Energy-saving roller compacted soil premixing and processing equipment

Abstract

The application discloses an energy-saving type roller compacted soil premixing and production processing equipment, and belongs to the technical field of road building material processing equipment. The whole machine comprises a conveyor frame, a material tank, a tank clamping and positioning mechanism, a bidirectional crushing mechanism, a warehouse wall anti-sticking collision mechanism, a spiral premixing mechanism, a pre-press feeding structure, a dust closed recovery mechanism and a load energy-saving electric control system. The gear turntable type clamping mechanism prevents the tank from slipping and leaking material. A pair of reverse crushing teeth uniformly crush soil and gravel. The eccentric linkage air bag periodically shakes and falls the accumulated material on the warehouse wall. The spiral blade uniformly premixes the solidified soil. The pre-press feeding ball at the bottom of the warehouse compacts the soil body in advance, reduces the roadbed rolling energy consumption, and is matched with a negative pressure dust recovery and automatic dust cleaning structure. A double load sensor linkage controller realizes motor step energy-saving regulation and control. The application synchronously solves six problems of traditional equipment, i.e., material leakage loss, uneven crushing, difficult cleaning of accumulated material on the warehouse wall, high on-site rolling energy consumption, dust pollution and idle power consumption. The application has the advantages of high continuous production efficiency, low raw material loss, remarkable energy-saving effect of the whole machine, and is suitable for batch processing of various solidified soils for municipal roadbeds and factory hardening.

Description

Technical Field

[0001] This invention relates to the technical field of raw material processing equipment for solidified soil road construction, specifically an energy-saving roller-compacted solidified soil premixing and production processing equipment. Background Technology

[0002] Roadbed and site hardening projects extensively utilize compacted soil as a filling base material. This soil is made by mixing undisturbed soil, a hardener, and aggregates in a specific ratio, followed by compaction and rolling. It boasts advantages such as high strength, good water stability, and low cost due to its local sourcing. The production of compacted soil involves multiple processes, including raw material transportation, crushing and screening, proportioning and mixing, and pre-compaction. Existing compacted soil mixing and processing equipment suffers from several industry-wide pain points. The material conveying station lacks an adaptive clamping and positioning mechanism, causing soil and aggregate bins to easily shift and slide on the conveyor belt. During mixing and material discharge, a large amount of material spills out, resulting in significant raw material loss and serious dust pollution. Large lumps of undisturbed clay and agglomerated sand and gravel are crushed by a single set of crushing teeth, resulting in uneven particle size. Large soil clumps and hard sand and gravel cannot be fully integrated with the curing agent after entering the mixing chamber, and the solidified soil has large dispersion in strength. Materials tend to stick to the walls of the mixing bin and accumulate, requiring manual cleaning, which takes a long time to shut down. Furthermore, the accumulated materials can significantly increase mixing energy consumption, resulting in poor energy efficiency of the equipment. Premixed and solidified soil has high looseness, and is directly discharged and transported to the compaction station. It has many internal pores, and the energy consumption for on-site compaction is doubled. There is no pre-compacted structure. The equipment lacks a matching dust closed recovery system, and the entire crushing and mixing process generates a large amount of dust, resulting in a poor working environment in the factory area, waste of raw materials due to dust, and the risk of environmental penalties. The motors in each process run at full load continuously. Without a gravity load induction energy-saving control structure, there is serious ineffective consumption of electrical energy under no-load and light-load conditions, resulting in high overall energy consumption of the equipment. Summary of the Invention

[0003] This invention aims to provide an energy-saving rolling-compacted solidified soil premixing and processing equipment, solving the technical problems of material leakage from the hopper, uneven particle size of crushed soil blocks, material adhesion and accumulation on the silo wall, high energy consumption during on-site rolling due to the lack of a pre-compression structure, lack of dust recovery, and high no-load energy consumption of the motor in existing solidified soil processing equipment. It realizes integrated production of raw material positioning, bidirectional crushing, silo wall self-cleaning, pre-compression, centralized dust recovery, and load-sensing energy saving.

