Automatic brick forming press

Abstract

This invention discloses an automatic brick forming press, belonging to a brick forming device, including a frame. A fixed nut is located on the upper crossbeam of the frame, and a main screw is installed inside the fixed nut. The main screw is threadedly engaged with the fixed nut. A slider is installed at the lower end of the main screw, and the slider is placed in a pressing chamber at the lower part of the frame. The slider also has sliding parts on both sides. Guide rails that mate with the sliding parts of the slider are provided on both sides of the pressing chamber. A hollow spline shaft is fixed at the upper end of the main screw, and a spline sleeve is fitted around the hollow spline shaft. The spline sleeve is movably mounted on the upper part of the frame. A second pulley is also fitted around the spline sleeve, and the second pulley is poweredly connected to the first pulley via a belt. A servo motor drives the main screw to rotate through the pulley and spline shaft. The pressing time and pressure of the slider on the brick blank can be adjusted by controlling the start / stop, forward / reverse rotation, and output speed of the servo motor. The CNC method reduces the technical difficulty of press operation and adapts to brick production with different technical requirements.

Description

Technical Field

[0001] This invention relates to a brick forming production device, and more specifically, to an automatic press for forming brick blanks. Background Technology

[0002] Refractory materials and sintered brick blanks for building construction are generally formed by compression molding using a double-disc friction press. The Liaoning Forging J67-630T friction brick press is a mainstream large-tonnage brick blank forming equipment in the industry. Figure 1 As shown, it mainly relies on a motor to drive the horizontal shaft and friction discs on both sides. Through a friction clutch, the flywheel rotates, which in turn drives the main screw to rotate and move linearly, causing the slider and upper mold to move downwards. This impacts and pressurizes the powder in the worktable mold box, maintaining static pressure to complete the pressing and forming of refractory bricks, non-fired bricks, and other brick blanks. Currently, this type of 630T friction brick press generally adopts a four-column integrated frame structure, consisting of an upper crossbeam, a lower worktable, and four upright columns forming a load-bearing frame capable of withstanding large-tonnage pressing loads. The transmission end uses a double friction disc opposing structure, relying on friction to transmit torque. This design is simple, provides high forming impact force, and is suitable for dry pressing processes of powder materials. The core transmission of the equipment uses a screw-nut transmission pair. A thrust ball bearing is installed at the connection between the screw and the slider to withstand the huge axial load during pressing, while ensuring flexible screw rotation and reducing rotational friction and component wear. However, the existing traditional J67-630T friction brick press still has technical defects in actual use, such as insufficient automation, complex parameter operation, high requirements for personnel's technical skills and experience, and a single press generally requires three people to operate. It also suffers from poor adjustability of the pressing process, poor stability of brick forming quality, and a high equipment failure rate. Therefore, it is necessary to study and improve the structure of this type of brick press. Summary of the Invention

[0003] One of the objectives of this invention is to address the aforementioned shortcomings by providing an automatic brick forming press, which aims to solve the technical problems of insufficient automation, complex parameter operation, poor process adjustability, and excessive manual labor required in the use of similar presses in the prior art.

[0004] To solve the above-mentioned technical problems, the present invention adopts the following technical solution: The present invention provides an automatic brick forming press, comprising a frame, a fixing nut on the upper part of the frame, a main screw installed inside the fixing nut, the main screw being threadedly engaged with the fixing nut, a slider installed at the lower end of the main screw, the slider being placed in a pressing cavity at the lower part of the frame, the slider having sliding parts on both sides, and guide rails on both sides of the pressing cavity cooperating with the sliding parts of the slider, a hollow spline shaft fixed at the upper end of the main screw, a spline sleeve fitted around the hollow spline shaft, the spline sleeve being movably mounted on the frame. At the upper part, a second pulley is also fitted on the outside of the spline sleeve. The second pulley is poweredly connected to the first pulley via a belt. The first pulley is mounted on the output shaft of the servo motor, which is also mounted on the upper part of the frame. The servo motor is used to drive the first pulley to rotate, so that the first pulley drives the second pulley to rotate via the belt, and then drives the main screw to rotate through the spline sleeve and the hollow spline shaft. This causes the main screw to engage with the fixed nut and move vertically up and down with the fixed nut as the reference, thereby driving the slider to move up and down.

