A liquid level control method and device for automatic filling of a steel pouring brick refractory glaze

Abstract

The present application relates to the technical field of liquid level control for automatic filling of steel pouring brick refractory glaze, and discloses a liquid level control method and device for automatic filling of steel pouring brick refractory glaze, wherein the liquid level control method for automatic filling of steel pouring brick refractory glaze comprises the following steps: step one, setting of a steel pouring brick weighing threshold value; step two, setting of a rotary disc rotation angle threshold value; and step three, automatic control of the liquid level during the steel pouring brick refractory glaze filling operation. The liquid level control device for automatic filling of steel pouring brick refractory glaze comprises: a proximity switch fixedly arranged on one side of the lower part of an electromagnetic valve; the steel pouring brick is vertically placed on a rotary disc; the rotary disc is fixedly arranged at the middle position of a support; and a weighing mechanism is uniformly arranged at equal angles around the periphery of the rotary disc. The present application has the following beneficial effects: 1. accurate determination of the liquid level of the refractory glaze in the steel pouring brick is achieved; and 2. the filling weight can be accurately measured while the refractory glaze in the steel pouring brick is accurately determined.

Description

Technical Field

[0001] This invention relates to the field of liquid level control technology for automatic filling of refractory glaze for cast steel bricks, and particularly to a liquid level control method and device for automatic filling of refractory glaze for cast steel bricks. Background Technology

[0002] Steel casting bricks are refractory bricks specifically designed for steel casting applications. They belong to the category of special refractory materials used in the metallurgical industry. Their core function is to construct channels through which molten steel flows during the steel casting process (such as tundish nozzles and pouring channels), withstanding the scouring, erosion, and sudden temperature changes of the high-temperature molten steel, thus ensuring the stable progress of the steel casting operation. Spraying refractory glaze onto steel casting bricks primarily aims to improve the surface's resistance to corrosion and ensure its thermal shock stability.

[0003] Patent No. 202410320608.6, entitled "Automatic Filling and Coating Device for Refractory Glaze for Casting Steel Bricks," discloses a servo turntable with a circular disc structure and through holes arranged in a circular array along its edge for placing the cast steel bricks. A large gear is fixedly connected to the lower end of the main shaft in the center of the turntable. The large gear is connected to a servo motor below the gear platform via a gear shaft. The servo motor drives a small gear to rotate, and through gear meshing, it drives the large gear and the servo turntable to rotate intermittently, realizing the switching of multiple casting steel brick positions. This, combined with a feeding device, completes continuous automated coating operations with high positioning accuracy. The above solution uses laser to accurately position the position of the casting steel brick to be coated and the liquid level of the glaze to be filled, precisely controlling the feeding timing and amount, ensuring the uniformity of glaze filling and coating, and avoiding errors caused by manual operation. The main technical problems with the aforementioned existing technology are: 1. During the filling and spraying of refractory glaze, glaze dust and splattered glaze droplets are continuously generated, which easily adhere to the surface of the laser ranging probe, obstructing the laser beam path and causing deviations in laser ranging. This makes it impossible to accurately detect the true liquid level in the storage chamber, ultimately resulting in too much or too little glaze being filled, affecting the coating quality of the cast steel bricks; 2. Laser ranging can only determine the liquid level by the liquid surface height and cannot directly obtain the weight of the discharged glaze. An additional metering device is required to control the amount of glaze used in a single cast steel brick, increasing the structural complexity and manufacturing cost of the equipment, making it impossible to simultaneously measure the filling weight of the cast steel bricks. Based on the above-mentioned defects in the existing technology, the inventor has developed a liquid level control method and device for automatic filling of refractory glaze for cast steel bricks, which can effectively solve the above-mentioned problems in the existing technology. Summary of the Invention

[0004] To address the problems in the prior art, this invention provides a liquid level control method and device for automatic filling of refractory glaze for steel bricks. The invention has a scientific and reasonable structural design. It uses the weighing threshold of the steel bricks and refractory glaze as the judgment signal of the refractory glaze liquid level, and realizes the automatic filling operation of refractory glaze for steel bricks through the linkage automatic control of the PLC control module.

[0005] This invention provides a liquid level control device for automatic filling of refractory glaze for cast steel bricks, including a support, a glaze tank, and a storage cylinder. The support is fixedly installed on the workshop floor, and the glaze tank is fixedly installed at the bottom center of the support. The glaze tank is a hollow, closed cuboid. The storage cylinder is fixedly installed at the top center of the support. The upper part of the glaze pumping pipe is fixedly connected to the right side of the storage cylinder, and the bottom of the glaze pumping pipe is fixedly connected to the upper center of the glaze tank. The upper end of the filling pipe is fixedly installed at the bottom of the storage cylinder, and the bottom of the filling pipe extends to the upper front side of the rotating disk. A solenoid valve is fixedly installed at the filling cylinder. The bottom of the material pipe is located at the lower part; a proximity switch is fixedly installed on the lower side of the solenoid valve, and the proximity switch is fixedly connected to the bottom surface of the material pipe; the steel bricks are placed vertically on the rotating disk; the rotating disk is fixedly installed in the middle of the support, and the weighing mechanism is evenly arranged at equal angles around the circumference of the rotating disk, and the weighing mechanism is fixed on the upper part of the rotating disk; the control system is fixedly installed in the middle of the right side of the support; the recovery cylinder is fixedly installed in the middle of the left side of the support, the upper part of the recovery pipe is fixedly connected to the bottom of the recovery cylinder, and the lower part of the recovery cylinder is fixedly connected to the upper middle part of the glaze box.