[0004] Technical solution An energy-saving roller-compacted solidified soil premixing and processing equipment includes a conveyor frame, a material carrying bin on the top of the conveyor frame, a load detection sensor fixed inside the conveyor frame, a whole-machine support frame erected outside the conveyor frame, a mixing installation frame fixed on the top of the whole-machine support frame, and a raw material feed bin erected on the top of the mixing installation frame. The equipment is characterized by further including a material bin clamping and positioning mechanism; the material bin clamping and positioning mechanism includes a track support, the track support is fixedly welded to the outer wall of the whole-machine support frame, a positioning slider is slidably mounted on the inner wall of the track support, a lifting slide rod is vertically fixed on the side wall of the positioning slider, an extended positioning sleeve is slidably sleeved outside the lifting slide rod, a clamping pressure plate is fixed at the outer end of the extended positioning sleeve, and a [missing information - likely a device or component] is fixed at the top of the extended positioning sleeve. L-shaped transmission slide bar; the left flange of the whole machine bearing bracket is fixed to clamp the drive motor, the output shaft of the clamping drive motor is rigidly connected to the rotary transmission shaft, the outer wall of the rotary transmission shaft is fixed to the drive gear, the outer side of the drive gear meshes with the arc-shaped gear disk, the bottom of the arc-shaped gear disk is coaxially fixed to the rotary turntable, the side wall of the rotary turntable is opened with a guide clamping groove, the inner wall of the guide clamping groove slides and fits in contact with the end of the L-shaped transmission slide bar for transmission; the outer wall of the rotary turntable is equipped with a lifting guide mechanism; the top of the mixing installation frame is equipped with a bidirectional crushing mechanism; the lower end of the raw material feed hopper is connected to the mixing and storage hopper, the inside of the mixing and storage hopper is equipped with a hopper wall anti-sticking and collision mechanism; a spiral pre-mixing mechanism is installed in the middle of the inner cavity of the mixing and storage hopper; a dust closed recovery mechanism is set at the bottom of the mixing and storage hopper.

[0005] Preferred: The energy-saving roller-compacted solidified soil premixing and processing equipment according to claim 1 is characterized in that the lifting and guiding mechanism includes an annular guide groove, which is formed in a ring on the outer wall of the rotating turntable, and the annular guide groove is connected to the guide clamping groove end to end; the top surface of the rotating turntable is integrally formed with an arc-shaped guide platform, the top surface of the arc-shaped guide platform is embedded with a gravity load sensor, and the outer wall of the arc-shaped guide platform is fixed with a vibration pad.

[0006] Preferred: The energy-saving roller-compacted solidified soil premixing and processing equipment according to claim 1 is characterized in that the bidirectional crushing mechanism includes a crushing servo motor, the crushing servo motor is bolted to the top of the mixing installation frame, the output end of the crushing servo motor is sleeved with a transmission belt, the transmission belt drives and connects to the main crushing shaft, the main crushing shaft extends laterally through the side wall of the raw material feed hopper into the hopper; primary crushing teeth are evenly arranged on the outer wall of the main crushing shaft; a driving meshing gear is fixed in the middle section of the main crushing shaft, the driving meshing gear meshes with a driven gear on its lower side, a secondary crushing shaft is fixed at the center of the driven gear, and secondary crushing teeth are arranged on the outer wall of the secondary crushing shaft.

[0007] Preferred: The energy-saving compacted solidified soil premixing and processing equipment according to claim 3 is characterized in that the anti-sticking and collision mechanism of the silo wall includes an eccentric drive shaft, both ends of which penetrate through the silo wall of the mixing and storage silo, and both ends of the eccentric drive shaft are synchronously connected to the output end of the crushing servo motor; eccentric wheels are fixed at both ends of the eccentric drive shaft; a convex sliding frame is fixed to the side wall of the mixing and storage silo, a concave sliding plate is slidably assembled on the outside of the convex sliding frame, and a reciprocating swing plate is integrally formed at the bottom of the concave sliding plate, the reciprocating swing plate has a first-stage swing groove, and the inner wall of the first-stage swing groove slides against the outer edge of the eccentric wheel.

[0008] Preferred: The energy-saving roller-compacted solidified soil premixing and processing equipment according to claim 4 is characterized in that: an extrusion cylinder is fixed to the side wall of the mixing and storage silo; an extrusion ball head is slidably assembled inside the extrusion cylinder; a push rod is fixed to the outside of the extrusion ball head; and a swing connecting rod is hinged to the outer end of the push rod; a reciprocating swing plate is provided with a secondary swing groove; and the end of the swing connecting rod is slidably embedded into the secondary swing groove; a vent is provided on the side wall of the extrusion cylinder; an expansion air bladder is connected to the inside of the extrusion cylinder; and the expansion air bladder is set in close contact with the inner wall of the mixing and storage silo.

[0009] Preferred: The energy-saving roller-compacted solidified soil premixing and processing equipment according to claim 5 is characterized in that the spiral premixing mechanism includes a main bevel gear, which is coaxially fixed to the middle of the eccentric drive shaft; a vertical mounting frame is fixed inside the mixing storage silo, and a mixing drive rod is rotatably assembled inside the vertical mounting frame; a driven bevel gear is fixed at the top of the mixing drive rod, and the driven bevel gear meshes perpendicularly with the main bevel gear; mixing and conveying blades are spirally arranged on the outer wall of the mixing drive rod; a pre-compression feeding ball is fixed in the middle section of the rotating transmission shaft, and the outer wall of the pre-compression feeding ball rolls against the inner wall of the bottom of the mixing storage silo; a pre-compression feeding cavity is opened inside the pre-compression feeding ball.

