Full-automatic forming device for homogeneous air brick

Abstract

According to the full-automatic forming device for the homogeneous air brick, a mold and a vibration table are fixed in a magnetic attraction mode, on one hand, a magnetic shielding means is adopted, so that paramagnetic materials such as steel fibers in castable are prevented from being influenced by magnetic force, and the purpose of homogenization is achieved; and on the other hand, the vibration table with the three-phase alternating-current vibration motor as a power source is automatically controlled through a PLC, the device can automatically recognize the amount of the castable in the mold, then the needed vibration force is adjusted, and automatic forming is achieved.

Description

TECHNICAL FIELD

[0001] The patent relates to a steel metallurgical furnace outside refining bottom blowing argon gas permeable brick and seat brick, in particular to a mold structure for casting of the gas permeable brick and seat brick, a fixing mode between the vibrating table and the vibrating table control mode and a forming method. BACKGROUND

[0002] The gas permeable brick is a core component of the outside refining process in the steel metallurgical field, and the significance of the gas permeable brick lies in stirring the molten steel by bottom blowing argon gas to achieve the effects of adjusting the composition of the molten steel, adjusting the temperature of the molten steel and removing inclusions.

[0003] In terms of structure, the gas permeable brick is generally divided into two parts: a gas permeable core and a gas permeable seat brick. Most of the gas permeable cores on the market are traditional slit type gas permeable cores, that is, the loss on ignition is pre-placed in the mold according to certain specification requirements, and the gas passage is generated after molding by firing. The specification, structure and distribution of the loss on ignition directly determine the related characteristics of the gas passage of the gas permeable core. In recent years, various structures of the gas permeable core have appeared, but without exception, there is a step of vibration forming, and the gas permeable seat brick also needs vibration forming. That is, the vibration is used to make the refractory castable with specific properties flow to fill the mold space. In this process, processes such as exhaust and particle free accumulation are involved to densify and homogenize the cast body, and then the cast body is solidified by chemical or physical methods to have a certain shape, and then subsequent process treatment is carried out. It can be seen that vibration forming is an indispensable process for the gas permeable brick product, and it is of great significance to optimize and create it.

[0004] The gas permeable core castable generally selects corundum-spinel or chromium oxide-corundum-spinel materials, and some no-baking gas permeable cores also add a part of steel fibers with a 446# brand. Such steel fibers have certain paramagnetism. Steel fibers are almost added in the seat brick, and such steel fibers also have certain paramagnetism.

[0005] In the refractory industry, there are two ways of vibration forming, vibration rod and vibration table. The former is placed in the mold, which is similar to the common concrete construction. This method is not suitable for the gas permeable brick.

[0006] The simple structure of the vibration table is to fix a suitable vibration source, such as a vibrating motor, on a working platform, and then suspend or place the working platform on several groups of vibration reduction springs that meet the requirements. The working table is driven to reciprocate by the vibration source, and the parameters of the vibration source and the spring parameters determine the parameters of the vibration table, such as the vibration direction, the excitation force and the load.

[0007] At present, the conventional vibration forming mode of the air brick is to fix the mold on the vibration platform by mechanical connection such as bolt connection or magnetic attraction, to add refractory castable after starting the vibration table, and finally to have a "point vibration" process, that is, to open and close the vibration table in a very short time, the purpose is to adjust the vibration force, so as to realize the surface flow state or exhaust function of the refractory castable.

[0008] Obviously, under the condition of frequent and high-intensity vibration, it is unreliable to fix the mold on the vibration table by mechanical means, the related parts are easy to loosen and damage, the degree of automation is not high, the production efficiency is low, and the product quality stability is unreliable.

[0009] The seat brick and part of the air core contain steel fibers, and the magnetic attraction method will also cause the steel fibers to sink and segregate to different degrees, resulting in uneven products and affecting the use effect. In actual application, many molten steel leakage accidents are caused by uneven steel fibers, but most of them are not deeply understood.

[0010] The air brick is located at the bottom of the ladle, which is a consumable material, and the working condition environment is extremely complex, and molten steel leakage accidents are easy to occur. In addition, its function is directly related to the stirring effect of molten steel, which directly determines the quality of the secondary refining. The service life of the air brick is the short board of the overall service life of the ladle refractory, and its service life directly determines the comprehensive cost and comprehensive energy consumption of the overall refractory of the ladle. The shape feature of the air core is a frustum with a very large height-diameter ratio, such as a commonly used air core with a height of 500mm and a medium diameter of only 120mm-160mm, which belongs to "slim type". The feeding is slow during forming, and the forming operation time is long, and the upper and lower parts are easy to appear uneven. It can be seen that the vibration method has a great influence, therefore, under the premise of pursuing high-quality products and high-safety products, in order to realize the above-mentioned "functional", "high life", "safety" characteristics, the vibration forming equipment should be matched with the weight and fluid characteristics of the refractory castable as much as possible, so as to manufacture high-quality and high-safety products.

[0011] The traditional method is to start the vibration table until the feeding is finished, and the vibration parameters are constant during the process, which are not matched with the castable added in the mold. Obviously, there is a lot of room for improvement in this process. SUMMARY

[0012] In view of the above-mentioned deficiencies, a series of technical solutions are adopted: 1, relay control, magnetic attraction method is used to fix the mold to form a steel fiber-free air brick castable

[0013] This structure consists of three parts: the breathable core or base brick mold, the vibration system, and the control unit. The mold requires a paramagnetic steel base plate with a thickness of 10mm-30mm. The vibration system includes one or more vibration motors, a symmetrical steel work platform, multiple vibration-damping springs of the same model, and one or more electromagnets. When the electromagnets are energized, they are attracted and fixed to the mold. When the electromagnets are de-energized, there is no active force between them and the mold, allowing the mold to be removed. The core components of the control unit are a multi-speed transfer switch, multiple circulating time relays, and a contactor. Three-phase AC power enters the vibration motor through the working end of the contactor. Each circuit of the multi-speed transfer switch is connected to a circulating time relay, and the output terminals of all circulating time relays are connected to the input terminals of the contactor control unit.

[0014] If there are multiple vibration motors, they must be of the same model and adjusted to the same exciting force.

[0015] The vibration motors are installed at the center of gravity below the working platform or symmetrically with the center of gravity. The electromagnets are fixed on the upper part of the working platform. The mold is above the electromagnets. The steel structure frame with the vibration motors and electromagnets is placed on the shock-absorbing springs.

[0016] The sum of the exciting forces of the vibration motors is 1.3-1.5 times the sum of the weight of the steel structure workbench, the weight of all vibration motors, the weight of all electromagnets, the weight of all molds, and the weight of the refractory castables filled in the molds.

[0017] The magnetic force exerted by the electromagnet on the mold is more than 1.1 times the exciting force.

[0018] The multi-speed transfer switch has 4-8 line positions, one of which is a normally open line.

