Rolling apparatus and rolling method

Abstract

The application discloses a rolling device and a rolling method, which are used for rolling powder into a brick blank and comprise oppositely arranged first and second pressing assemblies. The first pressing assembly comprises a first forming roller and a first pressure maintaining device, the first pressure maintaining device is provided with a first pressure maintaining piece, a first wear-resistant piece movably arranged and a plurality of rows of reciprocating driving pieces, each row is arranged side by side along a first direction, each row is arranged along a second direction, and the reciprocating driving pieces in each row have consistent pressure. The device further comprises a control unit configured to cooperatively control the displacement of the first forming roller and the first pressure maintaining device. According to the characteristics of the brick blanks with different thicknesses and formulas, the cooperative control mode can accurately adjust the pressure release process of the pressure maintaining device, so that the pressure release process is accurately matched with the expansion process of the brick blank, the problems of uneven internal stress release, crack or deformation of the brick blank caused by rough control of the pressure release are solved, the quality of the brick blank is improved, and the movement of the forming roller and the pressure maintaining device is ensured to be closely matched and highly coordinated.

Description

Technical Field

[0001] This invention relates to the field of roller press technology, and more particularly to a roller pressing device and roller pressing method. Background Technology

[0002] In the building ceramics production industry, roll forming is widely used to prepare ceramic powder into brick blanks. The basic process is as follows: ceramic powder is evenly spread on a running steel belt, and the powder is compacted by forming rollers to form a preliminary blank. Then, a pressure holding device is used to apply pressure to the preliminary blank, so that the internal stress is slowly released, and finally a brick blank with a certain strength is obtained.

[0003] However, in the pressure holding stage of brick blanks, the accuracy of pressure release control of the pressure holding device directly affects the quality of the brick blanks. Brick blanks of different thicknesses and with different formulations have different expansion characteristics during the molding process. If the pressure holding device cannot be precisely adjusted according to these differences, the pressure release will be difficult to match with the expansion process of the brick blanks, resulting in uneven stress distribution inside the brick blanks, which in turn leads to quality problems such as cracks or deformation.

[0004] Furthermore, the coordination of movement between the forming rollers and the pressure holding device is also a key factor affecting the forming quality. If their movements are not synchronized or their coordination is not tight, it will not only reduce the forming accuracy of the brick blank, but may also cause safety accidents such as collisions in the roller pressing equipment. Summary of the Invention

[0005] The purpose of this invention is to disclose a roll forming equipment and roll forming method that can precisely control the forming and holding pressure processes and can flexibly adapt to roll forming equipment of various specifications.

[0006] To achieve the above objectives, the present invention discloses a roller pressing device for roller pressing powder into brick blanks, comprising a first pressing component and a second pressing component arranged opposite to each other. The first pressing component includes a first forming roller and a first pressure holding device. The first pressure holding device includes a first pressure holding member, a first wear-resistant member movably disposed on the first pressure holding member, and a plurality of reciprocating drive members arranged side by side along a first direction. The reciprocating drive members are arranged in multiple rows along a second direction, and each of the reciprocating drive members acts on the first wear-resistant member, and the pressure of the reciprocating drive members in the same row is consistent. The first direction is the width direction of the powder laying, and the second direction is the conveying direction of the powder. The roller pressing device further includes a control unit configured to coordinately control the displacement of the first forming roller and the first pressure holding device.

[0007] By adopting the above scheme, the control unit can coordinate the displacement of the first forming roller and the first pressure holding device. Through this coordinated control method, the pressure release process of the pressure holding device can be precisely adjusted according to the characteristics of brick blanks with different thicknesses and formulations, so as to accurately match the expansion process of the brick blank. This effectively solves the problem of uneven stress release, cracking or deformation caused by coarse pressure release control of the pressure holding device, thus improving the quality of the brick blank. The coordinated control of the first forming roller and the first pressure holding device by the control unit not only helps to accurately control the pressure holding process, but also ensures close cooperation and high coordination between the movements of the forming roller and the pressure holding device.

[0008] Furthermore, the reciprocating drive component is a piston, and each piston is connected to a pneumatic control unit. The pneumatic control unit is communicatively connected to the control unit. The pneumatic control unit independently controls the air passage opening and closing of each piston and provides a uniform working pressure to all connected pistons.

[0009] By adopting the above scheme, the actions of each reciprocating drive component can be independently and precisely controlled according to the characteristics of different specifications of brick blanks in the first direction, ensuring that the pressure holding pressure is applied evenly and accurately, avoiding problems such as uneven release of internal stress, cracks or deformation caused by uneven pressure, effectively improving the quality of brick blank forming, and also adapting to the production needs of various specifications of products, enhancing the equipment's versatility and production flexibility.