[0005] As a preferred embodiment, a further technical solution is: the pressing chamber is further provided with a pressure-bearing platform, and a forming mold is installed on the pressure-bearing platform. The pressure-bearing platform and the forming mold are both located directly below the slider. The lower end of the slider is provided with a hammer and an upper template. The slider is used to drive the hammer and the upper template to move up and down, forming a cooperation with the forming mold.

[0006] A further technical solution is as follows: at least one brake cylinder is also installed on the upper part of the frame. The brake cylinder is connected to an external air source, and the output direction of the piston rod of the brake cylinder corresponds to the second pulley. The brake cylinder is used to drive the piston rod to extend the friction plate at its front end under the drive of the external air source, so as to contact the rim surface of the second pulley to form frictional resistance and prevent the second pulley from rotating.

[0007] A further technical solution is that a thrust ball bearing is also installed between the spline sleeve and the upper part of the frame. The thrust ball bearing is used to bear the rotation of the spline sleeve on the frame, so that the second pulley can drive the main screw to rotate through the spline sleeve and the hollow spline shaft.

[0008] A further technical solution is: a safety light curtain is installed inside the pressing cavity, the upper end of the safety light curtain corresponds to the initial position of the slider, and the lower end of the safety light curtain corresponds to the pressing position of the slider; the safety light curtain is connected to a servo control unit.

[0009] A further technical solution is as follows: the solenoid valve between the servo motor and the brake cylinder and the external air source is connected to the servo control unit; the servo control unit is used to control the start, stop, forward and reverse rotation and speed of the servo motor, and to control the extension and reset of the brake cylinder piston rod by controlling the opening and closing of the solenoid valve, and to stop the servo motor when receiving an abnormal signal from the safety light curtain.

[0010] Compared with the prior art, one of the beneficial effects of the present invention is that the servo motor drives the main screw to rotate through the pulley and spline shaft. The pressing time and pressure of the hammer at the lower end of the slider on the brick blank can be adjusted by controlling the start / stop, forward / reverse rotation and output speed of the servo motor. The CNC method reduces the technical difficulty of the press operation and saves labor. At the same time, the CNC method can also easily adjust and set the pressing process of the press on the brick blank, thereby adapting to the production of bricks with different technical requirements, improving the stability of the brick blank forming quality, simplifying the power transmission structure of the press, facilitating daily maintenance, and effectively reducing the failure rate of the equipment. Attached Figure Description

[0011] Figure 1 This is a schematic diagram of the structure of a friction brick press in the prior art.

[0012] Figure 2 This is a schematic diagram illustrating a structural aspect of an embodiment of the present invention.

[0013] Figure 3 for Figure 2 A detailed schematic diagram of a part of the diagram.

[0014] In the diagram, 11 is the motor, 12 is the horizontal shaft, 13 is the friction disc, 14 is the flywheel, 15 is the main screw, 201 is the frame, 202 is the fixing nut, 203 is the main screw, 204 is the slider, 205 is the pressing chamber, 206 is the guide rail, 207 is the hollow spline shaft, 208 is the spline sleeve, 209 is the first pulley, 210 is the second pulley, 211 is the servo motor, 212 is the pressure plate, 213 is the brake cylinder, 214 is the thrust ball bearing, 215 is the safety light curtain, and 216 is the servo control unit. Detailed Implementation

[0015] The invention will now be further described with reference to the accompanying drawings.

[0016] As mentioned in the background section, this invention is an improvement on the Liaoning Forging J67-630T friction brick press, specifically by... Figure 1The friction disc 13, horizontal shaft 12, flywheel 14, and support arm of the equipment shown are removed, while the original main screw and fixing nut remain unchanged. A hollow spline shaft is installed at the top of the original main screw (the original flywheel 14 position), and a spline sleeve is installed on the upper part of the frame's crossbeam to match it. A thrust ball bearing is installed at the lower part of the spline sleeve, and a large pulley is installed on the outside of the spline sleeve. A servo motor drives the large pulley and spline sleeve to rotate via belt drive, causing the hollow spline shaft and the main screw to rotate. The main screw's rotational motion is converted into a reciprocating motion through the fixing nut, realizing the pressing of brick blanks. At the same time, a pair of brake cylinders are added to the upper end face of the large pulley to brake the large pulley after each brick blank is pressed or when the power is off, ensuring that the slider does not slip when stopped or in the event of a power outage. A pneumatic lubrication machine is installed on the press maintenance platform to automatically add 00# grease to the spline shaft sleeve at regular intervals and to automatically lubricate the thrust ball bearing and the main screw (main nut).

