A processing system and method for removing mica button crust

Abstract

The application discloses a processing system and method for removing mica crystal lump furnace skin, and realizes step-by-step processing through end furnace skin cutting device, side furnace skin cutting device and side furnace skin stripping device arranged in series, which is suitable for the structural characteristics of the mica crystal lump, and can accurately control the ring cutting depth through the double-parameter feedback of the current and vibration signals, so that the furnace skin is completely removed, and the internal complete mica crystal is maximally protected from being damaged; the whole processing process can realize automatic continuous operation, greatly reduces the labor intensity of the operator, reduces the influence of dust and noise on the health of the operator, and has far higher processing efficiency than manual peeling, can meet the needs of industrial large-scale synthetic mica production, and has good application prospect.

Description

Technical Field

[0001] This invention relates to mica processing technology, specifically to a processing system and method for removing mica crystal deposits from furnace lining, belonging to the field of mica processing technology. Background Technology

[0002] Synthetic mica is made from five raw materials: silicon dioxide, magnesium oxide, aluminum oxide, potassium fluorosilicate, and potassium carbonate, which are melted at high temperatures and then cooled and crystallized. In industrial production, 14-16 tons of uniformly mixed raw materials are typically fed into a kiln lined with refractory bricks. After high-temperature melting and cooling, the raw materials crystallize to obtain a complete synthetic mica crystal mass. This mass is then processed into synthetic mica sheets through processes such as brick removal, peeling, and crushing.

[0003] Removing the furnace lining from synthetic mica crystals is a crucial step in the production process. Currently, the industry commonly employs manual tools such as pneumatic and electric picks to peel off the unreacted raw material or surrounding impurities (i.e., "furnace lining") layer by layer from the surface of the synthetic mica crystals. The advantage of this method is that manual operation allows for precise positioning of the removal area, peeling off the furnace lining layer by layer, and the operator can observe surface changes during the process to ensure that only the furnace lining is removed, minimizing damage to the synthetic mica crystals themselves. However, there are significant drawbacks:

[0004] 1) High labor intensity and safety risks: Due to the intense vibration and prolonged operation of pneumatic drills, long-term use can easily lead to fatigue, affecting operational efficiency. This places high demands on the physical strength and technical experience of the operators. Furthermore, the high-frequency vibration of the pneumatic drill and the debris generated during use pose certain safety hazards to the operators.

[0005] 2) Dust pollution: The pneumatic pick peeling process generates a large amount of dust, which affects the operating environment and the health of operators. It also requires the installation of dust removal systems and protective equipment, which increases production costs.

[0006] 3) Noise pollution: Pneumatic drills generate significant noise, which not only affects the health of operators (such as hearing damage) but also impacts the comfort of the working environment. Noise protection equipment is essential, but long-term noise pollution in the working environment is still difficult to avoid.

[0007] 4) Low work efficiency and high labor costs: Manual pneumatic pick peeling is inefficient. For mass production, pneumatic pick peeling may become a bottleneck, making it difficult to meet high production demands. Manual pneumatic pick peeling requires a large investment of human resources and is inefficient, resulting in high labor costs. Due to dust and noise issues, pneumatic pick operation requires strict protective equipment, such as dust masks, goggles, and earmuffs, which increases costs and operational inconvenience, affecting production efficiency.

[0008] In summary, the shortcomings of existing manual pneumatic picks for removing furnace lining make it uncompetitive in large-scale production, especially in production environments that prioritize high efficiency, low cost, and high quality. This method is often more suitable for small-batch, fine-tuning requirements or special operational scenarios. In other words, current technology lacks dedicated mica agglomerate removal equipment and mature process solutions adapted for industrial-scale automated removal. Therefore, achieving efficient, low-damage, and automated removal of mica agglomerate furnace lining is a pressing technical problem that needs to be solved in this field. Summary of the Invention

[0009] To address the problems of low efficiency and high intensity in manual peeling of mica crystals, this invention provides a processing system and method for removing the furnace lining of mica crystals. This processing system uses a series of interconnected end furnace lining cutting devices, side furnace lining cutting devices, and side furnace lining peeling devices to perform staged processing. It is also equipped with a signal acquisition and main control module to achieve precise depth control. This effectively solves the problems of high labor intensity, high pollution, and low efficiency in existing manual peeling methods. It can achieve fully automated operation of mica crystal peeling while ensuring that only the furnace lining is peeled off without damaging the internal mica crystals.

[0010] To achieve the above-mentioned technical objectives, the technical solution adopted by the present invention is as follows:

[0011] According to a first embodiment of the present invention, a processing system for removing mica crystal deposits from furnace lining is provided.

[0012] A processing system for removing mica crystal deposits from furnace linings includes a moving device, an end furnace lining cutting device, a side furnace lining slitting device, and a side furnace lining peeling device. The moving device includes a conveyor and a worktable mounted on the conveyor. The end furnace lining cutting device, side furnace lining slitting device, and side furnace lining peeling device are sequentially arranged on the conveyor according to the material's direction. The end furnace lining cutting device is a wire saw. The side furnace lining slitting device is a saw blade machine, equipped with an electrical signal collector and a vibration signal collector. The side furnace lining peeling device is a hammer-type striking machine.

[0013] Preferably, the conveyor includes a main frame and a conveying track. The worktable includes a support base, a rotary hydraulic lift, and a loading platform. The support base is mounted on the conveying track and can move along the track via rollers. The loading platform is mounted on the support base via a rotary hydraulic lift, which controls the rotation and height of the loading platform.

[0014] Preferably, the wire saw machine includes a gantry frame, a diamond wire saw, guide wheels, a main drive wheel, a tension wheel, a control box, and a transmission box. The gantry frame is mounted in a straddle configuration on the conveyor frame. Multiple guide wheels are distributed at the four corners of the gantry frame via bearings. The control box and transmission box are bolted to the frame on both sides of the gantry frame in the width direction, and are electrically connected. The main drive wheel is mounted on the transmission box and connected to a rotary motor inside the transmission box. The diamond wire saw surrounds all the guide wheels and the main drive wheel in a closed loop. The tension wheel is hinged to the gantry frame near the transmission box via a swing arm assembly, and is in contact with the outer surface of the diamond wire saw.

[0015] Preferably, the sawing machine includes a saw frame, a saw blade, and hydraulic cylinders. The saw frame is mounted in a straddle configuration on the conveyor frame. Vertical guide rails are provided on the columns on both sides of the saw frame, and the hydraulic cylinders are mounted on the vertical guide rails via vertical sliders. A traction motor and guide pulleys are provided at the top of the saw frame columns. The hydraulic cylinders and / or vertical sliders are connected to the traction motor via traction cables that pass over the guide pulleys. A cutting motor is mounted on the piston of the hydraulic cylinder. The saw blade is mounted horizontally on the shaft of the cutting motor. Preferably, both the electrical signal acquisition device and the vibration signal acquisition device are located on the hydraulic cylinders and / or the cutting motor.

[0016] Preferably, multiple saw blades and matching hydraulic cylinders, vertical sliders and cutting motors are independently installed on the columns on both sides of the saw frame from top to bottom.

[0017] Preferably, the hammer-type striking machine includes a support column, a top bracket, a lifting motor, a rack column, an eccentric drive box, an impact cylinder, and a striking hammer. The support column is located on one side of the conveyor frame. The top bracket is located at the top of the support column. The lifting motor is located on the top bracket. At least one rack column is provided on the outer circumference of the support column, and the upper end of the rack column meshes with the drive gear of the lifting motor. The eccentric drive box is fixedly mounted on a sliding seat at the bottom of the rack column (the sliding seat rises and falls with the rack column). The impact cylinder is located on the sliding seat and below the eccentric drive box, and the upper end of the impact cylinder is connected to the eccentric output end of the eccentric drive box via a hinged swing arm. The striking hammer is located at the lower end of the impact cylinder.

