Vibratory Coal Cake Compaction System
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Solution Overview
Problem
Existing methods for producing coal cakes for coking, such as mechanical stamping and hydraulic pressing, face inefficiencies in achieving uniform density and high throughput, and vibratory compaction methods have not been effectively implemented due to difficulties in handling compacted coal and binder usage.
Innovation Solution
A push-table vibrating machine with an oscillating table is used to compact coal into uniform blocks by combining vibratory and stamping actions, allowing for efficient production of high-density coal cakes without wear-prone stamping devices, using natural moisture or added binders for stability, and enabling large-format coal cakes with uniform density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical stamping devices are used to compact coal, then coal cakes can be produced, but the density is not uniformly distributed and the process requires successive layer-by-layer stamping which reduces productivity
Solution Approach 1:
The patent applies vibratory compaction using a vibrating table that oscillates the mould box containing coal material. This vibration method achieves uniform density distribution throughout the coal cake without requiring successive layer-by-layer stamping, thereby improving both manufacturing precision and productivity simultaneously
Solution Approach 2:
The patent replaces the traditional mechanical stamping system with a vibratory compaction system. Instead of using stamping rods and lifting devices, the invention uses a vibrating table with oscillatory motion to compact the coal material, eliminating the need for complex mechanical stamping mechanisms
2Productivity
If vibratory compaction is implemented with a suspended vibrator, then coal can be compacted, but the vibrator cannot be easily removed from solidified coal layers especially when binder is used
Solution Approach 1:
The patent segments the compaction process by using a mould box that can be separated from the vibrating table. The mould box containing the compacted coal cake can be easily removed and lifted away, solving the problem of vibrator removal from solidified coal layers while maintaining compaction efficiency
Solution Approach 2:
The patent introduces a mould box as an intermediary element between the vibrating table and the coal material. This mould box facilitates easy removal of the compacted coal cake and simplifies the operation by allowing the mould box to be lifted away after compaction, eliminating the difficulty of removing a suspended vibrator
3Manufacturing precision
If hydraulic pressing devices are used to produce coal cakes, then compaction can be achieved, but the method is complex and less efficient compared to vibratory methods
Solution Approach 1:
The patent replaces complex hydraulic pressing devices with a simpler vibratory compaction system. The vibrating table provides effective compaction through oscillatory motion, achieving uniform density distribution without requiring complex hydraulic mechanisms, thereby reducing device complexity while maintaining manufacturing precision
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method achieves high-output, uniformly compacted coal cakes with improved quality and efficiency, suitable for large coking oven chambers, by using vibratory compaction to produce coal blocks that can be easily stacked and transported, overcoming previous limitations in density and throughput.
Implementation Method 1
The mould box is vertically oscillated while the weight presses from above into the mould box so as to mould a vibration-compacted coal block
Implementation Method 2
A weight is placed on top of the mould box. The mould box is vertically oscillated while the weight presses from above into the mould box
Data Source
AI summary
A method for producing a coal cake that is suitable for coking and for subsequent charging of a coking oven chamber. At least one vibrating station including a push-table vibrating machine with an oscillatorily mounted vibrating table is provided. A mold box is clamped to the vibrating table. The mold box is filled with granular raw coal material. A weight is placed on top of the mold box. The mold box is vertically oscillated while the weight presses from above into the mold box so as to mold a vibration-compacted coal block. The vibration-compacted coal block is pushed off the vibrating table, using an ejector, onto an underlying support. The vibration-compacted coal block is pushed on the underlying support by a length (x) of the vibration-compacted coal block successive to another vibration-compacted coal block. The vibration-compacted coal blocks are successively stacked so as to form the coal cake. The coal cake is introduced into the coking oven chamber using a transporting device.