[0017] The electrical system was upgraded by replacing the original standard motors and control cabinets with 82kW servo motors. The new control cabinet features a touchscreen for parameter settings (speed, number of strikes, striking force, time), and includes a built-in PLC and servo drive controller. A centralized control panel is located next to the machine, transforming the brick press from manual to intelligent digital control. To minimize dust impact on the control cabinet, it is housed in a separate control room, approximately 10 meters from the press.

[0018] Based on the above improvements, refer to Figure 2 , Figure 3As shown, one embodiment of the present invention is an automatic brick forming press, which includes a frame 201. A fixing nut 202 is located on the upper part of the frame 201. A main screw 203 of the original equipment is installed inside the fixing nut 202, and the main screw 203 is threadedly engaged with the fixing nut 202. A slider 204 is installed at the lower end of the main screw 203. The slider 204 is placed in a pressing cavity 205 at the lower part of the frame 201. To ensure the stability of the slider 204's movement, sliding portions are provided on both sides of the slider 204. Guide rails 206, which cooperate with the sliding portions of the slider 204, are provided on both sides of the pressing cavity 205. More importantly, based on the above improvements, a hollow spline shaft 207 is fixed to the upper end of the main screw 203, and then a hollow spline shaft 207 is fitted onto the outside of the hollow spline shaft 207. Spline sleeve 208 is movably mounted on the upper part of frame 201. A second pulley 209 is also fitted on the outside of spline sleeve 208. The first pulley 210 is poweredly connected to the second pulley 209 via a belt. The first pulley 210 is mounted on the output shaft of the servo motor 211, which is also mounted on the upper part of frame 201. Through the aforementioned structural arrangement, the servo motor 211 can drive the second pulley 209 to rotate via the first pulley 210. This, in turn, drives the main screw 203 to rotate via spline sleeve 208 and hollow spline shaft 207. The main screw 203 engages with the fixing nut 202 and moves vertically with the fixing nut 202 as a reference, thereby driving the slider 204 to move vertically.

[0019] In this embodiment, similar to the previous device, in order to ensure the molding of the brick blank, a pressure plate 212 can be set in the pressing cavity 205. A molding mold is installed on the upper part of the pressure plate 212. The mold cavity of the molding mold is consistent with the shape of the brick blank to be molded. Then, the pressure plate 212 and the molding mold are both set directly below the slider 204. At the same time, in order to cooperate with the aforementioned molding mold, a hammer and an upper template can be fixed at the lower end of the slider 204, so that the slider 204 can drive the hammer and the upper template to move up and down, cooperate with the aforementioned molding mold, and press the brick blank into shape. On the other hand, to prevent the slider 204 from sliding down when stopped or when power is off, two brake cylinders 213 can be installed on the upper part of the frame 201. It is best to install one brake cylinder 213 on each side of the second pulley 209. Then, the aforementioned brake cylinders 213 are connected to an external air source, and the output direction of the piston rod of the brake cylinder 213 is aligned with the second pulley 209. Under the drive of the external air source, the piston rod of the brake cylinder 213 drives the friction plate at its front end to extend, thereby contacting the rim surface of the second pulley 209 to form frictional resistance, preventing the first pulley 209 from rotating, and thus preventing the slider 204 from sliding down when stopped or when power is off.

[0020] Furthermore, in this embodiment, a thrust ball bearing 214 can be installed between the spline sleeve 208 and the upper part of the frame 201 as described above. The thrust ball bearing 214 is used to support the rotation of the spline sleeve 208 on the frame 201, so that the second pulley 209 can drive the main screw 203 to rotate through the spline sleeve 208 and the hollow spline shaft 207. At the same time, in order to ensure that the slider 204 moves up and down within a safe stroke, a safety light curtain 215 can also be installed inside the pressing cavity 205. The upper end of the safety light curtain 215 corresponds to the initial position of the slider 204, and the lower end of the safety light curtain 215 corresponds to the pressing position of the slider 204; at the same time, the safety light curtain 215 is connected to the servo control unit 216. In this embodiment, the solenoid valve between the aforementioned servo motor 211 and brake cylinder 213 and the external air source is connected to the servo control unit 216. The servo control unit 216 is used to control the start, stop, forward and reverse rotation and speed of the servo motor 211, and to control the extension and reset of the piston rod of the brake cylinder 213 by controlling the opening and closing of the solenoid valve. When an abnormal signal is received from the safety light curtain 215, the servo motor 211 is stopped.