[0018] Preferably, a dust cover that folds and extends vertically is also fitted onto the rack post.

[0019] Preferably, a furnace slag collection mechanism is also provided on the lower side of the conveyor. The furnace slag collection mechanism includes a furnace slag conveyor belt and a furnace slag collection box located at the discharge end of the furnace slag conveyor belt.

[0020] Preferably, the processing system also includes a main control box, which is electrically connected to the conveyor, worktable, wire saw, saw blade machine, hammer impactor, and electrical signal and vibration signal acquisition devices. The main control box regulates the operating status of each component. Preferably, the main control box is a PLC control cabinet.

[0021] According to a second embodiment of the present invention, a method for removing mica crystal deposits from furnace lining is provided:

[0022] A method for removing mica crystal deposits from furnace lining, or a method for removing mica crystal deposits from furnace lining using the processing system described in the first embodiment, the method comprising the following steps:

[0023] S1: First, cut off the top and bottom furnace skin of the crystal along the horizontal direction of the crystal.

[0024] S2: Then, the furnace lining on the side of the crystal pile is circumferentially cut to form at least one annular slit. During the circumferential cutting process, the circumferential cutting depth is adjusted in real time according to the changes in the current signal and vibration energy signal of the circumferential cutting equipment, so that the annular slit extends to the interface between the furnace lining and the mica crystal.

[0025] S3: Finally, the furnace skin on the side of the crystal with the annular slit is peeled off layer by layer along the vertical direction of the crystal.

[0026] Preferably, in step S2, the real-time adjustment of the circumferential cutting depth based on changes in the current signal and vibration energy signal of the circumferential cutting equipment specifically includes:

[0027] S201: Use a ring-cutting device to cut only the furnace shell, and measure the operating current data and operating vibration energy data of the ring-cutting device during furnace shell cutting.

[0028] S202: Using a circumferential cutting device to cut only the mica crystal, the critical current data and critical vibration energy data of the circumferential cutting device when first contacting the mica crystal are measured.

[0029] S203: Set safe current threshold and safe vibration energy threshold based on operating current data, operating vibration energy data, critical current data, and critical vibration energy data.

[0030] S204: During the actual ring cutting process, the side furnace skin is cut at any position in the circumference of the crystal pile by continuously increasing the kerf depth. The current value and vibration energy value of the ring cutting equipment are monitored in real time. When the measured current value exceeds the safe current threshold and / or the measured vibration energy value exceeds the safe vibration energy threshold, the central control system normalizes the measured current value and measured vibration energy value and then merges them into a cutting index S according to the weight. When S exceeds the cutting index safety threshold, the cutting at the current position is stopped, and the cutting operation continues in the same way at the adjacent position along the circumference of the crystal pile (i.e., the side furnace skin is cut by continuously increasing the kerf depth). This cycle is repeated until a ring kerf is formed.

[0031] Preferably, the operating current data includes the average operating current I. A And the maximum fluctuation value of the operating current ΔI. The operating condition vibration energy data includes the average operating condition vibration energy E. A And the maximum fluctuation value of vibration energy under operating conditions, ΔE.

[0032] Preferably, the critical current value is set to I. C The critical vibration energy value is E C If the safe current threshold is I0 and the safe vibration energy threshold is E0, then: (I A +△I) <I0<I C (E) A +△E) <E0<E C .

[0033] Preferably, the current and vibration energy values ​​of the real-time acquired circumferential cutting equipment are normalized to obtain a normalized current value G and a normalized vibration value H. Then, the cutting index S is calculated using the normalized current value G as the primary factor and the normalized vibration value H as the secondary factor. Cutting stops when the obtained cutting index S is greater than or equal to the safety threshold S0; otherwise, the cutting operation continues. The cutting index S is calculated using the following mathematical model:

[0034] S = α·G + β·H (1).

[0035] In equation (1), α is the current energy weighting coefficient, with a value of 0.6~0.8. β is the vibration energy weighting coefficient, with a value of 0.2~0.4. α+β=1.

[0036] In this invention, during the production of synthetic mica, the surface of the mica crystals obtained after melting is coated with a layer of furnace lining (mica crystals coated with furnace lining are generally called mica clumps). This furnace lining is mainly composed of raw materials that did not fully participate in the melting reaction and refractory material impurities that have detached from the inner wall of the kiln. Its properties differ significantly from the pure mica crystals inside. Therefore, one of the important steps in mica processing is the removal of the furnace lining. Traditional processes often employ manual peeling, which has drawbacks such as high labor intensity, low production efficiency, and high safety risks. Furthermore, if existing stone processing equipment is simply used to remove the furnace lining from mica clumps, it is difficult to accurately control the cutting depth, which can easily cause significant damage to the intact mica crystals inside during the removal of the furnace lining, leading to a decrease in yield and affecting production profits. To address the aforementioned issues, the processing system provided by this invention sequentially arranges an end furnace lining removal device, a side furnace lining slit cutting device, and a side furnace lining peeling device along the material conveying direction. The side furnace lining slit cutting device is equipped with an electrical signal acquisition device and a vibration signal acquisition device. This system can automatically complete the entire process from end peeling and side circumferential cutting to side peeling in stages, eliminating the need for manual operation and effectively reducing labor intensity and production costs. Furthermore, it can acquire the equipment's operating parameters in real time during the cutting process, and determine whether the cutting depth has reached the interface between the furnace lining and the mica crystal by observing parameter changes. This allows for precise control of the slit depth, preventing over-cutting and damage to the mica crystal.

[0037] In this invention, the moving device includes a conveyor and a worktable mounted on the conveyor. Its function is to carry the mica crystals to be processed, driving them sequentially through an end furnace lining removal device, a side furnace lining slitting device, and a side furnace lining peeling device to complete the corresponding processing steps. This eliminates the need for manual transfer of the crystals, ensuring the continuity of the processing flow. The conveyor includes a main frame and a conveying track. The main frame is a frame structure, primarily serving a load-bearing and supporting function. The conveying track extends along the material conveying direction, providing a stable moving path for the worktable and matching the installation positions of each processing device, ensuring that the crystals can be accurately conveyed to the corresponding workstations according to the preset processing sequence. The worktable includes a support base, a rotary hydraulic lift, and a loading platform. The support base, as a basic load-bearing component, supports the overall weight of the rotary hydraulic lift, the loading platform, and the mica crystals to be processed. Furthermore, the support base uses a roller structure to ensure smooth movement along the conveying track, preventing the crystals from shaking or swaying during transport and ensuring the accuracy of the cutting position. The rotary hydraulic lift can simultaneously adjust the height and rotate the circumferentially of the platform, accommodating mica crystals of different heights and specifications to meet the positional adjustment requirements during end cutting and side circumferential cutting. It can also drive the crystals to rotate at a uniform speed, working in conjunction with the side circumferential cutting equipment to complete the full circumferential cutting without requiring circumferential movement of the equipment, thus simplifying the overall structural design of the processing equipment. It should be noted that the rotary hydraulic lift is an existing, mature piece of equipment; it only needs to provide stable support and load-bearing capacity while precisely controlling the rotation angle and lifting stroke to meet the adjustment requirements of this processing system. The platform is located at the top output end of the rotary hydraulic lift, used to directly fix the mica crystals to be processed. A corresponding limiting structure can be set according to the bottom contour of the crystal to prevent displacement during processing. Furthermore, to further improve the load-bearing capacity and stability of the worktable, grounding feet with wheels (capable of braking) can be installed at the bottom of the support base. These feet can support the base as it moves along the conveyor track.

