A six-head loading operation system for a tunnel kiln combined with an electric control mode

Abstract

The application discloses a tunnel kiln six-head loading operation system combined with an electric control mode, which comprises a rack platform, a PLC controller and a touch display screen, four mounting shells are installed on the rack platform, and a first loading material package shell is arranged at the left side of two mounting shells located at the front and rear sides. The six groups of loading execution units are respectively matched with independent screw motors, screw frequency converters and rotational speed encoders, and are matched with independent integrated degassing pipelines, material level meters and air vibration structures. Global synchronization and six-station asynchronous double-mode switching are realized through the PLC matched with the touch display screen. In the asynchronous mode, the rotational speed of the screw feeder, the height of the loading material package shell, the degassing negative pressure and the air vibration time length of any station can be adjusted independently. Process parameters are independently matched for different bulkiness powders and different specifications of the sagger. The loading weight, the powder compactness and the uniformity of each station are greatly improved. The defects of unified parameters of the multi-head equipment and large discrete color difference of the finished products are effectively solved. The sintering good product rate is significantly improved.

Description

Technical Field

[0001] This invention relates to the field of tunnel kiln technology, specifically to a six-head loading operating system for tunnel kilns combined with an electronic control method. Background Technology

[0002] In the tunnel kiln sintering production process of ultrafine powders such as lithium battery cathodes, ceramics, and graphite, the powder needs to be uniformly filled into a sagger before being sent into the tunnel kiln for continuous high-temperature sintering. The density and uniformity of the powder filling directly determine the consistency of the sintered product. Currently, the filling equipment in the industry is mainly divided into two categories: single-head filling machines and multi-head synchronous filling machines.

[0003] Traditional single-head filling equipment has low capacity and can only fill one sagger at a time. It cannot match the continuous feeding cycle of tunnel kiln production lines. When producing in large quantities, multiple machines need to be arranged in parallel, which occupies a large area of ​​workshop space. The equipment purchase and maintenance costs are high, making it difficult to adapt to the needs of large-scale mass production.

[0004] Traditional multi-head filling equipment often adopts a unified electrical control architecture for the whole machine. The six sets of screw feeding and lifting mechanisms share a common main frequency converter and a unified negative pressure degassing circuit. The parameters of the six stations are forced to be adjusted synchronously. It is impossible to set the screw speed, feeding height and degassing negative pressure separately for different sagger specifications and powder fluffiness. The filling weight and powder density of each station have large deviations, and the color difference and performance dispersion of the sintered product are prominent problems.

[0005] Existing multi-head equipment lacks independent single-station fault isolation electrical control logic. When any group of screw motors, lifting motors, degassing pipelines, or material level sensors experiences overload, blockage, or abnormal signal faults, the entire filling system will shut down, the entire tunnel kiln production line will stop, and the high-temperature saggers inside the kiln will be prone to overburning and scrapping due to prolonged retention, resulting in huge production capacity and material losses. To address this, we provide a tunnel kiln six-head filling operating system combined with an electrical control method. Summary of the Invention

[0006] The purpose of this invention is to provide a six-head loading operating system for tunnel kilns combined with an electronic control method to solve the problems mentioned in the background art.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a six-head loading operating system for a tunnel kiln, comprising a frame platform, a PLC controller, and a touch screen display. Four mounting shells are installed on the frame platform. A first loading shell is provided on the left side of the two mounting shells located on the front and rear sides, and a second loading shell is provided on the left side of the two mounting shells located in the middle position. A total of six loading execution units are provided on the first and second loading shells. One loading execution unit is provided on the first loading shell, and two loading execution units are provided on the second loading shell. Each loading execution unit includes a screw motor, and the screw motor is equipped with a screw frequency converter and a speed encoder.

[0008] The mounting housing is provided with a lifting drive assembly, which includes a fixed housing. The fixed housing is installed on the top of the mounting housing. A dual-axis motor is installed on the inner wall of the fixed housing. The dual-axis motor is provided with a lifting frequency converter and a braking relay. The dual-axis motor has a built-in electromagnetic braking coil. The electromagnetic braking coil is electrically connected to the corresponding braking relay. Drive sprockets are installed on the surfaces of the output shafts on both sides of the dual-axis motor.

[0009] Optionally, the filling execution unit includes a first sealing cover and a second sealing cover. There are two first sealing covers, which are respectively installed on the top of two first filling packing shells. There are two second sealing covers, which are respectively installed on the top of two second filling packing shells. A first support frame is installed on the top of the first sealing cover, and a second support frame is installed on the top of the second sealing cover.

[0010] Optionally, the number of screw motors is six, and they are respectively installed on the top of two first support frames and two second support frames. One set of screw motors is provided on the top of the first support frame, and two sets of screw motors are provided on the top of the second support frame. The bottom end of the output shaft of the screw motor on the first support frame passes through the first sealing cover and extends into the interior of the first packing shell, and the bottom end of the output shaft of the screw motor on the second support frame passes through the second sealing cover and extends into the interior of the second packing shell.

