A granulator for magnesium oxide

Abstract

This invention belongs to the field of powder material granulation technology, specifically a granulator for magnesium oxide. It includes a feeding system, a pressing system, a transmission system, and an intelligent control system. The feeding system is driven by a servo or frequency converter motor and is equipped with a material level sensor and a material flow sensor. The pressing system's outlet is equipped with an online particle size analyzer and a pressing zone temperature sensor. The transmission system's gearbox is equipped with temperature and oil pressure sensors. The main control unit of the intelligent control system receives signals from all sensors. On one hand, it uses a flow feedback closed-loop control to stabilize the feeding motor; on the other hand, it dynamically adjusts the feeding setpoint based on the online particle size analysis results to stabilize product quality. Simultaneously, it monitors equipment temperature and oil pressure for fault warnings. This invention achieves real-time monitoring and intelligent feedback control of key parameters in the granulation process, significantly improving product particle size consistency, production stability, and equipment operational safety.

Description

Technical Field

[0001] This utility model relates to the field of powder material granulation technology, and in particular to a granulator for magnesium oxide. Background Technology

[0002] Ring die roller granulators are widely used for dry granulation of powder materials such as magnesium oxide due to their high forming pressure, high particle strength, and stable output. The basic structure of existing ring die roller granulators generally includes a feeding system, a pressing system, and a transmission system. The feeding system is usually composed of an auger driven by a speed-regulating motor, which is used to transport magnesium oxide powder in the hopper to the pressing system. The pressing system mainly includes a stationary ring die (ring die), a rotating pressure roller, and a cutter. The powder is brought into the wedge-shaped extrusion zone between the ring die and the pressure roller, and is squeezed into the ring die hole under high pressure. Then it is cut into particles by the rotating cutter and finally discharged through the guide plate. The transmission system is a main motor that drives the pressure roller shaft and the cutter to rotate through a gearbox.

[0003] However, in actual production, the granulator with the above structure has the following significant shortcomings:

[0004] Poor feeding stability and adaptability: The physical properties of magnesium oxide powder (such as humidity, particle size distribution, and angle of repose) may vary from batch to batch or change over time (such as moisture absorption), resulting in unstable flowability. Although the feeding auger speed of existing equipment is adjustable, it is only manually set in an open loop and cannot be dynamically adjusted according to real-time material characteristics or pressing status. Too much feed may cause blockage in the pressing zone and motor overload; too little feed will result in insufficient molding pressure, resulting in powder or granules with substandard strength, affecting the consistency of product quality.

[0005] Product quality relies on human experience and offline testing: key quality indicators such as particle size and strength are mainly judged by operators taking samples from the discharge port periodically for offline laboratory analysis. This post-production testing method has serious lag and cannot reflect quality fluctuations in the production process in real time. When unqualified products are found, a large number of unqualified products have already been produced, resulting in waste of raw materials.

[0006] Lack of equipment status monitoring: The lubrication status and temperature of the gearbox, as well as the temperature rise caused by friction in the pressing area, are crucial to the long-term stable operation of the equipment and the quality of the particles (high temperature may affect the properties of some materials). Existing equipment lacks real-time monitoring of these key operating parameters, making it impossible to warn of potential mechanical failures (such as abnormal gear wear or bearing overheating) or process abnormalities, which is not conducive to achieving preventive maintenance and safe production.

[0007] Therefore, it is urgent to upgrade the existing magnesium oxide granulators to be intelligent in order to solve the above problems and achieve intelligent production with high quality, high stability and low energy consumption. Utility Model Content

[0008] Based on the technical problems existing in the prior art, this utility model proposes a granulator for magnesium oxide.

[0009] The present invention provides a granulator for magnesium oxide, comprising a base, a feeding system, a pressing system, a transmission system installed thereon, and an intelligent control system;

[0010] The feeding system includes a feeding box, an auger cylinder, an auger shaft, and a feeding drive motor. The feeding drive motor is a servo motor or a frequency converter motor, and its output end is connected to the auger shaft through a reducer. A material level sensor is provided in the feeding box, and a material flow sensor is provided at the discharge port of the auger cylinder.

[0011] The pressing system includes a pressing chamber fixed to the discharge end of the feeding box by bolts. The pressing chamber is equipped with a ring die, a pressure roller assembly, a cutter, and an inclined guide plate. An online particle size analyzer is provided at the particle discharge port of the pressing chamber. A pressing zone temperature sensor is provided on the outer wall or internal non-moving parts of the pressing chamber.

[0012] The transmission system includes a main motor and a gearbox. The main motor is connected to the input shaft of the gearbox via a coupling. The output of the gearbox drives a hollow shaft to rotate via a bevel gear pair. The hollow shaft extends into the pressing chamber and connects the pressure roller assembly and the cutter. A gearbox temperature sensor and an oil pressure sensor are provided on the housing of the gearbox.