[0019] The control scheme of the system is:

[0020] A multi-speed transfer switch has multiple circuits, one of which is normally off. When the switch is turned to position 1, line 1 is connected, and the other circuits are disconnected. When the switch is turned to position 2, line 2 is connected, and the other circuits are disconnected, and so on. When the switch is turned to the normally off circuit, there is no circuit. Except for the normally off circuit, each circuit is connected to a circulating time relay. The function of a circulating time relay is to connect for a certain period of time and then disconnect for a certain period of time, such as connecting for 30 seconds, disconnecting for 10 seconds, and so on. A circulating time relay can only set two sets of time: on time and disconnect time. Therefore, the control system requires multiple circulating time relays to set multiple different sets of on time and disconnect time. During operation, only one of the multiple relays is connected, and only one circuit is active. The relay controls the opening and closing of the contactor, thereby controlling the rotation and stopping of the vibration motor. For example, when the transfer switch is turned to position 1, the vibration motor will be on for 30 seconds, off for 10 seconds, and so on; after a certain period of time, when the transfer switch is turned to position 2, the on time of the cyclic time relay connected to gear 2 is set to 60 seconds, and the off time is set to 40 seconds, and the vibration motor will be on for 60 seconds, off for 40 seconds, and so on; turning the transfer switch to position 3 is similar; turning the transfer switch to the normally off position will stop the vibration motor from working.

[0021] The vibration motor's power is turned on and off via a time relay and contactor, and its inertia is used to control its output vibration force. When the vibration motor is powered on, its speed gradually reaches its maximum value, and the vibration force also gradually reaches its maximum value. If the power is disconnected before reaching the maximum value, or if the power is connected before the speed drops to zero, the desired vibration force can be achieved by repeating this cycle.

[0022] During the operation, people judge the weight of the castable added to the mold based on experience and set 4-6 groups of time relays to ensure appropriate vibration force. When there is more castable in the mold, the vibration force is adjusted to be larger.

[0023] The beneficial effects of this solution are that the mold and the vibration system are securely fixed and not loose; the mold is easy to remove, greatly improving production efficiency; at the same time, when there is less castable in the mold, that is, when the weight is light, a smaller vibration force is applied; the more castable in the mold, the greater the vibration force applied. This is in line with the scientific nature of material molding and will greatly avoid phenomena such as segregation and unevenness. This solution is suitable for vibration molding of castables without steel fibers. In addition, the residual magnetic force when the electromagnet acts on the mold may exert a force on certain particles in the castable, resulting in a certain order in the internal structure of the product, which may have a negative impact. In this case, the following solution can be adopted:

[0024] 2. Relay control, magnetically fix the mold to form the steel fiber-containing breathable brick casting material

[0025] This structure consists of three parts: a breathable core or base brick mold, a vibration system, and a control unit. The mold base, which contacts the magnetic suction cup, requires a paramagnetic steel portion with a thickness of 10mm-30mm. A magnetic shielding plate is embedded in the base directly below the product, close to the electromagnet. A certain distance between the shielding plate and the electromagnet is optimal, while the rest of the base contacts the electromagnet to generate the suction force. The vibration system consists of one or more vibration motors, a symmetrical steel work platform, multiple vibration damping springs of the same type, and one or more electromagnets. The electromagnets are fixed to the steel work platform. When the electromagnets are energized, they attract and secure the mold. When the electromagnets are de-energized, there is no active force between them, allowing the mold to be removed. The core components of the control unit are a multi-speed transfer switch, multiple circulating time relays, and a contactor. Three-phase AC power flows through the working terminal of the contactor and enters the vibration motor. Each circuit of the multi-speed transfer switch is connected to a circulating time relay, and the output terminals of all circulating time relays are connected to the input terminals of the contactor control unit.

[0026] If there are multiple vibration motors, they must be of the same model and adjusted to the same exciting force.

[0027] The magnetic shielding plate is made of an industrial plate with a thickness of 3-6 mm and has a magnetic shielding function, such as a metal aluminum plate.

[0028] The vibration motors are installed at the center of gravity below the working platform or symmetrically with the center of gravity. The electromagnets are fixed on the upper part of the working platform. The mold is above the electromagnets. The steel structure frame with the vibration motors and electromagnets is placed on the shock-absorbing springs.

[0029] The sum of the exciting forces of the vibration motors is 1.3-1.5 times the sum of the weight of the steel structure workbench, the weight of all vibration motors, the weight of all electromagnets, the weight of all molds, and the weight of the refractory castables filled in the molds.

[0030] The magnetic force exerted by the electromagnet on the mold is more than 1.1 times the exciting force.

[0031] The multi-speed transfer switch has 4-8 line positions, one of which is a normally open line.

[0032] The control scheme of the system is:

[0033] A multi-speed transfer switch has multiple circuits, one of which is normally off. When the switch is turned to position 1, line 1 is connected, and the other circuits are disconnected. When the switch is turned to position 2, line 2 is connected, and the other circuits are disconnected, and so on. When the switch is turned to the normally off circuit, there is no circuit. Except for the normally off circuit, each circuit is connected to a circulating time relay. The function of a circulating time relay is to connect for a certain period of time and then disconnect for a certain period of time, such as connecting for 30 seconds, disconnecting for 10 seconds, and so on. A circulating time relay can only set two sets of time: on time and disconnect time. Therefore, the control system requires multiple circulating time relays to set multiple different sets of on time and disconnect time. During operation, only one of the multiple relays is connected, and only one circuit is active. The relay controls the opening and closing of the contactor, thereby controlling the rotation and stopping of the vibration motor. For example, when the transfer switch is turned to position 1, the vibration motor will be on for 30 seconds, off for 10 seconds, and so on; after a certain period of time, when the transfer switch is turned to position 2, the on time of the cyclic time relay connected to gear 2 is set to 60 seconds, and the off time is set to 40 seconds, and the vibration motor will be on for 60 seconds, off for 40 seconds, and so on; turning the transfer switch to position 3 is similar; turning the transfer switch to the normally off position will stop the vibration motor from working.

[0034] The vibration motor's power is turned on and off via a time relay and contactor, and its inertia is used to control its output vibration force. When the vibration motor is powered on, its speed gradually reaches its maximum value, and the vibration force also gradually reaches its maximum value. If the power is disconnected before reaching the maximum value, or if the power is connected before the speed drops to zero, the desired vibration force can be achieved by repeating this cycle.

[0035] During the operation, people judge the weight of the castable added to the mold based on experience and set 4-6 groups of time relays to ensure appropriate vibration force. When there is more castable in the mold, the vibration force is adjusted to be larger.

[0036] This solution provides a reliable, non-loose connection between the mold and the vibration system, making the mold extremely easy to remove and significantly improving production efficiency. Magnetic shielding reduces or even eliminates the effect of magnetic forces on the distribution of steel fibers, making them more uniform. Furthermore, when the mold contains less castable material, i.e., lighter weight, a smaller vibration force is automatically applied. The greater the castable material, the greater the vibration force applied. This approach adheres to scientific principles of material forming and significantly avoids segregation and unevenness. However, control via time relays still has significant drawbacks.

[0037] 3. Frequency conversion control, magnetic fixation of mold to form steel fiber-free breathable brick casting material

[0038] The structure includes three parts, the air-permeable core or the seat brick mold part, the vibration system part, and the control part. The mold requires that the bottom plate is made of steel, has paramagnetism, and has a thickness of 10 mm-30 mm; the vibration system part includes one or more vibration motors, a symmetrical steel structure working platform, a plurality of damping springs of the same type, and one or more electromagnets. When the electromagnets are powered on, the mold is attracted and fixed; when the electromagnets are powered off, the mold has no active force, and the mold can be removed; the core component of the control part is a frequency converter. After the working alternating current is input into the frequency converter, it is input into the vibration motor.

