Gypsum board thickness self-adaptive adjusting rolling assembly

Abstract

The utility model relates to the technical field of gypsum board production equipment, in particular to a gypsum board thickness self-adaptive adjusting rolling assembly which comprises a mounting frame, a pressing roller, a servo electric cylinder, a sensor module and a control unit, the mounting frame is arranged on a working platform, and the pressing roller is arranged on the mounting frame; the servo electric cylinder is fixed at the top of the mounting frame, and the output end is rotationally connected with a compression roller; the hysteresis dampers are arranged on the two sides of the servo electric cylinder, and the axes of the hysteresis dampers are orthogonal to the servo electric cylinder. The sensor module comprises a pressure sensor embedded into the compression roller bearing seat and a thickness detection sensor mounted on the mounting frame; the control unit receives a signal of the sensor module and outputs a dynamic adjusting instruction, and the servo electric cylinder and the hysteresis damper are controlled to achieve self-adaptive adjustment of the distance between the roller press and the working platform. The plasterboard thickness adjusting device can achieve efficient and accurate thickness adjustment of plasterboards.

Description

Technical Field

[0001] This utility model relates to the technical field of gypsum board production equipment, specifically to a gypsum board thickness adaptive adjustment roller pressing assembly. Background Technology

[0002] In the production of paper-faced gypsum board, roll forming is the core process that determines the uniformity of board thickness. Existing roll forming equipment mostly uses hydraulic or mechanical adjustment mechanisms, such as the adjusting cylinder and buffer rod structure disclosed in patent CN114888942B. While these can achieve basic thickness control, they have the following drawbacks in practical applications: First, the response delay of the hydraulic system makes it impossible to match changes in the rheological properties of the gypsum slurry in real time, resulting in significant thickness deviations. Second, mechanical linkage adjustment mechanisms (such as positioning discs and limit grooves) rely on manual operation, resulting in long adjustment times per cycle, and the multi-stage hinged structure has assembly gaps, easily leading to cumulative errors. Third, traditional open-loop control systems lack dynamic compensation capabilities, easily reducing the thickness qualification rate when the moisture content of raw materials fluctuates or the production line speed changes. Fourth, the hydraulic system's pressure holding energy consumption accounts for a high proportion of the total machine energy consumption, requiring frequent maintenance (seales need to be replaced every 200 hours), severely restricting production efficiency.

[0003] To address the aforementioned issues, there is an urgent need for an adaptive adjustment scheme that can sense working conditions in real time, dynamically adjust the roller spacing, and has low maintenance costs, in order to improve the thickness accuracy of gypsum board and production efficiency. Utility Model Content

[0004] In view of this, the purpose of this utility model is to provide a gypsum board thickness adaptive adjustment roller pressing component, which can realize efficient and precise thickness adjustment of gypsum board.

[0005] To achieve the above objectives, this utility model provides the following technical solution:

[0006] A gypsum board thickness adaptive adjustment roller pressing assembly includes a mounting frame and a pressure roller, wherein the mounting frame is disposed on a work platform and the pressure roller is disposed on the mounting frame; further comprising:

[0007] A servo electric cylinder is fixed to the top of the mounting frame, and the pressure roller is rotatably connected to its output end.

[0008] The hysteresis damper is installed on both sides of the servo electric cylinder, and its axis is orthogonal to the servo electric cylinder.

[0009] The sensor module includes a pressure sensor embedded in the pressure roller bearing housing and a thickness detection sensor mounted on the mounting frame;

[0010] The control unit receives signals from the sensor module and outputs dynamic adjustment commands to control the servo electric cylinder and hysteresis damper to achieve adaptive adjustment of the distance between the roller and the working platform.

[0011] As a further embodiment of this utility model: the mounting frame includes a crossbeam and columns connected to both ends of the crossbeam, the servo electric cylinder is installed at both ends of the bottom surface of the crossbeam, and the hysteresis damper is installed on the inner side of the column.

[0012] As a further embodiment of this utility model, the servo electric cylinder and the hysteresis damper are provided with vibration isolation pads on the mounting base surface of the mounting bracket.

[0013] As a further improvement of this utility model, the surface of the pressure roller is provided with a micro-textured layer, the texture pattern being a regular array, which is used to reduce the adhesion between the gypsum board and the roller surface.

[0014] As a further improvement of this utility model: the pressure sensor monitors the pressure distribution of the roller gap in real time, and the thickness detection sensor adopts non-contact optical measurement.