[0011] Optionally, the bottom of the first packing shell and the bottom of the second packing shell are respectively equipped with an upper degassing pipe that communicates with them. The bottom end of the upper degassing pipe is equipped with a lower degassing pipe that communicates with it. A two-way solenoid valve and a negative pressure sensor are installed on the lower degassing pipe. The top of the first sealing cover and the top of the second sealing cover are both equipped with connecting pipes that communicate with them.

[0012] Optionally, a stirring rod is installed at the bottom end of the output shaft of the screw motor, a level gauge is installed on the left side of both the first and second packing shells, and an air vibration structure is installed at the bottom of the left side of both the first and second packing shells.

[0013] Optionally, a counterweight is provided inside the mounting housing, and a transmission chain is installed on the top of the counterweight corresponding to the position of the drive sprocket. Two brackets are installed on the inner wall of the fixed housing, and a rotating shaft is rotatably connected to the two brackets through two bearings. A guide sprocket is installed on the surface of the rotating shaft corresponding to the position of the drive sprocket. The end of the transmission chain away from the counterweight passes through the mounting housing, the drive sprocket, the guide sprocket, and the fixed housing in sequence and extends to the outside of the fixed housing. The ends of the two transmission chains on the same side away from the counterweight are fixedly connected by an adjusting plate.

[0014] Optionally, the bottom of the four adjustment plates is fixedly connected to two first support frames and two second support frames. Two guide sliders are installed on the right side of the adjustment plates, and a guide rail that is slidably connected to the guide sliders is installed on the left side of the mounting shell at the position corresponding to the guide sliders.

[0015] Optionally, the PLC controller is electrically connected to the lifting frequency converter, braking relay, screw frequency converter, two-way solenoid valve, negative pressure sensor, level gauge, air vibration structure and touch screen display screen via communication lines. The touch screen display screen is equipped with a six-station parameter editing area, synchronous switching button, asynchronous switching button and partitioned fault display area. The PLC controller has built-in timing storage program and fault isolation program. The fault isolation program is used to cut off the power supply circuit of all electrical components of a single loading execution unit when the corresponding electrical component fails, while keeping the power supply circuit of other stations connected.

[0016] Optionally, the PLC controller receives the screw motor encoder speed signal and has built-in quantitative adjustment hardware logic, which can independently adjust the output frequency of each screw frequency converter. The level gauge transmits high and low level switch signals to the PLC controller. The PLC controller has built-in two-level interlocking hardware logic, corresponding to the two output signals of material shortage indication and material overflow power-off, respectively. The PLC controller collects the current signals of each dual-axis motor and screw motor and the values ​​of each negative pressure sensor in real time. The touch screen displays fault information of each station separately in partitions.

[0017] A six-head loading electrical control method for a tunnel kiln, the method being used in the aforementioned six-head loading operating system for the tunnel kiln, includes the following steps:

[0018] S1. Workstation parameter setting steps: The operator selects the global synchronous mode or the six-station asynchronous mode through the touch screen. In the synchronous mode, the six filling execution units share the same set of parameters, including screw speed, lifting stroke, integrated negative pressure pipeline negative pressure, air vibration duration, and single box filling weight. In the asynchronous mode, each filling execution unit is independently set with screw motor speed, dual-axis motor lifting height, integrated negative pressure pipeline negative pressure, air vibration structure start and stop duration, and filling quantity threshold. Each set of parameters is stored independently and does not interfere with each other.

[0019] S2. Pre-degassing step of the silo: The PLC controller retrieves the built-in timing program, opens the double-way solenoid valve on the corresponding work station, the negative pressure sensor collects the pressure of the entire pipeline in real time, the PLC controller adjusts the negative pressure of the pipeline in a closed loop, and pre-degasses the loose powder inside the first and second packing shells.

[0020] S3. Loading Linkage Drive Steps: After the kiln furniture is conveyed to the PLC controller, multiple sets of electrical control actions are executed synchronously. The screw frequency converter is started to drive the screw motor. The powder discharge weight is controlled by the speed encoder in a closed loop. The stirring rod stirs and disperses the powder synchronously. The integrated negative pressure pipeline keeps the air ventilated and continuously completes the secondary sealing and degassing. The air vibration structure is started as needed to assist in feeding and avoid powder bridging and blockage. The dual-shaft motor is started, and the adjustment plate and support frame are moved downward along the guide rail through the drive sprocket and transmission chain. After reaching the preset height, the brake relay conducts the electromagnetic brake coil to lock the dual-shaft motor and stop the lifting action.

