Full-automatic ash discharging system and method of gypsum board calcining furnace

Abstract

The present application relates to the technical field of gypsum board processing, and discloses a full-automatic ash discharging system and method of a gypsum board calcining furnace, which comprises a discharging pipe connected to a hopper at the bottom of the calcining furnace, a sealing plate fixedly arranged on the discharging pipe, a discharging opening arranged on the sealing plate and connected to a discharge pipe, and a movable baffle hingedly arranged on the discharge pipe; a cleaning scraper is rotatably arranged on the sealing plate, and the scraping end of the cleaning scraper abuts against the inner side wall of the hopper and the surface of the sealing plate; an intermittent driving assembly for driving the cleaning scraper to rotate is arranged on the sealing plate, and a swing driving member linked with the intermittent driving assembly is connected to the movable baffle; the movable baffle is opened in linkage when the cleaning scraper rotates, and the movable baffle is closed in linkage when the cleaning scraper stops. Through the mechanical linkage of the intermittent driving assembly and the swing driving member, the full-automatic collaborative control of the intermittent rotation of the cleaning scraper and the synchronous opening and closing of the movable baffle is realized, and the problems of incomplete cleaning of accumulated ash and dust flying again caused by vibration attenuation or airflow impact in the prior art are solved.

Description

Technical Field

[0001] This invention relates to the field of gypsum board processing technology, specifically to a fully automatic ash removal system and method for a gypsum board calcining furnace. Background Technology

[0002] Gypsum board, as a lightweight, fire-resistant building material with good sound insulation properties, is widely used in modern building decoration. In the production process of gypsum board, the calcining furnace is the core equipment for dehydrating gypsum raw materials. After the raw materials (such as building gypsum powder) undergo a phase change reaction under heat in the calcining furnace, they are discharged through the ash hopper at the bottom of the furnace, thus completing the material flow.

[0003] In existing technologies, the ash discharge structure of the ash hopper at the bottom of the calcining furnace typically employs a gravity-feed design. This involves utilizing the inclined angle of the ash hopper's conical surface, relying on the powder's own gravity to fall to the discharge port. However, after high-temperature calcination, some fine powders that are unevenly heated or aggregated due to electrostatic adsorption during fluidization are prone to adhering to the inner wall of the ash hopper. Simultaneously, when humidity control fluctuates within the calcining furnace, trace amounts of free water in the gypsum powder can combine with the powder surface, forming a relatively strong adhesive layer, significantly increasing the coefficient of friction of the ash hopper's inner wall.

[0004] To address the aforementioned issues of wall adhesion and agglomeration, existing solutions mainly include the following: First, installing a vibratory motor or air hammer on the outside of the ash hopper to periodically apply high-frequency mechanical vibration, forcing the powder adhering to the inner wall to peel off. Second, using an air cannon purging device to utilize instantaneous high-pressure gas to impact the agglomerated areas inside the ash hopper.

[0005] However, for vibratory motors, the applied vibration acceleration decays rapidly as it is transmitted along the wall of the ash hopper. For thick or hard agglomerated layers with high moisture content, high-frequency vibration can only produce small deformation displacements on the wall, which is insufficient to fully destroy the shear stress inside the agglomerated layer, resulting in incomplete ash removal. Secondly, air gun purging is a pulsed, non-continuous operation with limited scouring depth. Furthermore, high-pressure airflow can easily cause a sudden change in the originally stable airflow field inside the ash hopper, leading to local dust re-entrainment and increased reflux, which affects the overall thermal efficiency of the calcining furnace.

[0006] Therefore, there is an urgent need to provide a fully automatic ash removal system for gypsum board calcining furnaces that can adapt to high-temperature dust conditions and has continuous arch breaking and ash removal capabilities. Summary of the Invention

[0007] The purpose of this invention is to provide a fully automatic ash removal system for a gypsum board calcining furnace, in order to solve the technical problem in the prior art that the vibration or blowing method can only loosen the accumulated ash locally and cannot form a continuous ash removal flow path, resulting in the disconnect between cleaning and ash removal and the repeated accumulation of ash in the ash hopper.

[0008] To solve the above-mentioned technical problems, the present invention specifically provides the following technical solution:

[0009] A fully automatic ash removal system for a gypsum board calcining furnace includes an ash hopper connected to the bottom of the calcining furnace, a feeding pipe connected to the bottom of the ash hopper, a sealing plate fixedly installed on the feeding pipe, a feeding port opened on the sealing plate, a feeding port fixedly connected to the discharge end of the feeding port, and a movable baffle hinged to the feeding pipe through a first hinge shaft.