[0015] By adopting the above technical solution, this utility model will have the following beneficial effects:

[0016] The pressure rollers are directly driven by servo electric cylinders, replacing the traditional hydraulic system. This eliminates oil pressure delay and achieves millisecond-level rapid response, ensuring real-time adjustment of the roller gap when the gypsum slurry flow state changes. It has low energy consumption and requires minimal maintenance. Orthogonally arranged hysteresis dampers work in conjunction with the servo electric cylinders to suppress mechanical vibration interference in the pressing process, avoiding thickness fluctuations caused by equipment vibration. Sensor modules collect real-time data on roller gap pressure and sheet thickness. The control unit integrates and analyzes this data, dynamically correcting adjustment commands to accurately compensate for fluctuations in raw material moisture content, temperature, and other parameters. The control unit synchronously adjusts the servo electric cylinders and hysteresis dampers based on real-time data, significantly reducing thickness deviation and improving product qualification rate.

[0017] Compared with existing technologies, the solution of this utility model can achieve efficient and precise thickness adjustment of gypsum board while reducing energy consumption and extending maintenance cycle, thus solving the industry pain points of traditional equipment such as slow adjustment, high energy consumption and reliance on manual intervention. Attached Figure Description

[0018] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0019] Figure 1This is a side view of the gypsum board thickness adaptive adjustment roller pressing assembly described in this embodiment of the present invention after installation.

[0020] Figure 2 for Figure 1 A front view of the gypsum board thickness adaptive adjustment roller assembly described in the embodiment.

[0021] The correspondence between the labels and component names in the attached figures is as follows:

[0022] 1. Mounting frame; 11. Crossbeam; 12. Column; 2. Pressure roller; 3. Working platform; 4. Servo electric cylinder; 5. Hysteresis damper; 61. Pressure sensor; 62. Thickness detection sensor. Detailed Implementation

[0023] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of this invention. Therefore, the following description is to be considered exemplary in nature and not restrictive.

[0024] Please refer to Figure 1 and Figure 2 In one embodiment of the gypsum board thickness adaptive adjustment roller pressing assembly provided by this utility model, the gypsum board thickness adaptive adjustment roller pressing assembly includes a mounting frame 1 and a pressure roller 2. The mounting frame 1 includes a crossbeam 11 and columns 12 integrally formed and connected to both ends of the crossbeam 11. The two columns 12 are respectively fixedly connected to both sides of the working platform 3 for conveying gypsum slurry. The pressure roller 2 is arranged inside the mounting frame 1 above the working platform 3 for squeezing gypsum slurry.

[0025] It should be noted that in the production of paper-faced gypsum board, the rolling process is located in the forming stage. The specific process is as follows: a uniformly mixed gypsum slurry (containing building gypsum, fiber, additives, etc.) is continuously poured between the upper and lower layers of facing paper, and the slurry is extruded and formed by multiple rolling presses.

[0026] The gypsum board thickness adaptive adjustment roller pressing assembly in this embodiment also includes a servo electric cylinder 4, a hysteresis damper 5, a sensor module, and a control unit:

[0027] The servo electric cylinder 4 is fixed to the top of the mounting bracket 1. Specifically, the servo electric cylinder 4 is vertically mounted on both ends of the bottom surface of the crossbeam 11 via flanges. The output end of the servo electric cylinder 4 extends downward, and the two ends of the pressure roller 2 are rotatably connected to the output ends of the two servo electric cylinders 4 via bearing seats. The hysteresis dampers 5 are set on both sides of the output end of the servo electric cylinder 4. The two hysteresis dampers 5 are mounted on the inner side of the column 12 via brackets, and the axis of the hysteresis dampers 5 is arranged at 90° orthogonal to the servo electric cylinder 4. In use, the servo electric cylinder 4 drives the pressure roller 2 to move up and down. If vibration occurs during this process, the output end of the servo electric cylinder 4 will cut the magnetic field lines and generate eddy currents (closed loop currents). The direction of the current will generate a magnetic field opposite to the original magnetic field, which will hinder the movement of the servo electric cylinder 4, thereby converting kinetic energy into heat energy (Joule heat) and achieving deceleration.

[0028] It should be noted that both the servo electric cylinder 4 and the hysteresis damper 5 are existing technologies. The servo electric cylinder 4 uses ball screw drive, has a built-in absolute encoder for real-time displacement feedback, an IP67 protection rating, an anodized surface treatment, and heat dissipation fins, with an integrated LED status indicator ring at the front end. The hysteresis damper 5 has a dual-cavity design; the main cavity is filled with magnetorheological fluid, and the secondary cavity is equipped with a temperature compensation diaphragm. It has a maximum damping force of 2000N, a response time of <10ms, and the coil windings are made of high-temperature resistant enameled wire arranged in a helical involute pattern. The outer shell is made of ceramic matrix composite material with a biomimetic honeycomb structure (wall thickness 3mm, honeycomb aperture φ5mm), and internal guide vanes.

[0029] Preferably, the servo electric cylinder 4 and the hysteresis damper 5 are provided with vibration isolation pads on the mounting base surface of the mounting bracket 1. The pads are made of nitrile rubber-metal laminate to prevent the servo electric cylinder 4 and the hysteresis damper 5 from vibrating and affecting the adjustment effect.