[0010] Preferred: The energy-saving roller-compacted solidified soil premixing and processing equipment according to claim 6 is characterized in that the dust closed recovery mechanism includes a sealed dust cover, the sealed dust cover is sealed and closed to the bottom discharge port of the mixing and storage silo; a limiting plate is fixed on the side of the sealed dust cover, the inner wall of the limiting plate is slidably limited to the outer edge of the rotating turntable; the top of the sealed dust cover is connected to a dust suction pipe, the lower end of the dust suction pipe is detachably equipped with a dust filter cloth, the top of the dust suction pipe is connected to a dust removal fan, and the dust removal fan frame is fixed on the top of the whole machine support bracket.

[0011] Preferred: The energy-saving compacted solidified soil premixing and processing equipment according to claim 7 is characterized in that the outer wall of the rotary transmission shaft is equipped with an automatic dust removal vibration mechanism; the automatic dust removal vibration mechanism includes a teardrop-shaped push block, which is fixedly sleeved on the rotary transmission shaft; a return spring is vertically fixed on the top surface of the sealed dust cover, a vibration pressure plate is fixed at the lower end of the return spring, a dust removal impact rod is vertically fixed at the bottom of the vibration pressure plate, and the lower end of the dust removal impact rod is arranged opposite to the surface of the dust filter cloth.

[0012] Preferred: The energy-saving roller-compacted solidified soil premixing and processing equipment according to claim 8 is characterized in that the load detection sensor, gravity load sensor, crushing servo motor, clamping drive motor, and dust removal fan are electrically connected to the whole machine energy-saving controller, and the controller automatically adjusts the output power of each motor according to the real-time load, and automatically reduces the load to save power under no-load conditions.

[0013] Beneficial effects This invention features a gear-driven rotary material box clamping and positioning mechanism. After the material box is conveyed to the mixing station, it is automatically clamped on both sides. The material box will not slip or deviate during the entire conveying and unloading process, which greatly reduces the spillage and loss of soil and aggregate. At the same time, it works with a sealed dust cover and a dust removal fan to achieve closed dust collection throughout the entire process, reducing raw material waste and environmental risks of dust in the plant area. A pair of counter-rotating bidirectional crushing blades are used to simultaneously and bidirectionally shear and crush large clay and gravel, resulting in uniform particle size of the crushed material. The solidifying agent is fully integrated with the soil, ensuring stable strength of the solidified soil subgrade and avoiding localized strength deficiencies. Equipped with an eccentric wheel linkage anti-sticking and collision mechanism for the bin wall, the squeeze airbag periodically vibrates to clean the soil adhering to the bin wall, eliminating the need for manual cleaning and reducing downtime. At the same time, the absence of material accumulation on the bin wall reduces the rotational resistance of the mixing blades, significantly reducing the equipment's mixing energy consumption and meeting the energy-saving design goals. The pre-compression feed balls at the bottom can pre-compress and compact the pre-mixed and solidified soil during the discharge stage, eliminating a large number of air pores inside the soil. After being transported to the roadbed compaction station, the load on the compaction equipment is reduced under the same degree of compaction, and the energy consumption of on-site construction is greatly reduced. The machine is equipped with dual load sensors (conveyor load + internal gravity load). The energy-saving controller dynamically adjusts the output power of each drive motor according to the real-time material load. It automatically reduces power during no-load and light-load conditions, eliminating the ineffective energy consumption caused by the motor running at full load. The overall energy-saving effect of the equipment is outstanding. The automatic dust removal vibration mechanism periodically impacts the dust filter cloth to prevent dust accumulation and clogging, and to reduce the dust collection efficiency. It eliminates the need for frequent manual disassembly and cleaning of the filter material, reducing the frequency of equipment maintenance. It integrates the entire process of conveying and positioning, bidirectional crushing, anti-sticking mixing, pre-compression, dust recovery, and energy-saving control, making it suitable for the batch continuous production of road solidified soil. Attached Figure Description

[0014] Figure 1 This is a three-dimensional assembly diagram of the entire machine of the present invention; Figure 2 This is a separate structural diagram of the conveyor frame and the material box of the present invention; Figure 3 This is a side view of the top-feed crushing mechanism of the present invention; Figure 4This is a top view of the material box clamping and positioning mechanism of the present invention; Figure 5 This is an exploded view of the lifting guide mechanism of the present invention; Figure 6 Detailed drawing of the annular groove fitting for the turntable guide groove; Figure 7 This is a cross-sectional view of the bidirectional crushing mechanism; Figure 8 A cross-sectional view of the collision mechanism inside the mixing and storage silo; Figure 9 for Figure 8 Detailed magnified view of the airbag at point A; Figure 10 This is a diagram of the internal structure of the spiral premixing mechanism; Figure 11 This is an assembly diagram showing the linkage between the spiral mixer and the pre-compressed feed ball. Figure 12 Detailed cross-sectional view of the pre-compression feed chamber; Figure 13 This is an overall diagram of the bottom dust collection mechanism; Figure 14 Detailed enlarged view of the dust removal vibration mechanism.

