Ceramic press industry development trend analysis

After decades of development, ceramic presses have reached a high level of industrial automation. However, with the improvement of China’s social development level, the use of ceramics equipment for energy conservation, consumption reduction, and increasingly stringent requirements, as well as a substantial increase in the single-line production capacity of tile production lines, has forced the press to save energy and environmental protection on the basis of the original technology. The further development of large output.

In terms of energy saving and consumption reduction, the study of presses is divided into a major direction and a secondary direction:

The main direction is to reduce the useless power loss of the press power source (pump station) output by introducing advanced control technology, and maximize the energy utilization rate. There are two main technologies in this area: servo control systems and frequency conversion control systems. The principle of these two technologies are the same. All of them are waiting in the working cycle of the press to keep the main motor running to a minimum or even stop. When the press needs energy supply, it can quickly start to meet the operating conditions of the press. .

The actual test shows that the energy efficiency of the servo control system can reach more than 30% compared with that of the ordinary asynchronous motor under the premise of satisfying the press work requirement, and the energy saving efficiency of the frequency conversion control system can reach 15% or more ( The lower the operating frequency of the press, the more obvious the energy saving effect). Relatively speaking, the frequency conversion control system has lower input costs than the servo control system, because the frequency conversion motor is much lower than the servo motor, and even a simple conversion of the ordinary three-phase asynchronous motor and the corresponding frequency conversion controller can be achieved. To achieve energy savings.

The secondary direction is to reduce the energy loss of the equipment itself by optimizing the mechanical structure of the press and the oil system, such as:

1. Optimize the structure of the press machine to reduce the pressing force required for brick molding as much as possible;

2, improve the structure of the valve to reduce the logic valve to open, shut down the required hydraulic oil;

3, to optimize the opening and closing sequence of each logic valve and time interval, to minimize the system's internal leakage;

4. Try to recover some of the high-pressure oil from the last press through the accumulator in the system for use in the next working cycle;

In terms of improving stand-alone output: After years of press technology adoption, the method of improving stand-alone output by increasing the frequency of presses has little potential to tap. The most effective way is to increase the output of a single work cycle. Give a very typical example:

In the past, single-line production of 800 × 800 (mm) size polished tiles had a daily output of 20,000 to 25,000 square meters. Usually, the conventional 3500T-4000T presses can meet five to six sets of requirements for the entire line. However, the current furnace has already achieved a daily production of 40,000 square meters or even 50,000 square meters. It also requires more than 10 presses according to the traditional configuration. If the oversized tonnage press supporting 7000T or more can press two 800×800 (mm) pieces each time, and the pressing frequency can be even closer to 3500T-4000T, the number of configuration presses can be reduced to 5-6 sets. The use of space at the production site can be greatly reduced, and auxiliary equipment associated with the press can be reduced accordingly, and the one-time investment cost of the ceramics company is greatly reduced. Subsequent cost reductions in equipment maintenance and accessories are no small numbers.

However, the weight of such a large tonnage press usually reaches more than 170 tons, which is far beyond the permissible weight of China's road transport, and has caused great difficulties in the transportation and handling of equipment. At present, press manufacturers are also actively developing new structures so that the overall structure of the press can be split and transported and assembled on the spot under the premise of ensuring the accuracy of the equipment.

In general, energy saving and consumption reduction and stand-alone production are the obvious trends reflected by the current press market. In the later development trend, the intelligentization of presses and the Internet of Things will also be the direction of press technology. Intelligent can greatly improve the quality of products and products for customers. The Internet of Things (IoT) enables manufacturers to accurately control the use, maintenance, and maintenance of the presses of manufacturers, and provide timely and appropriate technical services to ensure that they can continue to operate in the best conditions.