[0021] S4. Material level classification and interlocking control steps: The material level gauge continuously collects the material height inside the material bag shell in real time and uploads the signal to the PLC controller. When a low material level signal is detected, the PLC controller controls the corresponding screw frequency converter to reduce the frequency and decelerate and pause the lifting action. The touch screen displays a pop-up window to remind the user to replenish the material. When a high material level overflow signal is detected, the PLC controller immediately cuts off the output of the screw frequency converter in this group, closes the double-way solenoid valve on the corresponding station, shuts down the air vibration structure, and simultaneously outputs an audible and visual overflow alarm.

[0022] S5. Single-station fault isolation operation steps: The PLC controller continuously collects the operating current of four dual-axis motors and six screw motors, as well as the pressure values ​​of six sets of negative pressure sensors in real time. If any filling execution unit experiences motor overload, pipeline blockage, negative pressure abnormality, or material level exceeding the limit, the PLC controller will only cut off the power supply circuit of all electrical components in that station, and the corresponding station area on the touch screen will be highlighted with the fault. The other five filling execution units will complete the filling process completely, and the continuous production line of the tunnel kiln will not be interrupted.

[0023] S6. Cyclic and Fault Reset Steps: After the powder filling of a single set of kiln furniture is completed, the PLC controller controls the dual-axis motor to reverse the lifting adjustment plate to reset, waiting for the next kiln furniture to be fed. The cycle of all processes from S2 to S5 is executed. After the faulty workstation is repaired, the operator issues a fault reset command on the touch screen, and all electrical components of the workstation are restored to controlled operation.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0025] 1. The present invention provides six filling execution units, each equipped with an independent screw motor, screw frequency converter and speed encoder, and independent integrated degassing pipeline, material level gauge and air vibration structure. Through PLC and touch screen display, it realizes global synchronous and six-station asynchronous dual-mode switching. In asynchronous mode, the screw feeding speed, filling shell height, degassing negative pressure and air vibration duration can be adjusted for any station individually. The process parameters are independently matched for powders with different fluffiness and different sagger sizes. The filling weight and powder density uniformity of each station are greatly improved, effectively solving the defects of unified parameters and large color difference of finished products in multi-head equipment, and significantly improving the sintering yield.

[0026] 2. In this invention, the bottom of each material bag shell is connected to the upper and lower degassing pipes to form an integrated negative pressure pipeline. Each pipeline is equipped with an independent double-way solenoid valve and a negative pressure sensor. During the pre-degassing stage of filling and the feeding stage, secondary sealed degassing is carried out in stages with continuous air extraction to fully remove air trapped inside the ultrafine powder, eliminating the problems of voids, stratification, and loose material inside the crucible. The negative pressure circuits of each station are independent of each other, and blockage of a single station pipeline will not cause negative pressure fluctuations in the entire line. The degassing effect is stable and reliable. In addition, the screw motor output end is equipped with a stirring rod, which works in conjunction with the air vibration structure to continuously disperse and vibrate the powder during the feeding process, effectively preventing the ultrafine powder from bridging and blocking, ensuring continuous and uniform screw feeding, reducing the frequency of downtime for cleaning, and increasing the continuous operation time of the equipment.

[0027] 3. The lifting drive assembly of this invention uses a dual-axis motor paired with a drive sprocket and transmission chain to drive the adjustment plate and support frame to lift as a whole. The discharge height can be flexibly adjusted according to the size of the sagger. The dual-axis motor has a built-in electromagnetic brake coil and is equipped with an independent brake relay. After reaching the set height, the motor is locked instantly, eliminating the problem of inertial slump in the lifting mechanism. The height of the six saggers is uniform, resulting in higher filling consistency. The counterweight balances the lifting load, reduces the operating load of the dual-axis motor, and extends the service life of the motor. At the same time, the equipment is equipped with a graded material level interlocking electrical control logic. The material level gauge provides real-time feedback of high and low material level signals. When the material level is low, the speed is automatically reduced to remind replenishment, avoiding the screw running idle and wasting raw materials by dust. When the material level is high, all station components such as the screw, degassing, and air vibration are shut down simultaneously to prevent powder overflow and accumulation, eliminate dust safety hazards, and make the workshop production environment cleaner. Attached Figure Description

[0028] Figure 1 This is a three-dimensional structural diagram of the present invention;

[0029] Figure 2 This is a three-dimensional structural diagram of the mounting shell, the first filling housing, the second filling housing, the filling execution unit, and the lifting drive assembly of the present invention.

[0030] Figure 3 This is a three-dimensional cross-sectional view of the mounting shell, the first filling housing, the second filling housing, the filling execution unit, and the lifting drive assembly of the present invention.

[0031] Figure 4 This is a three-dimensional cross-sectional view of the second filling material casing, the filling execution unit, and the lifting drive assembly of the present invention.

[0032] Figure 5 This is a three-dimensional structural diagram of the lifting drive component of the present invention.

