Air brick forming device capable of adjusting vibration force

Abstract

An air brick forming device capable of adjusting vibration force comprises three parts, namely an air core or brick cup mold part, a vibration system part and a control part, and a bottom plate of the mold is required to be made of steel and has paramagnetism; the vibration system part comprises one or more vibration motors, a steel structure working platform, more than three damping springs and one or more electromagnets, when the electromagnets are powered on, the electromagnets are attracted and fixed to the mold, when the electromagnets are powered off, no active acting force exists between the electromagnets and the mold, and the mold can be moved away; the core component of the control part is the frequency converter, working alternating current is input into the frequency converter and then input into the vibration motor, the more castable in the mold is, the larger the applied vibration force is, control through the frequency converter is convenient and flexible, and the needed vibration force can be adjusted at any time.

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] 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 the bottom plate to be made of steel, to have paramagnetism, and to have a thickness of 10-30 mm; the vibration system part includes one or more vibration motors, a symmetrical steel structure work platform, multiple same type damping springs, and one or more electromagnets. When the electromagnets are powered on, the electromagnets attract and fix the mold; when the electromagnets are powered off, the mold has no active force and can be removed; the core component of the control part is a multi-gear switch, multiple cycle time relays, and a contactor. Three-phase alternating current enters the vibration motor through the contactor working end, each line of the multi-gear switch is connected with a cycle time relay, and the output ends of all cycle time relays are connected with the input end of the contactor control part.

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

[0015] The vibration motors are installed at the gravity center or symmetrically with the gravity center below the work platform, the electromagnets are fixed on the upper part of the work platform, the steel structure frame with the vibration motors and electromagnets installed thereon is placed on the damping 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 full refractory castable in the mold.

[0017] The magnetic force of the electromagnets acting on the mold is 1.1 times or more than the exciting force.

[0018] The multi-gear switch has 4-8 line gears, one of which is a constant-off line.

[0019] The control scheme of the system is as follows:

[0020] The function of the multi-position switch is that it has multiple lines, one of which is a normal-off line. When the switch is rotated to position 1, line 1 is connected and the other lines are disconnected, when the switch is rotated to position 2, line 2 is connected and the other lines are disconnected, and so on. When the switch is rotated to the normal-off line, there is no connection. In addition to the normal-off line, each line is connected to a cycle time relay. The function of the cycle time relay is that when it is working, it is connected for a certain period of time and then disconnected for a certain period of time, for example, connected for 30 seconds and disconnected for 10 seconds, and so on. A cycle time relay can only set two groups of time, i.e. working time and disconnection time, so the control system needs multiple cycle time relays to set multiple groups of different working time and disconnection time. When working, only one of the multiple groups of relays is connected, and only one line is working. The relay controls the connection and disconnection of the contactor, thereby controlling the rotation and stop of the vibration motor. For example, when the switch is rotated to position 1, the vibration motor will execute a cycle of 30 seconds on and 10 seconds off; after a certain period of time, the switch is rotated to position 2, the cycle time relay connected to position 2 is set to 60 seconds on and 40 seconds off, and the vibration motor will execute a cycle of 60 seconds on and 40 seconds off; rotating the switch to position 3 is similar; rotating the switch to the normal-off position will stop the vibration motor.

[0021] The power supply of the vibration motor is connected or disconnected through the time relay and the contactor, and the inertia of the vibration motor is used to control the output vibration force. When the power supply of the vibration motor is connected, its speed gradually reaches the maximum value, and the vibration force also gradually reaches the maximum value. If the power supply of the motor is disconnected before reaching the maximum value, or the power supply is connected before the speed drops to 0, a cycle of the required vibration force can be obtained.

[0022] During operation, the weight of the casting material added to the mold is determined by experience, and 4-6 groups of time relays are set to have appropriate vibration force. When there is more casting material in the mold, the vibration force is adjusted to be a little larger.

