Roller bar cotton plugging quantifying device for roller kiln

Abstract

The utility model discloses a roller kiln roller plug cotton quantifying device which comprises a plug cotton push rod and a plug cotton sleeve, an inner cavity of the plug cotton sleeve directionally penetrates and extends to two end faces so as to form a plug-in end and an extrusion end respectively, the rod end of the plug cotton push rod can extend into the inner cavity of the plug cotton sleeve from the plug-in end, and the rod end of the plug cotton sleeve can extend into the plug cotton sleeve from the extrusion end. The rod end of the cotton plugging push rod can act on the heat insulation cotton put in through the plugging end so as to compact the heat insulation cotton or eject the compacted heat insulation cotton out through the extrusion end. The extrusion end can be movably embedded into a roller rod end opening needing cotton filling, and the cotton filling push rod continuously pushes heat insulation cotton sent out through the extrusion end to enter an inner cavity of a roller rod.

Description

Technical Field

[0001] This utility model relates to the technical field of roller kilns, and in particular to a quantitative device for cotton stuffing in roller kilns. Background Technology

[0002] Currently, the lining process for ceramic rollers in the industry is generally characterized by its extensive and inefficient methods: operators rely heavily on experience to manually fill the ceramic fiber cotton, lacking both quantitative standards and specialized tools. Although some companies have established basic operating procedures, these are difficult to implement effectively due to the following systemic deficiencies:

[0003] 1. Quality control failure: Manual layering and packing results in a loose and fluffy distribution of cotton fibers, with an actual density of only 60-80% of the standard value (measured data). During operation, the cotton is prone to falling off, causing the insulation layer to fail.

[0004] 2. Increased equipment wear and tear: Deviation in packing depth causes dual risks - shallow packing (<100mm) increases the kiln heat loss rate by 8-12% (thermal imaging detection), resulting in increased unit energy consumption; excessive packing (>300mm) increases the thermal stress concentration of the roller working section by 40%, which accelerates the deterioration of the ceramic phase and increases the radial load on the transmission system.

[0005] 3. Production efficiency bottleneck: Manual operation of a single roller takes 5-8 minutes, and the pass rate fluctuates between 65-75%, which is difficult to meet the needs of large-scale production of more than 2,000 pieces per day.

[0006] Therefore, optimizing existing cotton stuffing processes, especially improving the accuracy and consistency of stuffing depth, is a key area for improvement in enhancing production efficiency and product quality. Utility Model Content

[0007] The purpose of this invention is to overcome the shortcomings of the prior art and provide a quantitative device for cotton stuffing in roller kilns.

[0008] To achieve the above objectives, this utility model provides a cotton-filling metering device for roller kilns, comprising a cotton-filling pusher and a cotton-filling sleeve. The inner cavity of the cotton-filling sleeve extends directionally to both end faces to form an insertion end and an extrusion end, respectively. The end of the cotton-filling pusher can extend into the inner cavity of the cotton-filling sleeve from the insertion end, and the end of the cotton-filling pusher can act on the insulation cotton placed through the insertion end to compact the insulation cotton or push the compacted insulation cotton out through the extrusion end. The extrusion end can be movably fitted into the end of the roller that needs to be filled with cotton, so that the cotton-filling pusher continuously pushes the insulation cotton delivered through the extrusion end into the inner cavity of the roller.

[0009] Furthermore, the push rod of the cotton stuffing rod is formed with a limiting part for contacting the plugging end of the cotton stuffing sleeve with a stop.

[0010] Furthermore, the end of the cotton-stuffing pusher extends directly into the inner cavity of the roller to push the pre-feeded insulation cotton.

[0011] Furthermore, when the cotton-stuffing push rod extends directly into the inner cavity of the roller, the limiting part can stop and abut against the end face of the roller.

[0012] Furthermore, the end of the cotton-stuffing push rod is integrally formed with a push block that matches the cross-sectional shape of the inner cavity of the cotton-stuffing sleeve.

[0013] Furthermore, the outer circumferential surface of the cotton-filled sleeve is provided with an observation port that communicates with the inner cavity of the cotton-filled sleeve, through which the fullness of the insulation cotton can be observed.

[0014] Furthermore, the outer peripheral surface of the cotton-filled sleeve is formed with a trumpet-shaped tube extending toward the extrusion end, wherein when the extrusion end is fitted into the end of the roller, the inner wall of the trumpet-shaped tube can stop and abut against the end face of the roller.