[0010] A cleaning scraper is rotatably mounted on the sealing plate. The scraping end of the cleaning scraper abuts against the inner wall of the ash hopper and the surface of the sealing plate, respectively. The sealing plate is also provided with an intermittent drive assembly for driving the cleaning scraper to rotate. This assembly is used to drive the cleaning scraper to rotate and scrape off the deposits on the inner wall of the ash hopper and the surface of the sealing plate during ash discharge, and to intermittently feed the dust into the discharge port and discharge it from the discharge pipe to prevent accumulation.

[0011] The movable baffle is connected to a swing drive component that is linked to the intermittent drive assembly. When the cleaning scraper rotates to clean and promote ash discharge, it drives the movable baffle to rotate and open the discharge pipe channel; when the cleaning scraper rotates one revolution and stops discharging ash, it drives the movable baffle to rotate and reset to close the discharge pipe.

[0012] Furthermore, the intermittent drive assembly includes a rotating shaft that rotates through the sealing plate, and the cleaning scraper is fixedly mounted on the rotating shaft;

[0013] The sealing plate is fixedly provided with a drive wheel via a rotating shaft. The drive wheel is fixedly provided with a drive rod along its diameter direction. A round pin is fixedly provided on the drive rod away from its center.

[0014] A grooved wheel is fixedly sleeved on the rotating shaft. The grooved wheel has a pin groove that matches the round pin. When the driving wheel rotates, the round pin intermittently enters the pin groove to drive the grooved wheel to rotate intermittently, thereby driving the rotating shaft to rotate intermittently.

[0015] Furthermore, a servo motor is fixedly installed on the outer wall of the ash hopper, and a drive shaft is fixedly connected to the output end of the servo motor. An active bevel gear is sleeved on the drive shaft.

[0016] The driven bevel gear is fixedly sleeved on the rotating shaft of the driving wheel, and the driven bevel gear meshes with the driving bevel gear.

[0017] Furthermore, the swing drive includes a guide plate fixedly sleeved on the rotating shaft. The guide plate has a guide groove with varying heights. One end of the movable baffle is hinged to a connecting ball head that is slidably engaged in the guide groove via a second hinge shaft. When the rotating shaft rotates intermittently, it drives the guide plate to rotate synchronously. The guide groove drives the connecting ball head to move up and down through its varying heights, thereby causing the movable baffle to swing around the first hinge shaft.

[0018] Furthermore, the guide plate has a disc-shaped structure, the guide groove extends continuously along the circumference of the guide plate, and the guide groove has an inclined section with varying heights in the circumference. When the connecting ball head slides in the guide groove, it moves up and down with the change in height of the guide groove.

[0019] Furthermore, multiple arch-breaking plates are fixedly installed on the conical surface of the ash hopper. The multiple arch-breaking plates are arranged at intervals along the circumference of the ash hopper, and each arch-breaking plate extends obliquely from the inner wall of the ash hopper toward the inlet of the lower feed pipe.

[0020] Furthermore, a set of laser sensors are provided on the side wall of the feeding pipe, which are used to detect the accumulation height of the material in the feeding pipe;

[0021] The laser sensor is connected to the servo motor signal to control the start and stop of the servo motor based on the detection result.

[0022] Furthermore, the intermittent drive assembly also includes a protective box, which is fixedly disposed on the inner side wall of the ash hopper, and both the driving bevel gear and the driven bevel gear are disposed inside the protective box;

[0023] Both the rotating shaft and the drive shaft rotate through the side wall of the protective box.

[0024] Furthermore, a method for removing ash from a fully automatic ash removal system based on the above-mentioned gypsum board calcining furnace includes the following steps:

[0025] S1: During the operation of the calcining furnace, gypsum powder falls into the ash hopper. Some of the powder adheres to the inner wall of the ash hopper and the surface of the sealing plate to form ash accumulation. When the material accumulation height in the feed pipe reaches the preset threshold of the laser sensor, the laser sensor sends a start signal to the servo motor.

[0026] S2: The servo motor starts and drives the active bevel gear to rotate continuously through the drive shaft. The active bevel gear drives the driven bevel gear and the active wheel to rotate synchronously. The pin on the active wheel moves in a circular motion with the active wheel.

[0027] S3: The round pin intermittently enters the pin groove of the grooved wheel during the movement, driving the grooved wheel to rotate intermittently. The grooved wheel drives the cleaning scraper and guide plate to rotate synchronously and intermittently through the rotating shaft. During the rotation, the cleaning scraper scrapes off the accumulated ash on the inner wall of the ash hopper and the surface of the sealing plate that it contacts at the scraping end and pushes it towards the downward discharge port.

