CN106739099A - 一种用于生物质对辊挤压成型的成型辊 - Google Patents
一种用于生物质对辊挤压成型的成型辊 Download PDFInfo
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Abstract
一种用于生物质对辊挤压成型的成型辊,辊体内设置有至少两条环形轨槽,每条环形轨槽内滚动设置有钢球,环形轨槽的表面分布有与成型槽数量对应的通孔,且在成型槽的底部设置有与通孔对应的凹孔,凹孔内设置有回弹机构,辊体转动时,钢球在环形轨槽内反向运动挤压回弹机构,使上凹弧形推板在钢球的推力与回弹力共同作用下顶起生物质。本发明通过在成型槽内设置上凹弧形推板,而该上凹弧形推板由回弹机构和在环形轨槽内运动的钢球共同作用使其顶起,从而将成型槽内的生物质推起,使其很容易的脱离成型槽,避免了由于生物质受热受压后膨胀粘附在成型槽内不能及时掉落的问题,提高了生物质产品的得率和挤压成型效率。
Description
技术领域
本发明涉及到秸秆类生物质成型加工领域,具体的说是一种用于生物质对辊挤压成型的成型辊。
背景技术
生物质包括植物通过光合作用生成的有机物如植物、动物及其排泄物、垃圾及有机废水等几大类。生物质的能源来源于太阳,所以生物质能是太阳能的一种。生物质是是太阳能最主要的吸收器和储存器,生物质通过光合作用能够把太阳能积聚起来,储存于有机物中,现有技术中广泛利用生物质制备颗粒饲料、燃料等。秸秆类生物质在利用时必须先进行粉碎,然后按一定的成型方式制成特定的模块。目前生产主要采用螺旋挤压、环模等来形成生物燃料块。对于新型的对辊成型方法,主要通过对辊的槽辊和光辊相挤压而成型。在成型过程中,槽辊转速、槽辊温度和槽辊压力等都会对生物质粉碎料的成型构成影响。但是在生产过程中,由于生物质在槽辊中受热受压后膨胀,导致粘附在槽辊的成型槽内,不能及时掉落,从而降低了产品得率,而且也影响了后续的生产。
发明内容
为解决现有的秸秆类生物质在对辊成型后由于受热受压后膨胀导致粘附在槽辊的成型槽内的问题,本发明提供了一种用于生物质对辊挤压成型的成型辊,该成型辊通过在成型槽内设置上凹弧形推板,且上凹弧形推板载回弹机构和环形轨槽内的钢球共同作用下,能够将成型槽内的生物质快速脱离成型槽,而且不会产生粘附现象,提高了产品的得率和加工速率。
本发明为解决上述技术问题所采用的技术方案为:一种用于生物质对辊挤压成型的成型辊,包括内部具有中空腔室以向其中通入热气的辊体,辊体的表面分布有成型槽,所述辊体内环贴其中空腔室的壁设置有至少两条环形轨槽,每条环形轨槽内滚动设置有钢球,环形轨槽的表面分布有与成型槽数量对应的通孔,且在成型槽的底部设置有与通孔一一对应的凹孔,每个凹孔内均设置有回弹机构,该回弹机构包括联动销和环绕联动销设置的压缩弹簧,压缩弹簧的一端固定于凹孔内,另一端与联动销上设有的挡板连接,所述联动销一端设有销头,另一端伸出凹孔后与设置在成型槽内的上凹弧形推板连接;所述压缩弹簧处于初始状态时,销头缩于通孔内,上凹弧形推板被顶起脱离成型槽的底部,在成型槽内的生物质被挤压时,上凹弧形推板被挤压贴合于成型槽底部,进而挤压压缩弹簧使销头伸出通孔后处于环形轨槽内,销头的自由端为斜面,且斜面的朝向与辊体的旋转方向一致,以使辊体转动时,钢球在环形轨槽内反向运动,通过斜面挤压联动销,使联动销在压缩弹簧弹力以及钢球通过斜面产生的推力共同作用下顶起上凹弧形推板。