[0038] In this invention, the end furnace skin removal device is a wire saw, including a gantry main frame, a diamond wire saw, a limiting guide wheel, a main drive wheel, a tension wheel, a control box, and a transmission box. The gantry main frame is the base support structure of the wire saw cutting module. The limiting guide wheel is rigidly fixed to the four corners of the gantry main frame by bearing seat bolts. The upper end of the tension wheel's swing arm assembly (containing a motor) is mounted on the side frame of the gantry main frame by a pin hinge, and the swing arm can swing slightly to adjust the rope tension. The diamond wire saw is powered by the main drive wheel, surrounds the limiting guide wheel, and performs a closed-loop high-speed cutting motion after being kept taut by the tension wheel, which can smoothly remove the top and bottom furnace skin of the mica crystal. Compared with traditional electric saw cutting, the cutting surface is flatter, the cutting process is easier to control, and it can reduce disturbance to the overall structure of the crystal. The tension wheel can be adjusted via the swing arm to ensure the diamond wire saw is always under appropriate tension, preventing slippage and detachment during cutting and ensuring the stability of the cutting operation. Before operation, cutting parameters can be preset via the control box. Combined with the height adjustment of the worktable, the cutting surface of the diamond wire saw can be aligned with the boundary between the top and bottom of the furnace lining, allowing for the removal of the furnace lining at the end in one pass, eliminating the need for multiple feeds and increasing work efficiency.

[0039] In this invention, the end-piece furnace lining removal device, serving as a wire saw cutting module, is used for the roughing and contouring of large-sized synthetic mica crystal boulders. It is primarily suitable for removing the bottom and top furnace lining material from synthetic mica crystal boulders. The specific operation involves fixing the synthetic mica crystal boulder onto a liftable and rotatable platform. The operator determines the cutting starting point using a mechanical alignment device and adjusts the diamond wire saw to the target position on the crystal boulder. Once prepared, the control box displays the crystal boulder's coordinates in real time. The operator inputs cutting depth, angle, and other parameters through the control interface and presses the start button. The wire saw then begins operation. After cutting, the crystal boulder moves along a track to the subsequent finishing module. Larger pieces of furnace lining material from the cutting module are conveyed to a centralized collection point via a conveyor belt. It should be noted that in this invention, the end-piece furnace lining removal device can also be a saw blade machine. During processing, the saw blade automatically rises and falls and automatically moves forward and backward until the end-piece furnace lining material is circumferentially cut, then returns to the starting position to await the arrival of the next crystal boulder.

[0040] In this invention, the side furnace skin slit cutting device is a saw blade machine, including a saw frame, saw blades, and hydraulic cylinders. This invention uses multiple independently configured saw blades to cooperate in the cutting operation. Multiple saw blades can simultaneously complete slit processing at different positions along the crystal mass height direction, dividing the side furnace skin into multiple independent layered units in one operation. This facilitates subsequent peeling operations, eliminating the need for multiple saw blade position adjustments and further improving processing efficiency. During the cutting process, an electrical signal acquisition device collects the operating current of the cutting motor in real time, and a vibration signal acquisition device collects the vibration energy generated by the saw blade during cutting. Because the furnace skin is loose and has low hardness, the corresponding operating current and vibration energy are relatively small during cutting. However, when the cutting depth reaches the denser and harder mica crystal, the cutting resistance increases rapidly, and the corresponding operating current and vibration energy also rise rapidly. Therefore, by using a preset safety threshold, it is possible to accurately determine whether the cutting head has reached the interface between the furnace skin and the mica crystal, automatically stopping the feed and fundamentally avoiding the problem of over-cutting and damaging the crystal. It should be noted that in this invention, the side furnace skin slit cutting device can also be a wire saw machine.

[0041] In this invention, the side furnace skin peeling device uses a hammer-type striking machine to complete the layered peeling operation. An eccentric drive box drives an impact cylinder to periodically oscillate via a hinged swing arm. Combined with the feed action of the impact cylinder itself, this drives the hammer to strike the furnace skin located between two adjacent annular slits at a stable frequency. The impact force causes the furnace skin, separated by the slits, to detach from the mica crystal surface. Compared to integrated cutting and peeling, this method only acts on the surface furnace skin and does not penetrate deep into the internal mica crystals, minimizing damage to the crystals during the peeling process. A lifting motor drives the entire striking mechanism vertically via a gear and rack mechanism, adapting to crystal clumps of different heights to complete peeling operations across the entire height range. A dust cover along the rack column prevents dust generated during cutting and peeling from entering the transmission structure, extending the equipment's service life and reducing maintenance costs.

[0042] In this invention, the side furnace skin cutting device and the side furnace skin peeling device are combined as a finishing module. The main components utilize a dry-cutting saw blade and a variable frequency speed-regulating motor to control the cutting depth, combined with an automatic continuous hammering machine to knock off the side furnace skin material. First, a saw blade machine (column-type cutter) driven by a variable frequency speed-regulating motor carries a dry-cutting saw blade. Under the control of the main control box, the saw blade performs circumferential cutting on the side of the crystal mass at a set depth. When the saw blade cuts through the furnace skin material and touches the harder synthetic mica crystal body, the cutting resistance increases instantaneously, leading to an increased load on the drive motor. Its operating current generates a peak value significantly higher than when cutting the furnace skin material. Simultaneously, the contact between the saw blade and the crystal triggers a specific structural vibration signal. This combined signal is fed back to the central control system of the main control box. The system immediately identifies that the crystal body has been touched and stops cutting at that point, moving to the next cutting point. After completing a full circumference cut, the saw blade automatically descends to the next layer to repeat the operation. Finally, the second stage of operation begins: mechanical hammering and peeling. After all circumferential cutting is completed, the crystal agglomerate is moved to a fixed striking station. The striking hammer applies impact force from top to bottom along the peel line between the furnace lining and the crystal body, causing the furnace lining to peel off in the direction of force, while the crystal body remains undamaged. Larger furnace lining materials generated by the cutting and finishing modules are conveyed to a centralized collection point, while smaller particles and dust are collected by a dust removal system. Furthermore, in the finishing module, temperature monitoring sensors (e.g., infrared temperature sensors) can be installed on the corresponding frames to monitor the surface temperature of the crystal agglomerate and the saw blade temperature. When both are overheated, the system prompts for saw blade replacement and switches the processing position. Water is not used for cooling in this process because the outer furnace lining material removed from the synthetic mica crystal agglomerate needs to be recycled and remelted, and moisture would have a significant impact on the melting of the synthetic mica crystals. Therefore, it is essential to prevent the crystal agglomerate from coming into contact with water during the removal and collection of the outer furnace lining material.

[0043] In this invention, the furnace lining removed and peeled off during processing falls directly into the furnace lining collection mechanism and is then conveyed by a furnace lining conveyor belt to the furnace lining collection box for centralized collection. This eliminates the need for manual cleaning of the work site, improving the working environment, reducing dust dispersion, and further reducing manual workload. All operations of the entire processing system are uniformly controlled by a PLC main control box. From material conveying, end cutting, side slit cutting to peeling and collection, the entire process can be automated. Operators only need to complete loading and unloading and parameter presets; they do not need to enter the processing area to operate, eliminating safety hazards in the manual peeling process at its source. Furthermore, since the above cutting processes all generate dust, the entire synthetic mica crystal agglomerate processing center can also use a closed dust removal system for protection and treatment. The closed dust removal system mainly consists of a sealed hood, a dust suction port, and a dust collector. The sealed hood encloses the entire synthetic mica crystal agglomerate peeling production line and has a built-in monitor, reducing dust dispersion while allowing operators to easily observe the work area. The dust extraction port is installed above or to the side of dust-generating points such as cutting and peeling stations to quickly capture dust particles. The airflow of the dust extraction system should be adjusted according to the amount of dust generated and the size of the space inside the hood to ensure stable negative pressure and prevent dust leakage. The air treated by the dust collector can be recycled back to the workshop, reducing the introduction of external air and saving energy. The dust collected by the dust collector can be reused in the furnace, which helps save resources and reduce production costs.