[0033] In the diagram: 1. Frame platform; 100. Mounting shell; 101. First filling casing; 102. Second filling casing; 2. Filling execution unit; 21. First sealing cover; 22. Second sealing cover; 23. First support frame; 24. Second support frame; 25. Screw motor; 26. Upper degassing pipe; 27. Lower degassing pipe; 28. Stirring rod; 29. ​​Level gauge; 210. Air vibration structure; 200. Connecting pipe; 3. Lifting drive assembly; 31. Fixed shell; 32. Dual-shaft motor; 33. Drive sprocket; 34. Counterweight; 35. Transmission chain; 36. Bracket; 37. Rotating shaft; 38. Guide sprocket; 39. Adjusting plate; 310. Guide slide rail. Detailed Implementation

[0034] 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.

[0035] Please see Figure 1-5A six-head loading operating system for a tunnel kiln includes a frame platform 1, a PLC controller, and a touch screen display. The frame platform 1 is made of thickened Q235 carbon steel, bent and welded, and coated with wear-resistant and anti-corrosion epoxy paint. Several support legs are welded to the bottom of the frame platform 1, and a railing is welded to the top of the frame platform 1. The PLC controller and touch screen display are respectively mounted on the frame platform 1. Four mounting shells 100 are welded to the frame platform 1. The mounting shells 100 are made of cold-rolled steel plate and stamped, with reserved lifting cavities inside. A fixing shell 31 is welded to the top of the mounting shell 100. A dual-axis motor 32 is bolted to the inner wall of the fixed shell 31. The dual-axis motor 32 is equipped with a lifting frequency converter and a braking relay. The dual-axis motor 32 has a built-in electromagnetic braking coil, which is electrically connected to the corresponding braking relay. The dual-axis motor 32 is a dual-output shaft frequency converter motor with a cast aluminum shell. It provides lifting power for the entire lifting mechanism. When the power is cut off or the position is reached, the coil is energized and locked to eliminate the inertial downward movement. Drive sprockets 33 are installed on the surfaces of the output shafts on both sides of the dual-axis motor 32. The drive sprockets 33 are made of 45 steel and are hardened to be wear-resistant and impact-resistant. They are used to mesh with the transmission chain 35 to transmit lifting power.

[0036] The mounting housing 100 contains a counterweight 34, which is a cast iron component. This counterweight 34 balances the weight of the support frame and the material bag housing, reducing the operating load on the dual-shaft motor 32. A transmission chain 35, made of 45# alloy steel roller chain, is installed on the top of the counterweight 34, corresponding to the position of the drive sprocket 33. This chain transmits the lifting force. Two brackets 36 are mounted on the inner wall of the fixed housing 31. A rotating shaft 37 is rotatably connected to each bracket 36 via two bearings. A guide sprocket 38, made of 45# steel and hardened, is installed on the surface of the rotating shaft 37, corresponding to the position of the drive sprocket 33. This guide sprocket 38 is used to change the direction of the chain drive, ensuring smooth lifting motion. The end of the chain 35 away from the counterweight 34 passes through the mounting shell 100, drive sprocket 33, guide sprocket 38 and fixed shell 31 in sequence and extends to the outside of the fixed shell 31. The ends of the two transmission chains 35 on the same side away from the counterweight 34 are fixedly connected by the adjusting plate 39. The adjusting plate 39 is made of thickened carbon steel plate, which drives the entire set of material bag shells to lift synchronously. It can be adapted to different saggers to adjust the discharge height. During the descent process, the powder in the sagger is compacted synchronously. The fixed shell 31, dual-shaft motor 32, drive sprocket 33, counterweight 34, transmission chain 35, bracket 36, rotating shaft 37, guide sprocket 38, adjusting plate 39 and guide slide rail 310 constitute the lifting drive assembly 3.

[0037] Two guide sliders are welded and installed on the right side of the adjusting plate 39. A guide rail 310, which slides and connects to the guide sliders, is welded and installed on the left side of the mounting housing 100 at the position corresponding to the guide sliders. The guide rail 310 is made of wear-resistant carbon steel. The sliders slide in cooperation with the rail, limiting the lifting trajectory of the adjusting plate 39 and preventing left-right and front-back offset. A first support frame 23 is welded and installed at the bottom of the two adjusting plates 39 at the front and rear positions, and a second support frame 24 is welded and installed at the bottom of the two adjusting plates 39 at the middle position. Both the first support frame 23 and the second support frame 24 are made of carbon steel profiles and serve as the fixed bearing base for the screw motor 25. A first sealing cover 21 is welded and installed at the bottom of the first support frame 23, and the second support frame 24... A second sealing cover 22 is welded and installed at the bottom. Both the first sealing cover 21 and the second sealing cover 22 are made of 304 stainless steel plate. The top of the first sealing cover 21 and the top of the second sealing cover 22 are welded and installed with connecting pipes 200 that communicate with them. The connecting pipes 200 are made of 304 stainless steel round pipes and serve as powder feeding channels for external feeding and conveying equipment. The bottom of the first sealing cover 21 is bolted with a first filling shell 101, and the bottom of the second sealing cover 22 is bolted with a second filling shell 102. Both the first filling shell 101 and the second filling shell 102 are made of 304 stainless steel and are integrally stamped. They are resistant to wear from ultrafine powders and are not easy to rust. They serve as sealed silos for temporary storage and discharge of powders.