[0010] Furthermore, the pneumatic control unit includes: multiple control valves connected between each piston and an air source for individually controlling the opening and closing of each piston and air source; a pressure regulating valve connected between each control valve and an air source for providing uniform pressure to all pistons; and an air tank for stabilizing pressure, the air tank being connected between the pressure regulating valve and the control valve, or the air tank being connected between the control valve and each piston; the first pressure-holding component is also provided with a third position detection unit for monitoring the position of the reciprocating drive component.

[0011] By adopting the above scheme, the pneumatic control unit realizes the on-demand switching of each reciprocating drive component through an independent control valve. The pressure regulating valve provides uniform pressure to all connected reciprocating drive components. With the stable air supply from the air tank, the pressure holding area and pressure consistency can be precisely controlled to avoid local overpressure or underpressure. At the same time, the third position detection unit on the first pressure holding component monitors the position of the reciprocating drive component and provides closed-loop feedback to the control unit to ensure that the pressure holding stroke is accurate and controllable.

[0012] Further, the width of the brick blank is set as W1; in the first direction, the distance between the outer edges of the two outermost reciprocating driving members among all activated reciprocating driving members is W2, and the distance between one edge of the brick blank and the outer edge of the activated reciprocating driving member closest to said edge is X, and 0mm < X ≤ 120mm.

[0013] By adopting the above solution, it is ensured that the action range of the reciprocating driving members is slightly smaller than the width of the brick blank, so as to prevent the reciprocating driving members from directly pressing on the edge of the brick blank to cause overpressure, cracking or deformation; meanwhile, X does not exceed 120mm, which also ensures that the edge region of the brick blank is still within the effective pressure-holding coverage, and uneven density or warping will not occur due to insufficient pressure.

[0014] Further, a plurality of rows of reciprocating driving members are arranged on the first pressure-holding device along the second direction, each row of reciprocating driving members is arranged side by side in the first direction, the working pressures of the reciprocating driving members in different rows are configured to be set to different values, and change in a gradient along the second direction.

[0015] By adopting the above solution, a gradually decreasing or increasing pressure curve can be applied according to the stress release or shrinkage characteristics of the brick blank in different stages of pressure holding, so as to achieve a smooth transition from pressure holding to pressure relief. This gradient pressure control effectively avoids internal stress concentration caused by sudden pressure change, and significantly reduces the risk of cracking, delamination or deformation of the brick blank.

[0016] Further, a safety threshold SH is preset in the rolling equipment, and the safety threshold SH satisfies: SH < S0 - 3mm; wherein, the vertical distance between the bottom end of the first wear-resistant member and the bottom end of the first forming roller is set as H1 = 0, the stroke of the reciprocating driving member is set as H2 = 0, and the extension of the tangent at the bottommost part of the first forming roller is tangent to the bottommost end of the first pressure-holding device, then the minimum distance between the first forming roller and the first pressure-holding device along the third direction is S0, and the third direction is a direction perpendicular to the horizontal plane.

[0017] By adopting the above solution, it is ensured that the first forming roller and the first pressure-holding device maintain a safety clearance of at least 3mm under any working conditions, effectively preventing mechanical collision between them.

[0018] Furthermore, the control unit is configured to: control the first pressure-holding device to move to the target position B according to the position A of the first forming roller, the preset height difference H1, and the stroke H2 of the reciprocating drive component, so that the first wear-resistant component presses the brick blank through the stroke H2; and satisfy the relationship: SH+H1+H2=S0, and 0mm≤H1≤5mm, 2mm≤H2≤6mm; wherein, the height difference H1 is the vertical distance between the bottom end of the first wear-resistant component and the bottom end of the first forming roller, and the stroke H2 is the actual extension amount of the reciprocating drive component.

[0019] By adopting the above scheme, the control unit can automatically calculate and coordinate the positions of the first forming roller and the first pressure holding device according to the target thickness of the brick blank, while flexibly adjusting the stroke of the wear-resistant plate and the reciprocating drive within the ranges of 0-5mm H1 and 2-6mm H2. This ensures reliable contact and pressure application of the pressure holding device to the surface of the brick blank, while also ensuring that the safety threshold always meets the structural constraints, effectively preventing collisions.

[0020] A rolling pressing method includes: a forming and holding pressure step: driving a first pressing component and a second pressing component to roll and form a spread powder; in the holding pressure stage, a first wear-resistant component applies a holding pressure to the brick blank; wherein, according to the width of the brick blank, a portion of the reciprocating drive component of the first holding pressure device in a first direction is selectively activated, and the orthogonal projection of the activated reciprocating drive component on the brick blank does not exceed the range of the brick blank.

[0021] By adopting the above scheme, during the molding and pressure holding steps, the reciprocating drive is selectively activated according to the width of the brick blank, and a safety distance is reserved at the edge to avoid over- or under-pressure at the edge, thereby significantly reducing the risk of deformation and cracking of the brick blank after firing. The overall method adopts adaptive pressure holding, which improves the molding quality and yield of brick blanks with different widths and formulas, while simplifying the production transition and debugging process.

