the bottom of the burnable outer membrane (11) and communicates with the concave surface (123) of the gray cone base (12).

4. The ash cone with a burnable outer film as described in claim 2, characterized in that: The burnable outer membrane (11) is made of one of the following materials: plant fiber paper, polyester material, paraffin paper, or engineering plastic.

5. An apparatus for manufacturing a burnable outer membrane based on any one of claims 1-4, characterized in that, The system includes a filling and arranging assembly (1), a filling and pressing assembly (2), a curing and burn-off assembly (3), and an automatic mechanism (4). The filling and arranging assembly (1) includes an outer mold (14) and a ash cone support plate (15). The outer mold (14) is formed by bonding a burnable outer film (11) to an ash cone base support (12). The ash cone support plate (15) is used to support and arrange multiple outer molds (14). The filling and pressing assembly (2) includes a lower ash cone mold (22), a hopper (222), a pressing channel (221), an ash cone pressing mechanism (21), and a mold pressing mechanism (23). The lower ash cone mold (22) is used to receive and position the outer molds (14) transferred by the automatic mechanism (4). The hopper (222) is used to store coal ash materials. The pressing channel (221) connects the hopper (222) with the outer mold located in the lower ash cone mold (22). The feed inlet (111) of the mold (14) is used to press the coal ash material in the hopper (222) into the cavity of the outer mold (14) through the pressing channel (221). The mold pressing mechanism (23) is used to press the lower mold (22) of the ash cone during the pressing process. The curing and burning-off assembly (3) includes a constant temperature furnace (31), a sample feeding rod (36) and a temperature measurement and control unit. The constant temperature furnace (31) is used to perform sequential curing heat treatment and burning-off heat treatment on the ash cone support plate (15) carrying the outer mold (14). The sample feeding rod (36) is used to send the ash cone support plate (15) into or out of the constant temperature furnace (31). The temperature measurement and control unit is used to monitor and adjust the temperature inside the constant temperature furnace (31). The automatic mechanism (4) is used to transfer the outer mold (14) from the ash cone support plate (15) to the lower mold (22).

6. The apparatus for manufacturing a burnable outer membrane for an ash cone as described in claim 5, characterized in that: The bottom of the gray cone base (12) is integrally formed with a positioning surface (121), and its side is provided with a clamping surface (122) in the circumferential direction. The positioning surface (121) cooperates with the positioning groove (151) of the gray cone support plate (15) for fixation. The gripper (41) of the automatic mechanism (4) is horizontally oriented towards the clamping surface (122) and fits and conforms to the clamping surface (122) to form a stable clamping.

7. The apparatus for manufacturing a burnable outer membrane for an ash cone as described in claim 5, characterized in that: A return spring (225) and a guide spring pin (227) are provided on the lower side of the mold base (223) of the lower mold of the ash cone (22). The return spring (225) and the guide spring pin (227) are both vertically installed in the spring mounting seat (226). The guide spring pin (227) is located in the center hole of the return spring (225). The two are coaxially arranged and elastically abut against the lower mold of the ash cone (22). The lower mold of the ash cone (22) is connected to the mold clamping mechanism (23) through the adapter plate (228). 28) A positioning groove (224) is provided on the mold base (223) and a matching inclined surface (229) is provided on both sides of the lower end of the positioning groove (224) corresponding to the mold base (223); the telescopic mechanism (212) of the ash cone pressing mechanism (21) is horizontally fixed to the outside of the hopper (222) through the mounting plate (213), and its output end is coaxially connected to the punch (211). The punch (211) moves in a reciprocating linear motion along the axial direction of the pressing channel (221) to continuously press the plastic coal ash into the cavity and compact it.

8. The apparatus for manufacturing a burnable outer membrane for an ash cone as described in claim 5, characterized in that: The mold clamping mechanism (23) includes a pressure head (231), a linkage mechanism (232), and an execution mechanism (233). The execution mechanism (233) is located on one side of the mold clamping mechanism (23). One end of the linkage mechanism (232) is hinged to the output end of the execution mechanism (233), and the other end extends vertically upward and is fixedly connected to the pressure head (231). The execution mechanism (233) drives the linkage mechanism (232) to extend and retract, thereby moving the pressure head (231) to apply a stable clamping force to the lower mold (22) of the gray cone.

9. The apparatus for manufacturing a burnable outer membrane for an ash cone as described in claim 5, characterized in that: The constant temperature furnace (31) has a quick-closing furnace door (34) hinged at the front opening. The linear mechanism (35) is horizontally fixed to the outer wall of the constant temperature furnace (31). Its output end is connected to the side of the quick-closing furnace door (34) via a connecting rod. It is used to control the quick-closing furnace door (34) to flip along the hinge axis to achieve opening and closing. The thermometer (32) is a sheathed thermocouple. Its probe extends vertically downward into the middle of the heating cavity of the constant temperature furnace (31). It can monitor the average temperature inside the cavity in real time and feed it back to the temperature control unit for adjustment.

10. The apparatus for manufacturing a burnable outer membrane for an ash cone as described in claim 9, characterized in that: The sample feeding rod (36) drives the gray cone support plate (15) that carries the outer mold (14) to rise and fall smoothly along the guide rail (33) of the constant temperature furnace (31); the feed port (111) of the burnable outer film (11) can be set on one or more sides of the cone, or set on the top of the burnable outer film (11).

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