[0044] In this invention, based on the aforementioned processing system, a corresponding method for removing the furnace lining of mica crystal lumps is also provided. Through a phased processing design, the furnace lining at the top and bottom of the crystal lump is first removed, and then a circumferential slit is cut to divide the side furnace lining into easily peelable layered units. Finally, the furnace lining is completely removed by tapping and peeling. The process logic fits the structural characteristics of the mica crystal lump and is suitable for large-scale continuous production. At the same time, taking advantage of the difference in physical properties between the furnace lining and the mica crystal, the cutting process will cause significant changes in the current and vibration parameters of the cutting equipment. By pre-calibrating the parameter thresholds, this invention can automatically identify the cutting depth during the circumferential cutting process by real-time monitoring, and accurately stop the cutter at the interface between the furnace lining and the crystal. This ensures that the furnace lining is completely removed and effectively avoids damage to the pure mica crystal inside, solving the long-standing problem of depth control accuracy in automated peeling processes.

[0045] In this invention, the significant physical differences between synthetic mica crystals and surface furnace lining material are cleverly utilized to design a multi-sensor fusion closed-loop control logic of "current as the main component, vibration as the auxiliary component, and dual verification": (1) Electrical signal acquisition: An electrical signal acquisition device (e.g., a current sensor or a power transmitter) is installed on the spindle drive motor of the drive saw blade (or wire saw) to monitor the changes in the motor's working current or power in real time. When the saw blade contacts the crystal body with higher hardness, the cutting resistance will increase instantaneously, resulting in an increase in the motor load, and its working current will generate a peak value that is significantly higher than when cutting furnace lining material. (2) Vibration signal acquisition: A vibration signal acquisition device (e.g., an acceleration sensor or an acoustic emission sensor) is installed at key positions near the cutting point, such as the tool holder, spindle bearing seat, or workpiece fixture near the cutting point. This sensor directly contacts the solid structure and is specifically designed to collect the solid-conducted sound (structural vibration) generated when the saw blade contacts the stone. Compared with noise propagated in the air, solid vibration signals are directly related to the processing state and can effectively avoid the interference of air noise generated by other surrounding equipment.

[0046] In this invention, the acquired raw signals need to be processed to extract effective features. Current signal processing: The central control system of the main control box performs low-pass filtering on the raw current signal from the current sensor to remove transient spike interference and extract a stable current value reflecting the cutting load trend. Vibration signal processing: The control system performs band-pass filtering on the vibration signal acquired by the accelerometer, retaining only signal components within a specific frequency range related to stone cutting and fracture, and eliminating low-frequency or high-frequency fixed noise generated by equipment such as motors, hydraulic pumps, and cooling fans. Then, the control system uses time-frequency analysis technology to calculate the energy value of the vibration signal in a specific frequency band in real time to identify the significant energy abrupt change in the vibration signal when the tool touches hard crystals. This characteristic is completely different from the stable vibration signal characteristics when cutting furnace slabs.

[0047] In this invention, the PLC main control box has a pre-set built-in algorithm that uses the current cutting index S, based on the fusion of current and vibration signals, as the core criterion to determine the accuracy control of the circumferential cutting depth. The cutting index S is a function of the real-time detected current value I and the real-time detected vibration energy value E of the circumferential cutting equipment, i.e., S = f(I, E) = α·G + β·H, where α is the weighting coefficient of the current energy (values ​​range from 0.6 to 0.8), β is the weighting coefficient of the vibration energy value (values ​​range from 0.2 to 0.4), and α > β, α + β = 1; G is the normalization function of the current signal, and H is the normalization function of the vibration signal. Cutting stops when the system calculates that the currently calculated cutting index S is greater than or equal to the safety threshold S0 set for the working condition; otherwise, cutting continues. The values ​​of the weighting coefficients α and β are calibrated using previous experimental data. During the pure cutting of the furnace slab, the average current I under the working condition is recorded.A and the average vibration energy E under operating conditions A After normalization, a lower signal reference value S is obtained. A When the crystal reaches the critical state, the critical current value I is recorded. C and critical vibration energy value E C After normalization, a significantly higher cutting critical value S was obtained. C Through multiple experiments, regression analysis or least squares fitting was used to determine what makes S... A With S C The α and β values ​​that maximize the distinguishability between them.

[0048] Definition of normalization function: Current normalization function G = (II A ) / (I C -I A ), where I A I is the average operating current during pure furnace lining cutting. C The critical current value is the value at which the crystal body is first touched, and I is the current value collected in real time. The vibrational energy normalization function is H = (EE...). A ) / (E C -E A ), where E A E represents the average vibration energy during pure furnace lining cutting. C The peak vibrational energy is the first point of contact with the crystal body, and E is the vibrational energy value acquired in real time. After normalization, both the current signal and the vibrational energy signal are mapped to dimensionless values ​​between 0 and 1, allowing for weighted comparisons and calculations within the same mathematical model.

[0049] Calibration method for the exponential safety threshold S0: Under the same working conditions as the actual processing conditions, first use a current sensor to collect the motor operating current curve when only cutting the furnace skin, and calculate its average operating current I. A And the maximum fluctuation value ΔI, then record the critical current value I when the saw blade first touches the crystal body. C Based on this, the reference value of the current normalization function is determined. Simultaneously, an accelerometer is installed on the tool holder or spindle bearing housing near the cutting point. This sensor is used to collect structural vibration signals when cutting only the furnace lining material. The system uses a built-in bandpass filter algorithm to filter out noise from stationary equipment such as motors and hydraulic pumps, extracting the effective signals related to cutting, and calculating the average value E of the operating condition vibration energy. A The maximum fluctuation value ΔE was recorded, and the saw blade continued to advance until it touched the crystal body. The characteristic energy peak E of the vibration signal at this point was recorded. C Based on this, the baseline value of the vibration energy normalization function was determined. During the pure furnace skin cutting stage, the measured current value was close to I. A The measured vibration energy value is close to E.A When G approaches 0 and H approaches 0, the S value is at a relatively low level (denoted as S1); at the instant the tool touches the crystal body, the measured current value is close to I. C The vibration energy value is close to E C When G approaches 1 and H approaches 1, the S value jumps to a high level close to 1 (denoted as S2). The cutting index safety threshold S0 is set as a reasonable value between S1 and S2, ensuring that the system can stably cut the furnace skin without misjudgment and respond promptly when it touches the crystal body. This also means that even if the vibration signal is slightly weak, the system can still reliably trigger a shutdown. Conversely, if the current signal is weak but the vibration signal is abnormally strong, the S value is unlikely to exceed the threshold due to the low vibration weight, thus realizing the "current as the main factor and vibration as the auxiliary factor" identification logic. The system continuously normalizes the real-time signals from the current sensor and acceleration sensor and calculates the current cutting index S value in real time. When the real-time calculated S value exceeds the preset threshold S0, the system automatically identifies "the saw blade has touched the crystal body" and immediately issues a command to control the drive motor and feed mechanism to stop the cutting, thereby avoiding damage to the crystal. This fusion identification mechanism can minimize the risk of a single sensor triggering a shutdown due to power grid fluctuations (leading to false current alarms) or accidental mechanical collisions (leading to false vibration alarms), because the probability of two independent sensors simultaneously generating false alarms is extremely low.

