Abstract: In view of the shortcomings of the previous coal gangue brick-making equipment,a new environmentally friendly excitation typebrick-making machine is provided,and the structure,working principle and steps,and characteristics of this brick-making machine areanalyzed.The equipment was practically applied in the village coal mine new wall material factory,which can produce various types ofshaped environmental protection cement bricks and effectively improve the efficiency of brick making.
Keywords: coal gangue;excitation;cement brick
Introduction
The harm of coal gangue is not only caused by spontaneous combustion and explosion, which pollutes the atmospheric environment of mining areas and endangers human health, but also mainly manifested in occupying a large amount of land, polluting soil, and water quality. Long term stacking of coal gangue can easily cause hazards such as sliding and collapse. The current processing and utilization of coal gangue mainly includes the following three aspects: using coal gangue as fuel for heating and power generation; The production of wall materials using coal gangue mainly involves the production of bricks and blocks from coal gangue; Using coal gangue to produce cement.
1. Analysis of the current situation of coal gangue brick production
Coal gangue is mainly used to produce sintered and non sintered bricks. The production of sintered bricks is made by replacing clay with coal gangue and processing it through processes such as crushing, forming, drying, and roasting. In order to obtain better products, the chemical composition content of coal gangue is generally controlled at 50% -70% SiO2, 10% -30% Al2O3, 8% Fe2O3, CaO<5%, MgO<3%, and SO2<1%. Coal gangue particles with a particle size requirement of<1 mm reach 65%. Bricks sintered from coal gangue have the characteristics of acid resistance, alkali resistance, and higher strength than clay bricks. At present, there are more than 10 gangue brick factories in Shanxi Province, with an annual output of 280 million bricks, which is the main way for Shanxi Province to extensively utilize coal gangue. Using coal gangue as the base material, adding curing agents (cement) and additives, non sintered bricks can also be produced. Currently, many units have successfully developed this technology and it is in the stage of promotion and application.
In the production process of coal gangue bricks, it is generally necessary to use brick making equipment to mix and vibrate various shaped cement bricks from scientifically proportioned coal gangue and other raw materials. The static pressure brick making machine used in the past did not have ideal results. In response to this situation, a new type of environmentally friendly vibration brick making machine was designed. In the process of producing cement bricks using the brick making machine, there is no need for sintering process, so the brick strength and effect are better.
2. Analysis of the structure, working principle, and characteristics of an environmentally friendly vibrating brick making machine
2.1 structural analysis
The structure of the new environmentally friendly vibration type brick making machine is shown in Figure 1, mainly including nine parts: frame, motor assembly, V-belt, cover assembly, vibration component, mold lifting component, mold, rotating assembly, and upper mold control assembly. From Figure 1, it can be seen that the frame is equipped with a mold lifting mechanism, with both the upper and lower molds located directly above the mold lifting mechanism. The upper mold control assembly is fixedly connected above the mold, and one end of the rotating assembly is fixedly connected to the frame, while the other end is connected to the upper mold control assembly. The vibration component is located below the mold lifting mechanism and connected to the mold lifting mechanism. The motor assembly is located on the left side of the frame, and the motor assembly is connected to the vibration component through a triangular belt.
Figure 1 Structural schematic diagram of a new environmentally friendly vibration type brick making machine (unit: mm)
According to the needs of production practice, the environmentally friendly vibration type brick making machine mold can be set in shapes such as I-shaped, rectangular, square, bone shaped, etc. to produce cement bricks of different shapes.
The vibration assembly structure of the environmentally friendly vibration type brick making machine is shown in Figure 2, mainly consisting of 5 components: bearing seat, eccentric shaft, V-belt, pulley, gasket, and bolt. Two bearing pedestals are fixedly connected to the frame separately; One end of the bearing seat is fixedly connected to the eccentric shaft, and the other end of the eccentric shaft extends outward through another bearing seat; The belt pulley is set in the peripheral area of the extension part where the eccentric shaft passes through another bearing seat. The outer side of the belt pulley is fixed to the belt pulley through gaskets and bolts, which can generate excitation force to achieve vibration operation and fully compact the coal gangue material in the mold. The use of belt pulleys effectively controls the excitation time and intensity of the equipment, thereby effectively improving the efficiency of brick making. A spring pad component is installed in the peripheral area of the bolt end, which can prevent the bolt from loosening during long-term vibration operation.