所述环形轨槽为中部向圆心方向凹陷的环状结构,其断面形状为U形,U形的两侧焊接在中空腔室的壁上,以形成容纳钢球的通道。
所述上凹弧形推板的底部与成型槽的底部相贴合,且其长度小于等于成型槽的长度。
所述凹孔为两段直径不同的通孔,且上部通孔的直径大于下部通孔的直径,以在两者交界处形成卡住压缩弹簧的卡台。
有益效果:本发明通过在成型槽内设置上凹弧形推板,而该上凹弧形推板由回弹机构和在环形轨槽内运动的钢球共同作用使其顶起,从而将成型槽内的生物质推起,使其很容易的脱离成型槽,避免了由于生物质受热受压后膨胀粘附在成型槽内不能及时掉落的问题,提高了生物质产品的得率和挤压成型效率。
附图说明
图1为辊体的结外部构示意图;
图2为辊体的内部结构示意图;
图3为本发明的剖视图;
图4为回弹机构的结构示意图;
附图标记:1、辊体,101、成型槽,102、中空腔室,103、凹孔,104、上凹弧形推板,2、环形轨槽,201、通孔,202、钢球,3、回弹机构,301、联动销,302、压缩弹簧,303、挡板,304、销头,305、斜面。
具体实施方式
如图所示,一种用于生物质对辊挤压成型的成型辊,包括内部具有中空腔室102以向其中通入热气的辊体1,辊体1的表面分布有成型槽101,所述辊体1内环贴其中空腔室102的壁设置有至少两条环形轨槽2,每条环形轨槽2内滚动设置有钢球202,环形轨槽2的表面分布有与成型槽101数量对应的通孔201,且在成型槽101的底部设置有与通孔201一一对应的凹孔103,每个凹孔103内均设置有回弹机构3,该回弹机构3包括联动销301和环绕联动销301设置的压缩弹簧302,压缩弹簧302的一端固定于凹孔103内,另一端与联动销301上设有的挡板303连接,所述联动销301一端设有销头304,另一端伸出凹孔103后与设置在成型槽101内的上凹弧形推板104连接;所述压缩弹簧302处于初始状态时,销头304缩于通孔201内,上凹弧形推板104被顶起脱离成型槽101的底部,在成型槽101内的生物质被挤压时,上凹弧形推板104被挤压贴合于成型槽101底部,进而挤压压缩弹簧302使销头304伸出通孔201后处于环形轨槽2内,销头304的自由端为斜面305,且斜面305的朝向与辊体1的旋转方向一致,以使辊体1转动时,钢球202在环形轨槽2内反向运动,通过斜面305挤压联动销301,使联动销301在压缩弹簧302弹力以及钢球202通过斜面305产生的推力共同作用下顶起上凹弧形推板104。
以上为本发明的基本实施方式,可在以上基础上做进一步的优化、改进和限定:
如,所述环形轨槽2为中部向圆心方向凹陷的环状结构,其断面形状为U形,U形的两侧焊接在中空腔室102的壁上,以形成容纳钢球202的通道;
又如,所述上凹弧形推板104的底部与成型槽101的底部相贴合,且其长度小于等于成型槽101的长度;
再如,所述凹孔103为两段直径不同的通孔,且上部通孔的直径大于下部通孔的直径,以在两者交界处形成卡住压缩弹簧302的卡台;
最后,所述环形轨槽2为两条,分别位于两端,每条成型槽101内的凹孔103也为分设于两端的两个,处于该成型槽101内的上凹弧形推板104的底部由两个联动销301固定连接。