[0050] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0051] 1. The processing system of this invention realizes the end cutting, side slit cutting, and layer peeling of mica crystal furnace skin in stages. The entire process is automated, requiring only a small number of auxiliary personnel, which greatly reduces the labor intensity of operators. At the same time, it avoids operators being exposed to dust and noise for a long time, eliminates the safety hazards caused by manual operation, and improves the working environment. Moreover, the processing efficiency is greatly improved, which can be adapted to large-scale continuous production. It breaks through the efficiency bottleneck of manual peeling and can meet the production capacity requirements of industrial mass synthesis of mica. This invention replaces the traditional manual pneumatic pick peeling, completely solving the problems of high labor intensity, dust and noise pollution, high safety risks, and low production efficiency of manual peeling, and can be adapted to the needs of large-scale industrial production.

[0052] 2. This invention controls the cutting depth by collecting current and vibration energy signals during the cutting process. It accurately determines the cutting depth based on the changes in these two types of signals, ensuring that the cut is precisely placed at the interface between the furnace skin and the mica crystal. This thoroughly removes the furnace skin while minimizing damage to the internal crystals, effectively improving the yield and reducing production losses. It meets the demand for efficient and low-damage descaling in the synthetic mica processing field and has strong practicality and promotional value.

[0053] 3. The processing system described in this invention has a reasonable structural design and a clear process logic. It is suitable for the actual production needs of industrialized mica crystal peeling processing, can effectively replace the traditional manual peeling process, promote the automation upgrade of the mica processing industry, and has high application value. Attached Figure Description

[0054] Figure 1 This is a top view of the processing system of the present invention.

[0055] Figure 2 This is a simplified structural diagram of the worktable of the processing system of the present invention.

[0056] Figure 3 This is a simplified structural diagram of the end furnace slag removal device of the processing system of the present invention.

[0057] Figure 4 This is a simplified structural diagram of the side furnace skin cutting device of the processing system of the present invention.

[0058] Figure 5 This is a simplified structural diagram of the side furnace skin peeling device of the processing system of the present invention.

[0059] Figure 6 This is a simplified diagram of the crystal after circumferential cutting according to the present invention.

[0060] Reference numerals: 1: Conveyor; 101: Main frame; 102: Conveyor track; 2: Workbench; 201: Support base; 202: Rotary hydraulic lift; 203: Loading platform; 3: Wire saw; 301: Gantry main frame; 302: Diamond wire saw; 303: Limiting guide wheel; 304: Main drive wheel; 305: Tensioning wheel; 306: Control box; 307: Transmission box; 308: Swing arm assembly; 4: Saw blade machine; 401: Saw frame; 402: Saw blade; 403: Hydraulic cylinder ; 404: Vertical guide rail; 405: Vertical slider; 406: Traction motor; 407: Guide pulley; 408: Traction cable; 409: Cutting motor; 5: Hammering machine; 501: Support column; 502: Top bracket; 503: Lifting motor; 504: Rack column; 505: Eccentric drive box; 506: Impact cylinder; 507: Hammer; 508: Sliding seat; 509: Articulated swing arm; 510: Dust cover; 6: Furnace skin conveyor belt; 7: Furnace skin collection box; 8: Main control box. Detailed Implementation

[0061] The technical solution of the present invention will be illustrated below with examples. The scope of protection sought by the present invention includes, but is not limited to, the following embodiments.

[0062] A processing system for removing mica crystal deposits from furnace linings includes a moving device, an end furnace lining cutting device, a side furnace lining slitting device, and a side furnace lining peeling device. The moving device includes a conveyor 1 and a worktable 2 mounted on the conveyor 1. The end furnace lining cutting device, side furnace lining slitting device, and side furnace lining peeling device are sequentially arranged on the conveyor 1 according to the material flow direction. The end furnace lining cutting device is a wire saw 3. The side furnace lining slitting device is a saw blade 4, on which an electrical signal collector and a vibration signal collector are installed. The side furnace lining peeling device is a hammer-type striking machine 5.

[0063] Preferably, the conveyor 1 includes a main frame 101 and a conveying track 102. The workbench 2 includes a support base 201, a rotary hydraulic lift 202, and a loading platform 203. The support base 201 is mounted on the conveying track 102 and can move along the conveying track 102 via rollers. The loading platform 203 is mounted on the support base 201 via the rotary hydraulic lift 202, and the rotation and height of the loading platform 203 are controlled by the rotary hydraulic lift 202.

[0064] Preferably, the wire saw machine 3 includes a gantry frame 301, a diamond wire saw 302, limiting guide wheels 303, a main drive wheel 304, a tensioning wheel 305, a control box 306, and a transmission box 307. The gantry frame 301 is mounted in a straddle configuration on the frame of the conveyor 1. Multiple limiting guide wheels 303 are distributed at the four corners of the gantry frame 301 via bearings. The control box 306 and transmission box 307 are respectively bolted to the frame on both sides of the gantry frame 301 in the width direction, and the control box 306 and transmission box 307 are electrically connected. The main drive wheel 304 is mounted on the transmission box 307 and connected to a rotary motor inside the transmission box 307. The diamond wire saw 302 surrounds all the limiting guide wheels 303 and the main drive wheel 304 in a closed loop. The tension wheel 305 is hinged to the gantry frame 301 on the side near the transmission box 307 via the swing arm assembly 308, and the tension wheel 305 is in contact with the outer side of the diamond wire saw 302.

[0065] Preferably, the sawing machine 4 includes a saw frame 401, a saw blade 402, and a hydraulic cylinder 403. The saw frame 401 is mounted in a straddle configuration on the frame of the conveyor 1. Vertical guide rails 404 are provided on the columns on both sides of the saw frame 401, and the hydraulic cylinder 403 is mounted on the vertical guide rails 404 via vertical sliders 405. A traction motor 406 and a guide pulley 407 are provided at the top of the columns of the saw frame 401. The hydraulic cylinder 403 and / or the vertical slider 405 are connected to the traction motor 406 via a traction cable 408 that passes over the guide pulley 407. A cutting motor 409 is provided on the piston of the hydraulic cylinder 403. The saw blade 402 is mounted horizontally on the shaft of the cutting motor 409. Preferably, both the electrical signal acquisition device and the vibration signal acquisition device are provided on the hydraulic cylinder 403 and / or the cutting motor 409.

[0066] Preferably, multiple saw blades 402 and matching hydraulic cylinders 403, vertical sliders 405 and cutting motors 409 are independently installed on the columns on both sides of the saw frame 401 from top to bottom.

[0067] Preferably, the hammer-type striking machine 5 includes a support column 501, a top bracket 502, a lifting motor 503, a rack column 504, an eccentric drive box 505, an impact cylinder 506, and a striking hammer 507. The support column 501 is disposed on one side of the frame of the conveyor 1. The top bracket 502 is disposed at the top of the support column 501. The lifting motor 503 is disposed on the top bracket 502. At least one rack column 504 is disposed on the outer circumferential side of the support column 501, and the upper end of the rack column 504 meshes with the drive gear of the lifting motor 503. The eccentric drive box 505 is fixedly disposed on a sliding seat 508 at the bottom of the rack column 504. The impact cylinder 506 is disposed on the sliding seat 508 and located below the eccentric drive box 505, and the upper end of the impact cylinder 506 is connected to the eccentric output end of the eccentric drive box 505 through a hinged swing arm 509. The striking hammer 507 is located at the lower end of the impact cylinder 506.