[0023] The beneficial effects of this scheme are that the mold and the vibration system are fixed and reliable, and do not loosen; the mold is easy to move away, greatly improving the production efficiency; at the same time, when there is less casting material in the mold, i.e. the weight is light, a smaller vibration force is applied, and the more casting material in the mold, the larger the vibration force applied. It conforms to the scientific nature of material forming, and can greatly avoid segregation, unevenness and other phenomena. This scheme is suitable for the vibration forming of casting material without steel fibers. In addition, the residual magnetic force of the electromagnet acting on the mold may produce force on some particles in the casting material, causing the internal structure of the product to have a certain order, which may have a negative impact. In view of this situation, the following scheme can be adopted:

[0024] 2, relay control, magnetically attract the mold to form a casting material containing steel fiber air brick

[0025] 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 in contact with the magnetic chuck has a steel part with paramagnetism and a thickness of 10-30 mm, and a magnetic shielding plate is inlaid in the bottom plate right below the product and close to the electromagnet side, and the magnetic shielding plate and the electromagnet have a certain distance which is optimal, and other parts of the bottom plate are in contact with the electromagnet to generate suction force; 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, the electromagnets are fixed with the steel structure working platform, the electromagnets are fixed with the mold when powered on, and the electromagnets have no active force on the mold when powered off, and the mold can be removed; the core component of the control part is a multi-gear switch, multiple cycle time relays, and a contactor. Three-phase alternating current enters the vibration motor through the contactor working end, each line of the multi-gear switch is connected with a cycle time relay, and the output ends of all cycle time relays are connected with the input end of the contactor control part.

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

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

[0028] The vibration motors are installed at the gravity center position or symmetrically with the gravity center position below the working platform, the electromagnets are fixed on the upper part of the working platform, the steel structure frame with the vibration motors and the electromagnets is placed on the damping 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 working platform, the weight of all vibration motors, the weight of all electromagnets, the weight of all molds, and the weight of the refractory castable filled in the mold.

[0030] The magnetic force of the electromagnets acting on the mold is 1.1 times or more than the exciting force.

[0031] The multi-gear switch has 4-8 line gears, one of which is a constant-off line.

[0032] The control scheme of the system is:

[0033] The function of the multi-position change-over switch is that it has multiple circuits, one of which is a normal-off circuit. When the switch is rotated to position 1, circuit 1 is connected and the other circuits are disconnected, when the switch is rotated to position 2, circuit 2 is connected and the other circuits are disconnected, and so on. When the switch is rotated to the normal-off circuit, there is no circuit connected. In addition to the normal-off circuit, each circuit is connected to a cycle time relay. The function of the cycle time relay is that when it is working, it is connected for a certain period of time and then disconnected for a certain period of time, for example, connected for 30 seconds and disconnected for 10 seconds, and so on. A cycle time relay can only set two groups of time, i.e. working time and disconnection time, so the control system needs multiple cycle time relays to set multiple groups of different working time and disconnection time. When working, only one of the multiple groups of relays is connected, and only one circuit is working. The relays control the connection and disconnection of the contactor, thereby controlling the rotation and stop of the vibration motor. For example, when the change-over switch is rotated to position 1, the vibration motor will execute the cycle of being connected for 30 seconds and disconnected for 10 seconds; after a certain period of time, the change-over switch is rotated to position 2, the cycle time relay connected to position 2 is set to be connected for 60 seconds and disconnected for 40 seconds, and the vibration motor will execute the cycle of being connected for 60 seconds and disconnected for 40 seconds; the same applies to position 3; when the change-over switch is rotated to the normal-off position, the vibration motor stops working.

[0034] The power supply of the vibration motor is connected or disconnected through the time relay and the contactor, and the inertia of the vibration motor is used to control the output vibration force. When the power supply of the vibration motor is connected, the rotation speed gradually reaches the maximum value, and the vibration force also gradually reaches the maximum value. If the power supply of the motor is disconnected before the maximum value is reached, or the power supply is connected before the rotation speed drops to 0, the required vibration force can be obtained by repeating the cycle.

[0035] During the operation, the weight of the casting material added to the mold is determined by experience, and 4-6 groups of time relays are set to have appropriate vibration force. When there is more casting material in the mold, the vibration force is adjusted to be a little larger.

[0036] The beneficial effects of this scheme are that the mold and the vibration system are fixed and reliable, and do not loosen, the mold is extremely easy to remove, and the production operation 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 the distribution more uniform; at the same time, when there is less casting material in the mold, i.e. when the weight is light, a smaller vibration force is automatically applied, and the more casting material in the mold, the larger the vibration force applied, which conforms to the scientificity of material forming and greatly avoids phenomena such as segregation and unevenness. However, there are still obvious defects in the control through the time relay.