[0028] S4: The guide plate rotates intermittently and synchronously with the rotating shaft. The guide groove drives the connecting ball head to move up and down through its height and inclination changes. The connecting ball head drives the movable baffle to swing around the first hinge shaft through the second hinge shaft. When the cleaning scraper pushes the accumulated ash to the discharge port, the movable baffle swings synchronously to open the channel of the discharge pipe and discharge the accumulated ash. When the cleaning scraper stops rotating, the movable baffle swings synchronously to reset and close the channel of the discharge pipe. The sealing surface of the movable baffle is in close contact with the end face of the discharge pipe to seal the channel of the discharge pipe.

[0029] S5: When the material accumulation height in the feed tube drops below the preset safety threshold of the laser sensor, the laser sensor sends a stop signal to the servo motor, the servo motor stops running, the cleaning scraper and the movable baffle remain in their current positions, the movable baffle remains in the state of closing the discharge tube channel, and the system returns to standby state.

[0030] Compared with the prior art, the present invention has the following advantages:

[0031] This invention integrates the cleaning scraper and the movable baffle into a parallel and coordinated process of "cleaning and discharging simultaneously" through purely mechanical linkage. During rotation, the cleaning scraper applies a continuous and stable scraping force to the inner wall of the ash hopper and the surface of the sealing plate. This direct-contact scraping method overcomes the shortcomings of vibratory motors, which suffer from attenuation of vibration acceleration along the wall surface and thus struggle to fully break down hardened agglomerates. Simultaneously, the scraped dust is actively pushed to the discharge port, unlike the pulse-type ash discharge method that relies on high-pressure gas impact and is prone to inducing dust re-entrainment. This invention achieves low-disturbance, periodic, and stable material conveying during the ash discharge process. Furthermore, the movable baffle opens and closes synchronously with the rotation rhythm of the cleaning scraper, opening the ash discharge channel only when the cleaning scraper actively feeds material, thus avoiding system air leakage caused by prolonged channel opening. Attached Figure Description

[0032] To more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings in the following description are merely exemplary, and those skilled in the art can derive other embodiments based on the provided drawings without creative effort.

[0033] Figure 1 A schematic diagram of a two-step calcination furnace system for gypsum board production is provided for the embodiments of this application.

[0034] Figure 2 This is a schematic diagram of the return air duct installation structure provided in an embodiment of this application.

[0035] Figure 3 This is a schematic diagram of the ash hopper structure provided in an embodiment of this application.

[0036] Figure 4 A plan view of the ash hopper provided for an embodiment of this application.

[0037] Figure 5 for Figure 4 Sectional view of AA.

[0038] Figure 6 This is a schematic diagram of the intermittent drive component structure provided in an embodiment of this application.

[0039] Figure 7 This is a schematic diagram of the overall structure of the feed port provided in an embodiment of this application.

[0040] Figure 8 This is a schematic diagram of the driving bevel gear and driven bevel gear provided in the embodiments of this application.

[0041] Figure 9 for Figure 8 Enlarged view of the structure at point A in the middle.

[0042] Figure 10 This is a schematic diagram of the overall structure of the discharge pipe when it is open, as provided in an embodiment of this application.

[0043] The reference numerals in the figure are as follows:

[0044] 1. Calcination furnace; 2. Cooler; 3. High-temperature smoke mixing chamber; 4. Cooling fan; 5. Return air duct; 6. Cyclone dust collector; 7. Ash hopper; 8. Arch breaking plate; 9. Sealing plate; 10. Cleaning scraper;

[0045] 701. Feed pipe; 702. Laser sensor;

[0046] 901. Feed port; 902. Discharge pipe; 903. Movable baffle; 904. First hinge shaft; 905. Guide plate; 906. Guide groove; 907. Connecting ball head; 908. Second hinge shaft;

[0047] 1001, Shaft; 1002, Grooved wheel; 1003, Drive wheel; 1004, Drive rod; 1005, Round pin; 1006, Pin groove; 1007, Protective box; 1008, Servo motor; 1009, Drive shaft; 1010, Drive bevel gear; 1011, Driven bevel gear. Detailed Implementation

[0048] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0049] like Figures 1-2 As shown, the fully automatic ash removal system for the gypsum board calcining furnace provided by this invention is applied in a two-step calcination process system. The system comprises a calcining furnace 1, a cooler 2, a high-temperature mixing chamber 3, a cooling fan 4, a return air duct 5, and a cyclone dust collector 6. The top outlet of the calcining furnace 1 is connected to the inlet of the cooler 2, and the outlet of the cooler 2 is connected to the inlet of the high-temperature mixing chamber 3. The outlet of the cooling fan 4 is connected to the cooling medium inlet of the cooler 2, used to introduce cooling air into the cooler 2 to cool the calcined gypsum powder. The outlet of the high-temperature mixing chamber 3 is connected to the inlet of the calcining furnace 1 through the return air duct 5, forming a hot air circulation loop, returning the hot air carrying the powder during the cooling process to the calcining furnace 1 to achieve waste heat recovery. A cyclone dust collector 6 is installed in the return air duct 5 to perform gas-solid separation on the hot air carrying dust in the return air duct 5, reducing the dust content in the return air and preventing excessive dust accumulation in the calcining furnace 1. An ash hopper 7 is connected to the bottom of the calcining furnace 1. The gypsum powder that has been calcined in the calcining furnace 1, along with some fine powder that has accumulated due to uneven heating or electrostatic adsorption, settles into the ash hopper 7 under gravity and is discharged by the fully automatic ash removal system. The ash hopper 7 is typically a cone-shaped structure, wider at the top and narrower at the bottom, to facilitate material concentration at the bottom. A feed pipe 701 is connected to the bottom of the ash hopper 7, forming the initial channel for material discharge from the ash hopper 7.