[0022] Furthermore, the forming and pressure holding steps further include: determining the position A of the first forming roller according to the target thickness of the brick blank; obtaining a preset safety threshold SH, the safety threshold SH being determined based on the structural distance S0 under the reference state; during the operation of the roller pressing equipment, the control unit determines the target position of the first pressure holding device according to the position A of the first forming roller, the preset height difference H1, and the stroke H2 of the reciprocating drive component, and controls it to move to the target position; wherein, the height difference H1 is the vertical distance between the bottom end of the first wear-resistant part and the bottom end of the first forming roller, satisfying 0mm≤H1≤5mm; the stroke H2 is the actual extension of the reciprocating drive component, satisfying 2mm≤H2≤6mm; and satisfying the relationship: SH+H1+H2=S0.

[0023] Further, the control unit monitors the actual position B of the first pressure holding device, calculates the difference between said actual position B and the position A of the first forming roll, and issues an alarm or a shutdown instruction when B-A<SH.

[0024] By adopting the above solution, it ensures that the pressure holding device reliably contacts the surface of the brick blank and applies pressure, while always maintaining a safe clearance, effectively preventing mechanical collision; the closed-loop monitoring and safety interlock mechanism greatly improves the automation degree, safety and reliability of the operation of the rolling equipment.

[0025] Compared with the prior art, the beneficial effects of the present invention are: 1. The control unit can cooperatively control the displacements of the first forming roll and the first pressure holding device, and accurately adjust the pressure release process of the pressure holding device according to the characteristics of brick blanks with different thicknesses and formulas, so that the pressure release process accurately matches the expansion process of the brick blank. It effectively solves the problems of uneven internal stress release, cracks or deformation of the brick blank caused by extensive pressure release control of the pressure holding device, and improves the quality of the brick blank. The cooperative control of the control unit is not only beneficial for accurately controlling the pressure holding process, but also ensures the close coordination and high coordination of the movement between the forming roll and the pressure holding device. It avoids the problems of reduced brick blank forming quality, such as poor product surface flatness and large size deviation, caused by unsynchronized movement or unclose cooperation between the two, meanwhile reduces the occurrence risk of safety accidents such as collision of the rolling equipment, and reduces the maintenance cost and downtime of the rolling equipment; 2. Since the control unit can realize cooperative control of the first forming roll and the first pressure holding device, when the rolling equipment is changed to produce products with different width specifications, there is no need for cumbersome component replacement and a large amount of parameter debugging work, which greatly shortens the production changeover time, reduces the occurrence of production interruption, improves the production efficiency, and further increases the economic benefits of the enterprise; 3. By setting that the pressure of reciprocating driving members in the same row is consistent and the pressure of multiple rows can present a gradient change, uniform pressure holding in the width direction and gradient stress release in the second direction are realized, which further improves the quality of the brick blank; meanwhile, through the accurate position relational expression and safety threshold setting, the collision risk of the rolling equipment is effectively avoided, and the production safety is improved. Description of Drawings

[0026] In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings required for the embodiments 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 these drawings without creative effort.

[0027] Figure 1 is a schematic side structural view of a rolling device according to an embodiment of the present invention; Figure 2This is a schematic diagram showing the positional structure of the first pressure-holding component and the first forming roller in an embodiment of the present invention; Figure 3 This is a partially enlarged structural diagram of area A of the first pressure-holding component according to an embodiment of the present invention; Figure 4 This is a schematic diagram of a first structure of the reciprocating drive component for the first pressure holding component according to an embodiment of the present invention; Figure 5 This is a schematic diagram of a second structure of the reciprocating drive component of the first pressure-holding component according to an embodiment of the present invention; Figure 6 This is a schematic diagram of a third structure of the reciprocating drive component of the first pressure-holding component according to an embodiment of the present invention; Figure 7 This is a schematic diagram of a fourth structure of the reciprocating drive component of the first pressure-holding component according to an embodiment of the present invention; Figure 8 This is a schematic diagram of a pneumatic control unit connection structure according to an embodiment of the present invention; Figure 9 This is a schematic diagram of another pneumatic control unit connection structure according to an embodiment of the present invention.