[0015] Attached reference numerals: 101, conveyor frame; 102, material carrying bin; 103, load detection sensor; 104, overall support bracket; 105, mixing mounting frame; 106, raw material feed bin; 2, bin clamping and positioning mechanism; 201, track support; 202, positioning slider; 203, lifting slide bar; 204, extension positioning sleeve; 205, clamping pressure plate; 206, L-shaped transmission slide bar; 21, clamping drive motor; 22, rotary transmission shaft; 23, drive gear. 24. Wheel; 25. Arc-shaped toothed disc; 26. Rotary turntable; 3. Guide clamping groove; 3. Lifting guide mechanism; 301. Annular guide groove; 302. Arc-shaped guide platform; 303. Gravity load sensor; 304. Vibrating pad; 4. Bidirectional crushing mechanism; 401. Crushing servo motor; 402. Transmission belt; 403. Main crushing shaft; 404. Primary crushing cutter teeth; 405. Active meshing gear; 406. Driven gear; 407. Secondary crushing shaft; 408. Secondary crushing shaft; 5. Crushing blades; 5. Anti-sticking and collision mechanism for bin walls; 501. Mixing and storage bin; 502. Eccentric drive shaft; 503. Eccentric wheel; 504. Convex sliding frame; 505. Concave sliding plate; 506. Reciprocating swing plate; 507. Primary swing groove; 51. Extrusion cylinder; 52. Extrusion ball head; 53. Push rod; 54. Swinging connecting rod; 55. Secondary swing groove; 56. Vent hole; 57. Expansion air bladder; 6. Spiral pre-mixing mechanism; 601. Main bevel gear; 602. 603. Vertical mounting frame; 604. Mixing drive rod; 605. Driven bevel gear; 606. Mixing and conveying blades; 607. Pre-compression feed ball; 608. Pre-compression feed chamber; 709. Dust enclosed recovery mechanism; 7001. Sealed dust cover; 71. Limiting plate; 7002. Dust suction pipe; 701. Dust filter cloth; 702. Dust removal fan; 803. Automatic dust removal vibration mechanism; 804. Teardrop-shaped push block; 805. Return spring; 806. Vibrating pressure plate; 807. Dust removal impact bar. Detailed Implementation

[0016] The following is in conjunction with the appendix Figures 1-14 The invention provides a complete and detailed description of the overall structure, complete solidified soil production process, multi-condition adaptation, energy-saving control logic, and equipment maintenance scheme. Equivalent substitutions and structural modifications obtained by those skilled in the art based on this embodiment without creative effort are all within the scope of protection of the claims of this invention.

[0017] Example 1: Standard Production Condition Assembly and Complete Processing Flow of Standard Municipal Roadbed Stabilized Soil I. Step-by-step assembly process of the whole machine The conveying unit is assembled with a horizontally mounted conveyor frame 101. Shock-absorbing feet are installed at the bottom of the frame. Multiple load detection sensors 103 are installed at equal intervals on the inner side of the frame, and the sensor signal lines are connected to the energy-saving controller of the whole machine. Material carrying bins 102 are arranged in a loop above the conveyor frame. The bins are used to hold raw soil, sand and gravel aggregates, and powdered curing agents. The whole machine bearing support 104 is welded as a whole on the outer side of the frame. The support is made of thickened channel steel and supports the upper crushing and mixing mechanism to ensure the rigidity of the equipment during operation.

[0018] The clamping and positioning mechanism is assembled with the left flange of the machine support bracket to fix the clamping drive motor 21. The output end of the motor is coaxially locked with the rotating transmission shaft 22. The track bracket 201 is welded to both sides of the bracket. The positioning slider 202 is installed inside the track. The slider is equipped with a lifting slide rod, an extended positioning sleeve and a clamping pressure plate. The drive gear 23 on the transmission shaft meshes with the arc-shaped gear plate 24 at the bottom of the rotating turntable. The side wall of the turntable is opened with an annular connecting guide clamping groove and an annular guide groove. The end of the L-shaped transmission slide rod slides into the groove. The rotation of the gear drives the four sets of clamping pressure plates to clamp the material box inward synchronously, so as to achieve synchronous positioning on all four sides.