本发明在工作时,生物质料进入到成型槽101内,当挤压成型时,随着生物质料在成型槽101内挤压成型时,成型槽101内的上凹弧形推板104被挤压贴紧成型槽101底部,此时,压缩弹簧302被进一步压缩,销头304随着联动销301向下伸出至环形轨槽2内;
当辊体1转动至下个成型槽101时,已完成挤压的成型槽101内的生物质没有外力的作用,压缩弹簧302的回弹力会给上凹弧形推板104以一定的向上的力,同时,由于辊体1的转动,环形轨槽2内的钢球202会向相反的方向运动,从而接触销头304的斜面305,并随着辊体1的进一步转动,钢球202对斜面305产生推力,最终,上凹弧形推板104在压缩弹簧302弹力以及钢球202通过斜面305产生的推力共同作用下顶起,从而使成型槽101内的生物质脱离成型槽101。
本发明中,所述上凹弧形推板104的材质可以为金属材质、陶瓷材质或钢化玻璃材质,但是优选的,上凹弧形推板104为从外向内依次为金属基层、金属与陶瓷高温结合层、陶瓷层和陶瓷釉层构成的多层结构;
所述金属基层为熔点高于1800℃的合金层,所述陶瓷层为表面具有微小孔隙的陶瓷,以使该陶瓷与金属基层在烧结时,金属基层的成分进入到微小孔隙中从而形成金属与陶瓷高温结合层,所述陶瓷釉层为陶瓷层外表面施加的釉料烧结后形成;
所述陶瓷层由主料、制孔剂和填充剂在1500℃条件下烧制而成,按照重量比,所述主料由38份煅烧高岭土、12份的粘土、18份的石英砂、5份的铝灰和3份的赤泥组成,制孔剂由7份细度不超过30微米的碳化硅细粉和2份的碱石灰组成,填充剂由6份细度不超过45微米的蓝晶石细粉和4份细度不超过5微米的活性氧化铝微粉组成;
所述陶瓷釉层选用烧结温度不超过1400℃的釉料烧结即可;
上述上凹弧形推板104的制作方法,包括以下步骤:
1)按照所述的比例称取组成陶瓷层的各物料进行混合,并依次向其中加入与物料总重相等的水、物料总重3%的丙酮和物料总重2%的工业植物油,拌合均匀制成细度为400目的泥浆,备用;
2)使用步骤1)制得的泥浆在熔点高于1800℃的金属基层的内表面塑型,再将静置晾干后入窑炉进行初次烧结,然后随炉冷却至常温;
所述初次烧结分为低温塑形段、中温烘烤段和氧化烧结段三部分,其中,低温塑形段是指使炉内温度从常温在6h均匀升高到400℃,并保持该温度2h,在此过程中,保持炉内氧气含量不高于5%;
所述中温烘烤段是指,使炉内温度从400℃在4h均匀升高到1000℃,在此过程中,保持炉内氧气含量不低于40%;
所述氧化烧结段是指,使炉内温度从1000℃在2h均匀升高到1500℃,并保持该温度3h,在此过程中,保持炉内氧气含量不低于40%;
3)选用陶瓷领域中烧结温度不超过1400℃的釉料制成料浆,并对初次烧结后形成的陶瓷层表面施釉并再次烧结,从而在陶瓷层表面形成光滑致密的陶瓷釉层即制得产品。
进一步的,所述金属与陶瓷高温结合层为金属基层与陶瓷层在高温下烧结后固化形成的连接层;
在进一步的,所述填充剂中还含有1.5份的滑石粉;
更进一步的,所述制孔剂中还含有1份的蛭石粉。