[0015] The advantages of this utility model using the above-mentioned solution are as follows: 1. Optimizing the cotton-filling process ensures that the cotton filling fullness of each roller meets the standard, reducing cotton shedding and avoiding inconsistent depth; 2. By precisely controlling the cotton filling depth and amount, the insulation effect of the active and passive sides is improved, reducing temperature fluctuations and equipment load increases caused by insufficient insulation during production. This reduces heat loss and lowers kiln energy consumption; 3. The quantitative cotton-filling tool extends the life of ceramic rollers, reducing the problems of increased kiln energy consumption due to excessively shallow filling and the lifespan issues of ceramic rollers due to excessively deep filling; effectively extending the service life of ceramic rollers, saving operating costs and reducing worker labor intensity; 4. Quantitative cotton filling makes the transmission load more uniform and stable, reducing the wear rate of transmission bearings, extending equipment life, reducing maintenance frequency and downtime, and improving equipment stability and reliability; significantly improving the efficiency of cotton-filling operations, reducing manual operation errors and time costs. It ensures stable cotton filling quality for each roller, providing a more uniform temperature environment for ceramic product firing, thereby improving product consistency and pass rate. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the cotton-plugging device for rollers in a roller kiln.

[0017] Figure 2 A schematic diagram showing the combination of a cotton-filling push rod and a cotton-filling sleeve.

[0018] Figure 3 A schematic diagram showing the combination of cotton-filling push rod, cotton-filling sleeve, and roller.

[0019] Figure 4 This is a schematic diagram showing how cotton-stuffing push rods and rollers can be used independently.

[0020] Among them, 1-cotton-filling push rod, 11-push block, 12-limiting part, 2-cotton-filling sleeve, 21-filling end, 22-extrusion end, 23-flare tube, 24-observation port, 3-roller bar, A-insulation cotton. Detailed Implementation

[0021] To more fully illustrate this utility model, a detailed description will be provided below in conjunction with the accompanying drawings. The drawings depict preferred embodiments of this utility model. However, it is worth noting that this utility model is not limited to these specific forms and can be implemented in various ways. These embodiments are provided to enable the reader to gain a deeper understanding of this utility model.

[0022] As attached Figure 1-4 As shown in this embodiment, a cotton-filling metering device for roller kilns includes a cotton-filling pusher 1 and a cotton-filling sleeve 2. The cotton-filling sleeve 2 has a straight cylindrical structure with a hollow inner cavity. The inner cavity of the cotton-filling sleeve 2 extends directionally to both end faces to form an insertion end 21 and an extrusion end 22, respectively. The insertion end 21 serves as the inlet side for inserting the insulation cotton A and / or the rod end of the cotton-filling pusher 1 into the inner cavity of the cotton-filling sleeve 2, and the extrusion end 22 serves as the outlet side for extending the insulation cotton A and / or the rod end of the cotton-filling pusher 1 out of the inner cavity of the cotton-filling sleeve 2.

[0023] In this embodiment, the cotton-stuffing pusher 1 is designed for multiple purposes. It can be used alone with the roller 3 or in combination with the cotton-stuffing sleeve 2. Ultimately, it can accurately push the compacted insulation cotton A into the designated position in the inner cavity of the roller 3, ensuring the accuracy of the cotton-stuffing depth and position.

[0024] Specifically, as shown in the attached document Figure 2 and 3 As shown, when the cotton-filling pusher 1 and the cotton-filling sleeve 2 are used together, the end of the cotton-filling pusher 1 can extend into the inner cavity of the cotton-filling sleeve 2 from the filling end 21, so that the end of the cotton-filling pusher 1 can act on the heat insulation cotton A inserted through the filling end 21. That is: first, place the cotton-filling sleeve 2 vertically and stably on a flat surface (such as the ground or a tabletop), so that the filling end 21 is facing upward and open, and the extrusion end 22 is facing downward and forms a temporary closed state through the flat surface (relying on the flat surface to prevent the heat insulation cotton A from falling off). Then, operate... Personnel take an appropriate amount of appropriately sized heat insulation cotton A (such as standard loose ceramic fiber cotton), tear it evenly, and fill it into the inner cavity of the cotton-filling sleeve 2 in 3-4 batches through the filling end 21 (the amount filled at one time shall not exceed 1 / 3 of the sleeve volume). After each filling of heat insulation cotton A, the cotton-filling push rod 1 is used to compact it in a step-by-step manner until the inner cavity of the cotton-filling sleeve 2 reaches the rated thickness (the thickness is preferably 150mm, indicating that the filling amount meets the requirements), ensuring that the heat insulation cotton A is tightly filled and evenly distributed in the inner cavity of the cotton-filling sleeve 2.