[0037] 3. Frequency conversion control, magnetically attract the mold to form a steel fiber-free air brick casting material (a kind of air brick forming device capable of adjusting vibration force)

[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] The structure includes three parts, the air-permeable core or the seat brick mold part, the vibration system part, and the control part. The bottom plate of the mold, which is required to contact 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 a certain distance, which is the best. Other parts of the bottom plate are in contact with the electromagnet to generate suction force. 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 fixed with the mold by suction. When the electromagnet is powered off, it has no active force on the mold, and the mold can be removed. The core component of the control part is the frequency converter.

[0048] If there are multiple vibration motors, they are required to be of the same type 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 gravity center or symmetrically with the gravity center below the working platform. The electromagnet is fixed on the upper part of the working platform. The steel structure frame with the vibration motor and the electromagnet is placed on the damping spring.

[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 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.

[0052] The magnetic force of the electromagnet acting on the mold is 1.1 times or more than the exciting force.

[0053] The control scheme of the system is that the knob of the frequency converter is connected to the working platform for convenient operation. The working AC power is connected to the vibration motor after passing through the frequency converter. The frequency of the current input to the vibration motor is changed through the frequency converter knob, thereby controlling the speed of the motor and finally controlling the vibration force of the vibration motor.

[0054] During the operation, the weight of the castable added to the mold is determined by experience, the frequency converter knob is adjusted, and the vibration force is appropriately adjusted. When there is more castable in the mold, the vibration force is adjusted a little larger.

[0055] The beneficial effects of this 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 scientific nature of material forming and greatly avoids segregation, unevenness, etc.; 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] This 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, there is no active force on the mold, and the mold can be removed; the core component of the control part is PLC and a frequency converter.

[0058] If there are multiple vibration motors, they must 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] The structure is divided into four parts: hopper, mold part, vibration system part, control part. The hopper is used for homogenizing and temporarily storing the water-mixed vibrating brick casting material, and the hopper is connected with a pressure sensor; the mold requires that the bottom plate is made of steel and has paramagnetism, and the thickness is 10-30 mm; the vibration system part is a magnetic type three-phase AC vibration motor driven vibration platform, which includes one or more vibration motors, a symmetrical steel structure working platform, a plurality of vibration reduction springs of the same type, and one or more electromagnets; when the electromagnet is powered on, the electromagnet is attracted and fixed with the mold; when the electromagnet is 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 and a PLC. The current signal of the pressure sensor is input to the PLC controller, the control rule is programmed in the PLC controller, the PLC controller is connected with the frequency converter and controls the output current frequency of the frequency converter, and the three-phase AC working current enters the frequency converter and then enters the vibration motor. The initial pouring material in the hopper is required to have a weight close to the weight of the pouring material required by the mold, the control rule is to determine the vibration force required by the pouring material added in the mold according to the weight of the remaining pouring material in the hopper, the less the weight of the remaining pouring material in the hopper, the more the pouring material in the mold, and the stronger the vibration force required. The PLC can adjust the frequency of the output current of the frequency converter according to the input analog signal, that is, the frequency input to the vibration motor, so as to change the rotating speed of the vibration motor and finally change the vibration force of the vibration motor.

[0075] If there are multiple vibration motors, they are required to be of the same type and to have the same exciting force.

[0076] 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 steel structure frame with the vibration motors and electromagnets is arranged on the vibration reduction 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 working platform, 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 mold.

[0078] The magnetic force of the electromagnet acting on the mold is 1.1 times the exciting force.

[0079] The control scheme of the system is as follows: the weight of the remaining pouring material in the hopper is measured by the pressure sensor, and the signal is input to the PLC controller. A curve is designed according to the weight of the remaining pouring material in the hopper and the vibration force required by the mold, the output frequency is modified according to the curve, 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 as to finally realize the automatic control of the vibration force.

[0080] The closer the weight of the initial castable in the hopper is to the desired castable weight, the more closely the actual vibration force meets the design requirements. During operation, since the mold is constantly vibrating, it's impossible to directly measure the weight of the added material. Instead, a pressure sensor placed in the hopper collects signals, effectively measuring the weight of the castable already in the mold from the side.

[0081] The beneficial effect of the present invention is that through the above method, it is basically and very accurately achieved that when there is less castable in the mold, that is, when the weight is light, a smaller vibration force is automatically applied. The more castable in the mold, the greater the vibration force applied. On the one hand, it conforms to the scientific nature of material molding, and on the other hand, it realizes the function of automatically adjusting the vibration force.