[0038] The bottom of the first packing housing 101 and the bottom of the second packing housing 102 are respectively welded and installed with an upper degassing pipe 26 that communicates with it. The bottom end of the upper degassing pipe 26 is welded and installed with a lower degassing pipe 27 that communicates with it. Both the upper degassing pipe 26 and the lower degassing pipe 27 are made of 304 stainless steel seamless pipe, forming an integrated negative pressure extraction pipeline. A double-way solenoid valve and a negative pressure sensor are installed on the lower degassing pipe 27. The first packing housing 101 and the second packing housing 102... A level gauge 29 is installed on the left side of the material bag shell 102. The level gauge 29 is a rotary paddle level sensor that collects high and low material level signals in the bin in real time and transmits them to the PLC controller to realize material shortage reminder and overflow power-off interlock. A pneumatic vibration structure 210 is installed at the bottom of the left side of the first filling bag shell 101 and the second filling bag shell 102. The pneumatic vibration structure 210 is a miniature pneumatic vibrator with a cast aluminum shell. The vibration acts on the side wall of the material bag shell to assist the powder to slide down and prevent material blockage and bridging.

[0039] A set of screw motors 25 is installed on the top of the first support frame 23. The screw motors 25 are variable frequency geared motors with cast aluminum housings and output shafts made of 45# tempered steel. Two sets of screw motors 25 are installed on the top of the second support frame 24. The bottom end of the output shaft of the screw motor 25 on the first support frame 23 passes through the first sealing cover 21 and extends into the interior of the first packing housing 101. The bottom end of the output shaft of the screw motor 25 on the second support frame 24 passes through the second sealing cover 22 and extends into the interior of the second packing housing 102. The screw motors 25 output… A stirring rod 28 is installed at the bottom of the output shaft. The bottom of the stirring rod 28 passes through the upper degassing pipe 26 and extends into the interior of the lower degassing pipe 27. The stirring rod 28 is made of wear-resistant 304 stainless steel bar with a polished surface. During rotation, it breaks up agglomerated powder to prevent powder bridging and clogging. The first sealing cover 21, the second sealing cover 22, the first support frame 23, the second support frame 24, the screw motor 25, the upper degassing pipe 26, the lower degassing pipe 27, the stirring rod 28, the level gauge 29, the air vibration structure 210, and the connecting pipe 200 constitute the filling execution unit 2.

[0040] The PLC controller is electrically connected to the lifting frequency converter, braking relay, screw frequency converter, double-way solenoid valve, negative pressure sensor, level gauge 29, air vibration structure 210, and touch screen display via communication lines. The touch screen display has a six-station parameter editing area, synchronous switching button, asynchronous switching button, and partitioned fault display area. The PLC controller has built-in timing storage program and fault isolation program. The fault isolation program is used to cut off the power supply circuit of all electrical components of a single loading execution unit 2 when a fault occurs, while the power supply circuits of other stations remain open. The PLC controller receives the encoder speed signal of screw motor 25 and has built-in quantitative adjustment hardware logic, which can independently adjust the output frequency of each group of screw frequency converters. The level gauge 29 transmits high and low level switch signals to the PLC controller. The PLC controller has built-in two-level interlocking hardware logic, corresponding to the two output signals of material shortage prompt and overflow power cut-off, respectively. The PLC controller collects the current signals of each dual-axis motor 32 and screw motor 25 and the values ​​of each negative pressure sensor in real time. The touch screen display displays the fault information of each station separately in partitioned areas.

[0041] An electrical control method for six-head loading in a tunnel kiln, the method being used in a six-head loading operating system for a tunnel kiln, includes the following steps:

[0042] S1. Workstation parameter setting steps: The operator selects the global synchronous mode or the six-station asynchronous mode through the touch screen. In the synchronous mode, the six filling execution units 2 share the same set of parameters, including screw speed, lifting stroke, integrated negative pressure pipeline negative pressure, air vibration duration, and single box filling weight. In the asynchronous mode, each filling execution unit 2 is independently set with screw motor 25 speed, dual-axis motor 32 lifting height, integrated negative pressure pipeline negative pressure, air vibration structure 210 start and stop duration, and filling quantity threshold. Each set of parameters is stored independently and does not interfere with each other.

[0043] S2. Pre-degassing step of the silo: The PLC controller retrieves the built-in timing program, opens the double-way solenoid valve on the corresponding work station, the negative pressure sensor collects the pressure of the entire pipeline in real time, the PLC controller adjusts the negative pressure of the pipeline in a closed loop, and pre-degassing the loose powder inside the first filling shell 101 and the second filling shell 102.