[0006] The support system includes a base frame, which is fixedly installed on the workshop floor. An upper frame is fixedly installed on the base frame, and a top frame is fixedly installed at the upper center of the upper frame. A recycling cylinder support frame is fixedly installed on the upper left side of the base frame. A glaze box is fixedly installed in the middle of the base frame. A rotating disc is fixedly installed at the bottom center of the upper frame. A storage cylinder is fixedly installed at the upper center of the top frame, and a recycling cylinder is vertically fixedly installed on the recycling cylinder support frame.

[0007] The glaze tank is equipped with a pump, and the pump outlet is fixedly connected to the bottom of the glaze pumping pipe. The pump in the glaze tank pumps the canned refractory glaze into the storage cylinder through the glaze pumping pipe.

[0008] The solenoid valve is fixedly connected to the PLC control module of the control system via a signal line.

[0009] The rotating disk includes a fixed plate, which is fixedly mounted at the center of the upper frame. The inner ring of the slewing bearing is fixedly mounted at the center of the fixed plate, and the outer ring of the slewing bearing is fixedly mounted at the center of the rotating disk body. A gear ring is fixedly mounted on the outer circumferential wall of the outer ring of the slewing bearing. The protective cover is cylindrical and fixedly mounted at the upper center of the rotating disk body. A stepper motor is fixedly mounted at the bottom left side of the fixed plate. The power output shaft of the stepper motor extends through the fixed plate to the upper position, and the drive gear is fixedly mounted at the upper end of the power output shaft of the stepper motor. The center of the encoder is mounted on the bottom power output shaft of the stepper motor. The encoder is fixedly connected to the bottom housing of the stepper motor through a connecting bracket and is fixedly connected to the PLC control module through a signal line.

[0010] The weighing mechanism includes a placement tray, which is circular with a central groove, and symmetrically fixed support ears on both sides of the placement tray. A steel brick is placed in the circular groove of the placement tray for weighing. A mounting screw is fixedly installed at the center of the bottom of the shell, and the shell is tightened and fixed to the rotating disk body by the mounting screw. The shell is a cylindrical shape with an open top and a closed bottom, and the ventilation slots are strip-shaped and evenly spaced around the outer wall of the shell at equal angles. Four weighing sensors are fixedly installed on the inner wall of the shell at equal angles. An elastic support column is fixedly installed on one side of the sensing head, and the elastic support column is used to buffer the gravitational impact of the placement tray and the steel brick.

[0011] The weighing sensor includes a weighing sensor body, a mounting bracket fixedly mounted on the outside of the weighing sensor body, and the weighing sensor body is fixedly mounted on the inner wall of the shell cylinder through the mounting bracket; a signal line slot is located at the upper middle position of the inner side of the weighing sensor body, and a sensing head is located at the upper center of the weighing sensor body. The signal line slot is used for plugging in and fixing the signal line; the weighing sensor is fixedly connected to the PLC control module through the signal line.

[0012] The elastic support column includes a lower support plate, and both the lower and upper support plates are disc-shaped. The lower support plate is fixedly installed on the upper part of the weighing sensor body and is horizontally aligned with the sensing head. The support column is vertically fixedly installed at the upper center of the lower support plate, and a limiting ring is fixedly installed at the lower position of the support column. The outer diameter of the limiting ring is larger than the diameter of the support column. A spring is fitted onto the support column, with the bottom of the spring fixed to the upper part of the limiting ring, and the upper support plate is fixedly installed on the upper part of the spring.

[0013] The height of the elastic support column is greater than the height of the sensor head.

[0014] The control system includes a support plate, which is fixedly mounted on the left side of the control panel and is fixedly connected to the front right side of the upper frame; a display screen is mounted on the upper front side of the control panel and is fixedly connected to the PLC control module via signal lines, and the PLC control module is fixedly mounted inside the rear side of the control panel.

[0015] The placement tray is placed on the upper support tray of the elastic support column of the weighing sensor, and a flexible silicone pad is laid in the circular groove of the placement tray.

[0016] This invention provides a liquid level control method for automatic filling of refractory glaze for steel bricks, comprising:

[0017] Step 1: Setting the weighing threshold for cast steel bricks: Based on the weight of the same batch of cast steel bricks (the weight of the same batch of cast steel bricks is the same standard weight), test the weight of the same batch of cast steel bricks when filled with refractory glaze. Then, set the weight of the cast steel bricks when filled with refractory glaze through the display screen of the control system. Finally, save the set weighing threshold for cast steel bricks.