[0050] like Figure 3-10 As shown, the ash hopper 7 typically has a conical structure that is wider at the top and narrower at the bottom, so as to facilitate the concentration of materials at the bottom. The bottom of the ash hopper 7 is connected to a discharge pipe 701, which forms the initial channel for the material to be discharged from the ash hopper 7.

[0051] like Figure 5 As shown, a sealing plate 9 is fixedly installed on the feed pipe 701. The sealing plate 9 is arranged horizontally, and its function is to seal the bottom of the feed pipe 701, forming a basic platform to support the material in the ash hopper 7.

[0052] A discharge port 901 is provided on the sealing plate 9, which serves as the sole channel for material to enter the subsequent discharge pipe. A discharge pipe 902 is fixedly connected to the discharge end of the discharge port 901, extending downwards to guide the material to the outside of the system. A movable baffle 903 is hinged to the discharge pipe 902 via a first hinge shaft 904. A sealing surface is provided on the side of the movable baffle 903 facing the discharge pipe 902 opening. When the movable baffle 903 is in the closed position, this sealing surface forms a surface contact seal with the end face of the discharge pipe 902 opening, thereby blocking the airflow path of external air into the calcining furnace 1 through the discharge pipe 902. The movable baffle 903 can swing around the first hinge shaft 904, thereby opening and closing the discharge pipe 902 channel. When not in use, the movable baffle 903 closes the discharge pipe 902 to act as an airlock, preventing external air from entering the calcining furnace 1 through the discharge pipe 902 and affecting the furnace atmosphere and thermal efficiency.

[0053] A cleaning scraper 10 is rotatably mounted on the sealing plate 9. The scraping end of the cleaning scraper 10 abuts against the inner wall of the ash hopper 7 and the surface of the sealing plate 9. This abutment relationship ensures that the cleaning scraper 10 can physically scrape off the accumulated ash and clumps adhering to the conical inner wall of the ash hopper 7 and the horizontal sealing plate 9 when rotating.

[0054] The sealing plate 9 is also equipped with an intermittent drive assembly for driving the cleaning scraper 10 to rotate. This intermittent drive assembly is used to drive the cleaning scraper 10 to rotate during ash discharge, so that it scrapes off the adhering material on the inner wall of the ash hopper 7 and the surface of the sealing plate 9, and intermittently pushes the scraped-off dust and the dust originally accumulated on the sealing plate 9 to the discharge port 901, and then discharges it from the discharge pipe 902, preventing dust from accumulating inside the ash hopper 7 for a long time.

[0055] A swing drive component, linked to the intermittent drive assembly, is connected to the movable baffle 903. This swing drive component drives the movable baffle 903 to rotate and open the discharge pipe 902 when the cleaning scraper 10 rotates to clean and facilitate ash discharge, allowing the dust pushed to the discharge port 901 by the cleaning scraper 10 to be smoothly discharged. When the cleaning scraper 10 rotates one revolution and stops discharging ash, the swing drive component drives the movable baffle 903 to rotate and reset, closing the discharge pipe 902. Through this mechanical linkage, the scraping action of the cleaning scraper 10 and the opening and closing action of the movable baffle 903 are strictly time-corresponding, achieving a coordinated working mode of "cleaning and discharging simultaneously," effectively solving the problems of incomplete cleaning and dust re-entrainment caused by vibration attenuation or airflow impact.

[0056] The following section, in conjunction with the accompanying drawings, provides a detailed explanation of the specific structure and working principle of the intermittent drive assembly and the oscillating drive component.