[0068] Preferably, a dust cover 510 that folds and extends vertically is also fitted onto the rack post 504.

[0069] Preferably, a furnace slag collection mechanism is also provided on the lower side of the conveyor 1. The furnace slag collection mechanism includes a furnace slag conveyor belt 6 and a furnace slag collection box 7 located at the discharge end of the furnace slag conveyor belt 6.

[0070] Preferably, the processing system also includes a main control box 8, which is electrically connected to the conveyor 1, worktable 2, wire saw 3, saw blade machine 4, hammer impactor 5, as well as electrical signal acquisition devices and vibration signal acquisition devices. The main control box 8 controls the operating status of each component. Preferably, the main control box 8 is a PLC control cabinet.

[0071] Example 1

[0072] like Figure 1-5 As shown, a processing system for removing mica crystal deposits from furnace lining includes a moving device, an end furnace lining cutting device, a side furnace lining slitting device, and a side furnace lining peeling device. The moving device includes a conveyor 1 and a worktable 2 mounted on the conveyor 1. According to the material flow direction, the end furnace lining cutting device, the side furnace lining slitting device, and the side furnace lining peeling device are sequentially arranged on the conveyor 1. The end furnace lining cutting device is a wire saw 3. The side furnace lining slitting device is a saw blade 4, on which an electrical signal collector and a vibration signal collector are installed. The side furnace lining peeling device is a hammer-type striking machine 5.

[0073] Example 2

[0074] The embodiment 1 is repeated, except that the conveyor 1 includes a main frame 101 and a conveying track 102. The workbench 2 includes a support base 201, a rotary hydraulic lift 202, and a loading platform 203. The support base 201 is disposed on the conveying track 102 and can move along the conveying track 102 via rollers. The loading platform 203 is disposed on the support base 201 via the rotary hydraulic lift 202, and the rotation and height of the loading platform 203 are controlled by the rotary hydraulic lift 202.

[0075] Example 3

[0076] The embodiment 2 is repeated, except that the wire saw machine 3 includes a gantry frame 301, a diamond wire saw 302, guide wheels 303, a main drive wheel 304, a tension wheel 305, a control box 306, and a transmission box 307. The gantry frame 301 is mounted in a straddle configuration on the frame of the conveyor 1. Multiple guide wheels 303 are distributed at the four corners of the gantry frame 301 via bearings. The control box 306 and transmission box 307 are bolted to the frame on both sides of the gantry frame 301 in the width direction, and are electrically connected. The main drive wheel 304 is mounted on the transmission box 307 and connected to a rotary motor inside the transmission box 307. The diamond wire saw 302 surrounds all the guide wheels 303 and the main drive wheel 304 in a closed loop. The tension wheel 305 is hinged to the gantry frame 301 on the side near the transmission box 307 via the swing arm assembly 308, and the tension wheel 305 is in contact with the outer side of the diamond wire saw 302.

[0077] Example 4

[0078] The embodiment 3 is repeated, except that the sawing machine 4 includes a saw frame 401, a saw blade 402, and a hydraulic cylinder 403. The saw frame 401 is mounted in a straddle configuration on the frame of the conveyor 1. Vertical guide rails 404 are provided on the columns on both sides of the saw frame 401, and the hydraulic cylinder 403 is mounted on the vertical guide rails 404 via vertical sliders 405. A traction motor 406 and a guide pulley 407 are provided at the top of the columns of the saw frame 401. The hydraulic cylinder 403 and / or the vertical slider 405 are connected to the traction motor 406 via a traction cable 408 that passes over the guide pulley 407. A cutting motor 409 is provided on the piston of the hydraulic cylinder 403. The saw blade 402 is mounted horizontally on the shaft of the cutting motor 409.

[0079] Example 5

[0080] Repeat Example 4, except that both the electrical signal acquisition device and the vibration signal acquisition device are mounted on the cutting motor 409.

[0081] Example 6

[0082] Repeat Example 5, except that multiple saw blades 402 and matching hydraulic cylinders 403, vertical sliders 405 and cutting motors 409 are independently installed on the columns on both sides of the saw frame 401 from top to bottom.

[0083] Example 7

[0084] The embodiment 6 is repeated, except that the hammer-type striking machine 5 includes a support column 501, a top bracket 502, a lifting motor 503, a rack column 504, an eccentric drive box 505, an impact cylinder 506, and a striking hammer 507. The support column 501 is located on one side of the frame of the conveyor 1. The top bracket 502 is located at the top of the support column 501. The lifting motor 503 is located on the top bracket 502. At least one rack column 504 is provided on the circumferential outer side of the support column 501, and the upper end of the rack column 504 meshes with the drive gear of the lifting motor 503. The eccentric drive box 505 is fixedly mounted on a sliding seat 508 at the bottom of the rack column 504. The impact cylinder 506 is located on the sliding seat 508 and below the eccentric drive box 505, and the upper end of the impact cylinder 506 is connected to the eccentric output end of the eccentric drive box 505 via a hinged swing arm 509. The striking hammer 507 is located at the lower end of the impact cylinder 506.

[0085] Example 8

[0086] The embodiment 7 is repeated, except that a dust cover 510 that folds and extends vertically is also fitted onto the rack post 504.

[0087] Example 9

[0088] Example 8 is repeated, except that a furnace slag collection mechanism is also provided on the lower side of the conveyor 1. The furnace slag collection mechanism includes a furnace slag conveyor belt 6 and a furnace slag collection box 7 located at the discharge end of the furnace slag conveyor belt 6.

[0089] Example 10

[0090] The process is repeated in Embodiment 9, except that the processing system also includes a main control box 8. The main control box 8 is electrically connected to the conveyor 1, worktable 2, wire saw 3, saw blade machine 4, hammer impactor 5, as well as an electrical signal acquisition device and a vibration signal acquisition device. The main control box 8 controls the operating status of each component. The main control box 8 is a PLC control cabinet.

[0091] The process of removing furnace lining from mica crystals using the processing system of this invention is as follows: The mica crystal to be processed is hoisted and fixed onto the platform 203 of the workbench 2. The crystal is adjusted to the designated processing height by a rotary hydraulic lift 202. Then, the conveyor 1 is started, driving the workbench 2 to move along the conveyor track 102, conveying the mica crystal to the end cutting station of the wire saw 3. When the crystal is in place, the wire saw 3 is started, and the diamond wire saw 302 operates under the drive of the main drive wheel 304, horizontally cutting from the top and bottom of the crystal to remove the top and bottom furnace lining. The removed end furnace lining falls into the collection area below and is conveyed to the furnace lining collection box 7 via the furnace lining conveyor belt 6 for centralized collection. After the end furnace lining is removed, the conveyor 1 continues to drive the workbench 2 to move, conveying the processed crystal to the side furnace lining cutting station, where it is processed by the saw blade machine 4. Before processing, the average current I corresponding to the furnace skin cutting condition is obtained in advance based on the test calibration. A The maximum fluctuation value of the operating current ΔI, and the critical current value I when cutting to the mica crystal. C This is used to set the safe current threshold I0, so that I A +△I<I0<I C Similarly, the safe vibration energy threshold E0 corresponding to the vibration signal is obtained through calibration, satisfying E A +△E<E0<E CThe relevant threshold values ​​are pre-imported into the main control box 8. During processing, the traction motor 406 drives the hydraulic cylinder 403 and the cutting motor 409 to move downwards along the vertical guide rail 404, driving the rotating saw blade 402 to horizontally cut into the crystal from the side. The electrical signal acquisition device and the vibration signal acquisition device transmit the current signal and vibration signal of the cutting motor 409 to the main control box 8 in real time. When the measured current reaches the safe current threshold I0 and the measured vibration energy reaches the safe vibration energy threshold E0, the main control box 8 sends a command to stop the saw blade 402 from continuing to cut downwards. Then, the rotary hydraulic lift 202 drives the crystal to rotate at a set angle, and the saw blade 402 cuts at the next position. This process is repeated until the crystal is cut around its circumference, forming an annular slit with a depth that just reaches the interface between the furnace skin and the crystal. If multiple sets of saw blades 402 are configured, they can simultaneously cut at different heights on the side of the crystal, forming multiple annular slits and improving the efficiency of subsequent layering and peeling. After the side seams are cut, conveyor 1 continues to move the crystal mass to the side peeling station, where the hammer-type striking machine 5 performs the peeling process. The lifting motor 503 drives the rack column 504 to adjust the striking hammer 507 to the set height. The eccentric drive box 505 drives the impact cylinder 506 to periodically reciprocate via the hinged swing arm 509. The striking hammer 507 strikes the furnace skin located between multiple annular seams vertically from top to bottom, causing the furnace skin to break and peel off from the crystal mass surface along the seam. The peeled side furnace skin falls into the furnace skin collection mechanism below for centralized collection and cleaning. After all peeling processes are completed, conveyor 1 moves the processed crystal mass to the discharge station, where the peeled mica crystal is lifted off the platform and ready for the next processing step.