[0044] S3. Loading Linkage Drive Steps: After the kiln furniture is delivered to the PLC controller, multiple sets of electrical control actions are executed synchronously. The screw frequency converter is started to drive the screw motor 25. The powder discharge weight is controlled by the speed encoder in a closed loop. The stirring rod 28 stirs and disperses the powder synchronously. The integrated negative pressure pipeline keeps the air ventilated and continuously completes the secondary sealing and degassing. The air vibration structure 210 is started as needed to assist in feeding and avoid powder bridging and blockage. The dual-shaft motor 32 is started. Through the drive sprocket 33 and the transmission chain 35, the adjusting plate 39 and the support frame are moved downward along the guide rail 310. After reaching the preset height, the brake relay conducts the electromagnetic brake coil to lock the dual-shaft motor 32 and stop the lifting action.

[0045] S4. Material level classification and interlocking control steps: The material level gauge 29 continuously collects the material height inside the material bag shell in real time and uploads the signal to the PLC controller. When a low material level signal is detected, the PLC controller controls the corresponding screw frequency converter to reduce the frequency and decelerate and pause the lifting action. The touch screen displays a pop-up window to remind the user to replenish the material. When a high material level overflow signal is detected, the PLC controller immediately cuts off the output of the screw frequency converter in this group, closes the double-way solenoid valve on the corresponding station, shuts down the air vibration structure 210, and simultaneously outputs an audible and visual overflow alarm.

[0046] S5. Single-station fault isolation operation steps: The PLC controller continuously collects the operating current of four dual-axis motors 32 and six screw motors 25 in real time, as well as the pressure values ​​of six sets of negative pressure sensors. If any of the filling execution units 2 experiences motor overload, pipeline blockage, negative pressure abnormality, or material level exceeding the limit, the PLC controller will only cut off the power supply circuit of all electrical components in that station, and the corresponding station area on the touch screen will be highlighted with the fault. The other five filling execution units 2 will complete the filling process completely, and the continuous production line of the tunnel kiln will not be interrupted.

[0047] S6. Cyclic and Fault Reset Steps: After the powder filling of a single set of kiln furniture is completed, the PLC controller controls the dual-axis motor 32 to reverse the lifting adjustment plate 39 to reset, waiting for the next kiln furniture to be fed. The cycle of all processes from S2 to S5 is executed. After the fault station is repaired, the operator issues a fault reset command on the touch screen, and all electrical components of the station are restored to controlled operation.

[0048] During use, the operator first completes the configuration of the whole machine parameters through the touch screen on the frame platform 1. The operator can select the global synchronous mode or the six-station asynchronous mode according to the production needs. In the synchronous mode, the six filling execution units 2 share the same set of parameters such as screw speed, lifting height, negative pressure and air vibration. In the asynchronous mode, the speed of the six screw motors 25, the lifting stroke of the dual-shaft motor 32, the negative pressure of the integrated degassing pipe, the start and stop time of the air vibration structure 210, and the filling weight of a single cask can be set independently for the first filling shell 101 and the second filling shell 102. The parameters are automatically stored.

[0049] After configuration, the powder is sent into the first filling shell 101 and the second filling shell 102 through the connecting pipe 200. The PLC controller program automatically starts the pre-degassing process, opens the double-way solenoid valve on the lower degassing pipe 27, and the negative pressure sensor provides real-time feedback of the pipeline pressure. The negative pressure is adjusted in a closed loop to pre-extract the air from the loose powder in the chamber and discharge the air trapped in the powder.

[0050] The tunnel kiln conveyor line transports empty saggers to the corresponding workstations of the equipment, triggering an arrival signal. The PLC controller simultaneously starts multiple sets of actions. The screw motor 25 drives the stirring rod 28 to rotate and feed the material. The output weight is controlled by the encoder in a closed loop. During operation, the air vibration structure 210 vibrates synchronously to prevent powder bridging and material blockage. The integrated upper degassing pipe 26 and lower degassing pipe 27 continuously extract air to complete secondary sealing degassing. At the same time, the dual-shaft motor 32 in the lifting drive assembly 3 drives the drive sprocket 33 and the transmission chain 35 to pull the adjusting plate 39, the first support frame 23, and the second support frame 24 to move downward along the guide rail 310, causing the entire material bag shell to descend. This can be adapted to the sagger to adjust the discharge gap. During the descent process, the powder inside the sagger is compacted simultaneously. After reaching the preset compaction height, the brake relay activates the electromagnetic brake coil built into the dual-shaft motor 32 to lock the lifting mechanism and prevent inertial descent.

[0051] During the filling process, the level gauge 29 monitors the material in the bin in real time. When a low level is detected, the corresponding screw motor 25 automatically reduces speed and stops lifting. A pop-up window on the touch screen reminds the user to replenish the material. When a high level overflow is detected, the screw, degassing solenoid valve and air vibration structure 210 of this group are immediately shut down, and an audible and visual alarm is triggered simultaneously.