[0057] like Figure 5As shown, the intermittent drive assembly includes a rotating shaft 1001 that rotates through the sealing plate 9. A cleaning scraper 10 is fixedly mounted on the upper end of the rotating shaft 1001 and rotates synchronously with the rotating shaft 1001. The rotating shaft 1001 is vertically arranged, with its lower end extending below the sealing plate 9. A drive wheel 1003 is fixedly mounted below the sealing plate 9 via a rotating shaft. A drive rod 1004 along its diameter is fixedly mounted on the drive wheel 1003, and a pin 1005 is fixedly mounted on one end of the drive rod 1004 away from its center. A grooved wheel 1002 is fixedly sleeved on the rotating shaft 1001. Several radial pin grooves 1006 adapted to the pins 1005 are formed on the outer peripheral wall of the grooved wheel 1002. When the drive wheel 1003 rotates continuously under external power, it drives the drive rod 1004 and the pins 1005 to perform circular motion. During the movement, the round pin 1005 intermittently enters the pin groove 1006 of the grooved wheel 1002, causing the grooved wheel 1002 to rotate by a fixed angle, and then disengages from the pin groove 1006, waiting for the next movement.

[0058] The intermittent rotation of the grooved wheel 1002 is transmitted to the cleaning scraper 10 via the rotating shaft 1001, enabling the cleaning scraper 10 to rotate intermittently. That is, it rotates a certain angle within a working cycle, pauses, and then continues to rotate. This intermittent motion allows the cleaning scraper 10 to form a stable scraping force on the inner wall of the ash hopper 7 at each stopping position, avoiding the problems of insufficient scraping force or material being carried away and blown away that may occur with continuous rotation. At the same time, it allows time for the material to settle towards the center of the sealing plate 9 under the action of gravity.

[0059] like Figure 2 , Figure 3 and Figure 4 As shown, a servo motor 1008 is fixedly mounted on the outer wall of the ash hopper 7. A drive shaft 1009 is fixedly connected to the output end of the servo motor 1008, extending into the ash hopper 7. A driving bevel gear 1010 is fitted onto the drive shaft 1009. A driven bevel gear 1011 is fixedly fitted onto the rotation shaft of the driving wheel 1003, meshing with the driving bevel gear 1010. After the servo motor 1008 starts, it drives the driving bevel gear 1010 to rotate via the drive shaft 1009. The driving bevel gear 1010 then drives the meshing driven bevel gear 1011 to rotate, thus providing power for the continuous rotation of the driving wheel 1003. This bevel gear transmission method converts the horizontal output torque of the servo motor 1008 into the vertical torque required to drive the driving wheel 1003, adapting to the overall layout requirements of mounting the motor on the side wall of the ash hopper 7 and arranging the grooved wheel mechanism below the sealing plate 9, ensuring smooth and reliable transmission.

[0060] like Figure 5 and Figure 2As shown, the oscillating drive includes a guide plate 905 fixedly sleeved on the rotating shaft 1001. The guide plate 905 rotates synchronously with the rotating shaft 1001. A guide groove 906 with varying inclinations is provided on the guide plate 905. One end of the movable baffle 903 is hinged via a second hinge shaft 908 to a connecting ball head 907 that is slidably engaged within the guide groove 906. When the rotating shaft 1001 rotates intermittently under the drive of the grooved wheel 1002, the guide plate 905 rotates synchronously. Due to its varying inclinations, the height of each point within the guide groove 906 changes continuously as it rotates with the guide plate 905. When the connecting ball head 907 slides within the guide groove 906, its height is forced to move up and down according to the changing trajectory of the guide groove 906. The up-and-down movement of the connecting ball head 907 drives the movable baffle 903 to oscillate around the first hinge shaft 904 via the second hinge shaft 908.

[0061] Specifically, when the cleaning scraper 10 rotates to the material-pushing position under the drive of the intermittent drive assembly, the guide plate 905 also rotates to the corresponding angle. The guide groove 906 lifts or presses down the connecting ball head 907, thereby causing the movable baffle 903 to swing. The second hinge shaft 908 is located at the side edge of the movable baffle 903, and the connecting ball head 907 is hinged to the movable baffle 903 via the second hinge shaft 908, allowing the up-and-down movement of the connecting ball head 907 to be converted into the swinging motion of the movable baffle 903 around the first hinge shaft 904. When the cleaning scraper 10 stops rotating, the guide plate 905 also stops at the corresponding position, and the guide groove 906 maintains the connecting ball head 907 in the position where the movable baffle 903 closes the discharge pipe 902. This achieves precise synchronization between the opening and closing of the movable baffle 903 and the movement of the cleaning scraper 10.

[0062] Optionally, the guide plate 905 has a disc-shaped structure, and the guide groove 906 extends continuously along the circumference of the guide plate 905, with undulating inclined sections in the circumferential direction. When the connecting ball head 907 slides within the guide groove 906, it moves up and down with the elevation changes of the guide groove 906. This design of a continuous annular groove allows the guide plate 905 to rotate continuously without resetting, matching the intermittent rotation characteristics of the Geneva wheel 1002.