[0018] Step 2: Setting the rotation angle threshold of the rotating disk: Ten weighing mechanisms are set at equal angles along the circumference of the rotating disk. A steel brick is placed on the placement plate of each weighing mechanism. The operator sets the rotation angle threshold of the rotating disk to 36° through the display screen according to the number of steel bricks and weighing mechanisms, and saves the set rotation angle threshold.

[0019] Step 3: Automatic control of liquid level during the filling of refractory glaze for steel bricks: First, the operator places the steel bricks on the weighing mechanism's placement tray, and lays a flexible silicone pad in the circular groove of the placement tray. Then, the operator presses the start button for automatic filling of refractory glaze on the control system's display screen. The PLC control module sends a start control command to the stepper motor of the rotating disk. The stepper motor starts rotating and drives the drive gear to rotate counterclockwise through the power output shaft. The counterclockwise rotation of the drive gear and the meshing of the gear ring drive the gear ring to rotate clockwise, which in turn drives the rotating disk to rotate through the slewing bearing. When the power output shaft rotates to an angle of 36°, the encoder transmits the detected rotation angle signal and the signal from the proximity switch sensing the steel brick to the PLC control module. After receiving the dual signals from the encoder and proximity switch, the PLC control module sends a stop control signal to the stepper motor. The rotating disk stops rotating, and at this time, the steel brick is directly below the filling pipe. Simultaneously, the PLC control module... A control command to open is sent to the solenoid valve, and the filling pipe pours refractory glaze into the cast steel brick. When the weighing sensor at the bottom of the cast steel brick reads the weight of the cast steel brick and refractory glaze, and the weight reaches the threshold set by the PLC control module, the cast steel brick is filled with refractory glaze. Simultaneously, the PLC control module sends a start-rotation control signal to the stepper motor and a close-rotation control signal to the solenoid valve, causing the solenoid valve to close. The stepper motor then performs a second rotation... Finally, the rotating disc body continues to rotate 36° to carry out the refractory glaze filling operation for the next steel brick. By repeating the above actions, the refractory glaze filling operation for all steel bricks on the rotating disc body can be completed. After all steel bricks have been filled with refractory glaze, a uniform glaze layer is formed on the inner wall of the steel bricks. Finally, the operator holds the support ears on both sides of the placement disc to remove all the steel bricks, pours the excess refractory glaze into the recycling cylinder, and returns the refractory glaze to the glaze box through the recycling pipe.

[0020] The beneficial effects of this invention are as follows: By setting up a glaze tank, storage cylinder, rotating disk, weighing mechanism, control system, recovery cylinder, and recovery pipe, and using an encoder to detect the rotation angle of the stepper motor to achieve rotational switching of the position of the steel brick on the rotating disk, the position signal of the steel brick detected by the proximity switch is used as a dual signal determination of the steel brick position by the PLC control module. Based on the weighing threshold of the steel brick, the PLC control module determines the liquid level of the refractory glaze in the steel brick by weighing the steel brick and refractory glaze in real time through the weighing sensor. Then, the PLC control module uses the automatic start and stop control of the solenoid valve and the stepper motor to realize the automatic filling of refractory glaze into the steel brick on the rotating disk; 1. It realizes the accurate judgment of the liquid level of the refractory glaze in the steel brick; 2. It can accurately measure the filling weight while accurately judging the refractory glaze in the steel brick. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the structure of the present invention;

[0022] Figure 2 This is a cross-sectional view of the rotating disk and the base frame of the present invention;

[0023] Figure 3 For the present invention Figure 2 Enlarged partial cross-sectional view of the stepper motor, encoder, drive gear and gear ring;

[0024] Figure 4 This is an exploded view of the weighing mechanism of the present invention;

[0025] Figure 5 This is a diagram showing the internal structure of the weighing mechanism of the present invention;

[0026] Figure 6 This is a schematic diagram of the weighing sensor and elastic support column of the present invention;

[0027] The diagram shows the following components: 1. Support frame; 11. Base frame; 12. Upper frame; 13. Top frame; 14. Recycling cylinder support frame; 2. Glaze tank; 3. Storage cylinder; 4. Glaze pump pipe; 5. Filling pipe; 6. Solenoid valve; 7. Proximity switch; 8. Casting brick; 9. Rotary disc; 91. Fixed plate; 92. Slewing bearing; 93. Rotary disc body; 94. Protective cover; 95. Stepper motor; 96. Power output shaft; 97. Encoder; 98. Drive gear; 99. Gear ring; 10. Weighing mechanism; 101. Placement tray; 102. Support lug; 103. 104. Shell, 105. Mounting screw, 106. Ventilation slot, 107. Weighing sensor, 1061. Weighing sensor body, 1062. Mounting bracket, 1063. Signal wire slot, 1064. Sensor head, 107. Elastic support column, 1071. Lower support plate, 1072. Upper support plate, 1073. Support column, 1074. Limit ring, 1075. Spring, 11. Control system, 111. Support plate, 112. Control panel, 113. Display screen, 114. PLC control module, 12. Recycling cylinder, 13. Recycling pipe. Detailed Implementation

[0028] The present invention will be further described below with reference to specific embodiments. These embodiments are only used to illustrate the present invention and are not intended to limit the scope of the present invention.