[0019] The top bidirectional crushing mechanism assembly and mixing mounting frame 105 is bolted to the top of the bearing support, and the raw material feeding hopper 106 is installed above the frame. The crushing servo motor 401 is fixed to the side of the mounting frame and connected to the main crushing shaft by belt drive. The main and auxiliary shafts rotate synchronously in opposite directions through a pair of meshing gears. The outer wall of the shaft is equipped with primary and secondary crushing blades, which are made of wear-resistant high manganese steel and are suitable for crushing high-hardness clay lumps and crushed stone. The motor output end synchronously leads out a transmission shaft to connect to the eccentric drive shaft inside the hopper, realizing synchronous linkage between crushing and hopper wall cleaning. They share a single power source, reducing motor configuration and lowering the overall energy consumption of the equipment.

[0020] The internal structure of the mixing silo is equipped with a raw material feeding silo with a sealed connection at the lower end to the mixing storage silo 501. The two sides of the silo wall are equipped with a convex sliding frame, a reciprocating swing plate and an eccentric wheel assembly. The vertical mounting frame in the middle of the silo fixes the spiral premixing mechanism. The main bevel gear in the middle of the eccentric drive shaft meshes perpendicularly with the driven bevel gear at the top of the mixing drive rod, which drives the mixing and conveying blades to spirally lift the soil, aggregate and curing agent to complete uniform premixing. The bottom of the silo is equipped with a rolling pre-compression feeding ball. The pre-compression feeding chamber runs through the mixing space inside the silo and compresses and pre-compacts the solidified soil when discharging.

[0021] The dust recovery and cleaning mechanism is assembled with a dust cover 701 at the bottom of the mixing and storage material outlet. The dust suction pipe at the top of the dust cover is connected to the dust removal fan, and the dust filter cloth can be detachably installed at the bottom of the pipe. A teardrop-shaped push block is fixed on the outer wall of the rotating drive shaft. A reset spring, a vibrating pressure plate, and a cleaning impact rod are vertically fixed on the top surface of the dust cover. When the drive shaft rotates, the push block periodically pushes up the pressure plate, and the spring falls back, causing the impact rod to strike the filter cloth, shaking off and intercepting dust to prevent the filter cloth from clogging and failing.

[0022] The electric control energy-saving system is equipped with load detection sensors, gravity load sensors, and all drive motors are connected to the whole machine energy-saving controller. The controller has a built-in load segment adjustment program, which collects the material inventory in the bin and the weight of the conveying bin in real time, and automatically adjusts the motor output power in three levels: no load, light load, and standard heavy load, to achieve energy-saving operation throughout the process.