[0021] refer to Figure 2 and Figure 3As shown, in actual use, in the standby state of the equipment described in the preferred embodiment of the present invention, the brick blank is placed on the forming mold and the pressure table 212 inside the pressing chamber 205. The safety light curtain 215 monitors the working area of ​​the pressing chamber 205 in real time. The servo control unit 216 issues a work command to start the servo motor 211. The servo motor 211 drives the second pulley 210 to rotate, which in turn drives the first pulley 209 and the spline sleeve 208 to rotate synchronously via belt transmission. The spline sleeve 208 transmits torque through the hollow spline shaft 207, driving the main screw 203 to rotate. The main screw 203 is threadedly engaged with the fixing nut 202 on the frame 201. Under the guidance and limitation of the guide rail 206 and the sliding part of the slider 204, the main screw 203 drives the slider 204 to feed downward in a straight line, pressing the brick blank on the forming mold and the pressure table 212. The thrust ball bearing 214 bears the axial load of the spline sleeve 208 rotation, ensuring smooth operation. After pressing is completed, the servo motor 211 rotates in reverse, driving the main screw 203 to reverse through the pulley and spline transmission structure, driving the slider 204 to move upward and reset to the initial position. During operation, if the safety light curtain 215 detects a foreign object or personnel accidentally entering the work area, it immediately sends an abnormal signal to the servo control unit 216. The servo control unit 216 immediately shuts down the servo motor 211 and simultaneously controls the air source solenoid valve to open. The piston rod of the brake cylinder 213 drives the friction plate at its front end to extend, generating frictional resistance on the rim surface of the second pulley 209, locking the second pulley 209 from rotating, and causing the slider 204 to stop immediately, achieving safety protection. After the hazard is eliminated, the servo control unit 216 controls the piston rod of the brake cylinder 213 to reset, and the equipment returns to the standby and ready-to-start state.

[0022] As can be seen from the above embodiments, the automatic brick forming press provided by the present invention has the following characteristics: The input settings for different brick forming and pressing parameters are simple and easy to learn, and can be handled by process engineers or foremen. Operators can learn to operate the equipment in just one day after very simple training, which reduces the dependence of brick forming quality on the operator's skills and experience.

[0023] The number of operators per press has been reduced from 3 to 2: one person weighs the material and feeds it into the mold, while the other removes the bricks. The position of machine operator has been eliminated, reducing the technical difficulty of operation and enabling user-friendly operation.

[0024] The impact force can be digitally set arbitrarily within the nominal range of the equipment, allowing for initial light strikes followed by heavy strikes; the impact speed can also be digitally set, with the slider speed decreasing from fast to slow; the number of strikes can also be set as needed. The slider's impact stroke and the brick blank's exit point can be easily adjusted.

[0025] Maintenance is simple. The key points of daily maintenance are to ensure that the pneumatic lubrication machine is always in oil supply and that all fasteners are complete and secure, which effectively reduces the equipment failure rate.

[0026] Operation parameter settings: ① Number of hits: Number of hits in the current mode; ② Rise height: Exhaust height of the slider (upper template); ③ Rise speed: Upward movement speed of the slider (upper template); ④ Fall speed: Downward movement speed of the slider (upper template); ⑤ Deceleration height: Position when the slider (upper template) transitions to the material-attacking speed after a rapid downward movement; ⑥ Deceleration speed: Downward material-attacking speed of the slider (upper template); ⑦ Impact force: Percentage of impact force.

[0027] When the automatic brick forming press of the present invention is used: Production figures are calculated from the point when the machine reached relatively normal production levels. It operated for 29 days, with two shifts per day, producing a total of 286.17 tons (steel-ladle bricks). The average daily output was 12.29 tons. Initially, output was lower as operators needed time to familiarize themselves with the changes in the process. Later, as operators became more proficient, output gradually increased; for example, a single shift produced 9.26 tons, and a single day produced 17.78 tons. Before the modification, the machine's average daily output was 14 tons. Based on current operating conditions, the output per machine after the modification is now close to the pre-modification average, and the expected output may slightly exceed the pre-modification level.

[0028] Comparison of product quality indicators:

[0029] Through comparative analysis of product indicators before and after the modification, the product quality indicators after the modification are relatively stable and consistent, and there are no significant fluctuations in quality indicators (the high temperature flexural strength tester was unable to conduct comparative analysis of high temperature indicators due to a malfunction).