[0013] The intelligent control system includes:

[0014] The main control unit is fixedly installed in the equipment base or in a separate control cabinet;

[0015] The human-machine interface is connected to the main control unit and is used for parameter setting, status display and alarm.

[0016] The signal output terminals of the level sensor, material flow sensor, online particle size analyzer, pressing zone temperature sensor, gearbox temperature sensor, and hydraulic pressure sensor are all electrically connected to the corresponding signal input terminals of the main control unit.

[0017] The control output terminal of the main control unit is electrically connected to the driver of the feeding drive motor, forming a closed-loop control circuit for the feeding amount.

[0018] The main control unit is also equipped with an alarm output module, the output of which is connected to an audible and visual alarm.

[0019] Furthermore, the material flow sensor is a powder flow meter based on the impact force principle or a non-contact microwave flow meter, and its measuring probe is installed in the discharge pipe below the auger cylinder outlet or directly opposite the discharge flow stream.

[0020] Furthermore, the online particle size analyzer is a particle size analysis probe based on image recognition or laser diffraction principles, with its detection window facing the particle flow falling from the outlet of the pressing chamber.

[0021] Furthermore, the intelligent control system also includes a cloud data platform or factory host computer system that is communicatively connected to the main control unit for remote data storage, analysis and display.

[0022] Furthermore, the human-machine interface is a touch screen, which integrates and displays real-time flow curves, particle size distribution diagrams, temperature trend diagrams, equipment operating status, and alarm information.

[0023] Furthermore, the main control unit is a programmable logic controller or an industrial computer.

[0024] Furthermore, the housings of the feeding box, pressing chamber, and gearbox are all equipped with wiring interfaces to facilitate sensor wiring and maintenance.

[0025] Compared with the prior art, this utility model provides a granulator for magnesium oxide, which has the following beneficial effects:

[0026] 1. The actual feed rate is monitored in real time by a material flow sensor. The main control unit compares it with the set flow rate calculated based on process parameters such as target particle size. The speed of the feed drive motor is dynamically adjusted by algorithms such as PID, thereby accurately controlling the amount of material entering the pressing zone. This effectively overcomes the feeding fluctuation caused by changes in material flowability and provides a prerequisite for stable pressing. The material level sensor is used to prevent the feed box from being empty or overflowing.

[0027] 2. The online particle size analyzer can continuously and in real time measure the particle size distribution of the produced particles. The main control unit compares the detected actual particle size with the preset target particle size range. When the particle size continues to deviate from the set range, the main control unit can automatically adjust the set value of the feed rate, forming an advanced control closed loop with particle size as the core quality indicator. This transforms post-event detection into pre-event and in-event control, greatly ensuring product consistency and reducing the scrap rate.

[0028] 3. Gearbox temperature and oil pressure sensors can monitor the health status of the transmission system in real time. Abnormally high temperatures may indicate poor lubrication or component wear, while low oil pressure may indicate oil leakage or oil pump failure. The pressing zone temperature sensor can monitor process temperature rise, preventing overheating from affecting the properties of magnesium oxide particles or equipment safety. All sensor data can be displayed in real time on the human-machine interface and will trigger audible and visual alarms when safety thresholds are exceeded, prompting operator intervention and enabling predictive maintenance to avoid sudden shutdowns.

[0029] 4. The human-machine interface centrally displays all key parameters and curves, facilitating operator monitoring. Data can be uploaded to the cloud or factory management system, enabling production data traceability, providing data support for process optimization, and supporting remote monitoring and diagnostics. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0031] Figure 2 This is a schematic diagram of the feeding system of this utility model;

[0032] Figure 3 This is a schematic diagram of the first angle structure inside the pressing system of this utility model;

[0033] Figure 4 This is a schematic diagram of the second angle structure inside the pressing system of this utility model.

[0034] In the diagram: 100, Equipment base; 200, Feeding system; 210, Feeding box; 220, Screwdriver cylinder; 230, Screwdriver shaft; 240, Feeding drive motor; 250, Reducer; 260, Material level sensor; 270, Material flow sensor; 300, Pressing system; 310, Pressing chamber; 320, Ring die; 330, Press roller assembly; 340, Cutter; 350, Inclined guide plate; 360, Online particle size analyzer; 370, Pressing zone temperature sensor; 400, Transmission system; 410, Main motor; 420, Gearbox; 430, Driving bevel gear; 440, Driven bevel gear; 450, Hollow shaft. Detailed Implementation

[0035] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0036] In the description of this utility model, it should be understood that the terms upper, lower, front, back, left, right, top, bottom, inside, outside, etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0037] like Figure 1 and Figure 4 As shown, the granulator for magnesium oxide provided by this utility model includes a base 100, a feeding system 200, a pressing system 300 and a transmission system 400 installed on the base 100. The improvement lies in the integration of an intelligent control system.