[0028] Explanation of key figure labels: 1. First pressing assembly; 11. First driving roller; 12. First forming roller; 13. First driven roller; 14. First pressure holding device; 141. Pressure holding cylinder; 142. Pressure holding beam; 143. First pressure holding component assembly; 1431. First pressure holding component; 1432. First floating plate; 1433. First wear-resistant component; 1434. Guide mechanism; 1435. Reciprocating drive component; 15. First steel strip; 2. Second pressing assembly; 21. Second driving roller; 22. First... 23. Second driven roller; 24. Second pressure holding device; 241. Second pressure holding plate assembly; 2411. Second wear-resistant plate; 2412. Second limit plate; 25. Second steel strip; 3. Resistance device; 4. Pneumatic control unit; 41. Air inlet switch; 42. Pressure regulating valve; 43. Pressure sensor; 44. Air tank; 45. Pipeline; 46. Control valve; 47. Vacuum generator; 5. Brick blank; 7. Third position detection unit; 8. Control unit. Detailed Implementation

[0029] 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. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0030] In this invention, the terms "upper," "lower," "left," "right," "front," "rear," "top," "bottom," "inner," "outer," "middle," "vertical," "horizontal," "lateral," and "longitudinal" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. These terms are primarily for the purpose of better describing the invention and its embodiments, and are not intended to limit the indicated devices, elements, or components to having a specific orientation, or to be constructed and operated in a specific orientation.

[0031] Furthermore, in addition to indicating direction or positional relationship, some of the aforementioned terms may also have other meanings. For example, the term "above" may also be used in certain situations to indicate a dependency or connection. Those skilled in the art can understand the specific meaning of these terms in this invention based on the specific circumstances.

[0032] Furthermore, the terms "installation," "setup," "equipped with," "connection," and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral structure; 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, or an internal connection between two devices, components, or parts. Those skilled in the art can understand the specific meaning of these terms in this invention based on the specific circumstances.

[0033] Furthermore, the terms "first," "second," etc., are primarily used to distinguish different devices, elements, or components (which may be the same or different in specific type and construction), and are not intended to indicate or imply the relative importance or quantity of the indicated devices, elements, or components. Unless otherwise stated, "a plurality of" means two or more.

[0034] The technical solution of the present invention will be further described below with reference to the embodiments and accompanying drawings.

[0035] Please refer to the embodiments of the present invention. Figures 1 to 9 As shown, a roller pressing device is designed for rolling powder into brick blanks, wherein the powder is preferably ceramic powder. The roller pressing device has a horizontal layout and mainly includes a first pressing component 1 and a second pressing component 2 arranged opposite to each other, as well as a frame for mounting these components.

[0036] The first pressing assembly 1 includes a first driving roller 11, a first forming roller 12, a first driven roller 13, a first pressure holding device 14, and a first steel strip 15 wound around these rollers. The first driving roller 11 is a power input component that provides driving force for the operation of the entire first steel strip 15.

[0037] The second pressing assembly 2 includes a second driving roller 21, a second forming roller 22, a second driven roller 23, a second pressure holding device 24, and a second steel strip 25 wound around these rollers. The first forming roller 12 is one of the core forming components, used to press against the second forming roller 22 to determine the thickness and surface morphology of the brick blank. The second driving roller 21 is synchronously driven with the first driving roller 11 to ensure that the linear speeds of the first steel strip 15 and the second steel strip 25 are consistent. The second forming roller 22 is paired with the first forming roller 12 to jointly complete the compaction and forming of the powder.

[0038] In order to maintain pressure on the molded brick blanks to slowly release their internal stress, such as Figure 1 , Figure 2 , Figure 3 As shown, a set of the first pressure-holding device 14 and the second pressure-holding device 24 are provided, located above and below the brick blank 5 respectively, and fixed to the frame. The first pressure-holding device 14 specifically includes a pressure-holding cylinder 141, a pressure-holding beam 142, and a first pressure-holding component assembly 143. The cylinder body of the pressure-holding cylinder 141 is fixed to the frame, and the output end of the pressure-holding cylinder 141 is connected to the pressure-holding beam 142 to drive the first pressure-holding component assembly 143 to perform upward and downward movements, and to provide the resistance force required for the release of the brick blank 5 after molding. The pressure-holding beam 142 transmits the force of the pressure-holding cylinder 141 and distributes it evenly to the first pressure-holding component assembly 143.

[0039] like Figure 2 , Figure 3 As shown, the first pressure-holding component assembly 143 includes, from top to bottom, a first pressure-holding component 1431, a first floating plate 1432, and a first wear-resistant component 1433 stacked on top of each other. The upper part of the first pressure-holding component 1431 is fixedly connected to the pressure-holding beam 142. The first wear-resistant component 1433 is in direct contact with the first steel belt 15, and the first steel belt 15 applies the pressure-holding force to the brick blank 5 below. The second pressure-holding device 24 includes a second pressure-holding plate assembly 241 disposed opposite to the first pressure-holding device 14. The second pressure-holding plate assembly 241 includes, from top to bottom, a second wear-resistant plate 2411 and a second limiting plate 2412 stacked on top of each other, for providing stable support force to the lower part of the brick blank 5.