[0023] II. Complete process of premixing and processing solidified soil corresponds to steps S1~S8 of claim 10. S1. Raw Material Feeding and Conveying: Manually, unprocessed soil, crushed stone aggregate, and powdered soil stabilizer are fed into the raw material feeding hopper in batches. The conveyor chain drives the material-carrying bins forward. Load detection sensors at the bottom of the bins collect the total weight of the materials in real time, and the weight signal is transmitted to the energy-saving controller in real time to predict and adjust the motor power level in advance. S2. Automatic Bin Positioning and Clamping: When the bin is conveyed to the work station directly below the mixing area, the controller triggers the clamping drive motor to start. The rotating transmission shaft drives the drive gear to drive the arc-shaped gear disk and the rotating turntable to rotate synchronously. The turntable guide clamping groove pushes four sets of L-shaped transmission slide rods to retract synchronously. The lifting slide rods drive the clamping pressure plate to clamp the material-carrying bin from four sides. Throughout the entire process of conveying, crushing, and dropping, the bins do not shift or tip over, eliminating soil spillage and loss from the source. S3. The bidirectional synchronous crushing servo motor drives the main crushing shaft to rotate forward via a transmission belt. The active meshing gear drives the driven gear and the secondary crushing shaft to rotate in the opposite direction. Two sets of crushing blades, one forward and one reverse, synchronously shear large pieces of clay and lumps of sand and gravel. The bidirectional extrusion crushing results in uniform particle size. After large pieces of material are completely crushed, they fall into the mixing and storage bin below, ensuring that the curing agent and soil are fully mixed, resulting in uniform roadbed forming strength. S4. The bin wall anti-sticking self-cleaning crushing servo motor synchronously drives the eccentric wheels at both ends of the eccentric drive shaft to rotate continuously. The eccentric wheels reciprocate to push the reciprocating swing plate to swing left and right. The swing linkage drives the extrusion ball head to periodically extrude air inside the cylinder. After the air is squeezed into the expansion airbag, the airbag expands. When the eccentric wheel rotates to the non-extrusion zone, the airbag retracts. The periodic expansion and contraction of the airbag vibrates the inner wall of the mixing bin, shaking off the adhering lumps of soil. There is no need to stop the machine to manually shovel material, reducing mixing resistance and lowering motor load energy consumption. S5. In the spiral premixing process, the main bevel gear in the middle of the eccentric drive shaft synchronously drives the driven bevel gear and the mixing drive rod to rotate. The mixing and conveying blades spirally lift the soil, sand, gravel, and curing agent from bottom to top, continuously spiraling and mixing to achieve full premixing. The uniformly mixed and cured soil sinks downward to the discharge area at the bottom of the bin. S6. The pre-compacting discharge turntable rotates continuously. The L-shaped transmission slide rod lifts the clamping mechanism along the annular guide groove, and the material carrying box is lifted as a whole into the sealed dustproof cover's enclosed space. The rotating transmission shaft synchronously drives the pre-compacting feed ball to roll and compress the mixed and cured soil at the bottom of the bin. The compression eliminates a large number of air pores inside the soil, and the density of the pre-compacted cured soil is improved. After being transported to the roadbed compaction station, the energy consumption of the compaction equipment is reduced by more than 30% under the same compaction standard. S7. Dust closed-loop recovery and cleaning process: The dust removal fan continuously extracts dust from the bin under negative pressure during crushing and mixing. The dust-laden airflow enters the dust collection pipe, and the dust filter cloth intercepts soil dust, while clean air is discharged. With each rotation of the rotating drive shaft, the teardrop-shaped pusher pushes up the vibrating pressure plate, the reset spring quickly falls back, and the dust removal impact rod strikes the surface of the dust filter cloth, causing the attached dust to automatically fall back into the mixing bin. This not only avoids filter cloth clogging and dust collection failure but also recovers dust raw materials, eliminating raw material waste.S8, with load adaptive energy-saving control, the top surface gravity load sensor of the arc guide table collects the material inventory inside the mixing bin in real time. When there is no material in the bin and it is unloaded, the controller automatically reduces the power of the crushing motor, clamping motor, and fan by 40%; when there is a small amount of material in the bin and it is lightly loaded, the power is reduced by 20%; when the bin is full of material, the rated output power is restored under standard working conditions, eliminating the continuous full-load idling of the motor and reducing the overall production energy consumption of the machine by 22%.

[0024] Example 2: Optimization Scheme for High-Capacity Adaptation in Large-Scale Roadbed Engineering Equipment optimization and adjustments were made for the continuous production of large-scale solidified soil on highways: The conveyor frame has been lengthened to 12m and equipped with 6 sets of material carrying bins for cyclic conveying. The load detection sensors are densely arranged to improve the accuracy of weight detection. The power of the crushing servo motor has been increased to 7.5kW, and the crushing blades have been thickened with a wear-resistant alloy layer, making them suitable for large blocks of original hard clay. The spiral premixing blades are widened, and the mixing and storage silo volume is expanded to 6m³, increasing the single mixing capacity. The dust removal fan has increased air volume, the dust collection pipe has been thickened, and a double-layer dust filter cloth has been added, improving the recovery efficiency under high dust conditions. Actual test results: Under continuous 24-hour uninterrupted production conditions, the raw material spillage loss has been reduced from 11% of traditional equipment to 1.2%, the strength dispersion coefficient of solidified soil has been significantly reduced, the overall power saving of the machine is 22.7%, the energy consumption of on-site roadbed compaction construction has been reduced by 31%, and the monthly manual cleaning and maintenance hours of the equipment have been reduced by 85%.

[0025] Example 3: Hardening and Lightweight Adaptation Scheme for Small Factory Areas Lightweight models were used for small-scale hardening projects in the factory area. Each motor uses a low-power servo motor, the conveyor frame is shortened to 4m, and the single-box loading capacity of the material bin is reduced; Simplified crusher blade arrangement, suitable for small pieces of purchased externally screened soil; The energy-saving controller retains the basic logic of three-level load adjustment and the automatic unload function is fully retained; Operational effect: In intermittent small-batch production conditions, the power consumption of the equipment during standby and no-load is reduced by 45%, the raw material loss of small projects is controllable, and dust is completely enclosed with no spillage.

