Brick Lining Forming Method Using Variable Back Face Width
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Solution Overview
Problem
The existing methods for forming brick linings in kilns and furnaces are inefficient due to the complexity and time required for selecting and arranging differently-shaped bricks, leading to increased manufacturing costs and workload.
Innovation Solution
A method using bricks identical in taper angle, height dimension, and length dimension, with varying back face widths, to simplify the brick lining process, allowing for continuous use of identically-shaped bricks across tier regions with different pre-lining radii, and reducing the need for multiple brick shapes and packing complexities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If two types of differently-shaped bricks with different taper angles are used to cope with various tier regions, then the number of brick shapes can be minimized, but the brick lining forming work becomes complicated and time-consuming
Solution Approach 1:
The invention changes the parameter being varied from taper angle to back face width. By keeping the taper angle constant and only varying the back face width of bricks, the lining work is simplified while still accommodating different tier regions with different pre-lining radii. This resolves the contradiction by finding a different parameter to control that achieves adaptability without increasing operational complexity.
2Ease of operation
If bricks are preliminarily arranged in a pallet in a given order to facilitate lining work, then the lining work is facilitated, but it takes time and effort for packing and checking
Solution Approach 1:
The invention applies homogeneity by using bricks with the same taper angle throughout, which makes all bricks more uniform and similar in shape. This reduces the need for careful differentiation and checking during packing and lining operations, thereby reducing the time and effort required for preliminary arrangement while still facilitating the lining work.
3Productivity
If identically-shaped bricks are used in each tier region, then the efficiency of brick lining forming work is improved, but it takes a lot of time for exchange work of molding dies
Solution Approach 1:
The invention applies local quality by allowing only the back face width parameter to vary while keeping all other brick parameters (taper angle, height, length) identical. This enables the use of a common molding die design for all bricks, eliminating the need for die exchange, while still providing local variation in back face width to accommodate different tier regions, thus improving productivity without time loss from die exchange.
Data Source
AI summary
It is intended to provide a method for forming a brick lining to construct a sidewall of a kiln/furnace, while improving efficiency of brick lining forming work without causing any increase in manufacturing cost of bricks to be used. The brick lining forming method comprises stacking a plurality of tiers of bricks, respectively, on a plurality of tier regions of an inner surface of a hollow approximately cylindrical-shaped peripheral portion of a kiln/furnace to construct a side wall of the kiln/furnace, wherein two or more of the plurality of tier regions are different in terms of pre-lining radius, wherein only bricks identical in terms of taper angle and height dimension are used, except for an adjustment brick, in each of the two or more tier regions different in terms of the pre-lining radius, wherein bricks identical in terms of the taper angle, the height dimension and length dimension, and different in terms of back face width, are used in at least a part of each of the two or more tier regions.