[0082] 8. Fully automatic steel fiber breathable brick forming system

[0083] 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 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. The rest of the base plate is in contact with the electromagnet to generate suction. The vibration source of the vibration unit is a three-phase AC vibration motor. The core components of the control unit are the inverter and PLC. The three-phase AC power is input to the inverter and then output to the vibration motor. The analog signal from the pressure sensor is input to the PLC controller, which then inputs the analog signal from the PLC into the inverter. A control rule is programmed into the PLC controller, using the analog signal from the pressure sensor as a variable. The PLC controller adjusts the inverter's output current frequency according to the control rule, thereby regulating the vibration motor's speed and outputting adjustable vibration force.

[0084] If there are multiple vibration motors, they must be of the same model and adjusted to the same exciting force.

[0085] 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.

[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 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.

[0087] The magnetic force exerted by the electromagnet on the mold is more than 1.1 times 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 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 above 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 according to a conventional method, 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 suction type ventilation core vibration part;

[0119] Figure 3 : magnetic shielded ventilation 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 : ventilation core cross section schematic diagram;

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

[0128] Figure 12 : magnetic shielded, magnetic suction type ventilation core vibration part.

[0129] In the figure: ①: vibration table steel structure, ②: electromagnet, ③: shock absorbing spring, ④: foundation, ⑥: guide device, ⑦: ventilation 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 passage, gas chamber, metal cover plate, air inlet pipe, gas-permeable core, gas-permeable base brick, working main power supply, 380v, AC, contactor, multi-position change-over switch, control current signal, three-phase AC power. DETAILED DESCRIPTION

[0130] 1, making a mold with a magnetic shielding plate

[0131] Take the whole type gas-permeable base brick mold ⑧ as an example, the product size is 360x360x550mm, which is a commonly used brick type, that is, the cross section is a square of 360mm, and the height is 550mm.

[0132] Mold bottom plate The thickness is 20mm thick plain carbon steel, Q235, and the mold bottom plate The size is 460x460x20mm. The magnetic shielding plate The thickness of the metal aluminum plate is 6mm, the size is 370x370x6mm, and the magnetic shielding plate is welded between the mold bottom plate , the depth of the embedded magnetic shielding plate in the mold bottom plate is 8mm, and the magnetic shielding plate does not contact the electromagnet ②.

[0133] The side plate of the base brick mold ⑧ is made according to the conventional method, and the thickness of the plain carbon steel is 10mm, which is fixed by bolts.

[0134] Take the gas-permeable core mold ⑦ as an example, the product size is φ120 / φ172-H520, which is a commonly used brick type, the gas-permeable core is a frustum of cone, the small end diameter is 120mm, the large end diameter is 172mm, and the height is 520mm. When forming, the large end is above, so the small end is connected with the mold bottom plate , the size of the mold bottom plate is 200x200x20mm, the magnetic shielding plate is made of a metal aluminum plate with a thickness of 4mm, the size is φ120x4mm, and is embedded in the mold bottom plate , the lower surface is flush with the mold bottom plate .

[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 main 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 inverter ①0, the main power supply Connect to the inverter ①0 input terminal, and the current is output to the vibration motor after passing through the inverter ①0 Connect the knob of the inverter ①0 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. Prepare the materials according to the formula. In the example, 150 kg is prepared. The formula of the breathable core is divided into the main material part and the additive part. The main material part: T66 plate corundum produced by Anmai Aluminum, with specifications of 3-6mm, 1-3mm, 0.6-1mm, 0.2-0.6mm, less than 180 mesh, and less than 325 mesh, with the mass contents of 18%, 22%, 8%, 8%, 10%, and 6%, respectively; the mass contents of secar71 cement, CMA72 spinel cement, sintered aluminum-magnesium spinel less than or equal to 325 mesh, and bimodal α-Al2O3 are 3%, 4%, 7%, and 4%, respectively. The above proportions refer to the proportions of all main materials. The proportions of the remaining additives refer to the proportions of all main materials. The mass contents of FS60 water reducer, anti-bleeding additive, and composite retarder are 0.09%, 0.03%, and 0.015%, respectively.

[0155] 6.3. Pre-mix the materials below 325 mesh in a ball mill to make them uniform. Use polyurethane mixing balls for mixing.

[0156] 6.4. Dry-mix all the raw materials for a second time using a planetary mixer for 12 minutes to ensure uniform mixing.

[0157] 6.5. Add the mixed bulk materials into the planetary mixer. Add 5.7 kg of clean tap water at one time, i.e. the water addition amount is 3.8%, and stir for 5 minutes.