[0039] If there are multiple vibration motors, they are required to be of the same type and adjusted to the same exciting force.

[0040] The vibration motors are installed at the gravity center or symmetrically with the gravity center below the working platform, the electromagnets are fixed on the upper part of the working platform, and the steel structure frame with the vibration motors and electromagnets installed thereon is placed on the damping springs.

[0041] The sum of the exciting forces of the vibration motors is 1.3-1.5 times the sum of the weight of the steel structure working platform, the weight of all vibration motors, the weight of all electromagnets, the weight of all molds, and the weight of the full refractory castable in the mold.

[0042] The magnetic force of the electromagnets acting on the mold is 1.1 times or more than the exciting force.

[0043] The control scheme of the system is that the knob of the frequency converter is connected to the working platform to facilitate operation, the working alternating current is connected to the vibration motor after passing through the frequency converter, the current frequency input into the vibration motor is changed through the frequency converter knob, the speed of the motor is controlled, and finally the vibration force of the vibration motor is controlled.

[0044] During the operation process, the vibration force required by the weight of the castable added into the mold is determined by human judgment, the frequency converter knob is adjusted, the appropriate vibration force is obtained, and when there is more castable in the mold, the vibration force is adjusted a little larger.

[0045] The beneficial effects of this scheme are that the fixation between the mold and the vibration system is reliable and does not loosen, the mold is extremely easy to remove, the production operation efficiency is greatly improved, the smaller vibration force is automatically applied when the castable in the mold is less, that is, the weight is light, the more castable in the mold, the larger the vibration force applied, the scientificity of material forming is met, and the phenomena such as segregation and unevenness are greatly avoided, the control through the frequency converter is convenient and flexible, and the required vibration force can be adjusted at any time.

[0046] 4, frequency conversion control, and the mold is fixed in a magnetic attraction mode to form a castable containing steel fiber air-permeable brick

[0047] This structure consists of three parts: the air-permeable core or base brick mold, the vibration system, and the control unit. The mold requires that at least the base plate in contact with the magnetic suction cup be made of paramagnetic steel with a thickness of 10mm-30mm. A magnetic shielding plate is embedded in the base plate directly below the product, close to the electromagnet. A certain distance between the shielding plate and the electromagnet is optimal, while the rest of the base plate contacts the electromagnet to generate the suction force. The vibration system includes one or more vibration motors, a symmetrical steel work platform, multiple damping springs of the same model, and one or more electromagnets. When the electromagnets are energized, they are fixed to the mold. When the electromagnets are de-energized, there is no active force between them and the mold, allowing the mold to be removed. The core component of the control unit is the frequency converter.

[0048] If there are multiple vibration motors, they must be of the same model and adjusted to the same exciting force.

[0049] The magnetic shielding plate is made of aluminum plate with a thickness of 3-6 mm.

[0050] The vibration motors are installed at the center of gravity below the working platform or symmetrically with the center of gravity. The electromagnets are fixed on the upper part of the working platform. The mold is above the electromagnets. The steel structure frame with the vibration motors and electromagnets is placed on the shock-absorbing springs.

[0051] The sum of the exciting forces of the vibration motors is 1.3-1.5 times the sum of the weight of the steel structure workbench, the weight of all vibration motors, the weight of all electromagnets, the weight of all molds, and the weight of the refractory castables filled in the molds.

[0052] The magnetic force exerted by the electromagnet on the mold is more than 1.1 times the exciting force.

[0053] The control scheme of this system is: the inverter knob is connected to the work platform for easy operation, the working AC power is connected to the vibration motor after passing through the inverter, and the current frequency input to the vibration motor is changed by the inverter knob, thereby controlling the motor speed and ultimately the vibration force of the vibration motor.

[0054] During the operation, people judge the weight of the castable added to the mold based on experience and adjust the inverter knob to achieve appropriate vibration force. When there is more castable in the mold, the vibration force is adjusted to be larger.

[0055] The beneficial effects of the scheme are that the mold and the vibration system are fixed reliably and not loose, the mold is extremely easy to remove, and the production efficiency is greatly improved; through the magnetic shielding method, the influence of magnetic force on the distribution of steel fibers is reduced or even avoided, making it more uniform; at the same time, when the mold has less casting material, i.e., when it is light, a smaller vibration force is automatically applied, and the more casting material in the mold, the greater the vibration force applied, which conforms to the material forming science and greatly avoids segregation, unevenness and other phenomena; the frequency converter control is more convenient and flexible, and the vibration can be adjusted at any time. However, the frequency converter control needs manual operation, and the automatic degree is still low.

[0056] 5. Time-controlled steel fiber-free air brick forming system

[0057] The structure includes three parts, an air core or seat brick mold part, a vibration system part, and a control part. The mold requires a steel base plate with paramagnetism and a thickness of 10-30 mm; the vibration system part includes one or more vibration motors, a symmetrical steel structure workbench, multiple same type damping springs, and one or more electromagnets. When the electromagnet is powered on, it is attracted and fixed to the mold, and when the electromagnet is powered off, the mold has no active force and can be removed. The core component of the control part is PLC and a frequency converter.

[0058] If there are multiple vibration motors, they are required to be of the same type and adjusted to the same excitation force.

[0059] The vibration motors are installed at or symmetrically with the center of gravity below the workbench, and the electromagnets are fixed to the upper part of the workbench. The steel structure frame with vibration motors and electromagnets is placed on the damping springs.

[0060] The sum of the excitation forces of the vibration motors is 1.3-1.5 times the sum of the weight of the steel structure workbench, the weight of all vibration motors, the weight of all electromagnets, the weight of all molds, and the weight of the full refractory casting material in the mold.

[0061] The magnetic force of the electromagnet acting on the mold is 1.1 times or more of the excitation force.

[0062] The control scheme of the system is: using the PLC analog quantity module to control the current frequency of the frequency converter output, then controlling the rotating speed of the motor, and finally controlling the vibration force. The parameters of the frequency converter are set as analog quantity control, the time and vibration percentage curve graph is designed according to the feeding time and the required vibration force, the frequency of the current output by the frequency converter is programmed and modified in the PLC controller according to the curve graph, the vibration force of the vibration motor is judged, and the final current frequency at different times is determined. The shorter the time is, the less the material in the mold is, and the smaller the required vibration force is. The vibration percentage refers to the ratio of the output vibration force to the maximum vibration force of the motor. If the vibration percentage is 100%, it is the maximum vibration force. If the vibration percentage is 0, there is no vibration. The vibration percentage and the input current frequency of the vibration motor are in a functional relationship.

[0063] The beneficial effects of the present application are: through the above method, the mold is automatically subjected to a smaller vibration force when the pouring material in the mold is less, i.e. when the weight is light. The more the pouring material in the mold is, the greater the vibration force is. PLC control has high reliability and can realize the molding of multiple products with different weights. Only the required curve graph needs to be selected. The scheme conforms to the scientificity of material molding and can greatly avoid segregation, unevenness and other phenomena.