[0025] Next, align the extrusion end 22 of the stuffing sleeve 2, filled with insulation cotton A, with the end port of the roller 3 to be stuffed, thus movably inserting it into the end port of the roller 3. Then, using the stuffing pusher 1, push the compacted insulation cotton A through the extrusion end 22 into the inner cavity of the roller 3 from inside the stuffing sleeve 2. The stuffing pusher 1 continues to push the insulation cotton A delivered through the extrusion end 22 into the inner cavity of the roller 3 until the stuffing pusher 1 and the stuffing sleeve 2 reach the limit position (at this point, the insulation cotton A is exactly 140-150mm deep into the inner cavity of the roller 3, ensuring the depth meets the process requirements). Finally, remove the stuffing sleeve 2 and the stuffing pusher 1. The above operations complete the insertion of insulation cotton A into the inner cavity of the roller 3, ensuring both the fullness and consistent depth of the insulation cotton A, and avoiding problems such as insufficient or excessive filling.

[0026] Specifically, as shown in the attached document Figure 4 As shown, when the cotton-filling pusher 1 and the roller 3 are used together, they are mainly used to perform secondary pushing and adjustment of the insulation cotton A embedded in the inner cavity of the roller 3. In particular, after all the rollers 3 are inserted into the kiln body as required, the insulation cotton A on the passive side of the kiln body of the roller 3 needs to be pushed and adjusted a second time. That is, the cotton-filling pusher 1 is inserted directly into the inner cavity of the roller 3 through the end of the roller 3 to push the insulation cotton A to continue to move deeper until the cotton-filling pusher 1 and the end of the roller 3 cooperate to reach the limit position (at this time, the insulation cotton A is exactly 300mm deep into the inner cavity of the roller 3, ensuring the heat preservation effect and stability of the insulation cotton A in the high temperature environment).

[0027] In this embodiment, the body of the cotton-stuffing push rod 1 is formed with a limiting part 12 (the limiting part 12 is a block structure that protrudes vertically from the body of the cotton-stuffing push rod 1). When the cotton-stuffing push rod 1 is used in combination with the cotton-stuffing sleeve 2, the limiting part 12 can be used to stop and contact the insertion end 21 of the cotton-stuffing sleeve 2 (corresponding to the position where the heat insulation cotton A penetrates into the inner cavity of the roller 3 by 140-150mm). When the cotton-stuffing push rod 1 and the roller 3 are used alone, the limiting part 12 can stop and contact the end face of the roller 3 (corresponding to the position where the heat insulation cotton A penetrates into the inner cavity of the roller 3 by 300mm).

[0028] In this embodiment, the end of the cotton-filling push rod 1 is integrally formed with a push block 11 that matches the cross-sectional shape of the inner cavity of the cotton-filling sleeve 2. The diameter of the push block 11 is 0.5-1mm smaller than the inner diameter of the sleeve, which ensures smooth sliding and prevents leakage of the insulation cotton A fibers. Thus, the push block 11 is used to better press and fit with the insulation cotton A in the inner cavity of the cotton-filling sleeve 2, thereby ensuring the fullness of the insulation cotton A.

[0029] In this embodiment, the outer circumferential surface of the cotton-filling sleeve 2 is provided with an observation port 24 that communicates with the inner cavity of the cotton-filling sleeve 2. The observation port 24 is located at a distance of 21150mm from the insertion end. When the insulation cotton A is filled to the lower edge of the observation port 24, the rated thickness is reached. That is, the fullness of the insulation cotton A can be checked through the observation port 24. Specifically, when the insulation cotton A is put in and compacted, if the operator can clearly see the insulation cotton A through the observation port 24, it means that the thickness of the insulation cotton A has reached 150mm, indicating that the filling amount and saturation meet the requirements.