[0030] Preferably, the surface of the pressure roller 2 is provided with a micro-textured layer. The texture pattern is a regular array of diamond-shaped grooves with a groove depth of 0.1-0.3 mm, a spacing of 1.5 mm, a groove width of 0.2 mm, and the groove direction is at a 45° angle to the direction of movement of the gypsum board. The design of the micro-textured layer can reduce the adhesion between the gypsum board and the roller surface of the pressure roller 2.

[0031] The sensor module includes a pressure sensor 61 and a thickness detection sensor 62. The pressure sensor 61 is embedded in the bearing seats at both ends of the pressure roller 2, 3mm away from the roller surface, and monitors the pressure distribution of the roller gap in real time. The thickness detection sensor 62 is installed in the middle of the bottom surface of the crossbeam 11 and aligned with the edge of the gypsum board. It scans the thickness of the board in real time in a non-contact manner (10-50mm away from the surface of the gypsum board), covering a width of 1500mm (adapting to different specifications of boards). The control unit is connected to the sensor module, the servo electric cylinder 4, and the hysteresis damper 5. By receiving signals from the sensor module and outputting dynamic adjustment commands, it controls the servo electric cylinder 4 and the hysteresis damper 5 to achieve adaptive adjustment of the distance between the roller and the working platform 3.

[0032] Specifically, the control unit integrates fuzzy control and prediction algorithms, which can dynamically and collaboratively adjust the servo electric cylinder 4 and the hysteresis damper 5 according to the pressure gradient and thickness deviation. Specifically, the control unit adopts the existing hardware architecture, and its core controller can be a Beckhoff CX series embedded controller (such as CX5130); its FPGA module can be a Xilinx Zynq-7000 series.

[0033] The method of use or working principle of this utility model is as follows:

[0034] When dynamically adjusting the thickness of the gypsum board, the thickness detection sensor 62 scans the surface of the gypsum board and generates a thickness distribution cloud map; the pressure sensor 61 collects the pressure of the roller gap of the pressure roller 2 in real time; the control unit inputs the thickness and pressure data into the model, calculates the thickness deviation and pressure gradient, and then uses a fuzzy hybrid algorithm to generate the displacement command of the servo electric cylinder 4 and the current command of the damper; after receiving the displacement command, the servo electric cylinder 4 pushes the pressure roller 2 to adjust the distance between the pressure roller 2 and the working platform 3; the hysteresis damper 5 changes the viscosity of the magnetorheological fluid according to the current command to suppress the vibration of the pressure roller 2 in real time (because the high-speed adjustment of the servo electric cylinder 4 is prone to mechanical impact, it is necessary to instantly enhance the damping force in the corresponding direction according to the data of the pressure sensor 61 to suppress the vibration amplitude); the thickness detection sensor 62 verifies the adjusted thickness, and if the deviation exceeds the preset value, it triggers secondary compensation.

[0035] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A gypsum board thickness adaptive adjustment roller pressing assembly, comprising a mounting frame (1) and a pressure roller (2), wherein the mounting frame (1) is disposed on a working platform (3), and the pressure roller (2) is disposed on the mounting frame (1); characterized in that, Also includes: A servo electric cylinder (4) is fixed to the top of the mounting frame (1), and the pressure roller (2) is rotatably connected to the output end; The hysteresis damper (5) is set on both sides of the servo electric cylinder (4), and its axis is orthogonal to the servo electric cylinder (4); The sensor module includes a pressure sensor (61) embedded in the bearing seat of the pressure roller (2) and a thickness detection sensor (62) mounted on the mounting frame (1); The control unit receives the sensor module signal and outputs dynamic adjustment instructions to control the servo electric cylinder (4) and the hysteresis damper (5) to achieve adaptive adjustment of the distance between the roller and the working platform (3).

2. The gypsum board thickness adaptive adjustment roller pressing assembly according to claim 1, characterized in that: The mounting frame (1) includes a crossbeam (11) and columns (12) connected to both ends of the crossbeam (11). The servo electric cylinder (4) is installed at both ends of the bottom surface of the crossbeam (11), and the hysteresis damper (5) is installed on the inner side of the column (12).

3. The gypsum board thickness adaptive adjustment roller pressing assembly according to claim 2, characterized in that: The servo electric cylinder (4) and the hysteresis damper (5) are provided with vibration isolation pads on the mounting base surface of the mounting bracket (1).

4. The gypsum board thickness adaptive adjustment roller pressing assembly according to claim 1, characterized in that: The surface of the pressure roller (2) is provided with a micro-textured layer, and the textured pattern is a regular array, which is used to reduce the adhesion between the gypsum board and the roller surface of the pressure roller (2).

5. The gypsum board thickness adaptive adjustment roller pressing assembly according to claim 1, characterized in that: The pressure sensor (61) monitors the pressure distribution of the roll gap of the pressure roller (2) in real time, and the thickness detection sensor (62) adopts non-contact optical measurement.

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