[0158] 6.6, put the stirred castable into the hopper middle.

[0159] 6.7, pour the castable from the hopper Six sets of breathable core molds ⑦ are added. If the casting material is added manually, it is necessary to accurately ensure that the amount of casting material added to each breathable core mold ⑦ is basically the same. In this example, six sets of breathable core molds ⑦ are added according to a specific device, which can ensure that the casting material added to each breathable core mold ⑦ is the same.

[0160] 6.8, after the feeding is completed, the hopper There is still some castable in the hopper. Clear it so that the vibration can be executed according to the end of the curve.

[0161] 6.9. After forming, cure at 50-60℃ for 8h. After removing the mold⑦, dry at 110-150℃ for 24h. Then, keep it warm at 1560℃ for 3h and cool it naturally. Cut the bricks without obvious defects such as cracks into 40×40×160mm strip samples. Cut 2 samples from each brick, for a total of 6 strips. Then dry them at 110℃ for 24h to complete the sample production.

[0162] 6.10, the average value of the above sample block is detected by the national standard method: 1560℃ firing for 3 hours, the bending strength is 52.7MPa, the compressive strength is 282.5MPa; the linear change rate is 0.05%. The above sample block is directly placed into the furnace at 1100℃, and kept for 30min, then moved to room temperature for 10min, and then placed into the furnace at 1100℃ again for 30min, and so on for 3 times to measure the bending strength retention rate, that is, the ratio of residual strength to original strength (52.7MPa) is 43.9%.

[0163] 7, the example of the method for making uniform base brick:

[0164] The uniformity mainly refers to the distribution of steel fibers. The judgment method is to cut the base brick along the center line longitudinally, and the cross section can show the distribution of steel fibers. The index in the example is tested from the air permeable base brick made by industrialization, which is cut into a sample block with a size of 40x40x160mm, which is completely different from the sample block with a size of 40x40x160mm directly formed. The example is a method for controlling the steel fiber base brick by time.

[0165] 7.1, using Figure 6 The time-controlled device is used to make air permeable base bricks. The base brick mold ⑧ adopts the base brick mold ⑧ described in example 1, which has a magnetic shielding plate There are 2 groups of molds ⑧, and the frequency value in the PLC Figure 8 is adjusted according to the curve.

[0166] 7.2, according to the formula, the weight of the material in the example is 320Kg, and the outer air permeable base brick is made, that is, the air permeable core is not pre-placed in the base brick. The formula of the air permeable base brick is divided into main material part and additive part. The main material part: tabular corundum with specifications of 8-15mm, 5-8mm, 3-5mm, 1-3mm, 0.6-1mm, 0.2-0.6mm, and less than 325 mesh, with mass contents of 24%, 10%, 15%, 10%, 6%, 6%, and 8% respectively; seear71 cement, CMA72 type spinel cement, less than or equal to 325 mesh electric melting type aluminum magnesium spinel, and a-Al2O3 with mass contents of 5%, 3%, 10%, and 3% respectively. The above proportions refer to the proportion of the sum of all main materials; the proportion of the remaining part refers to the proportion of the sum of all main materials. The mass contents of steel fiber with a brand of 446#, FS10 water reducing agent, anti-bleeding additive, and composite retarder are 1.5%, 0.12%, 0.03%, and 0.02% respectively.

[0167] 7.3, the materials below 325 mesh are uniformly pre-mixed by a ball mill. Polyurethane mixing balls are selected during 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 observed 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 breathable brick forming device with adjustable vibration force, characterized by: This device consists of three parts: a breathable core or base brick mold part, a vibration system part, and a control part. The mold requires the base plate to be made of steel and have paramagnetism; the vibration system part includes one or more vibration motors, a steel structure working platform, three or more vibration-damping springs, and one or more electromagnets. When the electromagnet is energized, it is attracted and fixed to the mold. When the electromagnet is de-energized, there is no active force between it and the mold, and the mold can be removed; the core component of the control part is the frequency converter, and the working AC power is input into the frequency converter and then into the vibration motor.

2. A molding device according to claim 1, characterized in that: The inverter knob is connected to the work platform for easy operation. The inverter knob changes the frequency of the current input to the vibration motor, which in turn controls the motor speed and ultimately the vibration force of the vibration motor. During the operation, the vibration force required by the weight of the castable added to the mold is manually determined and the inverter knob is adjusted to achieve the appropriate vibration force.

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