[0038] The feeding system 200 includes a feeding box 210, a horizontally arranged auger cylinder 220, an auger shaft 230 inside, and a drive unit. The drive unit uses a servo motor as the feeding drive motor 240, which is connected to a reducer 250 via a coupling. The output shaft of the reducer 250 drives the auger shaft 230 to rotate via a key connection. A radar or ultrasonic level sensor 260 is installed on the upper side wall of the feeding box 210 to continuously monitor the level of magnesium oxide powder in the box. An impact powder flow meter or microwave flow meter is installed as a material flow sensor 270 on the connecting pipe between the discharge port at the end of the auger cylinder 220 and the inlet of the pressing system 300. Its measuring probe is installed on the material channel below the discharge port of the auger cylinder 220 to measure the mass of material delivered to the pressing zone per unit time in real time.

[0039] The pressing system 300 includes a pressing chamber 310 fixed to the discharge end of the feed box 210 by flanges and bolts. Inside the pressing chamber 310, a ring die 320 is fastened to the inner wall of the chamber by bolts. A pressure roller assembly 330 consisting of two pressure rollers is mounted on the end of an empty shaft 450 by bearings. The empty shaft 450 is driven to rotate by the transmission system 400, causing the pressure rollers to roll on the inner surface of the ring die 320. A cutter 340 is fixed to the empty shaft 450 by a bracket and rotates with the shaft to cut the strip-shaped material extruded from the ring die orifice. An inclined guide plate 350 is welded to the pressing chamber. At the bottom of the pressing chamber 310, the particles are guided to exit. An online particle size analyzer 360 is installed outside the particle outlet of the pressing chamber 310. The online particle size analyzer 360 is a particle size analysis probe based on image recognition or a laser diffraction particle size analysis probe. Its camera is facing the particle flow falling from the outlet of the pressing chamber 310, capturing particle images in real time and analyzing their particle size distribution. A thermocouple-type pressing zone temperature sensor 370 is embedded on the outer wall or internal non-rotating parts of the pressing chamber 310 to indirectly monitor the frictional temperature rise during the pressing process.

[0040] The transmission system 400 includes a main motor 410 and a gearbox 420. The main motor 410 is a three-phase asynchronous motor, which is connected to the input shaft of the gearbox 420 through an internal toothed flexible coupling. The gearbox 420 is equipped with a lubrication system. Its output transmits power to the empty shaft 450 through a pair of meshing active bevel gears 430 and passive bevel gears 440. One end of the empty shaft 450 is connected to the passive bevel gear 440 through a key, and the other end extends into the pressing chamber 310 to drive the pressure roller assembly 330 and the cutter 340. A resistance temperature sensor is installed on the housing of the gearbox 420 as a gearbox temperature sensor, and a piezoresistive pressure sensor is installed as an oil pressure sensor. The detection ends of the gearbox temperature sensor and the oil pressure sensor extend into the lubricating oil sump and the pressure oil circuit of the gearbox 420, respectively, to monitor the lubricating oil temperature and the oil circuit pressure.

[0041] The core of the intelligent control system is a programmable logic controller or industrial computer installed in a protective control cabinet as the main control unit, and an industrial touch screen as the human-machine interface. It is connected to the main control unit through a communication cable and installed in an easily accessible position next to the equipment. It is used to display the real-time feed rate curve, real-time particle size distribution map, temperature trend graphs, equipment operating status and alarm information, and is used to input process control parameters. The audible and visual alarm is installed in a conspicuous place on the equipment.

[0042] All sensor signal lines are led out through the pre-set waterproof wiring interface on the equipment housing and connected to the analog input module or dedicated communication interface of the main control unit. The servo driver control terminal of the feed drive motor 240 is connected to the analog output module of the main control unit, and the input terminal of the audible and visual alarm is connected to the digital output module of the main control unit.

[0043] The intelligent control system also includes a remote data interface that communicates with the main control unit, used to connect to a cloud data platform or a factory host computer system.

[0044] The workflow is as follows:

[0045] The operator first sets the target particle size range, the initial value of the target feed rate, the upper limit of the gearbox temperature alarm, the lower limit of the oil pressure alarm, and other process and equipment parameters through the human-machine interface.

[0046] When the equipment is started, the main motor 410 runs, driving the pressure roller and cutter to rotate. The main control unit outputs a signal according to the set feeding amount to control the feeding drive motor 240 to start feeding. Magnesium oxide powder is conveyed from the feeding box 210 through the auger. The material flow sensor 270 feeds back the detected flow signal to the main control unit in real time. The proportional-integral-derivative control program inside the main control unit compares the detected flow with the set flow, calculates the control quantity and outputs it to the driver of the feeding drive motor 240 to adjust the auger speed in real time, so that the actual feeding amount accurately tracks the set value, forming a flow closed loop.