[0064] 6. Time control system for forming of air brick containing steel fiber

[0065] The structure includes three parts, an air core or base brick mold part, a vibration system part, and a control part. The bottom plate that requires contact with the magnetic chuck is made of steel and has paramagnetism, with a thickness of 10-30 mm. A magnetic shielding plate is embedded in the bottom plate below the product, close to the electromagnet side. The magnetic shielding plate and the electromagnet have a certain distance, which is the best. The other parts of the bottom plate are in contact with the electromagnet to generate an attractive force. The vibration part is a vibration platform driven by a three-phase AC vibration motor. The core component of the control part is PLC and a frequency converter.

[0066] If there are multiple vibration motors, they must be of the same model and adjusted to the same exciting force.

[0067] The vibration motors are installed at the center of gravity or symmetrically with the center of gravity below the working platform. The electromagnet is fixed to the upper part of the working platform. The steel structure frame with the vibration motor and the electromagnet is placed on the damping spring.

[0068] The sum of the exciting forces of the vibration motors is 1.3-1.5 times the sum of the weight of the steel structure working table, the weight of all vibration motors, the weight of all electromagnets, the weight of all molds, and the weight of the full refractory pouring material in the mold.

[0069] The magnetic force of the electromagnet acting on the mold is 1.1 times or more than the exciting force.

[0070] The magnetic shielding plate is selected from an aluminum plate with a thickness of 3-6 mm.

[0071] The control scheme of the system is: using the PLC analog module to control the current frequency of the frequency converter output, then controlling the rotating speed of the motor, and finally controlling the vibration force. The parameters of the frequency converter are set to analog control, the time and vibration percentage curve diagram are designed according to the feeding time and required vibration force, the frequency of the current output by the frequency converter is modified according to the curve diagram, the vibration force of the vibration motor is judged, and the final parameters are determined. The shorter the time is, the less the material in the mold is, and the smaller the required vibration force is. The vibration percentage refers to the ratio of the output vibration force to the maximum vibration force of the motor. If the vibration percentage is 100%, it is the maximum vibration force. If the vibration percentage is 0, there is no vibration. The vibration percentage and the input current frequency of the vibration motor are in a functional relationship.

[0072] The beneficial effects of the present application are: through the magnetic shielding mode, the influence of magnetic force on the distribution of steel fibers is reduced or even avoided, so that the distribution of steel fibers is more uniform; when the amount of cast material in the mold is small, i.e. the weight is light, a small vibration force is automatically applied; the more the cast material in the mold, the greater the vibration force applied. PLC control has high reliability and can realize the molding of multiple products with different weights. Only the required curve diagram needs to be selected. This scheme conforms to the scientificity of material molding and can greatly avoid segregation, unevenness and other phenomena.

[0073] The feeding time is controlled, which has a high degree of automation, but it has certain mechanical properties and cannot completely apply appropriate vibration force according to the weight of the cast material in the mold. Therefore, the following scheme can be adopted: 7. Full-automatic steel fiber-free air brick molding system

[0074] This structure consists of four parts: a hopper, a mold, a vibration system, and a control unit. The hopper is used to homogenize and temporarily store the water-mixed, air-permeable brick castable. It is also connected to a pressure sensor. The mold requires a paramagnetic steel base plate with a thickness of 10mm-30mm. The vibration system is a vibration platform driven by a magnetic three-phase AC vibration motor. It includes one or more vibration motors, a symmetrical steel work platform, multiple vibration damping springs of the same model, and one or more electromagnets. When the electromagnets are energized, they engage and secure the mold. When the electromagnets are de-energized, there is no active force acting on the mold, allowing the mold to be removed. The core components of the control unit are the frequency converter and programmable logic controller (PLC). The current signal from the pressure sensor is input into the PLC controller, where control rules are programmed. The PLC controller is connected to the frequency converter and controls the frequency of the frequency converter's output current. The three-phase AC operating current enters the frequency converter and is then output to the vibration motor. The weight of the initial castable in the hopper must be close to the weight of the castable required for the mold. The control rule determines the vibration force required for the castable added to the mold based on the weight of the remaining castable in the hopper. The less castable weight remains in the hopper, the more castable is added to the mold, and the stronger the vibration force required. The PLC adjusts the frequency of the inverter's output current (i.e., the frequency input to the vibration motor) based on the input analog signal, thereby changing the motor's speed and, ultimately, the vibration force.

[0075] If there are multiple vibration motors, they must be of the same model and adjusted to the same exciting force.

[0076] The vibration motors are installed at the center of gravity below the working platform or symmetrically with the center of gravity. The electromagnets are fixed on the upper part of the working platform. The mold is above the electromagnets. The steel structure frame with the vibration motors and electromagnets is placed on the shock-absorbing springs.

[0077] The sum of the exciting forces of the vibration motors is 1.3-1.5 times the sum of the weight of the steel structure workbench, the weight of all vibration motors, the weight of all electromagnets, the weight of all molds, and the weight of the refractory castables filled in the molds.

[0078] The magnetic force exerted by the electromagnet on the mold is more than 1.1 times the exciting force.

[0079] The system's control scheme involves using a pressure sensor to measure the weight of the remaining castable in the hopper and inputting the signal into a PLC controller. A curve is designed based on the remaining castable weight and the required vibration force for the mold. Using the curve, the system modifies the output frequency, determines the vibration force of the vibration motor, and determines the final parameters. The PLC uses this curve relationship to control the inverter's output frequency, which in turn controls the motor's speed, ultimately achieving automatic control of the vibration force.

[0080] The closer the weight of the initial casting material in the hopper to the weight of the required casting material, the more the actual vibration force meets the design requirements. During the operation, the mold is always in vibration, so the weight of the added material cannot be directly collected, and only the signal can be collected by arranging a pressure sensor in the hopper, which is equivalent to collecting the weight of the casting material added to the mold from the side.

[0081] The beneficial effects of the present application are that, through the above method, the mold is automatically applied with a smaller vibration force when the casting material in the mold is less, i.e., the weight is light, and the vibration force is greater when the casting material in the mold is more, which meets the material forming science on the one hand and realizes the function of automatically adjusting the vibration force on the other hand.

[0082] 8. Full-automatic steel fiber-containing air brick forming system (a full-automatic forming device of homogeneous air brick)

[0083] This structure is divided into four parts: a hopper, a mold part, a vibration system part, and a control part. The hopper is used for homogenizing and temporarily storing the water-mixed air brick casting material, and the hopper is also connected with a pressure sensor; the bottom plate of the mold, which is required to be in contact with the magnetic chuck, is made of steel and has paramagnetism, and the thickness is 10-30 mm; a magnetic shielding plate is inlaid in the bottom plate below the product and close to the electromagnet side, and the distance between the magnetic shielding plate and the electromagnet is optimal; the other parts of the bottom plate are in contact with the electromagnet to generate an attraction force; the vibration source of the vibration part is a three-phase alternating current vibration motor; the core components of the control part are a frequency converter and a PLC; the three-phase alternating current power input into the frequency converter is output into the vibration motor; the analog signal of the pressure sensor is input into the PLC controller; the analog signal of the PLC controller is input into the frequency converter; the control rule with the pressure sensor analog signal as the variable is programmed in the PLC controller; the PLC controller adjusts the output current frequency of the frequency converter according to the control rule, so that the rotating speed of the vibration motor is adjusted, and the adjustable vibration force is output.