[0063] like Figure 5As shown, the intermittent drive assembly also includes a protective box 1007. The protective box 1007 is fixedly mounted on the inner wall of the ash hopper 7, and both the driving bevel gear 1010 and the driven bevel gear 1011 are located inside the protective box 1007. The side wall of the protective box 1007 has shaft holes for the rotating shaft 1001 and the drive shaft 1009 to pass through, and each shaft hole is equipped with a sealing ring to prevent dust from entering the protective box. Both the rotating shaft 1001 and the drive shaft 1009 rotatably pass through the side wall of the protective box 1007. The protective box 1007 isolates the bevel gear transmission mechanism from the high-temperature, high-dust environment inside the ash hopper 7, preventing dust from entering the gear meshing area and causing wear or jamming, thus ensuring the long-term stable operation and reliability of the transmission mechanism under harsh working conditions.

[0064] like Figure 5 As shown, multiple anti-arching plates 8 are fixedly installed on the conical surface of the ash hopper 7. These anti-arching plates 8 are arranged at intervals along the circumference of the ash hopper 7, each extending obliquely from the inner wall of the ash hopper 7 towards the inlet of the lower feed pipe 701. When gypsum powder falls into the ash hopper 7, it may form an "arch" due to internal friction between materials and adhesion to the wall, hindering the downward flow of the material. The anti-arching plates 8 apply additional shearing and guiding action to the material, breaking up any potential arch structures and allowing the material to flow smoothly to the bottom, assisting the cleaning scraper 10 in ash removal. The uniform circumferential arrangement of the multiple anti-arching plates 8 enables anti-arching treatment of the material throughout the entire circumference of the ash hopper 7.

[0065] like Figure 6 As shown, a set of laser sensors 702 are arranged opposite each other on the side wall of the feeding pipe 701. The laser sensors 702 are used to detect the accumulation height of the material inside the feeding pipe 701. The laser sensors 702 are connected to the servo motor 1008 via signals.

[0066] The laser sensor 702 includes a transmitter and a receiver. The transmitter emits a laser beam, and the receiver receives the laser signal passing through the inside of the feed tube 701. When the material accumulation height inside the feed tube 701 does not exceed the installation height of the laser sensor 702, the receiver can receive a strong laser signal; when the material accumulation height inside the feed tube 701 rises to the point of blocking the laser beam, the laser signal received by the receiver weakens or disappears. The laser sensor 702 determines the material accumulation height based on the change in the received signal intensity and converts the detection result into an electrical signal, which is then transmitted to the control system of the servo motor 1008.

[0067] When the detected material accumulation height reaches a preset threshold, the control system automatically starts the servo motor 1008, driving the cleaning scraper 10 to rotate and remove ash. When the material accumulation height drops below the preset safety height, the control system automatically shuts off the servo motor 1008, stopping ash removal. Through this closed-loop control, the ash removal system achieves fully automatic start and stop based on the actual ash accumulation, avoiding idling or excessive operation of the servo motor 1008, saving energy, and improving the system's intelligence level.

[0068] Based on the above-mentioned fully automatic ash removal system, the present invention also provides a method for using the system, specifically including the following steps:

[0069] In the initial state, the movable baffle 903 is in the closed position, the channel of the discharge pipe 902 is closed, and the servo motor 1008 is in standby state.

[0070] During the operation of the calcining furnace 1, gypsum powder continuously falls into the ash hopper 7. Some of the powder adheres to the inner wall of the ash hopper 7 and the surface of the sealing plate 9, forming ash accumulation. When the material accumulation height in the feed pipe 701 gradually rises and reaches the preset threshold that triggers the laser sensor 702, the laser sensor 702 sends a start signal to the servo motor 1008.

[0071] Upon receiving the start signal, the servo motor 1008 begins operation, driving the drive bevel gear 1010 to rotate continuously via the drive shaft 1009. The drive bevel gear 1010 drives the driven bevel gear 1011 and the drive wheel 1003 to rotate synchronously. The pin 1005 on the drive wheel 1003 then performs a circular motion.

[0072] During its movement, the pin 1005 intermittently enters the pin groove 1006 of the Geneva wheel 1002, driving the Geneva wheel 1002 to rotate intermittently. The intermittent rotation of the Geneva wheel 1002 is transmitted to the cleaning scraper 10 and the guide plate 905 via the rotating shaft 1001. Driven by the rotating shaft 1001, the cleaning scraper 10 rotates on the sealing plate 9 in an intermittent stepping manner. During rotation, the scraping end of the cleaning scraper 10 continuously contacts the inner wall of the ash hopper 7 and the surface of the sealing plate 9, scraping off the accumulated ash adhering to them, and pushing the scraped dust and the original accumulated ash on the sealing plate 9 towards the central discharge port 901.