[0029] This invention provides a liquid level control method and device for automatic filling of refractory glaze for steel bricks:

[0030] like Figure 1 As shown, the support frame 1 is fixedly installed on the workshop floor. The support frame 1 includes a base frame 11, which is fixedly installed on the workshop floor. The upper frame 12 is fixedly installed on the base frame 11. The top frame 13 is fixedly installed at the upper center of the upper frame 12. The recycling cylinder support frame 14 is fixedly installed on the upper left side of the base frame 11. The glaze box 2 is fixedly installed in the middle position of the base frame 11. The rotating disk 9 is fixedly installed at the bottom center of the upper frame 12. The storage cylinder 3 is fixedly installed at the upper center of the top frame 13. The recycling cylinder 12 is vertically fixedly installed on the recycling cylinder support frame 14.

[0031] The aforementioned arrangement of the base frame 11, upper frame 12, and top frame 13 forms a layered structure for the support 1. The base frame 11 serves two purposes: firstly, it provides fixed support for the upper frame 12, top frame 13, and the recycling cylinder support frame 14; secondly, it provides space for the fixed installation of the glaze tank 2. The upper frame 12 provides space for the fixed installation of the rotating disc 9, and the filling of the refractory glaze for the steel bricks 8 also takes place within the space of the upper frame 12. The top frame 13 provides a platform for the fixed installation of the storage cylinder 3. The recycling cylinder support frame 14 provides stable support for the fixed installation of the recycling cylinder 12.

[0032] like Figure 1As shown, the glaze tank 2 is a hollow, closed cuboid; the storage cylinder 3 is fixedly installed at the top center of the support 1; the upper part of the glaze pumping pipe 4 is fixedly connected to the right side of the storage cylinder 3, and the bottom of the glaze pumping pipe 4 is fixedly connected to the upper center of the glaze tank 2. The purpose of this arrangement is to use the pump in the glaze tank 2 to pump the glaze in the glaze tank 2 to the storage cylinder 3 at regular intervals through the coordinated arrangement of the glaze tank 2, the storage cylinder 3, and the glaze pumping pipe 4; the pump can be controlled by setting the timed start-up control time in the PLC control module 114, which can automatically control the start and stop of the pump at regular intervals to realize the timed delivery of glaze from the glaze tank 2 to the storage cylinder 3.

[0033] like Figure 1 As shown, the upper end of the filling pipe 5 is fixedly installed at the bottom of the storage cylinder 3, and the bottom of the filling pipe 5 extends to the upper front side of the rotating disk 9; the solenoid valve 6 is fixedly installed at the lower bottom of the filling pipe 5.

[0034] The main purpose of the above setup is to utilize the gravity of the refractory glaze in the storage cylinder 3 so that when the PLC control module 114 automatically controls the solenoid valve 6 to open, the refractory glaze in the storage cylinder 3 can be filled into the cast iron brick 8 through the filling pipe 5, thereby realizing the filling-type molding of the refractory glaze on the inner wall of the cast iron brick 8.

[0035] like Figure 1 As shown, the proximity switch 7 is fixedly installed on the lower side of the solenoid valve 6, and the proximity switch 7 is fixedly connected to the bottom surface of the filling pipe 5. The main purpose of this arrangement is that, through the proximity switch 7 and the dual signal action of the rotation angle value detected by the encoder 97 of the rotary disk 9, the specific position of the steel brick 8 can be determined, thereby improving the reliability of the positioning of the steel brick 8 (in the event of a failure of the proximity switch 7 or the encoder 97, the normal operation of the refractory glaze filling of the steel brick 8 can be maintained).

[0036] like Figure 1 , 2As shown in Figure 3, the cast steel brick 8 is placed vertically on the rotating disk 9. The rotating disk 9 is fixedly installed in the middle of the support 1. The rotating disk 9 includes a fixed plate 91, which is fixedly installed in the center of the upper frame 12. The inner ring of the slewing bearing 92 is fixedly installed in the center of the fixed plate 91, and the outer ring of the slewing bearing 92 is fixedly installed in the center of the rotating disk body 93. The gear ring 99 is fixedly installed on the outer circumference of the outer ring of the slewing bearing 92. The protective cover 94 is cylindrical and is fixedly installed in the upper center of the rotating disk body 93. The stepper motor 95 is fixedly installed on the bottom left side of the fixed plate 91. The power output shaft 96 of the stepper motor 95 extends through the fixed plate 91 to the upper position. The drive gear 98 is fixedly installed at the upper end of the power output shaft 96 of the stepper motor 95. The center of the encoder 97 is installed on the bottom power output shaft 96 of the stepper motor 95. The encoder 97 is fixedly connected to the bottom housing of the stepper motor 95 through a connecting bracket. The encoder 97 is fixedly connected to the PLC control module 114 through a signal line.