[0030] In addition to the above, it should be noted that the terms "one embodiment," "another embodiment," and "embodiment" used in this specification refer to specific features, structures, or characteristics described in connection with that embodiment, which are included in at least one embodiment described in the general description of this application. The appearance of the same expression in multiple places in the specification does not necessarily refer to the same embodiment. Furthermore, when a specific feature, structure, or characteristic is described in connection with any embodiment, the intention is to suggest that implementing such a feature, structure, or characteristic in conjunction with other embodiments also falls within the scope of this invention.

[0031] Although the invention has been described herein with reference to several illustrative embodiments, it should be understood that many other modifications and implementations can be devised by those skilled in the art, which will fall within the scope and spirit of the principles disclosed herein. More specifically, various variations and modifications can be made to the components and / or layout of the subject matter arrangement within the scope of the disclosure, drawings, and claims. Besides variations and modifications to the components and / or layout, other uses will be apparent to those skilled in the art.

Claims

1. An automatic brick forming press, comprising a frame (201), wherein a fixing nut (202) is provided on the upper part of the frame (201), a main screw (203) is installed in the fixing nut (202), the main screw (203) is threadedly engaged with the fixing nut (202), a slider (204) is installed at the lower end of the main screw (203), the slider (204) is placed in a pressing cavity (205) at the lower part of the frame (201), the slider (204) also has sliding parts on both sides, and guide rails (206) are provided on both sides of the pressing cavity (205) to cooperate with the sliding parts of the slider (204), characterized in that: A hollow spline shaft (207) is fixed at the upper end of the main screw (203). A spline sleeve (208) is fitted on the outside of the hollow spline shaft (207). The spline sleeve (208) is movably installed on the upper part of the frame (201). A second pulley (209) is also fitted on the outside of the spline sleeve (208). The second pulley (209) is poweredly connected to the first pulley (210) through a belt. The first pulley (210) is installed on the output shaft of the servo motor (211). The servo motor (211) is also installed on the upper part of the frame (201). The servo motor (211) is used to drive the first pulley (210) to rotate, so that the first pulley (210) drives the second pulley (209) to rotate through the belt, and then drives the main screw (203) to rotate through the spline sleeve (208) and the hollow spline shaft (207), so that the main screw (203) cooperates with the fixed nut (202) and moves up and down linearly with the fixed nut (202) as the reference, thereby driving the slider (204) to move up and down.

2. The automatic brick forming press according to claim 1, characterized in that: The pressing chamber (205) is also provided with a pressure bearing platform (212), on which a forming mold is installed. The pressure bearing platform (212) and the forming mold are both located directly below the slider (204). The lower end of the slider (204) is provided with a hammer and an upper template. The slider (204) is used to drive the hammer and the upper template to move up and down, forming a cooperation with the forming mold.

3. The automatic brick forming press according to claim 1, characterized in that: Two brake cylinders (213) are also installed on the upper part of the frame (201). The brake cylinders (213) are connected to an external air source, and the output direction of the piston rod of the brake cylinder (213) corresponds to the second pulley (209). The brake cylinder (213) is used to drive the piston rod to extend the friction plate at its front end under the drive of the external air source, so as to contact the rim surface of the second pulley (209) to form frictional resistance and prevent the second pulley (209) from rotating.

4. The automatic brick forming press according to claim 1, characterized in that: A thrust ball bearing (214) is also installed between the spline sleeve (208) and the upper part of the frame (201). The thrust ball bearing (214) is used to support the rotation of the spline sleeve (208) on the frame (201), so that the second pulley (209) can drive the main screw (203) to rotate through the spline sleeve (208) and the hollow spline shaft (207).

5. The automatic brick forming press according to claim 1, characterized in that: A safety light curtain (215) is installed on the inner side of the pressing cavity (205). The upper end of the safety light curtain (215) corresponds to the initial position of the slider (204), and the lower end of the safety light curtain (215) corresponds to the pressing position of the slider (204). The safety light curtain (215) is connected to the servo control unit (216).

6. The automatic brick forming press according to claim 1 or 5, characterized in that: The solenoid valve between the servo motor (211) and the brake cylinder (213) and the external air source is connected to the servo control unit (216); the servo control unit (216) is used to control the start, stop, forward and reverse rotation and speed of the servo motor (211), and to control the extension and reset of the piston rod of the brake cylinder (213) by controlling the opening and closing of the solenoid valve, and to stop the servo motor (211) when receiving an abnormal signal from the safety light curtain (215).

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