[0073] Meanwhile, the guide plate 905 rotates intermittently in sync with the rotating shaft 1001. Due to its varying inclination, the guide groove 906 on the guide plate 905 drives the connecting ball head 907 to move up and down during rotation. The connecting ball head 907, through the second hinge shaft 908, drives the movable baffle 903 to swing around the first hinge shaft 904. The specific linkage logic is as follows: when the cleaning scraper 10 rotates to the stage of pushing dust into the discharge port 901, the guide plate 905 also rotates to the corresponding angle. The guide groove 906 drives the connecting ball head 907 to a position where the movable baffle 903 opens the discharge pipe 902 channel. At this time, the dust, under the pushing force of the cleaning scraper 10 and its own gravity, falls through the discharge port 901 into the discharge pipe 902 and is discharged. When the cleaning scraper 10 completes one pushing action and stops rotating, the guide plate 905 also stops. The guide groove 906 keeps the connecting ball head 907 in the position that makes the movable baffle 903 close the discharge pipe 902 again, blocking the ash discharge channel.

[0074] When the dust pushed out causes the material accumulation height in the feed pipe 701 to drop below the preset safety threshold of the laser sensor 702, the laser sensor 702 sends a stop signal to the servo motor 1008. The servo motor 1008 stops running, the cleaning scraper 10 and the movable baffle 903 both stop at their current positions, the movable baffle 903 remains closed, and the system returns to standby mode, waiting for the next dust accumulation height to reach the trigger threshold.

[0075] Through the above steps, the ash removal system automatically and intermittently cleans and removes ash based on the actual ash accumulation in the ash hopper 7 and the discharge pipe 701, achieving fully automatic operation. At the same time, the reliable closure of the movable baffle 903 during non-ash removal periods effectively prevents air leakage from the system.

[0076] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and not to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. All such modifications or substitutions should be covered within the protection scope of this application, and should not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application. Therefore, the protection scope of this application should be determined by the protection scope of the claims.

Claims

1. A fully automatic ash removal system for a gypsum board calcining furnace, characterized in that, Includes an ash hopper (7) connected to the bottom of the calcining furnace (1), the bottom of the ash hopper (7) is connected to a feeding pipe (701), a sealing plate (9) is fixedly provided on the feeding pipe (701), a feeding port (901) is opened on the sealing plate (9), a feeding pipe (902) is fixedly connected to the discharge end of the feeding port (901), and a movable baffle (903) is hinged on the feeding pipe (902) through a first hinge shaft (904). A cleaning scraper (10) is rotatably provided on the sealing plate (9). The scraping end of the cleaning scraper (10) abuts against the inner wall of the ash hopper (7) and the surface of the sealing plate (9) respectively. The sealing plate (9) is also provided with an intermittent drive assembly for driving the cleaning scraper (10) to rotate. This assembly is used to drive the cleaning scraper (10) to rotate and scrape off the attached material on the inner wall of the ash hopper (7) and the surface of the sealing plate (9) during ash discharge, and to intermittently send the dust into the discharge port (901) and discharge it from the discharge pipe (902) to prevent accumulation. The movable baffle (903) is connected to a swing drive component that is linked to the intermittent drive component. When the cleaning scraper (10) rotates to clean and promote ash discharge, the movable baffle (903) is driven to rotate to open the channel of the discharge pipe (902); when the cleaning scraper (10) rotates one revolution to stop ash discharge, the movable baffle (903) is driven to rotate and reset to close the discharge pipe (902).

2. The fully automatic ash removal system for a gypsum board calcining furnace according to claim 1, characterized in that, The intermittent drive assembly includes a rotating shaft (1001) that rotates through the sealing plate (9), and the cleaning scraper (10) is fixedly mounted on the rotating shaft (1001); The sealing plate (9) is fixedly provided with a drive wheel (1003) via a rotating shaft. The drive wheel (1003) is fixedly provided with a drive rod (1004) along its diameter direction. A round pin (1005) is fixedly provided on the drive rod (1004) away from its center. A grooved wheel (1002) is fixedly sleeved on the rotating shaft (1001). The grooved wheel (1002) has a pin groove (1006) that matches the round pin (1005). When the driving wheel (1003) rotates, the round pin (1005) intermittently enters the pin groove (1006) to drive the grooved wheel (1002) to rotate intermittently, thereby driving the rotating shaft (1001) to rotate intermittently.

3. The fully automatic ash removal system for a gypsum board calcining furnace according to claim 2, characterized in that, A servo motor (1008) is fixedly installed on the outer wall of the ash hopper (7). The output end of the servo motor (1008) is fixedly connected to a drive shaft (1009). An active bevel gear (1010) is sleeved on the drive shaft (1009). The driven bevel gear (1011) is fixedly sleeved on the rotating shaft of the driving wheel (1003), and the driven bevel gear (1011) meshes with the driving bevel gear (1010).