[0084] If there are multiple vibration motors, the same model is required, and the exciting forces are adjusted to be the same.

[0085] The vibration motors are installed at the gravity center or symmetrically with the gravity center below the working platform, the electromagnets are fixed on the upper part of the working platform, the mold is above the electromagnets, and the steel structure frame with the vibration motors and electromagnets is placed on the damping springs.

[0086] The sum of the exciting forces of the vibration motors is 1.3-1.5 times the sum of the weight of the steel structure working table, the weight of all the vibration motors, the weight of all the electromagnets, the weight of all the molds, and the weight of the full refractory casting material in the molds.

[0087] The magnetic force of the electromagnets acting on the mold is 1.1 times or more than the exciting force.

[0088] The magnetic shielding plate is made of aluminum plate with a thickness of 3-6 mm.

[0089] The control scheme of the system is: according to the weight of the remaining casting material in the hopper after the mold is filled, the weight of the casting material in the hopper during operation reflects the weight of the casting material added in the mold, and the vibration force required for the casting material in the mold is determined by taking the weight of the remaining casting material in the hopper as a variable; the weight of the remaining casting material in the hopper is measured by a pressure sensor, and the signal is input into a PLC controller; a curve graph is designed according to the weight of the remaining casting material in the hopper and the vibration force required for the mold; the output frequency is modified according to the curve graph, the vibration force of the vibration motor is judged, and the final parameters are determined. The PLC controls the output frequency of the frequency converter through the curve relationship, and then controls the speed of the motor, so as to finally realize automatic control of the vibration force.

[0090] The closer the initial weight of the casting material in the hopper to the required weight of the casting material, the more the actual vibration force meets the design requirements. During operation, since the mold is always in vibration, the weight of the added material cannot be directly collected, and only the signal can be collected by arranging a pressure sensor in the hopper, which is equivalent to collecting the weight of the casting material added in the mold from the side.

[0091] The beneficial effects of the present application are: through the above method, a smaller vibration force is automatically applied when the casting material in the mold is less, i.e. the weight is light; the more the casting material in the mold, the greater the vibration force applied. The uniform distribution of steel fibers in the product is realized by the method of magnetic shielding, which meets the scientificity of material forming on the one hand and realizes the function of automatically adjusting the vibration force on the other hand.

[0092] 9. A forming method of a high-performance air-permeable core:

[0093] The high performance includes two aspects: one aspect is the application of the new raw materials currently appearing, and the other aspect is the use of the forming method of the present application to improve the performance of the air-permeable core material and the air-permeable core product.

[0094] The forming system includes four parts: a hopper, a mold part, a vibration system part, and a control part. The hopper is used for homogenizing and temporarily storing the water-stirred air-permeable brick casting material, and the hopper is also connected with a pressure sensor; the mold requires a steel base plate with paramagnetism and a thickness of 10-30 mm; the vibration system part includes one or more vibration motors, a symmetrical steel structure working platform, multiple same type damping springs, and one or more electromagnets; when the electromagnet is powered on, it is attracted and fixed with the mold, and when the electromagnet is powered off, it has no active force with the mold, and the mold can be removed; the core components of the control part are a frequency converter and a PLC.

[0095] If there are multiple vibration motors, they are required to be of the same type and adjusted to the same exciting force.

[0096] The vibration motor is installed at the gravity center position below the work platform or symmetrically with the gravity center position, the electromagnet is fixed on the upper part of the work platform, the mold is on the electromagnet, and the steel structure frame provided with the vibration motor and the electromagnet is arranged on the damping spring.

[0097] The sum of the exciting forces of the vibration motors is 1.3-1.5 times the sum of the weight of the steel structure workbench, the weight of all the vibration motors, the weight of all the electromagnets, the weight of all the molds and the weight of the full refractory castable in the mold.

[0098] The magnetic force of the electromagnet acting on the mold is 1.1 times the exciting force.

[0099] In the forming system, the three-phase alternating current power input is input into the frequency converter, the analog signal of the pressure sensor is input into the PLC controller, the analog control signal of the PLC controller is input into the frequency converter, the control rule with the pressure sensor analog signal as a variable is programmed in the PLC controller, the variable is the output current frequency of the frequency converter, the PLC controller adjusts the output current frequency of the frequency converter according to the control rule, so that the rotating speed of the vibration motor is adjusted, and the adjustable vibration force is output, the weight of the initial castable in the hopper is the weight of the castable required to be filled in the mold, when the weight in the hopper decreases, the weight of the castable in the mold increases, and the required vibration force also increases, so that the vibration force is applied to the castable.

[0100] The control scheme of the system is that the weight of the remaining castable in the hopper is measured by the pressure sensor, the signal is input into the PLC controller, the curve diagram is designed according to the weight of the remaining castable in the hopper and the required vibration force of the mold, the output frequency is modified according to the curve diagram, the vibration force of the vibration motor is judged, and the final parameters are determined. The PLC controls the output frequency of the frequency converter through the curve relationship, and then controls the rotating speed of the motor, so that the vibration force is finally automatically controlled.

[0101] The closer the weight of the initial castable in the hopper to the weight of the required castable, the more the actual vibration force meets the design requirements. During the operation, since the mold is always in vibration, the weight of the added castable cannot be directly collected, and only the signal can be collected by arranging the pressure sensor in the hopper, which is equivalent to collecting the weight of the castable added into the mold from the side.

[0102] The formula of the air-permeable core comprises a main material part and an additive part, the main material part: tabular corundum produced by Anmai Aluminum Industry, with a critical particle size of 6 mm, a mass content of 78-85%, a mass content of sicar71 cement of 2-4%, a mass content of CMA72 spinel cement of 3-5%, sintered aluminum magnesium spinel, less than or equal to 325 mesh, a mass content of 6-8%, and bimodal alpha-Al2O3, a mass content of 4-5%, wherein the proportion of all materials less than or equal to 325 mesh in the above ingredients is 20-26%, and the proportion of the additive part is the proportion of the sum of all main materials, a mass content of FS60 water reducing agent of 0.06-0.08%, a mass content of anti-bleeding additive of 0-0.03%, and a mass content of composite retarder of 0-0.02%.

[0103] The basic indexes of the material prepared by the above-mentioned proportioning and molding method are as follows: the prepared product is cut into a sample block with a size of 40*40*160 mm, and is fired at 1560 DEG C for 3 hours, the bending strength is not less than 46 MPa, and the compressive strength is not less than 260 MPa; after being fired at 1560 DEG C for 3 hours and cooled, the sample block is directly placed into a furnace at 1100 DEG C, and is kept for 30 min, then is moved to normal temperature and kept for 10 min, and then is placed into the furnace at 1100 DEG C again and kept for 30 min, and the above-mentioned cycle is repeated for 3 times to measure the strength retention rate, that is, the proportion of residual strength and original strength, which is not less than 38%.

[0104] The present application has the following beneficial effects: by the above-mentioned method, a smaller vibration force is automatically applied to the mold when the amount of castable in the mold is small, that is, when the weight is light, the vibration force applied is greater when the amount of castable in the mold is greater, and the function of automatically adjusting the vibration force is realized. The air-permeable core material prepared by the present application has obvious performance advantages, and the sample block required for testing is cut from an industrial product, which is quite different from the properties of a sample block directly poured into a mold, and the present application is more consistent with the actual situation.