[0040] To achieve precise local pressure control and flexibly adapt to brick blanks of different widths, such as... Figure 3As shown, a guide mechanism 1434, such as a guide rod and guide groove, guide column, or guide cylinder, is provided between the first pressure-holding member 1431 and the first floating plate 1432 to ensure that the two can move relative to each other in the vertical direction and remain stable. The ends of the guide mechanism 1434 are provided with anti-detachment structures, such as a baffle at the guide groove or a stop at the end of the guide column, to prevent the first floating plate 1432 from detaching from the first pressure-holding member 1431 during movement. Preferably, at least two guide mechanisms 1434 are provided, and in this embodiment, they are provided at both ends of the first pressure-holding member 1431. A reciprocating drive member container is formed between the two guide mechanisms 1434, and the reciprocating drive member 1435 is disposed within this container. As a specific form of the reciprocating drive member 1435, a piston is used in this embodiment.

[0041] See Figure 4-7 As shown, the reciprocating drive unit 1435 is provided with at least one row, and each row is provided with at least one. When multiple rows are provided, it is along the conveying direction of the brick blank 5 (i.e., Figure 3 The components are arranged side-by-side in the left-right direction (i.e., the second direction). In this embodiment, multiple reciprocating drive components 1435 are arranged side-by-side along the first direction, and each reciprocating drive component 1435 acts on the same first wear-resistant component 1433. The reciprocating drive components 1435 in the same row are provided with a uniform working pressure by the pneumatic control unit 4 to ensure that the pressure holding pressure in the first direction of the brick blank 5 is uniform. When multiple rows of reciprocating drive components 1435 are arranged along the second direction, the working pressure of the reciprocating drive components 1435 in different rows can be set to different values. For example, the pressure is higher at the beginning and the pressure can be gradually reduced later, thereby realizing the stress gradient release along the second direction. The first pressure holding component 1431, the first floating plate 1432, and the reciprocating drive components 1435 together constitute a pneumatic actuation unit. When the reciprocating drive component 1435 is activated, it pushes the first floating plate 1432 and the first wear-resistant component 1433 to float up and down relative to the first pressure holding component 1431.

[0042] To precisely control the movement of the reciprocating drive 1435, each reciprocating drive 1435 is connected to a pneumatic control unit 4. For example... Figure 8 , Figure 9 As shown, the pneumatic control unit 4 includes an air inlet switch 41, a pressure regulating valve 42, a pressure sensor 43, an air tank 44, pipelines 45, and multiple control valves 46 corresponding to the reciprocating drive components 1435. The air inlet switch 41 controls the on / off state of the main air supply. The pressure regulating valve 42 provides a uniform working pressure to all connected reciprocating drive components. This pressure can be adjusted manually or automatically controlled by the controller based on the reading from the pressure sensor 43, ensuring the uniformity and consistency of the holding pressure. The air tank 44 stores compressed air, buffering pressure fluctuations in the system to ensure pressure stability and prevent abnormal operation of the first wear-resistant component due to pressure instability. The air tank 44 can be configured with one (e.g., Figure 8 shown in the figure, it is arranged on the main pipeline upstream of the control valve 46), or may be arranged in plurality (as Figure 9 shown in the figure, arranged on the branch pipelines downstream of each control valve 46), or arranged both upstream and downstream. The plurality of control valves 46 independently control the on-off of the gas circuit of each reciprocating driving member 1435. In addition, a third position detection unit 7 for monitoring the position of the reciprocating driving member 1435, that is, the relative position between the first floating plate 1432 and the first pressure holding member 1431, is further arranged on the first pressure holding member 1431, for example, a gap detection sensor.

[0043] As Figure 8 shown in the figure, when it is required to produce a brick blank 5 with a specific width W1, the pneumatic control unit 4 can only open the control valves 46 of the reciprocating driving members 1435 within the corresponding width W2 according to the width of the brick blank 5, so that W2≤W1, and ensure that the distance between one side edge of the brick blank 5 and the outer edge of the reciprocating driving member 1435 that is closest to the edge and is opened , and 0mm<X≤120mm, for example, X=50mm.

[0044] It should be noted that the unopened reciprocating driving members 1435 can be set to return to a high position by default, that is, not in contact with the first floating plate 1432. Of course, they can also be set to apply no pressure, so that they are in a natural relaxed state, that is, in contact with the first floating plate 1432, but do not apply pressure to the first floating plate 1432.

[0045] The core principle of this arrangement is: if W1<W2, that is, the opening width of the reciprocating driving members is greater than the width of the brick blank 5, there is no support of the brick blank 5 under the reciprocating driving members located outside the width range of the brick blank 5. When these reciprocating driving members press downward, they will press down both sides of the first wear-resistant member 1433, causing the first wear-resistant member 1433 to bend and deform, resulting in insufficient pressure holding pressure in the edge area of the brick blank 5, failure to fully release stress, and ultimately leading to cracks on the edge of the brick blank 5. By setting W2≤W1, it is ensured that there is the brick blank 5 as a support under all opened reciprocating driving members, thereby ensuring the uniformity and effectiveness of pressure holding, and solving the problem of edge cracks of the brick blank 5. This design enables that when the roll pressing equipment switches production to products with different widths, it only needs to change parameters in the control system and select to open the corresponding reciprocating driving members, without replacing any mechanical parts, which greatly improves the production switching efficiency and the universality of the roll pressing equipment.