[0037] The aforementioned slewing bearing 92, gear ring 99, stepper motor 95, encoder 97, drive gear 98, and power output shaft 96 are configured to automatically control the rotation position of the cast steel brick 8 by using the encoder 97 to detect the rotation angle of the turntable body 93, and using the PLC control module 114 to automatically start and stop the stepper motor 95.

[0038] like Figure 1 , 2 As shown in Figures 4 and 5, the weighing mechanism 10 is evenly arranged at equal angles around the circumference of the rotating disk 9, and is fixed to the upper part of the rotating disk 9. The weighing mechanism 10 includes a placement plate 101, which is a circle with a circular groove at its center. Support ears 102 are symmetrically fixed on both sides of the placement plate 101. The steel brick 8 is placed in the circular groove of the placement plate 101 for weighing. A mounting screw 104 is fixedly installed at the bottom center of the shell cylinder 103, and the shell cylinder 103 is tightened and fixed to the rotating disk 9 by the mounting screw 104. On the turntable body 93; the shell 103 is a cylindrical shape with an open top and a closed bottom, the ventilation slot 105 is strip-shaped, and the ventilation slot 105 is evenly and equally angled around the outer wall of the shell 103; the weighing sensor 106 is fixedly installed on the inner wall of the shell 103, and four weighing sensors 106 are fixedly installed on the inner wall of the shell 103 at equal angles; the elastic support column 107 is fixedly installed on one side of the sensing head 1064, and the elastic support column 107 is used to buffer the gravity impact of the placement plate 101 and the steel brick 8.

[0039] With the aforementioned placement tray 101 and support ears 102, when the refractory glaze is being poured, the steel brick 8 is placed on the placement tray 101, and a silicone pad is laid in the circular groove of the placement tray 101. The silicone pad, with its own flexible properties, plays a role in sealing the bottom of the steel brick 8, preventing the refractory glaze from leaking from the bottom edge of the steel brick 8. At the same time, the support ears 102 make it convenient for operators to place or pick up the steel brick 8.

[0040] The aforementioned arrangement of the shell 103 and ventilation slot 105 provides space for fixing the load cell 106 and a cavity for heat dissipation. The ventilation slot 105 dissipates the heat emitted by the load cell 106, thus achieving the function of heat dissipation.

[0041] The aforementioned configuration of the weighing sensor 106 and the elastic support column 107 allows the weighing sensor 106 to measure the weight of the refractory glaze in the cast steel brick 8 in real time. This achieves both weighing of the refractory glaze in the cast steel brick 8 and, by comparing the weighing threshold of the cast steel brick 8 set in the PLC control module 114 with the real-time detected weight, determining whether the refractory glaze in the cast steel brick 8 is full. This provides control signals for the PLC control module 114 to automatically control the stepper motor 95 and the solenoid valve 6. The elastic support column 107 ensures that when the placement tray 101 and the cast steel brick 8 are placed on the weighing sensor 106, the placement tray 101 first contacts the elastic support column 107. At this time, the elastic support column 107 uses its own elastic force to provide flexible support for the placement tray 101 and the cast steel brick 8, preventing the weight of the placement tray 101 and the cast steel brick 8 from directly impacting the sensing head 1064 of the weighing sensor 106 and damaging the weighing sensor 106.

[0042] like Figure 6 As shown, the elastic support column 107 includes a lower support plate 1071, and both the lower support plate 1071 and the upper support plate 1072 are disc-shaped. The lower support plate 1071 is fixedly installed on the upper part of the weighing sensor body 1061 and is horizontally corresponding to the sensing head 1064. The support column 1073 is vertically fixedly installed at the upper center of the lower support plate 1071. The limiting ring 1074 is fixedly installed at the lower position of the support column 1073, and the outer diameter of the limiting ring 1074 is larger than the diameter of the support column 1073. The spring 1075 is fitted on the support column 1073, and the bottom of the spring 1075 is fixed to the upper part of the limiting ring 1074. The upper support plate 1072 is fixedly installed on the upper part of the spring 1075.

[0043] The aforementioned arrangement of the lower support plate 1071 and the upper support plate 1072 allows the elastic support column 107 to be fixed to the load cell body 1061 using the lower support plate 1071; while the upper support plate 1072 provides stable flexible support for the placement plate 101, preventing the sensing head 1064 of the load cell 106 from being damaged by the gravity impact of the placement plate 101 or the cast iron brick 8.

[0044] like Figure 1 As shown, the control system 11 includes a support plate 111, which is fixedly mounted on the left side of the control panel 112 and is fixedly connected to the front right side of the upper frame 12; the display screen 113 is mounted on the upper front side of the control panel 112 and is fixedly connected to the PLC control module 114 via signal lines; the PLC control module 114 is fixedly mounted inside the rear side of the control panel 112.

[0045] The above settings are made via the display screen 113. Operators can set the weighing threshold for steel bricks and the rotation angle threshold for the rotary table via the display screen 113, and then save them in the control system 11.