[0105] 10. A method for manufacturing a uniform seat brick,

[0106] The uniformity mainly refers to the uniform distribution of steel fibers in the seat brick.

[0107] The structure includes four parts: hopper part; seat brick mold part, vibration system part, control part. The hopper is a container for homogenizing and temporarily storing the mixed casting material; the bottom plate of the mold required to be in contact with the magnetic chuck is made of steel, has paramagnetism, and has a thickness of 10-30 mm; a magnetic shielding plate is inlaid in the bottom plate right below the product and close to the electromagnet side; the magnetic shielding plate and the electromagnet have an optimal distance; the other parts of the bottom plate are in contact with the electromagnet to generate an attractive force; the vibration part is a vibration table with a three-phase AC vibration motor as a vibration source, and the mold is fixed in a magnetic way; the core component of the control part is PLC and a frequency converter. If there are multiple vibration motors, they are required to be of the same model and adjusted to the same exciting force.

[0108] The vibration motors are installed at the gravity center or symmetrically to the gravity center below the working platform, the electromagnets are fixed on the upper part of the working platform, the mold is on the electromagnets, and the steel structure frame installed with the vibration motors and electromagnets is placed on the damping springs.

[0109] The sum of the exciting forces of the vibration motors is 1.3-1.5 times the sum of the weight of the steel structure working table, the weight of all the vibration motors, the weight of all the electromagnets, the weight of all the molds, and the weight of the full refractory casting material in the molds.

[0110] The magnetic force of the electromagnets acting on the mold is 1.1 times or more than the exciting force.

[0111] The magnetic shielding plate is made of an aluminum plate with a thickness of 3-6 mm.

[0112] In the molding system, the three-phase AC power input into the frequency converter is output into the vibration motor, the analog control signal of the PLC controller is input into the frequency converter, the control rule with the charging time as a variable is programmed in the PLC controller, the variable is the output current frequency of the controlled frequency converter, the PLC controller adjusts the output current frequency of the frequency converter according to the control rule, so that the rotating speed of the vibration motor is adjusted, and the adjustable vibration force is output at the same time; with the continuous charging time, the weight of the casting material in the mold increases, and the required vibration force also increases, so that the casting material is vibrated with the vibration force corresponding to the weight of the casting material.

[0113] The control scheme of the system is: using the PLC analog module to control the current frequency of the frequency converter output, then controlling the rotating speed of the motor, and finally controlling the vibration force. The parameters of the frequency converter are set to analog control, the time and vibration percentage curve graph are designed according to the feeding time and the required vibration force, the frequency of the current output by the frequency converter is modified according to the curve graph, the vibration force of the vibration motor is judged, and the final parameters are determined. The shorter the time is, the less the material in the mold is, and the smaller the required vibration force is. The vibration percentage refers to the ratio of the output vibration force to the maximum vibration force of the motor. If the vibration percentage is 100%, it is the maximum vibration force. If the vibration percentage is 0, there is no vibration. The vibration percentage and the input current frequency of the vibration motor are in a functional relationship.

[0114] The formula of the air-permeable base brick includes a main material part and an additive part. The main material part includes tabular corundum with a critical particle size of 15 mm and a mass content of 75-80%, secar71 cement with a mass content of 3-5%, CMA72 type spinel cement with a mass content of 3-4%, sintered aluminum magnesium spinel with a mass content of 8-10%, and double-peak alpha-Al2O3 with a mass content of 3-5%. The proportion of all materials with a size of 325 mesh or less in the above ingredients is 26-32%, which is the proportion of the sum of all main materials. The proportion of the additive part is the proportion of the sum of all main materials. The mass content of FS60 water reducing agent is 0.08-0.12%, the mass content of anti-sweating additive is 0.01-0.03%, and the mass content of composite retarder is 0.001-0.03%.

[0115] The material prepared by the above-mentioned proportioning and molding method has the following properties: the steel fibers are uniformly distributed; the prepared product is cut into a 40*40*160mm sample block, which is fired at 1560℃ for 3 hours and then cooled; the bending strength is not less than 38MPa, and the compressive strength is not less than 150MPa; the sample block fired at 1560℃ for 3 hours is directly placed into a 1100℃ furnace, kept for 30min, moved to room temperature for 10min, and then placed into the 1100℃ furnace again for 30min, and this cycle is repeated for 3 times to measure the strength retention rate, i.e. the ratio of residual strength to original strength, which is not less than 45%.

[0116] The present application has the following advantages: through the above-mentioned method, a smaller vibration force is automatically applied to the mold when the amount of castable material in the mold is small, i.e. the weight is light. As the feeding time continues, the more castable material in the mold, the greater the vibration force applied. The function of adjusting the vibration force according to the need is realized. The prepared base brick has obvious performance advantages, and the steel fibers are uniformly distributed. The sample block required for testing is cut from an industrial product, which is quite different from the properties of a sample block directly poured into the required shape. The present application is more consistent with the actual situation. BRIEF DESCRIPTION OF DRAWINGS

[0117] Figure 1 : magnetic shielded seat brick mold;

[0118] Figure 2 : unshielded magnetic attraction type air core vibration part;

[0119] Figure 3 : magnetic shielded air core seat brick vibration forming part;

[0120] Figure 4 : relay control vibration force control scheme diagram;

[0121] Figure 5 : manual variable frequency control vibration force control scheme diagram;

[0122] Figure 6 : time control vibration force control scheme diagram;

[0123] Figure 7 : fully automatic control vibration force control scheme diagram;

[0124] Figure 8 : feeding time and vibration percentage relationship example diagram;

[0125] Figure 9 : remaining castable weight in the hopper and vibration percentage relationship example diagram;

[0126] Figure 10 : air core cross section schematic diagram;

[0127] Figure 11 : whole brick cross section schematic diagram;

[0128] Figure 12 : magnetic shielded, magnetic attraction type air core vibration part.

[0129] In the figure: ①: vibration table steel structure, ②: electromagnet, ③: shock absorbing spring, ④: foundation, ⑥: guide device, ⑦: air core mold, ⑧: seat brick mold, ⑨: control part, ⑩: frequency converter, vibration part, vibration motor, mold, hopper part, pressure sensor, PLC, feeding time and vibration percentage curve, remaining castable weight in the hopper and vibration percentage curve, cyclic time relay: magnetic shield plate, mold bottom plate, heat-resistant steel cylinder, refractory material, Gas channels, Air chamber, Metal cover, Intake pipe, Breathable core, Breathable seat bricks, Working main power supply, 380V, AC, contactors, Multi-position switch, Control current signal, Three-phase alternating current. DETAILED DESCRIPTION

[0130] 1. Make a magnetic shielding plate mold

[0131] Taking the integral breathable seat brick mold ⑧ as an example, the product size is 360×360×550mm, which is a relatively common brick type, that is, a square with a cross section of 360mm and a height of 550mm.