[0046] In order to realize rapid and accurate return of the reciprocating driving members, the present invention also configures a vacuum generating device 47 for the reciprocating driving members. As Figure 8As shown, the vacuum generating device 47 (such as a vacuum generator or vacuum pump) is connected to the gas path of the reciprocating drive component 1435. That is, each control valve 46 is connected to the gas source through a general vacuum generator and a vacuum control valve to complete the return operation of the reciprocating drive component 1435. When the reciprocating drive component 1435 needs to return, the vacuum generating device 47 is activated to evacuate the cavity of the reciprocating drive component, creating a negative pressure. This quickly overcomes residual pressure and mechanical resistance, generating strong suction to accelerate the return of the reciprocating drive component and shorten the action time. Furthermore, the negative pressure environment effectively avoids problems such as return vibration, incomplete return, or inaccurate reset caused by residual pressure or gas compressibility, ensuring that the first wear-resistant part 1433 can accurately reset each time, providing a stable and reliable initial state for the next pressure holding cycle, and significantly improving the stability and control accuracy of the roller pressing equipment.

[0047] To achieve a high degree of automation and precise control, this roll forming equipment also integrates an advanced control system and sensors. The control unit 8, such as a PLC or industrial computer, is the brain of the entire roll forming equipment. It connects and coordinates the control of various actuators, such as the pressure holding cylinder 141, the drive cylinder of the first forming roller 12, the pneumatic control unit 4, and the detection sensors.

[0048] To precisely control the dynamic process of forming and holding pressure, the roller pressing equipment is equipped with multiple position detection units. The first position detection unit (not shown), such as a magnetostrictive displacement sensor or a grating ruler, is used to detect the position A of the first forming roller 12, which is determined by the target thickness of the brick blank 5. The second position detection unit (not shown) is used to detect the position B of the first holding pressure device 14, specifically detecting the position of the reciprocating drive rod of the holding pressure cylinder 141, thereby determining the vertical position of the entire first holding pressure assembly 143. In addition, a third position detection unit 7 is provided to monitor the stroke H2 of the reciprocating drive 1435 (i.e., the displacement of the first floating plate 1432 relative to the first holding pressure component 1431, the stroke range of which is determined by the mechanical structure, for example, 2mm-6mm). Of course, in some embodiments, when the roller pressing equipment's drive is sufficiently precise, position detection units may not be required.

[0049] In order to ensure absolute operational safety of the rolling equipment, the present invention sets a safety control logic. A safety threshold SH is preset in the system, and the safety threshold SH is determined based on the structural distance S0 in a reference state. The reference state is defined as: the vertical distance H1 between the bottom end of the first wear-resistant member 1433 and the bottom end of the first forming roller 12 is 0, the stroke H2 of the reciprocating drive member 1435 is 0, and the extension line of the tangential line at the bottommost part of the first forming roller 12 is tangent to the bottommost end of the first pressure holding device 14. At this time, the minimum distance between the first forming roller and the first pressure holding device along the third direction is S0, and the third direction is a direction perpendicular to the horizontal plane. The safety threshold SH satisfies: SH < S0 - 3 mm, so as to ensure a safety margin of at least 3 mm.

[0050] It should be noted that in the reference state, the bottommost end of the first pressure holding device is tangent to the extension line of the tangential line at the bottommost part of the first forming roller, but the two do not actually contact each other, and a certain gap is reserved therebetween. The initial gap is recorded as S0, and S0 > 3 mm. The safety threshold SH satisfies SH < S0 - 3 mm, so as to ensure that the actual gap between the first forming roller and the first pressure holding device is always greater than 3 mm during the operation of the rolling equipment.

[0051] The control unit 8 is configured to: control the first pressure holding device 14 to move to a target position B according to the position A of the first forming roller 12, the preset height difference H1 and the stroke H2 of the reciprocating drive member 1435, so that the first wear-resistant member 1433 presses the brick blank 5 through the stroke H2; and satisfy the relational expressions: SH + H1 + H2 = S0, 0 mm ≤ H1 ≤ 5 mm, and 2 mm ≤ H2 ≤ 6 mm. The control unit 8 also monitors the difference between the actual position B of the first pressure holding device 14 and the position A of the first forming roller 12. When B - A < SH, it indicates that the distance between the first pressure holding device 14 and the first forming roller 12 is too short and there is a collision risk. The control unit immediately issues an alarm or directly triggers an emergency shutdown command, thereby effectively protecting the safety of the rolling equipment.