[0047] The compressed granules are monitored in real time by an online particle size analyzer. The analyzed particle size data is transmitted to the main control unit. The main control unit program continuously compares the particle size value with the set range. If the particle size value continues to deviate, the main control unit can automatically adjust the feed rate setting value slightly according to the preset strategy, thereby adjusting the extrusion pressure and stabilizing the particle quality. At the same time, the operator can also choose to manually intervene according to the trend. This constitutes an advanced control closed loop with particle size as the core.

[0048] Throughout the process, the data from the gearbox temperature sensor, oil pressure sensor, and pressing zone temperature sensor 370 are displayed as trend curves in real time on the human-machine interface. Once the temperature or pressure exceeds the safety threshold, the main control unit triggers an audible and visual alarm and displays a prominent alarm message on the interface. The material level sensor 260 is used for low material level alarms to prevent material interruption.

[0049] All production process data can be uploaded by the main control unit to the factory manufacturing execution system or cloud server via Ethernet module, enabling data archiving and remote monitoring.

[0050] 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 granulator for magnesium oxide, comprising a base (100), and a feeding system (200), a pressing system (300), and a transmission system (400) mounted on the base (100), characterized in that: It also includes intelligent control systems; The feeding system (200) includes a feeding box (210), an auger cylinder (220), an auger shaft (230), and a feeding drive motor (240), the output end of which is connected to the auger shaft (230) through a reducer (250); a material level sensor (260) is provided inside the feeding box (210), and a material flow sensor (270) is provided at the discharge port of the auger cylinder (220); The pressing system (300) includes a pressing chamber (310), which is equipped with a ring die (320), a pressure roller assembly (330), a cutter (340), and an inclined guide plate (350); an online particle size analyzer (360) is provided at the discharge port of the pressing chamber (310); and a pressing zone temperature sensor (370) is provided on the pressing chamber (310). The transmission system (400) includes a main motor (410) and a gearbox (420). The main motor (410) drives the input shaft connected to the gearbox (420). The output shaft of the gearbox (420) drives a hollow shaft (450) to rotate through a gear pair. The hollow shaft (450) extends into the pressing chamber (310) and connects the pressure roller assembly (330) and the cutter (340). A gearbox temperature sensor and an oil pressure sensor are provided on the housing of the gearbox (420). The intelligent control system includes a main control unit and a human-machine interface; The signal output terminals of the material level sensor (260), material flow sensor (270), online particle size analyzer (360), pressing zone temperature sensor (370), gearbox temperature sensor, and oil pressure sensor are all electrically connected to the corresponding signal input terminals of the main control unit. The control output terminal of the main control unit is electrically connected to the driver of the feeding drive motor (240); The alarm output terminal of the main control unit is connected to an audible and visual alarm.

2. The granulator for magnesium oxide according to claim 1, characterized in that: The material flow sensor (270) is an impact powder flow meter or a microwave flow meter, and its measuring probe is installed on the material channel below the discharge port of the auger cylinder (220).

3. The granulator for magnesium oxide according to claim 1, characterized in that: The online particle size analyzer (360) is an image recognition-based particle size analysis probe or a laser diffraction particle size analysis probe, and its detection window is directly facing the particle flow falling from the outlet of the pressing chamber (310).

4. The granulator for magnesium oxide according to claim 1, characterized in that: The pressing zone temperature sensor (370) is disposed on the outer wall or internal non-rotating part of the pressing chamber (310); the detection ends of the gearbox temperature sensor and the oil pressure sensor extend into the lubricating oil pool and the pressure oil circuit of the gearbox (420), respectively.

5. The granulator for magnesium oxide according to claim 1, characterized in that: The main control unit is a programmable logic controller or an industrial computer, which is configured to perform the following functions: receive and process data from various sensors; and control the speed of the feeding drive motor (240) in a closed loop according to the feedback value of the material flow sensor (270) to stabilize the feeding amount. The particle size data received from the online particle size analyzer (360) is compared with a preset target range; and the audible and visual alarm is triggered when the monitored values ​​of the gearbox temperature sensor and the oil pressure sensor exceed a preset safety threshold.

6. The granulator for magnesium oxide according to claim 1, characterized in that: The human-machine interface is a touch screen, which is used to display the real-time feed rate curve, real-time particle size distribution map, temperature trend graphs, equipment operating status and alarm information, and is used to input process control parameters.

7. The granulator for magnesium oxide according to any one of claims 1 to 6, characterized in that: The intelligent control system also includes a remote data interface that is communicatively connected to the main control unit, for connecting to a cloud data platform or a factory host computer system.

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