Kiln Car Loading Device for Simultaneous Rack Transfer
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Solution Overview
Problem
Existing kiln car transportation, loading, and unloading systems are inefficient, leading to excessive energy consumption and storage needs due to multiple kiln cars being reheated after each firing process.
Innovation Solution
A device and method that utilize a kiln car transport unit and a firing frame transport unit to simultaneously unload and reload kiln cars during transport, eliminating the need for intermediate storage and transverse sliding devices, and reducing energy usage by minimizing the number of kiln cars outside the kiln.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple kiln cars are stored outside the furnace and reheated for each firing cycle, then the loading and unloading process can be completed, but energy consumption increases and storage space is required
Solution Approach 1:
The patent combines the loading and unloading operations into a single integrated process. The loading device simultaneously unloads fired racks from the kiln car and loads new green racks onto it during the return journey, eliminating the need for separate storage and reheating of multiple kiln cars. This merging of operations resolves the contradiction by maintaining productivity while reducing energy consumption.
Solution Approach 2:
The patent prepares the kiln car in advance by pre-loading green racks onto the return journey path before the actual firing cycle completes. This preliminary action ensures that when the kiln car returns, loading can occur immediately without waiting for separate storage operations, thereby reducing the number of kiln cars needing simultaneous reheating and reducing energy consumption.
2Productivity
If multiple kiln cars are stored outside the furnace, then continuous firing operations can be maintained, but storage space and device complexity increase
Solution Approach 1:
The patent merges the functions of storage, loading, and unloading into a single integrated loading device. The device includes a storage area for green racks and a mechanism that simultaneously performs unloading of fired racks and loading of green racks during the kiln car's return journey. This eliminates the need for separate storage areas and complex transport infrastructure for multiple kiln cars, reducing device complexity while maintaining continuous operation.
Solution Approach 2:
The loading device is designed with multi-functionality, serving as both a storage system for green racks and a loading/unloading mechanism. The same device structure that stores green racks also performs the loading operation onto the returning kiln car, eliminating the need for separate dedicated storage facilities and reducing overall system complexity.
3Ease of operation
If traditional loading and unloading systems are used, then the process can be completed, but time is lost due to sequential operations
Solution Approach 1:
The patent implements continuous operation by performing loading and unloading actions simultaneously during the kiln car's return journey. The loading device continuously feeds green racks onto the kiln car while it moves back, rather than waiting for sequential operations. This eliminates idle time and maintains continuous useful action throughout the cycle, resolving the time loss contradiction.
Solution Approach 2:
The loading device prepares green racks in advance and positions them for immediate loading onto the returning kiln car. This preliminary preparation eliminates waiting time during the loading operation, as racks are ready to be loaded the moment the kiln car arrives, thereby reducing the total cycle time while maintaining ease of operation.
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3b
AI summary
A device (1) for transporting, loading and/or unloading a kiln car (3) is proposed, comprising a kiln (2), a storage rack (5), a loading device (4) and a kiln car (3), wherein the kiln (2) is designed for firing material, and the kiln (2) has transport means (10) to guide the kiln car (3) through the kiln (2) for firing the material, and wherein a firing rack (6) is arranged in the kiln car (3) and the material is arranged in the firing rack (6), and wherein the storage rack (5) has several storage places (11) and each storage place (11) is designed to accommodate at least one firing rack.It is essential that the loading device (4) has a furnace car transport unit (40) for removing the furnace car from the transport means (10), for transporting the furnace car from the end of the furnace to the beginning of the furnace and for placing the furnace car on the transport means (10), and that the loading device (4) further has a firing rack transport unit (50) for receiving the firing rack from the furnace car (3) and/or from the shelf storage, for transporting the firing rack between the furnace car (3) and the shelf storage (5) and for placing the firing rack (6) in the furnace car (3) and/or in the shelf storage (5).