[0052] In conclusion, through the cooperative control of the first forming roller and the first pressure holding device by the control unit 8, the reciprocating drive member pressure holding units with consistent pressure in the same row and capable of achieving gradient change among multiple rows, as well as precise reference and safety control logic, the rolling equipment of the present embodiment effectively solves the problems of inaccurate stress release, difficult production changeover and safety risks existing in rolling equipment, significantly improves the forming quality and production efficiency of the brick blank 5, and can flexibly adapt to the production requirements of various specifications of high-quality building materials.

[0053] The present invention also relates to a rolling method of a rolling device, which is applied to the foregoing rolling device, and realizes high-quality and high-efficiency production of brick blanks 5 through precise step control and parameter setting. The method mainly comprises the following steps: S1: forming and pressure holding step: The first pressing assembly 1 and the second pressing assembly 2 are driven to roll-form the distributed powder material. In the pressure holding stage, the holding pressure is applied to the brick blank 5 by the first wear-resistant member 1433. Wherein, part of the reciprocating driving members 1435 in the first direction of the first pressure holding device 14 are selectively started according to the width of the brick blank 5, and the orthographic projection of the started reciprocating driving members 1435 on the brick blank 5 does not exceed the range of the brick blank 5.

[0054] During the pressure holding process, the control unit 8 executes the following dynamic control sub-steps: S11: Position acquisition and cooperative control: The position A of the first forming roller 12 is determined according to the target thickness of the brick blank 5. A preset safety threshold SH is acquired, and the safety threshold SH is determined based on the structural distance S0 in the reference state. During the operation of the rolling equipment, the control unit 8 determines the target position of the first pressure holding device 14 according to the position A of the first forming roller 12, the preset height difference H1 and the stroke H2 of the reciprocating driving member 1435, and controls the first pressure holding device 14 to move to the target position. Wherein, the height difference H1 is the vertical distance between the bottom end of the first wear-resistant member 1433 and the bottom end of the first forming roller 12, which satisfies 0mm≤H1≤5mm; the stroke H2 is the actual extension amount of the reciprocating driving member 1435, which satisfies 2mm≤H2≤6mm; and the relational expression SH+H1+H2=S0 is satisfied.

[0055] S12: Safety monitoring: The control unit 8 monitors the actual position B of the first pressure holding device 14, and calculates the difference between the actual position B and the position A of the first forming roller 12. When B-A<SH, an alarm or shutdown instruction is issued.

[0056] Step 2: Continuous pressure holding and blank discharging step: In the normal production process, the first pressure holding device 14 maintains a set position, and the holding pressure applied by the reciprocating driving member 1435 through the first wear-resistant member 1433 continuously acts on the moving brick blank 5. After passing under the first pressure holding device 14, the brick blank 5 naturally completes the pressure holding process, then continues to move forward along with the second steel belt 25, and enters subsequent processes such as cutting, drying and firing. When it is necessary to switch production to brick blanks with different thicknesses or handle abnormal conditions (such as brick blank defects, equipment failures), the control unit 8 drives the first pressure holding device 14 to lift and lower as a whole through the pressure holding oil cylinder 141, so as to precisely adjust its vertical position to adapt to new process requirements.

[0057] Throughout the pressure holding process, the reciprocating drive component 1435 typically remains extended to maintain a stable pressure. When pressure needs to be released (e.g., during shutdown maintenance, abnormal handling, or production adjustment), the vacuum generator 47 is activated to evacuate the reciprocating drive component cavity, causing the reciprocating drive component 1435 to quickly and smoothly retract to the predetermined position. This avoids return jitter, lag, or incomplete positioning caused by gas compressibility or residual pressure, ensuring a precise and consistent starting state for the next startup.

[0058] Through the above methods, this roller pressing equipment achieves a high degree of automation and precise control throughout the entire process from forming to pressure holding. Consistent pressure in the same row and gradient pressure control across multiple rows ensure precise stress release along the second direction; collaborative control algorithms and safety logic prevent collisions within the roller pressing equipment. These technologies work together to solve problems such as cracks, deformation, and poor flatness caused by uneven stress release in the roller pressing process, significantly improving the yield and quality stability of the brick blanks 5, and flexibly meeting the market's demand for diverse, high-quality ceramic brick blanks.

[0059] The technical means disclosed in this invention are not limited to those disclosed in the above embodiments, but also include technical solutions composed of any combination of the above technical features. It should be noted that those skilled in the art can make various improvements and modifications without departing from the principles of this invention, and these improvements and modifications are also considered within the scope of protection of this invention.