[0052] During operation, the PLC controller continuously collects the current of four dual-axis motors 32 and six screw motors 25, as well as the negative pressure values ​​of each pipeline. If a certain group of filling execution units 2 experiences motor overload, pipeline blockage, or material level exceeding the limit, the system will only cut off all electrical power supply to that station, while the other five groups continue filling. The tunnel kiln production line does not need to be stopped, and the screen displays the faulty station for easy maintenance.

[0053] After a single cassette is filled, the PLC controller controls the dual-axis motor 32 to reverse and lift the entire cassette shell back to its original position, awaiting the next cassette feeding cycle for the entire filling process.

[0054] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A six-head loading operating system for a tunnel kiln, characterized in that: The system includes a rack platform (1), a PLC controller, and a touch screen. The rack platform (1) is equipped with four mounting shells (100). The left side of the two mounting shells (100) located on the front and rear sides is provided with a first filling shell (101), and the left side of the two mounting shells (100) located in the middle is provided with a second filling shell (102). A total of six filling execution units (2) are provided on the first filling shell (101) and the second filling shell (102). One filling execution unit (2) is provided on the first filling shell (101), and two filling execution units (2) are provided on the second filling shell (102). The filling execution unit (2) includes a screw motor (25), and the screw motor (25) is equipped with a screw frequency converter and a speed encoder respectively. The mounting housing (100) is provided with a lifting drive assembly (3), which includes a fixed housing (31). The fixed housing (31) is installed on the top of the mounting housing (100). A dual-axis motor (32) is installed on the inner wall of the fixed housing (31). The dual-axis motor (32) is provided with a lifting frequency converter and a braking relay. The dual-axis motor (32) has a built-in electromagnetic braking coil. The electromagnetic braking coil is electrically connected to the corresponding braking relay. Drive sprockets (33) are installed on the surfaces of the output shafts on both sides of the dual-axis motor (32).

2. The tunnel kiln six-head loading operating system according to claim 1, characterized in that: The loading execution unit (2) includes a first sealing cover (21) and a second sealing cover (22). There are two first sealing covers (21) and they are respectively installed on the top of two first filling shells (101). There are two second sealing covers (22) and they are respectively installed on the top of two second filling shells (102). A first support frame (23) is installed on the top of the first sealing cover (21), and a second support frame (24) is installed on the top of the second sealing cover (22).

3. The tunnel kiln six-head loading operating system according to claim 2, characterized in that: The number of screw motors (25) is six and they are respectively installed on the top of the two first support frames (23) and the top of the two second support frames (24). The top of the first support frame (23) is provided with a set of screw motors (25), and the top of the second support frame (24) is provided with two sets of screw motors (25). The bottom end of the output shaft of the screw motor (25) on the first support frame (23) passes through the first sealing cover (21) and extends into the interior of the first packing shell (101). The bottom end of the output shaft of the screw motor (25) on the second support frame (24) passes through the second sealing cover (22) and extends into the interior of the second packing shell (102).

4. The tunnel kiln six-head loading operating system according to claim 3, characterized in that: The bottom of the first packing shell (101) and the bottom of the second packing shell (102) are respectively equipped with an upper degassing pipe (26) that communicates with them. The bottom end of the upper degassing pipe (26) is equipped with a lower degassing pipe (27) that communicates with it. A double-pass solenoid valve and a negative pressure sensor are installed on the lower degassing pipe (27). The top of the first sealing cover (21) and the top of the second sealing cover (22) are both equipped with connecting pipes (200) that communicate with them.

5. The tunnel kiln six-head loading operating system according to claim 4, characterized in that: A stirring rod (28) is installed at the bottom of the output shaft of the screw motor (25). A level gauge (29) is installed on the left side of both the first filling shell (101) and the second filling shell (102). An air vibration structure (210) is installed at the bottom of the left side of both the first filling shell (101) and the second filling shell (102).

6. The tunnel kiln six-head loading operating system according to claim 5, characterized in that: The mounting housing (100) is provided with a counterweight (34) inside. A transmission chain (35) is installed on the top of the counterweight (34) at the position corresponding to the drive sprocket (33). Two brackets (36) are installed on the inner wall of the fixed housing (31). A rotating shaft (37) is rotatably connected to the two brackets (36) through two bearings. A guide sprocket (38) is installed on the surface of the rotating shaft (37) at the position corresponding to the drive sprocket (33). The end of the transmission chain (35) away from the counterweight (34) passes through the mounting housing (100), the drive sprocket (33), the guide sprocket (38) and the fixed housing (31) in sequence and extends to the outside of the fixed housing (31). The ends of the two transmission chains (35) on the same side away from the counterweight (34) are fixedly connected by an adjusting plate (39).

7. The tunnel kiln six-head loading operating system according to claim 6, characterized in that: The bottom of the four adjustment plates (39) is fixedly connected to two first support frames (23) and two second support frames (24). Two guide sliders are installed on the right side of the adjustment plates (39). A guide rail (310) that is slidably connected to the guide sliders is installed on the left side of the mounting shell (100) at the position corresponding to the guide sliders.