[0092] Application Examples

[0093] The mica crystals were peeled using the processing system described in Example 10:

[0094] First, a synthetic mica crystal agglomerate with a diameter of 2.5 m and a height of 2 m is transported to the processing station of the wire saw machine 3 along with the worktable 2. The diamond wire saw 302 is aligned with the bottom of the crystal agglomerate to be cut. The cutting system is started through the control box 306 and the transmission box 307. The diameter of the diamond wire saw used is 5 mm, and the cutting speed is 15 cm / min. The bottom of the crystal agglomerate is cut first. After the cutting is completed, the loose material on the worktable 2 is pushed to the furnace skin conveyor belt 6 for collection. Then, the height of the worktable 2 is adjusted so that the diamond wire saw 302 is aligned with the top of the crystal agglomerate to be cut. After the cutting is completed, the loose material is pushed to the furnace skin conveyor belt 6 for collection. Then, the crystal agglomerate is moved to the next processing station along with the worktable 2. The total time for this stage is about 40 minutes (including about 6 minutes for posture adjustment and furnace skin cleaning).

[0095] When the crystal ingot reaches the processing station of the sawing machine 4, the conveyor 1 stops running. The worktable 2 lifts the crystal ingot to the target height and then automatically rotates at a speed of 0.02r / min. The main control box 8 starts the saw blade 402 to perform slitting processing on the side furnace of the crystal ingot. The lifting stroke of the saw blade is 2.1m, and the processing speed is 1cm / min. Under the current working condition, the rated current of the cutting motor 409 is 20A. Through experimental calibration: the average working condition current I when purely cutting the furnace skin A =8A, the maximum fluctuation value of the working condition current ΔI=2A; the average working condition vibration energy E A =0.5V 2 , the maximum fluctuation value of the working condition vibration energy ΔE=0.1V 2 ; the critical current value I when the crystal body is touched for the first time C =12A, the critical vibration energy value E when the crystal body is touched for the first time C =2.0V 2 . The current weight coefficient α=0.7 and the vibration weight coefficient β=0.3 (α>β) are set, so the cutting index S=0.7×G+0.3×H. In the stage of purely cutting the furnace skin, the current and vibration energy are usually close to the average value, but may reach a certain upper limit due to material unevenness or fluctuation. Therefore, the extreme case of this stage is taken while leaving a more sufficient safety margin: that is, I1=10A, E1=1.0V 2 , G1=(I1-I A ) / (I C -I A )=0.5, H1=(E1-E A ) / (E C -E A )=0.33, so the cutting index S1 at this time is 0.45; when the saw blade touches the high-hardness crystal body, the current and vibration energy will rise significantly and approach the critical value, and the signal level at the beginning of this stage is taken: I2=11.5A, E2=1.5V 2 , the calculation shows that G2=0.875, H2=0.67, S2=0.81, so the index safety threshold under the current working condition should satisfy: 0.45<S0≤0.81. Considering that signal fluctuations may exist in actual working conditions and the feed mechanism requires a certain response time, the value of S0 should be appropriately biased to the upper-middle position to leave a safety margin. Therefore, the current cutting index safety threshold S0 is set to 0.7. After cutting for a period of time, the current measured current I=11.6A is detected in real time, then G=0.9; the current measured vibration energy E=1.6V 2When H = (1.6 - 0.5) / (2.0 - 0.5) = 0.73, the current cutting index value S = 0.7 × 0.9 + 0.3 × 0.73 = 0.849 > 0.7. Since S > S0, the system determines that the saw blade 402 (driven by the cutting motor 409) has contacted the crystal body and issues a stop command. The saw blade 402 is then moved circumferentially to the next position to continue circumferential cutting, repeating the above process until a circumferential cut is obtained. The total time for this stage is approximately 280 minutes (including approximately 30 minutes for attitude adjustment and furnace slag cleaning). It should be noted that the above calculations are performed without units; the units are only used for measuring the signal amplitude and do not affect the final judgment result of the cutting index.

[0096] When the crystal agglomerate reaches the processing station of the hammer-type impactor 5, the conveyor 1 stops running, the worktable 2 lifts the crystal agglomerate to the target height, the lifting motor 503 drives the rack column 504 downward, and adjusts the hammer 507 to the top position of the uppermost layer of furnace skin. Then, the eccentric drive box 505 starts, driving the impact cylinder 506 to perform periodic reciprocating swings. The hammer 507 continuously strikes the furnace skin at the annular cut with a set impact force, causing that section of furnace skin to fall off the surface of the crystal agglomerate along the cut. After the uppermost section of furnace skin is peeled off, the lifting motor 503 drives the hammer 507 to move down to the position between the next two annular cuts, and repeats the above hammering and peeling operation until all the furnace skin between all annular cuts is peeled off. All the furnace skin fragments generated during the peeling process fall into the furnace skin conveyor belt 6 below and are directly transported to the furnace skin collection box for unified collection, preventing them from scattering in the processing area and causing dust accumulation. The total time for this stage is approximately 70 minutes (including about 10 minutes for posture adjustment and furnace slag cleaning).

[0097] Statistics show that the total peeling time for this synthetic mica crystal was approximately 6.5 hours, representing a processing efficiency increase of over 60% compared to traditional manual pneumatic pick peeling (approximately 16 hours). The final mica crystals showed no damage from over-cutting, achieving a yield of 98.5%, significantly higher than traditional peeling methods. The entire process requires only manual intervention during hoisting and unloading; all other steps are automated, eliminating the need for operators to enter the processing area. This completely avoids the health hazards of dust and noise, eliminates the safety risks of manual operation, and meets the processing needs of large-scale industrial synthetic mica production.

[0098] It should be noted that the above embodiments are merely typical examples of the present invention and are not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A processing system for removing mica crystal deposits from furnace lining, characterized in that: The processing system includes a moving device, an end furnace scabbard removal device, a side furnace scabbard cutting device, and a side furnace scabbard peeling device; the moving device includes a conveyor (1) and a worktable (2) set on the conveyor (1); according to the direction of the material, the end furnace scabbard removal device, the side furnace scabbard cutting device, and the side furnace scabbard peeling device are sequentially distributed on the conveyor (1); the end furnace scabbard removal device is a wire saw (3); the side furnace scabbard cutting device is a saw blade machine (4), and an electrical signal collector and a vibration signal collector are set on the saw blade machine (4); the side furnace scabbard peeling device is a hammer-type striking machine (5).