[0132] mold base Thickness is 20mm thick plain carbon steel, Q235, mold bottom plate The dimensions are 460×460×20mm. Magnetic shielding plate A 6mm thick aluminum plate with a size of 370×370×6mm is used for magnetic shielding. With mold base The mold base is welded between the Inlaid magnetic shielding plate The depth is 8mm, magnetic shielding plate There is no contact with the electromagnet ②.

[0133] The side plates of the base brick mold ⑧ are made of ordinary carbon steel with a thickness of 10mm and fixed with bolts according to conventional practices.

[0134] Take the breathable core mold ⑦ as an example. The product size is φ120 / φ172-H520, which is a more common brick type. The breathable core is a cone with a small end diameter of 120mm, a large end diameter of 172mm, and a height of 520mm. When molding, the large end is above, so the small end is adjacent to the bottom plate of the mold. Connection, the size of the mold base is 200×200×20mm, magnetic shielding plate A 4mm thick aluminum plate with a size of φ120×4mm is used and embedded in the mold bottom plate. Middle and lower surfaces and mold base flush.

[0135] The cone barrel of the mold ⑦ is made of any steel with a wall thickness of 12mm, cut into two halves along the busbar line, and fixed with bolts. Secure with bolts.

[0136] When using, the mold Hoisted on the electromagnet, located at the center of gravity of the working platform of the vibration table steel structure ①, if there are multiple molds Simultaneous operation, mold The mold should be symmetrical with the center of gravity of the vibration table steel structure ① working platform. The force-bearing part fits tightly with the electromagnet ②, and the mold assembly is completed when the electromagnet power is turned on.

[0137] 2. Make a magnetic vibration table①:

[0138] Designed based on the formed base brick, the working load is 300Kg of castable material, the two molds ⑧ weigh 180Kg, and the total weight is 480Kg. Design the vibration table steel structure ①, the steel structure weighs 280Kg, and the work surface size is 800×600mm; the vibration source is a three-phase AC vibration motor The speed is 1450 rpm, the amplitude is 4-8mm, the power is 1.75KW, the eccentric block is adjusted to the maximum, and the number is one; electromagnet ② uses two bar-shaped electromagnetic suction cups with a magnetic force of 150N / cm2. Electromagnet ② is embedded in the steel structure ① of the vibration table, and the upper surface is flush with the steel structure working platform; shock-absorbing spring ③ uses compression steel springs, the number is four, the height is 265mm, and the single support weight is 120Kg. Vibration-absorbing pads are arranged at both ends of the shock-absorbing spring ③, and the guide device is coated with butter to reduce friction noise.

[0139] 3. Make the relay Control device ⑨:

[0140] The control system ⑨ includes a 5-speed transfer switch 4 circulating time relays A contactor transfer switch Each of the 4 lines is connected to a circulating time relay 4 circulating time relays Connecting the contactor Control circuit. Working power supply Through the contactor Connecting the vibration motor

[0141] Setting the cyclic time relay in line 1 The working time is 3 seconds and the disconnection time is 2 seconds. When rotating to line 1, the vibration motor Press the power button to cycle on for 3 seconds and off for 2 seconds.

[0142] Setting the cyclic time relay in line 2 The working time is 5 seconds and the disconnection time is 3 seconds. When rotating to line 2, the vibration motor Press the power button to cycle on for 5 seconds and off for 3 seconds.

[0143] Setting the cyclic time relay in line 3 The working time is 10 seconds and the disconnection time is 2 seconds. When rotating to line 3, the vibration motor Press the power button to cycle on for 10 seconds and off for 2 seconds.

[0144] Setting the cyclic time relay in line 4 The working time is 20 minutes. When rotating to line 4, the vibration motor Keep the power on for 20 minutes.

[0145] When working, according to the mold The amount of castable added is selected by the switch The line starts from gear 1, when the mold When there is more material in the machine, turn it to gear 2, and so on. When the molding is completed, turn it from gear 4 to gear 1, and finally turn it to the normally closed gear to complete the work.

[0146] 4. Make a frequency conversion control device ⑨:

[0147] The main components of the control device ⑨ are the frequency converter ⑩, the main power supply Connect to the input terminal of the inverter ⑩, and the current is output to the vibration motor after passing through the inverter ⑩ Connect the inverter's knob to the workbench for easy operation.

[0148] The function of the inverter is to change the frequency of the input current, thereby changing the three-phase AC motor When working, the vibration motor is directly controlled by the external knob of the inverter ⑩ The speed of the mold When there is less material in the mold, the vibration frequency can be reduced by the external knob. As the amount of castable added increases, the vibration force is gradually adjusted.

[0149] 5. Make a fully automatic control device:

[0150] First make the hopper Volume 120dm 3 ,hopper A pressure sensor is installed below A pressure sensor The current signal is input to the PLC in an analog manner ; the PLC analog module controls the frequency value of the frequency converter, which in turn controls the speed of the motor, and finally controls the vibration force. The parameters of the frequency converter are set to analog control. The time and vibration percentage curve graph are designed according to the weight of the remaining casting material in the hopper and the vibration force required for the casting material in the mold. Referring to the curve graph, modify the different output frequencies in the PLC to determine the vibration force of the vibration motor and determine the final parameters. The main power supply is input to the frequency converter (10) and then to the vibration motor

[0151] 6. High-performance air-permeable core manufacturing method example:

[0152] The high performance, on the one hand, applies to the new raw materials that have appeared so far, and on the other hand, uses a full-automatic molding method to improve the performance of air-permeable core materials and air-permeable core products. The indicators mentioned in the example are tested by cutting 40x40x160mm samples from the industrialized air-permeable core, which is completely different from the 40x40x160mm samples directly molded.

[0153] 6.1, using Figure 7 the full-automatic control device (9) shown in example 5 to manufacture air-permeable cores, the mold uses the air-permeable core mold (7) described in example 1, with a magnetic shielding plate There are 6 groups of air-permeable core molds (7). Three of them do not have gas passage forming loss, which is the purpose of cutting the required sample block. If the gas passage is preformed, it will not be able to cut the required size sample block. Adjust the frequency value in the PLC Figure 9 according to the curve shown.

[0154] ​6.2, according to the formula, the example of 150Kg, breathable core formula of the main material and additive part, main material part: Anmai aluminum production type T66 tabular corundum, specifications for 3-6mm, 1-3mm, 0.6-1mm, 0.2-0.6mm, less than 180 mesh, less than 325 mesh, the mass content is 18%, 22%, 8%, 8%, 10%, 6% respectively; secar71 cement, CMA72 type spinel cement, less than or equal to 325 mesh sintered alumina-magnesia spinel, the mass content of double-peak type alpha-Al2O3 is 3%, 4%, 7%, 4% respectively, the above ratio refers to the proportion of all the main material; the proportion of the rest of the additive part refers to the proportion of all the main material, the mass content of FS60 water reducing agent, anti bleeding additive, composite retarder is 0.09%, 0.03%, 0.015% respectively.

[0155] 6.3, the material below 325 mesh is uniformly premixed by ball mill, and polyurethane mixing ball is selected during mixing.

[0156] 6.4, all raw materials are dry mixed twice, and planetary mixer is used for mixing for 12 min to make the mixture uniform.

[0157] 6.5, the mixed bulk material is added into the stirrer, the stirrer is planetary, 5.7Kg of clean tap water is added at one time, that is, the water content is 3.8%, and stirring is performed for 5 min.