[0046] The above-mentioned settings of the PLC control module 114 can utilize the sensing signals detected by the proximity switch 7 and the encoder 97 as control signals to determine the position of the steel brick 8 on the rotating disk 9, and at the same time realize the automatic start and stop control of the stepper motor 95.

[0047] The above-mentioned settings of PLC control module 114 compare the weight threshold of cast steel brick with the weight signal detected in real time by weighing sensor 106. When the weight of cast steel brick 8 and refractory glaze detected in real time reaches the weight threshold of cast steel brick, it is determined whether the refractory glaze inside cast steel brick 8 is filled, thereby realizing automatic control of the liquid level for automatic filling of refractory glaze in cast steel brick.

[0048] like Figure 1 The recovery cylinder 12 is fixedly installed at the middle left side of the support 1. The upper part of the recovery pipe 13 is fixedly connected to the bottom of the recovery cylinder 12, and the lower part of the recovery cylinder 12 is fixedly connected to the middle upper part of the glaze box 2. The main purpose of this arrangement is that after the steel bricks are completely filled, the operator can recover the excess refractory glaze from the steel bricks 8 into the glaze box 2 through the recovery cylinder 12 and the recovery pipe 13, thus achieving the recycling of the refractory glaze.

[0049] like Figure 1-6 As shown, the present invention provides a liquid level control method for automatic filling of refractory glaze for steel bricks, comprising:

[0050] Step 1: Setting the weighing threshold of cast steel bricks: Based on the weight of cast steel bricks 8 in the same batch (the weight of cast steel bricks 8 in the same batch is the same standard weight), test the weight of cast steel bricks 8 in the same batch when filled with refractory glaze, and then set the weight of cast steel bricks when filled with refractory glaze through the display screen 113 of the control system 11. Finally, save the set weighing threshold of cast steel bricks 8.

[0051] Step 2: Setting the rotation angle threshold of the rotating disk: Ten weighing mechanisms 10 are set at equal angles along the circumference of the rotating disk 9. A steel brick 8 is placed on the placement plate 101 of each weighing mechanism 10. The operator sets the rotation angle threshold of the rotating disk 9 to 36° through the display screen 113 according to the number of steel bricks 8 and weighing mechanisms 10, and saves the set rotation angle threshold.

[0052] Step 3: Automatic control of liquid level during the filling operation of refractory glaze for steel bricks: First, the operator places the steel bricks 8 on the placement tray 101 of the weighing mechanism 10, and lays a flexible silicone pad in the circular groove of the placement tray 101; then, the operator presses the start button for automatic filling of refractory glaze through the display screen 113 of the control system 11. The PLC control module 114 sends a control command to start the rotation of the stepper motor 95 of the rotating disk 9. The stepper motor 95 starts to rotate, and drives the drive gear 98 to rotate counterclockwise through the power output shaft 96. The transmission meshing action of the gear ring 99 drives the gear ring 99 to rotate clockwise, which in turn drives the rotating disk to rotate through the slewing bearing 92. When the power output shaft 96 rotates to an angle of 36°, the encoder 97 transmits the detected rotation angle signal and the signal from the proximity switch 7 sensing the steel brick 8 to the PLC control module 114. After receiving the dual signals from the encoder 97 and the proximity switch 7, the PLC control module 114 sends a stop rotation control signal to the stepper motor 95, and the rotating disk body 93 stops rotating. At this time, the steel brick 8 is exactly rotated to the position directly below the filling pipe 5. At the same time, the PLC control... The control module 114 sends an opening control command to the solenoid valve 6, and the filling pipe 5 fills the cast steel brick 8 with refractory glaze. When the weighing sensor 106 of the weighing mechanism 10 at the bottom of the cast steel brick 8 weighs and reads the weight values ​​of the cast steel brick 8 and the refractory glaze, when the weight value reaches the casting steel brick weighing threshold set by the PLC control module 114, the cast steel brick 8 is filled with refractory glaze. At the same time, the PLC control module 114 sends a start rotation control signal to the stepper motor 95, and simultaneously sends a close control signal to the solenoid valve 6, solenoid valve 6 closes; the stepper motor 95... The rotation action eventually causes the rotating disk body 93 to continue rotating by 36°, and the refractory glaze filling operation for the next steel brick 8 is carried out. By repeating the above action, the refractory glaze filling operation for all steel bricks 8 on the rotating disk body 93 can be completed. After all steel bricks 8 have been filled with refractory glaze, a uniform glaze layer is formed on the inner wall of the steel bricks 8. Finally, the operator holds the support ears 102 on both sides of the placement plate 101 to remove all the steel bricks 8, pours the excess refractory glaze into the recovery cylinder 12, and returns the refractory glaze to the glaze box 2 through the recovery pipe 13.