2. The processing system according to claim 1, characterized in that: The conveyor (1) includes a main frame (101) and a conveying track (102); the workbench (2) includes a support base (201), a rotary hydraulic lift (202) and a loading platform (203); the support base (201) is set on the conveying track (102) and can move along the conveying track (102) by rollers; the loading platform (203) is set on the support base (201) by the rotary hydraulic lift (202), and the rotation and height of the loading platform (203) are controlled by the rotary hydraulic lift (202).

3. The processing system according to claim 1 or 2, characterized in that: The wire saw machine (3) includes a gantry frame (301), a diamond wire saw (302), a limiting guide wheel (303), a main drive wheel (304), a tensioning wheel (305), a control box (306), and a transmission box (307); the gantry frame (301) is arranged in a straddle configuration on the frame of the conveyor (1); multiple limiting guide wheels (303) are distributed at the four corners of the gantry frame (301) via bearings; the control box (306) and the transmission box (307) are respectively fixed to both sides of the gantry frame (301) in the width direction by bolts. The frame is electrically connected between the control box (306) and the transmission box (307); the main drive wheel (304) is mounted on the transmission box (307) and connected to the rotary motor inside the transmission box (307); the diamond wire saw (302) surrounds all the limit guide wheels (303) and the main drive wheel (304) in a closed loop; the tension wheel (305) is hinged to the gantry frame (301) on the side near the transmission box (307) via the swing arm assembly (308), and the tension wheel (305) is in contact with the outer side of the diamond wire saw (302).

4. The processing system according to any one of claims 1-3, characterized in that: The sawing machine (4) includes a saw frame (401), a saw blade (402), and a hydraulic cylinder (403); the saw frame (401) is mounted in a straddle configuration on the frame of the conveyor (1); vertical guide rails (404) are provided on the columns on both sides of the saw frame (401), and the hydraulic cylinder (403) is mounted on the vertical guide rails (404) via vertical sliders (405); a traction motor (406) and a guide pulley (407) are provided at the top of the columns of the saw frame (401). The hydraulic cylinder (403) and / or the vertical slider (405) are connected to the traction motor (406) via a traction cable (408) that passes over the guide pulley (407); a cutting motor (409) is provided on the piston of the hydraulic cylinder (403); the saw blade (402) is mounted horizontally on the shaft of the cutting motor (409); preferably, both the electrical signal acquisition device and the vibration signal acquisition device are provided on the hydraulic cylinder (403) and / or the cutting motor (409); As a preferred embodiment, multiple saw blades (402) and matching hydraulic cylinders (403), vertical sliders (405) and cutting motors (409) are independently installed on the columns on both sides of the saw frame (401) from top to bottom.

5. The processing system according to any one of claims 1-4, characterized in that: The hammer-type striking machine (5) includes a support column (501), a top bracket (502), a lifting motor (503), a rack column (504), an eccentric drive box (505), an impact cylinder (506), and a striking hammer (507); the support column (501) is located on one side of the frame of the conveyor (1); the top bracket (502) is located at the top of the support column (501); the lifting motor (503) is located on the top bracket (502); at least one rack is provided on the outer circumferential side of the support column (501). The rack column (504) is connected to the drive gear of the lifting motor (503) at its upper end; the eccentric drive box (505) is fixedly mounted on the sliding seat (508) at the bottom of the rack column (504); the impact cylinder (506) is mounted on the sliding seat (508) and located on the lower side of the eccentric drive box (505), and the upper end of the impact cylinder (506) is connected to the eccentric output end of the eccentric drive box (505) through the hinged swing arm (509); the hammer (507) is mounted on the lower end of the impact cylinder (506). Preferably, a dust cover (510) that folds and extends vertically is also fitted onto the rack post (504).

6. The processing system according to any one of claims 1-5, characterized in that: A furnace skin collection mechanism is also provided on the lower side of the conveyor (1); the furnace skin collection mechanism includes a furnace skin conveyor belt (6) and a furnace skin collection box (7) provided at the discharge end of the furnace skin conveyor belt (6); and / or The processing system also includes a main control box (8), which is electrically connected to the conveyor (1), workbench (2), wire saw (3), saw blade machine (4), hammer hammer (5), electrical signal collector and vibration signal collector; the main control box (8) controls the operating status of each component; preferably, the main control box (8) is a PLC control cabinet.

7. A method for removing mica crystal deposits from furnace lining, or a method for removing mica crystal deposits from furnace lining using the processing system described in any one of claims 1-6, characterized in that: The method includes the following steps: S1: First, cut off the top and bottom furnace skin of the crystal along the horizontal direction of the crystal; S2: Then, the furnace skin on the side of the crystal pile is circumferentially cut to form at least one annular slit. During the circumferential cutting process, the circumferential cutting depth is adjusted in real time according to the changes in the current signal and vibration energy signal of the circumferential cutting equipment, so that the annular slit can penetrate to the junction of the furnace skin and the mica crystal. S3: Finally, the furnace skin on the side of the crystal with the annular slit is peeled off layer by layer along the vertical direction of the crystal.

8. The method according to claim 7, characterized in that: In step S2, the real-time adjustment of the circumferential cutting depth based on changes in the current signal and vibration energy signal of the circumferential cutting equipment specifically includes: S201: Use a ring-cutting device to cut only the furnace shell, and measure the operating current data and operating vibration energy data of the ring-cutting device during furnace shell cutting; S202: Using a circumferential cutting device to cut only the mica crystal, the critical current data and critical vibration energy data of the circumferential cutting device when first contacting the mica crystal were measured; S203: Set the safe current threshold and safe vibration energy threshold based on operating current data, operating vibration energy data, critical current data, and critical vibration energy data; S204: During the actual circumferential cutting process, the side furnace skin is cut at any position in the circumferential direction of the crystal pile by continuously increasing the kerf depth. The current value and vibration energy value of the circumferential cutting equipment are monitored in real time. When the measured current value exceeds the safe current threshold and / or the measured vibration energy value exceeds the safe vibration energy threshold, the central control system normalizes the measured current value and measured vibration energy value and merges them into a cutting index S according to the weight. When S exceeds the cutting index safety threshold, the cutting at the current position is stopped, and the cutting operation continues in the same way at the adjacent position along the circumferential direction of the crystal pile. This cycle is repeated until a circumferential kerf is formed.

9. The method according to claim 8, characterized in that: The operating current data includes the average operating current I. A and the maximum fluctuation value of the operating current ΔI; the operating vibration energy data includes the average value of the operating vibration energy E. A and the maximum fluctuation value of vibration energy under operating conditions, ΔE; Preferably, the critical current value is set to I. C The critical vibration energy value is E C If the safe current threshold is I0 and the safe vibration energy threshold is E0, then: (I A +△I) <I0<I C (E) A +△E) <E0<E C .

10. The method according to claim 8 or 9, characterized in that: The real-time acquired current and vibration energy values ​​of the circumferential cutting equipment are normalized to obtain a normalized current value G and a normalized vibration value H. Then, the cutting index S is calculated using the normalized current value G as the primary factor and the normalized vibration value H as the secondary factor. Cutting is stopped when the obtained cutting index S is greater than or equal to the safety threshold S0; otherwise, the cutting operation continues. The cutting index S is calculated using the following mathematical model: S = α·G + β·H (1); In equation (1), α is the current energy weighting coefficient, with a value of 0.6~0.8; β is the vibration energy weighting coefficient, with a value of 0.2~0.4; α+β=1.

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