[0030] In this embodiment, the outer peripheral surface of the cotton-filling sleeve 2 is formed with a trumpet-shaped tube 23 extending toward the extrusion end 22. When the extrusion end 22 is inserted into the end of the roller 3, the inner wall of the trumpet-shaped tube 23 can stop and abut against the end face of the roller 3. The stop and abutment between the trumpet-shaped tube 23 and the roller 3 achieves the positioning effect of the cotton-filling sleeve 2, preventing the extrusion end 22 of the cotton-filling sleeve 2 from going too deep into the end of the roller 3.

[0031] In summary, by standardizing the cotton-stuffing process described above, the fullness of cotton stuffing on each roller 3 is ensured to meet the standard, reducing cotton shedding and avoiding inconsistent stuffing depth. Precise control of the stuffing depth and amount improves the insulation effect of both the active and passive edges, reducing temperature fluctuations and increased equipment load during production. It also reduces heat loss, lowers kiln energy consumption, and mitigates the problems of increased kiln energy consumption due to excessively shallow stuffing and shortened lifespan of the ceramic roller 3 due to excessively deep stuffing; effectively extending the service life of the ceramic roller 3, saving operating costs and reducing worker workload. It significantly improves the efficiency of cotton stuffing operations, reducing errors and time costs associated with manual operation. It ensures stable cotton stuffing quality on each roller 3, providing a more uniform temperature environment for ceramic product firing, thereby improving product consistency and yield.

[0032] The embodiments described above are merely preferred embodiments of this utility model and are not intended to limit the utility model in any way. Any modifications or alterations made by those skilled in the art to the technical solution of this utility model without departing from its scope are equivalent embodiments of this utility model. Therefore, all equivalent changes made based on the concept of this utility model without departing from its scope should be covered within the protection scope of this utility model.

Claims

1. A roller kiln roller bar cotton plug quantifying device, characterized by: The application relates to a cotton plug pushing rod (1) and a cotton plug sleeve (2), the inner cavity of the cotton plug sleeve (2) extends through two end faces to form a plug-in end (21) and an extrusion end (22) respectively, wherein the rod end of the cotton plug pushing rod (1) can extend into the inner cavity of the cotton plug sleeve (2) from the plug-in end (21), and the rod end of the cotton plug pushing rod (1) can act on the heat insulation cotton (A) put in through the plug-in end (21) to compact the heat insulation cotton (A) or push out the compacted heat insulation cotton (A) through the extrusion end (22); the extrusion end (22) can be movably embedded into the port of a roller (3) requiring cotton plug, so that the cotton plug pushing rod (1) continuously pushes the heat insulation cotton (A) sent out through the extrusion end (22) into the inner cavity of the roller (3).

2. A roll bar plug cotton dosing device for a roller kiln as claimed in claim 1, characterised in that: The rod body of the cotton plug pushing rod (1) is formed with a limiting part (12) for abutting against the plug-in end (21) of the cotton plug sleeve (2).

3. A roll bar plug cotton dosing device for a roller kiln as claimed in claim 2, characterised in that: The rod end of the cotton plug pushing rod (1) directly extends into the inner cavity of the roller (3) to push the pre-sent heat insulation cotton (A).

4. A roll bar plug cotton dosing device for a roller kiln as claimed in claim 3, characterised in that: When the cotton plug pushing rod (1) directly extends into the inner cavity of the roller (3), the limiting part (12) can abut against the end face of the roller (3).

5. A roll bar plug cotton dosing device for a roller kiln as claimed in claim 1, characterized in that: The rod end of the cotton plug pushing rod (1) is integrally formed with a pushing block (11) matching the sectional shape of the inner cavity of the cotton plug sleeve (2).

6. A roll bar plug cotton dosing device for a roller kiln as claimed in claim 1, characterized in that: The outer periphery of the cotton plug sleeve (2) is provided with an observation opening (24) communicating with the inner cavity of the cotton plug sleeve (2), and the fullness of the heat insulation cotton (A) can be observed through the observation opening (24).

7. A roll bar plug cotton quantifying device for a roller kiln as claimed in claim 1, characterized in that: The outer periphery of the cotton plug sleeve (2) is formed with a horn sleeve (23) extending towards the extrusion end (22), wherein when the extrusion end (22) is embedded into the end of the roller (3), the inner wall of the horn sleeve (23) can abut against the end face of the roller (3).

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