Figure 2 Schematic diagram of the vibration assembly structure of the brick making machine (unit: mm)
The selection of the environmentally friendly vibration type brick making machine motor is a 4 kW three-phase asynchronous motor. There is a cover assembly above the motor assembly, as shown in Figure 3. The cover assembly mainly includes three major components: the cover body, vibration operating mechanism, bracket, and connecting plate. One end of the cover body is vertically connected to two brackets, and the other end extends above the motor assembly; The excitation operation mechanism includes an excitation mechanism and a gear pull wire, which are hinged with the cover body, and the gear connection excitation mechanism is connected to the motor gear; The two brackets are set in parallel mode, and each bracket is equipped with upper and lower connection plates. The brackets are effectively connected to the rack through the connection plates. During the operation of the motor, a large amount of heat will be generated, and if touched directly, it will be hot to the hand. Therefore, a cover is installed for safety protection. The staff can control the length of the shift cable by manipulating the handle of the excitation mechanism to rotate, thereby controlling the gear position of the motor, adjusting the power of the motor, and adjusting the speed change of the motor, ultimately ensuring the excitation intensity and duration of the vibration components.
Figure 3 Schematic diagram of the cover assembly structure of the brick making machine (unit: mm)
2.2 Working principle and operating steps
The working principle of this new environmentally friendly vibration type brick making machine: The vibration components use a 4 kW three-phase asynchronous motor as the power source, and are transmitted to the position where the vibration components are generated through a triangular belt for vibration action. Under the action of this vibration force, the coal gangue raw material particles in the mold will move along a vibration direction, and the raw material particles will gradually be densely filled and combined. This process is the vibration process, and under this process, Bricks have very high strength; The mold lifting mechanism drives the lower mold to move up in a straight line. During the process of moving up in a straight line, the upper mold remains in a state of pressing the brick blank. The lower mold continues to move up, and the brick blank comes out of the mold. The lower mold drives the upper mold to move up together, thus achieving the complete demolding process of the brick blank.
The operation steps of this new environmentally friendly vibration type brick making machine are as follows: firstly, operate the handle of the upper mold control assembly to separate the upper and lower molds of the mold, and rotate the upper mold around the rotation axis to a 90 ° side position; Secondly, by properly operating the handle of the mold lifting mechanism, a gap can be formed between the lower mold part of the mold and the equipment base. After placing a dedicated support plate in the gap position, the mold lifting mechanism can be restored; Thirdly, pour the coal gangue raw materials prepared in proportion into the lower mold, and carry out uniform and leveling operations. Then, rotate the upper mold 90 ° to return to its original position and restore it. Operate the handle of the upper mold control assembly to make the upper and lower molds fit and compact the materials in the lower mold cavity; Fourthly, start the motor to excite the vibrating components and compact the materials inside the mold; Fifthly, operate the handle of the mold lifting mechanism to drive the lower mold upward in a straight line, press the brick blank, and then demould; Sixth, use a pallet to remove the adobe and maintain it in a cool and dry place.
2.3 Analysis of equipment characteristics
The main characteristics of this new environmentally friendly vibration type brick making machine include: using a mechanical linkage mechanism to achieve compression and demolding actions; Using an eccentric shaft to achieve vibration forming. The overall structure of this new environmentally friendly vibration type brick making machine is simple, easy to operate, and can effectively control the excitation time and intensity, effectively improving the work efficiency of brick making.
3. Practical application and effect analysis
A pilot test was conducted on this type of brick making machine, which can produce flower bed bricks, wall bricks, solid bricks, etc., with good production efficiency. The cost of this new environmentally friendly vibrating brick making machine is about 10000 yuan, and it only requires one worker to operate flexibly. It does not require high theoretical and technical knowledge from workers, and only requires a simple understanding of the proportion of various raw materials. The new environmentally friendly vibration type brick making machine can create good safety and economic benefits for enterprises, and has made positive contributions to the green and environmentally friendly utilization of coal gangue.