Claims

1. A roller pressing device, characterized in that, A tool for rolling powder into brick blanks includes a first pressing component and a second pressing component arranged opposite to each other. The first pressing component includes a first forming roller and a first pressure holding device. The first pressure holding device includes a first pressure holding component, a first wear-resistant component movably disposed on the first pressure holding component, and a plurality of reciprocating drive components arranged side by side along a first direction. The reciprocating drive components are arranged in multiple rows along a second direction. Each of the reciprocating drive components acts on the first wear-resistant component, and the pressure of the reciprocating drive components in the same row is consistent. The first direction is the width direction of the powder laying, and the second direction is the conveying direction of the powder. The rolling equipment also includes a control unit configured to coordinate the displacement of the first forming roller and the first pressure holding device.

2. The roller pressing equipment according to claim 1, characterized in that, The reciprocating drive component is a piston, and each piston is connected to a pneumatic control unit. The pneumatic control unit is communicatively connected to the control unit. The pneumatic control unit independently controls the air passage of each piston and provides a uniform working pressure to all connected pistons.

3. The roller pressing equipment according to claim 2, characterized in that, The pneumatic control unit includes: Multiple control valves are connected between each piston and the air source for individually controlling the opening and closing of each piston and the air source. A pressure regulating valve, connected between each of the control valves and the air source, for providing uniform pressure to all the pistons; and A gas cylinder for stabilizing pressure, the gas cylinder being connected between the pressure regulating valve and the control valve, or the gas cylinder being connected between the control valve and each of the pistons; The first pressure-holding component is also provided with a third position detection unit for monitoring the position of the reciprocating drive component.

4. The roller pressing equipment according to claim 1, characterized in that, Let the width of the brick blank be W1. Along the first direction, the distance between the outermost edges of the two outermost reciprocating drive components among all activated reciprocating drive components is W2. Then, the distance between one edge of the brick blank and the outer edge of the nearest activated reciprocating drive component is... , and 0mm <X≤120mm。 5. The roller pressing equipment according to claim 1, characterized in that, The first pressure holding device is provided with multiple rows of reciprocating drive members along the second direction. Each row of reciprocating drive members is arranged in parallel along the first direction. The working pressure of the reciprocating drive members in different rows can be set to different values ​​and varies in a gradient along the second direction.

6. The roller pressing equipment according to claim 1, characterized in that, The roller pressing equipment has a preset safety threshold SH, which satisfies: SH <S0-3mm; Wherein, the vertical distance H1 between the bottom end of the first wear-resistant part and the bottom end of the first forming roller is set to 0, the stroke H2 of the reciprocating drive part is set to 0, and the extension line of the bottommost tangent of the first forming roller is tangent to the bottommost end of the first pressure holding device. At this time, the minimum distance between the first forming roller and the first pressure holding device along the third direction is S0, where the third direction is the direction perpendicular to the horizontal plane.

7. The roller pressing equipment according to claim 6, characterized in that, The control unit is configured to: Based on the position A of the first forming roller, the preset height difference H1, and the stroke H2 of the reciprocating drive component, the first pressure holding device is controlled to move to the target position B, so that the first wear-resistant component presses the brick blank through the stroke H2. Furthermore, it satisfies the following relationships: SH+H1+H2=S0, and 0mm≤H1≤5mm, 2mm≤H2≤6mm; Wherein, the height difference H1 is the vertical distance between the bottom end of the first wear-resistant part and the bottom end of the first forming roller, and the stroke H2 is the actual extension amount of the reciprocating drive part.

8. A rolling pressing method, characterized in that, Applied to the roll pressing apparatus according to any one of claims 1-7, comprising: Molding and pressure maintaining step: driving a first pressing assembly and a second pressing assembly to perform roll molding on laid powder; in the pressure maintaining stage, a first wear-resistant member applies a pressure maintaining force to a brick blank; wherein, part of reciprocating driving members in a first direction of a first pressure maintaining device are selectively started according to the width of the brick blank, and the orthographic projection of the started reciprocating driving members on the brick blank does not exceed the range of the brick blank.

9. The rolling method according to claim 8, characterized in that, The molding and pressure maintaining step further comprises: determining the position A of a first molding roller according to the target thickness of the brick blank; acquiring a preset safety threshold SH, wherein the safety threshold SH is determined based on the structural distance S0 in a reference state; during the operation of the roll pressing apparatus, the control unit determines the target position of the first pressure maintaining device according to the position A of the first molding roller, a preset height difference H1 and the stroke H2 of the reciprocating driving member, and controls the first pressure maintaining device to move to the target position; wherein, the height difference H1 is the vertical distance between the bottom end of the first wear-resistant member and the bottom end of the first molding roller, which satisfies 0mm≤H1≤5mm; the stroke H2 is the actual extension amount of the reciprocating driving member, which satisfies 2mm≤H2≤6mm; and the relational expression: SH+H1+H2=S0 is satisfied.

10. The rolling method according to claim 9, characterized in that, The molding and pressure maintaining step further comprises: the control unit monitors the actual position B of the first pressure maintaining device, calculates the difference between the actual position B and the position A of the first molding roller, and issues an alarm or shutdown instruction when B-A<SH.

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