[0026] Example 4: Standardized structural parameters of the whole machine and its practical application effect Crushing mechanism: main / auxiliary crushing shaft speed difference 1:1.2, crushing blade hardness HRC52, single crushing particle size control 0~15mm; The clamping mechanism has a single clamping stroke of 0~180mm, and is suitable for material bins with a width of 0.8~2.2m; The preloading feed ball rolls are compressed at a pressure of 12kN, and the soil porosity decreases by 28% after preloading. The dust collector fan has a negative pressure of -2200Pa and a dust interception and recovery rate of 98.5%. Energy-saving control levels: 60% of rated power under no-load, 80% of rated power under light load, and 100% of rated power under heavy load; Actual comprehensive benefits: Compared with traditional solidified soil mixing equipment without clamping, pre-compression, or load control, raw material loss is reduced by 90%, overall production energy consumption is reduced by 22%, on-site roadbed compaction energy consumption is reduced by 30%, monthly manual cleaning hours are reduced by 85%, and dust pollution fully meets environmental protection control requirements.

[0027] It should be noted that the present invention is not limited to the above embodiments. Any technical solution that is based on the core innovative structure of the present invention, namely "automatic clamping and positioning of the hopper, bidirectional synchronous crushing, airbag hopper wall anti-sticking, spiral pre-mixing, bottom pre-compression and compaction, closed-loop dust recovery, and load-sensing graded energy saving", and makes conventional dimensional adjustments or equivalent replacements to the motor power, hopper volume, blade size, and conveying length, falls within the protection scope of the present invention.

Claims

1. An energy-saving roller-compacted solidified soil premixing and processing equipment, comprising a conveyor frame (101), a material carrying bin (102) disposed on the top of the conveyor frame (101), a load detection sensor (103) fixed inside the conveyor frame (101), a whole machine support bracket (104) erected outside the conveyor frame (101), a mixing installation frame (105) fixed on the top of the whole machine support bracket (104), and a raw material feed bin (106) erected on the top of the mixing installation frame (105), characterized in that, It also includes a material box clamping and positioning mechanism (2); the material box clamping and positioning mechanism (2) includes a track bracket (201), the track bracket (201) is fixedly welded to the outer wall of the whole machine bearing bracket (104), the inner wall of the track bracket (201) is slidably fitted with a positioning slider (202), the side wall of the positioning slider (202) is vertically fixed with a lifting slide rod (203), the outside of the lifting slide rod (203) is slidably fitted with an extension positioning sleeve (204), the outer end of the extension positioning sleeve (204) is fixed with a clamping pressure plate (205), and the top of the extension positioning sleeve (204) is fixed with an L-shaped transmission slide rod (206); the left flange of the whole machine bearing bracket (104) is fixed with a clamping drive motor (21), the output shaft of the clamping drive motor (21) is rigidly connected to a rotary transmission shaft (22), and the outer wall of the rotary transmission shaft (22) is fixed with a main The drive gear (23) meshes with the outer side of the arc-shaped gear disk (24), and the bottom of the arc-shaped gear disk (24) is coaxially fixed with the rotating turntable (25). The side wall of the rotating turntable (25) is provided with a guide clamping groove (26), and the inner wall of the guide clamping groove (26) slides and fits with the end of the L-shaped transmission slide rod (206) for transmission. The outer wall of the rotating turntable (25) is equipped with a lifting guide mechanism (3). The top of the mixing installation frame (104) is equipped with a bidirectional crushing mechanism (4). The lower end of the raw material feed hopper (106) is connected to the mixing storage hopper (501), and the mixing storage hopper (501) is equipped with a hopper wall anti-sticking collision mechanism (5). The middle of the inner cavity of the mixing storage hopper (501) is equipped with a spiral pre-mixing mechanism (6). The bottom of the mixing storage hopper (501) is provided with a dust closed recovery mechanism (7).

2. The energy-saving roller-compacted solidified soil premixing and processing equipment according to claim 1, characterized in that, The lifting guide mechanism (3) includes an annular guide groove (301), which is formed in an annular shape on the outer wall of the rotating turntable (25). The annular guide groove (301) is connected to the guide clamping groove (26) end to end. The top surface of the rotating turntable (25) is integrally formed with an arc-shaped guide platform (302). The top surface of the arc-shaped guide platform (302) is fitted with a gravity load sensor (303). The outer wall of the arc-shaped guide platform (302) is fixed with an vibration pad (304).

3. The energy-saving roller-compacted solidified soil premixing and processing equipment according to claim 1, characterized in that, The bidirectional crushing mechanism (4) includes a crushing servo motor (401), which is bolted to the top of the mixing mounting frame (105). The output end of the crushing servo motor (401) is connected to a transmission belt (402), which is connected to the main crushing shaft (403). The main crushing shaft (403) extends laterally through the side wall of the raw material feed hopper (106) into the hopper. The outer wall of the main crushing shaft (403) is equidistantly provided with first-stage crushing blades (404). The middle section of the main crushing shaft (403) is fixed with an active meshing gear (405), and the lower side of the active meshing gear (405) meshes with a driven gear (406). The center of the driven gear (406) is fixed with a secondary crushing shaft (407), and the outer wall of the secondary crushing shaft (407) is provided with second-stage crushing blades (408).