[0053] Various modifications to the above embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be adapted to the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A liquid level control method for automatic filling of refractory glaze for steel bricks, characterized in that: Step 1: Setting the weighing threshold for cast steel bricks: Based on the weight of cast steel bricks in the same batch (the weight of cast steel bricks in the same batch is the same standard weight), test-weigh the same batch of cast steel bricks when fully filled with refractory glaze. Then, set the weight of the cast steel bricks when fully filled with refractory glaze through the display screen of the control system, and finally save the set weighing threshold for cast steel bricks; Step 2: Setting the rotation angle threshold for the rotating disk: Ten weighing mechanisms are set at equal angles along the circumference of the rotating disk. One cast steel brick is placed on the placement plate of each weighing mechanism. The operator sets the rotation angle threshold of the rotating disk to 36° through the display screen according to the number of cast steel bricks and weighing mechanisms, and saves the set rotation angle threshold; Step 3: Setting the rotation angle threshold for the rotating disk; Step 4: Setting the rotation angle threshold for the rotating disk: Based on the number of cast steel bricks and weighing mechanisms, the operator sets the rotation angle threshold of the rotating disk to 36° through the display screen, and saves the set rotation angle threshold; Step 5: Setting the rotation angle threshold for the rotating disk; Step 6: Setting the rotation angle threshold for the rotating disk; Step 7: Setting the rotation angle threshold for the rotating disk; Step 8: Setting the rotation angle threshold for the rotating disk; Step 9: Setting the rotation angle threshold for the rotating disk; Step 10: Setting the rotation angle threshold for the rotating disk; Step 11: Setting the rotation angle threshold for the rotating disk; Step 12: Setting the rotation angle threshold for the rotating disk; Step 13: Setting the rotation angle threshold for the rotating disk; Step 14: Setting the rotation angle threshold for the rotating disk; Step 15: Setting the rotation angle threshold for the rotating disk; Step 16: Setting the rotation angle threshold for the rotating disk; Step 17: Setting the rotation angle threshold for the rotating disk; Step 18: Setting the rotation angle threshold for the rotating disk; Step 19: Setting the rotation angle threshold for the rotating disk; Step 10: Setting the rotation angle threshold III. Automatic Level Control During the Refractory Glaze Filling Operation for Steel Bricks: First, the operator places the steel bricks onto the weighing mechanism's placement tray, and lays a flexible silicone pad in the circular groove of the tray. Then, the operator presses the start button for automatic refractory glaze filling on the control system's display screen. The PLC control module sends a start control command to the stepper motor of the rotating disk. The stepper motor begins to rotate, driving the drive gear counterclockwise via the power output shaft. The counterclockwise rotation of the drive gear meshes with the gear ring, driving the gear ring clockwise. This, in turn, drives the rotating disk through the slewing bearing. When the power output shaft rotates to 36°, the encoder detects the rotation level. The rotation angle signal and the proximity switch, sensing the signal from the steel brick, are transmitted together to the PLC control module. Upon receiving both signals from the encoder and proximity switch, the PLC control module sends a stop signal to the stepper motor, halting the rotation of the rotating disk. At this point, the steel brick is directly below the filling pipe. Simultaneously, the PLC control module sends an open control command to the solenoid valve, allowing the filling pipe to fill the steel brick with refractory glaze. When the weighing sensor at the bottom of the steel brick reads the weight of the steel brick and refractory glaze, and the weight reaches the steel brick weighing threshold set by the PLC control module, the steel brick is fully filled with refractory glaze. At the same time, the PLC control module... A control signal to start rotation is sent to the stepper motor, while the PLC control module sends a control signal to close the solenoid valve, causing the solenoid valve to close. The stepper motor's secondary rotation action ultimately drives the rotating disk body to continue rotating by 36°, allowing for the next refractory glaze filling operation on the steel brick. This process is repeated to complete the refractory glaze filling operation on all the steel bricks on the rotating disk body. After all the steel bricks have been filled with refractory glaze, a uniform glaze layer is formed on the inner wall of the steel bricks. Finally, the operator holds the support ears on both sides of the placement tray to remove all the steel bricks, pours the excess refractory glaze into the recycling cylinder, and returns the refractory glaze to the glaze box through the recycling pipe.

2. A liquid level control device for automatic filling of refractory glaze for steel bricks, comprising a support, a glaze tank, and a storage cylinder; the support is fixedly installed on the workshop floor, the glaze tank is fixedly installed at the bottom center of the support, and the glaze tank is a hollow, closed cuboid; the storage cylinder is fixedly installed at the top center of the support, the upper part of the glaze pumping pipe is fixedly connected to the right side of the storage cylinder, and the bottom of the glaze pumping pipe is fixedly connected to the upper center of the glaze tank; characterized in that: The upper end of the filling pipe is fixedly installed at the bottom of the storage cylinder, and the bottom of the filling pipe extends to the upper front side of the rotating disk; the solenoid valve is fixedly installed at the lower bottom of the filling pipe; the proximity switch is fixedly installed on the lower side of the solenoid valve, and the proximity switch is fixedly connected to the bottom surface of the filling pipe; the steel bricks are placed vertically on the rotating disk; the rotating disk is fixedly installed in the middle of the support, and the weighing mechanism is evenly arranged at equal angles around the circumference of the rotating disk, and the weighing mechanism is fixed on the upper part of the rotating disk; the control system is fixedly installed in the middle right side of the support; the recovery cylinder is fixedly installed in the middle left side of the support, the upper part of the recovery pipe is fixedly connected to the bottom of the recovery cylinder, and the lower part of the recovery cylinder is fixedly connected to the middle upper part of the glaze box.