[0158] 6.6, the stirred casting material is put into the hopper .

[0159] 6.7, the casting material is added into the 6 groups of breathable core molds ⑦ from the hopper , if the addition is manual, the amount of casting material added into each breathable core mold ⑦ needs to be basically the same, and in the example, the 6 groups of breathable core molds ⑦ are added according to the specific device, so that the casting material added into each breathable core mold ⑦ is the same.

[0160] 6.8, after the addition is completed, the remaining casting material is still in the hopper , at this time, the hopper should be emptied, and vibration can be performed according to the end of the curve.

[0161] 6.9, after the molding is completed, the curing is performed at a temperature of 50-60℃ for 8h, the mold ⑦ is removed, drying is performed at 110-150℃ for 24h, then the firing is performed at 1560℃ for 3h, and then natural cooling is performed, the brick blank without obvious defects such as cracks is cut into 40×40×160mm strip-shaped sample blocks, 2 sample blocks are cut from each brick blank, a total of 6 sample blocks, and then drying is performed at 110℃ for 24h, and the sample block production is completed.

[0162] 6.10. The above-mentioned specimens were tested according to national standard methods, and the average values ​​of the following indicators were: flexural strength of 52.7 MPa and compressive strength of 282.5 MPa after sintering at 1560°C for 3 hours; the linear variation rate was 0.05%. The above-mentioned specimens were directly placed in an 1100°C furnace, held at that temperature for 30 minutes, then brought to room temperature and held for 10 minutes, and then placed in an 1100°C furnace again for 30 minutes. This cycle was repeated three times, and the flexural strength retention rate, i.e., the ratio of the residual strength to the original strength (52.7 MPa), was measured to be 43.9%.

[0163] 7. Example of uniform seat brick production method:

[0164] The term "uniformity" primarily refers to the distribution of steel fibers. This can be determined by cutting the block longitudinally along its centerline. The cross-section will reveal the distribution of the steel fibers. The indicators described in this example were tested on 40×40×160mm specimens cut from industrially manufactured, breathable block blocks. This is distinct from the typically directly formed 40×40×160mm specimens. This example utilizes a time-controlled method for steel fiber-containing block blocks.

[0165] 7.1, Utilization Figure 6 The time-controlled device shown in the figure is used to make the breathable seat brick, and the seat brick mold ⑧ adopts the seat brick mold ⑧ described in Example 1, with a magnetic shielding plate There are 2 sets of molds⑧, press Figure 8 The curve shown is used to debug the PLC The frequency value in .

[0166] 7.2, prepare the materials according to the formula. The weight of the materials in the example is 320 kg. The external-mounted breathable base brick is made. That is, the base brick does not have a pre-installed breathable core. The formula of the breathable base brick is divided into the main material part and the additive part. The main material part is plate-shaped corundum with specifications of 8-15mm, 5-8mm, 3-5mm, 1-3mm, 0.6-1mm, 0.2-0.6mm, less than 325 mesh, and the mass content is 24%, 10%, 15%, 10%, 6%, 6%, and 8% respectively; The mass contents of 71 cement, CMA72 spinel cement, fused aluminum-magnesium spinel less than or equal to 325 mesh, and α-Al2O3 are 5%, 3%, 10%, and 3%, respectively. The above proportions refer to the proportions of the sum of all main ingredients; the proportions of the remaining parts refer to the proportions of the sum of all main ingredients. The mass contents of 446# steel fiber, FS10 water reducer, anti-bleeding additive, and composite retarder are 1.5%, 0.12%, 0.03%, and 0.02%, respectively.

[0167] 7.3. Pre-mix the materials below 325 mesh in a ball mill to make them uniform. Use polyurethane mixing balls for mixing.

[0168] 7.4, all raw materials are dry-mixed for the second time, and mixed for 15 min by a planetary mixer to make them well mixed.

[0169] 7.5, the mixed dry materials are put into a mixer, which is a planetary mixer, and 12.8 Kg of clean tap water is added at one time, i.e. the water amount is 4%, and the mixture is stirred for 6 min.

[0170] 7.6, the stirred casting material is put into a hopper .

[0171] 7.7, the casting material is put into the molds ⑧ from the hopper , and the amount of the casting material put into each mold ⑧ is basically the same, and in this example, the casting material is put into the molds ⑧ by a specific device to make the amount of the casting material put into each mold ⑧ the same.

[0172] 7.8, after the molding is completed, the molds ⑧ are cured at a temperature of 50-60℃ for 8 h, and then dried at 110-150℃ for 24 h after the molds ⑧ are removed.

[0173] 7.9, the dried green bricks are cut along the center line in the longitudinal direction to determine the distribution of the steel fibers, and then cut into strip-shaped samples with a size of 40 x 40 x 160 mm, dried at 110℃ for 24 h, and then fired at 1560℃ for 3 h, and then naturally cooled to complete the sample preparation.

[0174] 7.10, it is found by observing the cut surface that the steel fibers are distributed obviously and uniformly, and the steel fibers made by the conventional method sink obviously more. The average values of the indexes of the above samples detected by the national standard method are as follows: the bending strength is 40.2 MPa, the compressive strength is 178.5 MPa after being fired at 1560℃ for 3 h; the bending strength retention rate, i.e. the ratio of the residual strength to the original strength (40.2 MPa), is 58.6% after the above samples are directly put into a furnace at 1100℃ for 30 min, moved to a normal temperature for 10 min, and then put into the furnace at 1100℃ again for 30 min, and the above cycle is repeated for 3 times.

Claims

1. A fully automatic forming device for homogeneous breathable bricks, characterized by: The device consists of four parts: a hopper part, a mold part, a vibration system part, and a control part. The hopper is also connected to a pressure sensor. The mold requires that at least the bottom plate that contacts the magnetic suction cup is made of steel, has paramagnetism, and has a thickness of 10mm-30mm. A magnetic shielding plate is embedded in the bottom plate directly below the product, close to the electromagnet side. It is optimal if the magnetic shielding plate and the electromagnet have a certain distance. The other parts of the bottom plate are in contact with the electromagnet to generate an attractive force. The vibration source of the vibration part is a three-phase AC vibration motor. The core components of the control part are the frequency converter and PLC. The three-phase AC power supply is input into the frequency converter and then output to the vibration motor. The analog signal of the pressure sensor is input into the PLC controller. The analog signal of the PLC controller is input into the frequency converter. The control rule with the analog signal of the pressure sensor as the variable is programmed into the PLC controller. The PLC controller adjusts the output current frequency of the frequency converter according to the control rule, so that the speed of the vibration motor is adjusted and the adjustable vibration force is output at the same time.

2. The forming device according to claim 1, characterized in that: the electromagnet The magnetic force acting on the mold is more than 1.1 times the exciting force, and the magnetic shielding plate is made of an aluminum plate with a thickness of 3-6 mm.

3. The device according to claim 1, wherein: The weight of the remaining castable in the hopper is the weight required after the mold is filled. During operation, the weight of the castable in the hopper reflects the weight of the castable added to the mold. The weight of the remaining castable in the hopper is used as a variable to determine the vibration force required for the castable in the mold, ultimately achieving automatic control of the vibration force.

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