4. The fully automatic ash removal system for a gypsum board calcining furnace according to claim 2, characterized in that, The swing drive includes a guide plate (905) fixedly sleeved on the rotating shaft (1001). The guide plate (905) has a guide groove (906) with varying heights. One end of the movable baffle (903) is hinged to a connecting ball head (907) that is slidably engaged in the guide groove (906) via a second hinge shaft (908). When the rotating shaft (1001) rotates intermittently, it drives the guide plate (905) to rotate synchronously. The guide groove (906) drives the connecting ball head (907) to move up and down through its varying heights, thereby driving the movable baffle (903) to swing around the first hinge shaft (904).

5. The fully automatic ash removal system for a gypsum board calcining furnace according to claim 4, characterized in that, The guide plate (905) has a disc-shaped structure. The guide groove (906) extends continuously along the circumference of the guide plate (905), and the guide groove (906) has an inclined section with varying heights in the circumference. When the connecting ball head (907) slides in the guide groove (906), it moves up and down with the change in height of the guide groove (906).

6. The fully automatic ash removal system for a gypsum board calcining furnace according to claim 1, characterized in that, Multiple arch-breaking plates (8) are fixedly installed on the conical surface of the ash hopper (7). The multiple arch-breaking plates (8) are arranged at intervals along the circumference of the ash hopper (7). Each arch-breaking plate (8) extends obliquely from the inner wall of the ash hopper (7) towards the inlet of the lower feed pipe (701).

7. The fully automatic ash removal system for a gypsum board calcining furnace according to claim 1, characterized in that, A set of laser sensors (702) are provided opposite to each other on the side wall of the feeding pipe (701). The laser sensors (702) are used to detect the stacking height of the material in the feeding pipe (701). The laser sensor (702) is connected to the servo motor (1008) to control the start and stop of the servo motor (1008) according to the detection result.

8. The fully automatic ash removal system for a gypsum board calcining furnace according to claim 3, characterized in that, The intermittent drive assembly also includes a protective box (1007), which is fixedly disposed on the inner side wall of the ash hopper (7), and the driving bevel gear (1010) and the driven bevel gear (1011) are both disposed inside the protective box (1007); Both the rotating shaft (1001) and the drive shaft (1009) rotate through the side wall of the protective box (1007).

9. A method for removing ash from a fully automatic ash removal system for a gypsum board calcining furnace according to any one of claims 1-8, characterized in that, Includes the following steps: S1: During the operation of the calcining furnace (1), gypsum powder falls into the ash hopper (7). Some powder adheres to the inner wall of the ash hopper (7) and the surface of the sealing plate (9) to form ash accumulation. When the material accumulation height in the feed pipe (701) reaches the preset threshold of the laser sensor (702), the laser sensor (702) sends a start signal to the servo motor (1008). S2: The servo motor (1008) starts and drives the active bevel gear (1010) to rotate continuously through the drive shaft (1009). The active bevel gear (1010) drives the driven bevel gear (1011) and the active wheel (1003) to rotate synchronously. The round pin (1005) on the active wheel (1003) moves in a circle with the active wheel (1003). S3: The round pin (1005) intermittently enters the pin groove (1006) of the Geneva wheel (1002) during the movement, driving the Geneva wheel (1002) to rotate intermittently. The Geneva wheel (1002) drives the cleaning scraper (10) and the guide plate (905) to rotate synchronously and intermittently through the rotating shaft (1001). During the rotation, the cleaning scraper (10) scrapes off the accumulated ash on the inner wall of the ash hopper (7) and the surface of the sealing plate (9) that it contacts at the scraping end and pushes it towards the lower discharge port (901). S4: The guide plate (905) rotates intermittently in sync with the rotating shaft (1001). The guide groove (906) drives the connecting ball head (907) to move up and down through its height and inclination changes. The connecting ball head (907) drives the movable baffle (903) to swing around the first hinge shaft (904) through the second hinge shaft (908). When the cleaning scraper (10) pushes the accumulated ash to the discharge port (901), the movable baffle (903) swings synchronously to open the channel of the discharge pipe (902) so that the accumulated ash can be discharged. When the cleaning scraper (10) stops rotating, the movable baffle (903) swings synchronously to reset and close the channel of the discharge pipe (902). The sealing surface of the movable baffle (903) is in close contact with the end face of the discharge pipe (902) to close the channel of the discharge pipe (902). S5: When the material accumulation height in the feed pipe (701) drops below the preset safety threshold of the laser sensor (702), the laser sensor (702) sends a stop signal to the servo motor (1008), the servo motor (1008) stops running, the cleaning scraper (10) and the movable baffle (903) remain in their current positions, the movable baffle (903) remains closed to the discharge pipe (902) channel, and the system returns to standby mode.

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