4. The energy-saving roller-compacted solidified soil premixing and processing equipment according to claim 3, characterized in that, The anti-sticking and collision mechanism (5) of the silo wall includes an eccentric drive shaft (502), with both ends of the eccentric drive shaft (502) penetrating through the silo wall of the mixing and storage silo (501). Both ends of the eccentric drive shaft (502) are synchronously connected to the output end of the crushing servo motor (401). Eccentric wheels (503) are fixed at both ends of the eccentric drive shaft (502). A convex sliding frame (504) is fixed to the side wall of the mixing and storage silo (501). A concave sliding plate (505) is slidably assembled on the outside of the convex sliding frame (504). A reciprocating swing plate (506) is integrally formed at the bottom of the concave sliding plate (505). A first-level swing groove (507) is opened on the reciprocating swing plate (506). The inner wall of the first-level swing groove (507) slides against the outer edge of the eccentric wheel (503).

5. The energy-saving roller-compacted solidified soil premixing and processing equipment according to claim 4, characterized in that, The side wall of the mixing and storage silo (501) is fixed with an extrusion cylinder (51), and an extrusion ball head (52) is slidably assembled inside the extrusion cylinder (51). A push rod (53) is fixed on the outside of the extrusion ball head (52), and a swing connecting rod (54) is hinged to the outer end of the push rod (53). A secondary swing groove (55) is opened on the reciprocating swing plate (506), and the end of the swing connecting rod (54) is slidably embedded in the secondary swing groove (55). A vent hole (56) is opened on the side wall of the extrusion cylinder (51), and an expansion air bladder (57) is connected to the inside of the extrusion cylinder (51). The expansion air bladder (57) is fitted to the inner wall of the mixing and storage silo (501).

6. The energy-saving roller-compacted solidified soil premixing and processing equipment according to claim 5, characterized in that, The spiral pre-mixing mechanism (6) includes a main bevel gear (601), which is coaxially fixed in the middle of the eccentric drive shaft (502); a vertical mounting frame (602) is fixed inside the mixing storage silo (501), and a mixing drive rod (603) is rotatably assembled inside the vertical mounting frame (602). A driven bevel gear (604) is fixed at the top of the mixing drive rod (603), and the driven bevel gear (604) meshes perpendicularly with the main bevel gear (601); mixing and conveying blades (605) are spirally arranged on the outer wall of the mixing drive rod (603); a pre-pressurizing feed ball (606) is fixed in the middle section of the rotating transmission shaft (22), and the outer wall of the pre-pressurizing feed ball (606) rolls against the inner wall of the bottom of the mixing storage silo (501). A pre-pressurizing feed cavity (607) is opened inside the pre-pressurizing feed ball (606).

7. The energy-saving roller-compacted solidified soil premixing and processing equipment according to claim 6, characterized in that, The dust enclosed recycling mechanism (7) includes a sealed dust cover (701), which is sealed and closed to the bottom outlet of the mixing and storage silo (501); a limiting plate (71) is fixed on the side of the sealed dust cover (701), and the inner wall of the limiting plate (71) slides and limits the outer edge of the rotating turntable (25); the top of the sealed dust cover (701) is connected to the dust suction pipe (702), the lower end of the dust suction pipe (702) is detachably equipped with a dust filter cloth (703), the top of the dust suction pipe (702) is connected to the dust removal fan (704), and the frame of the dust removal fan (704) is fixed on the top of the whole machine support bracket (104).

8. The energy-saving roller-compacted solidified soil premixing and processing equipment according to claim 7, characterized in that, The outer wall of the rotary transmission shaft (22) is equipped with an automatic dust removal vibration mechanism (8); the automatic dust removal vibration mechanism (8) includes a teardrop-shaped push block (801), which is fixedly sleeved on the rotary transmission shaft (22); a reset spring (802) is vertically fixed on the top surface of the sealed dust cover (701), a vibration pressure plate (803) is fixed at the lower end of the reset spring (802), and a dust removal impact rod (804) is vertically fixed at the bottom of the vibration pressure plate (803), with the lower end of the dust removal impact rod (804) arranged opposite to the surface of the dust filter cloth (703).

9. The energy-saving roller-compacted solidified soil premixing and processing equipment according to claim 8, characterized in that, The load detection sensor (103), gravity load sensor (303), crushing servo motor (401), clamping drive motor (21), and dust removal fan (704) are electrically connected to the whole machine energy-saving controller. The controller automatically adjusts the output power of each motor according to the real-time load and automatically reduces the load to save power in no-load conditions.

Images