3. The liquid level control device for automatic filling of refractory glaze for steel bricks according to claim 2, characterized in that: The support system includes a base frame, which is fixedly installed on the workshop floor. An upper frame is fixedly installed on the base frame, and a top frame is fixedly installed at the upper center of the upper frame. A recycling cylinder support frame is fixedly installed on the upper left side of the base frame. A glaze box is fixedly installed in the middle of the base frame. A rotating disc is fixedly installed at the bottom center of the upper frame. A storage cylinder is fixedly installed at the upper center of the top frame, and a recycling cylinder is vertically fixedly installed on the recycling cylinder support frame.

4. The liquid level control device for automatic filling of refractory glaze for cast steel bricks according to claim 2, characterized in that: A pump is installed in the glaze tank, and the pump outlet is fixedly connected to the bottom of the glaze pumping pipe. The pump in the glaze tank pumps the canned refractory glaze into the storage cylinder through the glaze pumping pipe. The solenoid valve is fixedly connected to the PLC control module of the control system through a signal line.

5. The liquid level control device for automatic filling of refractory glaze for cast steel bricks according to claim 2, characterized in that: The rotating disk includes a fixed plate, which is fixedly mounted at the center of the upper frame. The inner ring of the slewing bearing is fixedly mounted at the center of the fixed plate, and the outer ring of the slewing bearing is fixedly mounted at the center of the rotating disk body. A gear ring is fixedly mounted on the outer circumferential wall of the outer ring of the slewing bearing. The protective cover is cylindrical and fixedly mounted at the upper center of the rotating disk body. A stepper motor is fixedly mounted at the bottom left side of the fixed plate. The power output shaft of the stepper motor extends through the fixed plate to the upper position, and the drive gear is fixedly mounted at the upper end of the power output shaft of the stepper motor. The center of the encoder is mounted on the bottom power output shaft of the stepper motor. The encoder is fixedly connected to the bottom housing of the stepper motor through a connecting bracket and is fixedly connected to the PLC control module through a signal line.

6. The liquid level control device for automatic filling of refractory glaze for steel bricks according to claim 2, characterized in that: The weighing mechanism includes a placement tray, which is circular with a central groove, and symmetrically fixed support ears on both sides of the placement tray. A steel brick is placed in the circular groove of the placement tray for weighing. A mounting screw is fixedly installed at the center of the bottom of the shell, and the shell is tightened and fixed to the rotating disk body by the mounting screw. The shell is a cylindrical shape with an open top and a closed bottom, and the ventilation slots are strip-shaped and evenly spaced around the outer wall of the shell at equal angles. Four weighing sensors are fixedly installed on the inner wall of the shell at equal angles. An elastic support column is fixedly installed on one side of the sensing head, and the elastic support column is used to buffer the gravitational impact of the placement tray and the steel brick.

7. The liquid level control device for automatic filling of refractory glaze for steel bricks according to claim 6, characterized in that: The weighing sensor includes a weighing sensor body, a mounting bracket fixedly mounted on the outside of the weighing sensor body, and the weighing sensor body is fixedly mounted on the inner wall of the shell cylinder through the mounting bracket; a signal line slot is located at the upper middle position of the inner side of the weighing sensor body, and a sensing head is located at the upper center of the weighing sensor body. The signal line slot is used for plugging in and fixing the signal line; the weighing sensor is fixedly connected to the PLC control module through the signal line.

8. The liquid level control device for automatic filling of refractory glaze for steel bricks according to claim 6, characterized in that: The elastic support column includes a lower support plate, and both the lower and upper support plates are disc-shaped. The lower support plate is fixedly installed on the upper part of the weighing sensor body and is horizontally aligned with the sensing head. The support column is vertically fixedly installed at the upper center of the lower support plate, and a limiting ring is fixedly installed at the lower position of the support column. The outer diameter of the limiting ring is larger than the diameter of the support column. A spring is fitted onto the support column, with the bottom of the spring fixed to the upper part of the limiting ring, and the upper support plate is fixedly installed on the upper part of the spring.

9. The liquid level control device for automatic filling of refractory glaze for steel bricks according to claim 2, characterized in that: The control system includes a support plate, which is fixedly mounted on the left side of the control panel and is fixedly connected to the front right side of the upper frame; a display screen is mounted on the upper front side of the control panel and is fixedly connected to the PLC control module via signal lines, and the PLC control module is fixedly mounted inside the rear side of the control panel.

10. The liquid level control device for automatic filling of refractory glaze for cast steel bricks according to claim 6, characterized in that: The placement tray is placed on the upper support tray of the elastic support column of the weighing sensor, and a flexible silicone pad is laid in the circular groove of the placement tray.

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