8. The tunnel kiln six-head loading operating system according to claim 7, characterized in that: The PLC controller is electrically connected to the lifting frequency converter, braking relay, screw frequency converter, double-way solenoid valve, negative pressure sensor, level gauge (29), air vibration structure (210) and touch screen respectively through communication lines. The touch screen is provided with a six-station parameter editing area, synchronous switching button, asynchronous switching button and partitioned fault display area. The PLC controller has built-in timing storage program and fault isolation program. The fault isolation program is used to cut off the power supply circuit of all electrical components of the station only when the electrical component corresponding to a single loading execution unit (2) fails, while the power supply circuit of the other stations remains conductive.

9. The tunnel kiln six-head loading operating system according to claim 8, characterized in that: The PLC controller receives the encoder speed signal of the screw motor (25), has built-in quantitative adjustment hardware logic, and can independently adjust the output frequency of each screw inverter. The level gauge (29) transmits high and low level switch signals to the PLC controller. The PLC controller has built-in two-level interlocking hardware logic, which corresponds to the two output signals of material shortage prompt and overflow power failure, respectively. The PLC controller collects the current signals of each dual-axis motor (32) and screw motor (25) and the values ​​of each negative pressure sensor in real time. The touch screen displays fault information of each station separately in different areas.

10. A six-head electrical control method for loading in a tunnel kiln, characterized in that: This electronic control method is used in the tunnel kiln six-head loading operating system according to any one of claims 1-9, and includes the following steps: S1. Steps for setting station parameters: Operators select global synchronous mode or six-station asynchronous mode through the touch screen. In synchronous mode, the six filling execution units (2) share the same set of parameters: screw speed, lifting stroke, integrated negative pressure pipeline negative pressure, air vibration duration and single box filling weight. In asynchronous mode, each filling execution unit (2) is set independently with screw motor (25) speed, dual-axis motor (32) lifting height, integrated negative pressure pipeline negative pressure, air vibration structure (210) start and stop duration and filling quantitative threshold. Each set of parameters is stored independently and does not interfere with each other. S2, Pre-degassing step of the silo: The PLC controller calls the built-in timing program, opens the double-way solenoid valve on the corresponding work station, the negative pressure sensor collects the pressure of the entire pipeline in real time, the PLC controller adjusts the negative pressure of the pipeline in a closed loop, and pre-degassing the loose powder inside the first filling shell (101) and the second filling shell (102). S3, Loading linkage drive steps: After the kiln furniture is delivered to the PLC controller, multiple sets of electrical control actions are executed synchronously. The screw frequency converter is started to drive the screw motor (25). The weight of the powder output is controlled by the speed encoder in a closed loop. The stirring rod (28) stirs and disperses the powder synchronously. The integrated negative pressure pipeline keeps the air ventilated and continuously completes the secondary sealing degassing. The air vibration structure (210) is started as needed to assist in feeding and avoid powder bridging and blockage. The dual-shaft motor (32) is started. Through the drive sprocket (33) and transmission chain (35), the adjusting plate (39) and the support frame are driven to move downward along the guide rail (310). After reaching the preset height, the brake relay conducts the electromagnetic brake coil to lock the dual-shaft motor (32) and stop the lifting action. S4, Material level classification and interlocking control steps: The material level gauge (29) continuously collects the material height inside the material bag shell in real time and uploads the signal to the PLC controller. When a low material level signal is identified, the PLC controller controls the corresponding screw frequency converter to reduce the frequency and decelerate and pause the lifting action. The touch screen pops up a material shortage pop-up window to remind the user to replenish the material. When a high material level overflow signal is identified, the PLC controller immediately cuts off the output of the screw frequency converter in this group, closes the double-pass solenoid valve on the corresponding station, shuts down the air vibration structure (210), and outputs an audible and visual overflow alarm. S5. Single-station fault isolation operation steps: The PLC controller continuously collects the working current of four dual-axis motors (32) and six screw motors (25) in real time, as well as the pressure values ​​of six sets of negative pressure sensors. If any of the filling execution units (2) experiences motor overload, pipeline blockage, negative pressure abnormality, or material level exceeding the limit, the PLC controller will only cut off the power supply circuit of all electrical components in that station, and the corresponding station area on the touch screen will be highlighted with the fault. The other five filling execution units (2) will complete the filling process, and the tunnel kiln continuous production line will not be interrupted. S6. Cyclic and fault reset steps: After the powder filling of a single set of kiln furniture is completed, the PLC controller controls the dual-axis motor (32) to reverse the lifting adjustment plate (39) to reset, wait for the next kiln furniture to be fed, and cycle through all processes from S2 to S5. After the fault station is repaired, the operator issues a fault reset command on the touch screen, and all electrical components of the station are restored to controlled operation.

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