当上凹弧形推板104选用上述特殊材质时,以烧制陶瓷的常规原料高岭土、粘土、石英、铝灰和赤泥作为主料,其中混入碳化硅和碱石灰作为制孔剂,既可确保烧成后含有一些开放型气孔或称开口气孔,而且也不会影响其强度;碳化硅在高温氧化气氛中容易发生氧化反应:SiC+2O2→CO2+SiO2,该反应开始温度较高,1000℃开始明显氧化,颗粒越细,则氧化速度越快,反应产物CO2的逸出容易造成陶瓷表面形成开口气孔,这些气孔在高温下会被软化的金属基层的分子迁移所填充,从而形成金属与陶瓷高温结合层;而反应产物SiO2具有较高活性,与氧化铝反应生成莫来石,从而在陶瓷内形成莫来石增强体;同时,本发明中填充剂在高温下,其中的蓝晶石细粉,既可确保生成较多的莫来石相,保证制品的力学强度,蓝晶石从1100℃左右开始分解、生成莫来石和SiO2,1300℃以后显著分解转化,由于该莫来石化反应伴随有16-18%的体积膨胀,因此还可填充由于碳化硅氧化产生的孔隙,使单个孔隙变小,整体孔隙率降低,并且会改变陶瓷内孔隙的形状和分布,从而使其在与釉料结合烧制时,部分釉料渗入孔隙内填充和堵塞孔隙。
采用这种独特的材质的作用如下:
a)以烧制陶瓷的常规原料高岭土、粘土、石英、铝灰和赤泥作为主料,其中混入碳化硅和碱石灰作为制孔剂,既可确保烧成后的陶瓷中含有一些开放型气孔或称开口气孔,而且也不会影响其强度,通过加入高温下体积膨胀的蓝晶石粉,使得开放型气孔明显缩小,从而在陶瓷内部和表面形成细小的气孔,从而使其在高温下与金属基层形成金属与陶瓷高温结合层,使两者紧密结合,进一步增强了耐磨性和优异的热传导性;
b)陶瓷层在使用原料制成泥浆时,除了加入常规的水之外,还加入了丙酮和工业植物油,这两种物质混合在泥浆里,在低温塑形阶段能够缓慢的气化,从而脱离泥浆,并在表面形成微小的气孔,而且也能增强泥料的粘性,防止泥浆表面出现裂纹导致在后续烧制中损坏。
Claims (4)
1.一种用于生物质对辊挤压成型的成型辊,包括内部具有中空腔室(102)以向其中通入热气的辊体(1),辊体(1)的表面分布有成型槽(101),其特征在于:所述辊体(1)内环贴其中空腔室(102)的壁设置有至少两条环形轨槽(2),每条环形轨槽(2)内滚动设置有钢球(202),环形轨槽(2)的表面分布有与成型槽(101)数量对应的通孔(201),且在成型槽(101)的底部设置有与通孔(201)一一对应的凹孔(103),每个凹孔(103)内均设置有回弹机构(3),该回弹机构(3)包括联动销(301)和环绕联动销(301)设置的压缩弹簧(302),压缩弹簧(302)的一端固定于凹孔(103)内,另一端与联动销(301)上设有的挡板(303)连接,所述联动销(301)一端设有销头(304),另一端伸出凹孔(103)后与设置在成型槽(101)内的上凹弧形推板(104)连接;所述压缩弹簧(302)处于初始状态时,销头(304)缩于通孔(201)内,上凹弧形推板(104)被顶起脱离成型槽(101)的底部,在成型槽(101)内的生物质被挤压时,上凹弧形推板(104)被挤压贴合于成型槽(101)底部,进而挤压压缩弹簧(302)使销头(304)伸出通孔(201)后处于环形轨槽(2)内,销头(304)的自由端为斜面(305),且斜面(305)的朝向与辊体(1)的旋转方向一致,以使辊体(1)转动时,钢球(202)在环形轨槽(2)内反向运动,通过斜面(305)挤压联动销(301),使联动销(301)在压缩弹簧(302)弹力以及钢球(202)通过斜面(305)产生的推力共同作用下顶起上凹弧形推板(104)。
2.根据权利要求1所述的一种用于生物质对辊挤压成型的成型辊,其特征在于:所述环形轨槽(2)为中部向圆心方向凹陷的环状结构,其断面形状为U形,U形的两侧焊接在中空腔室(102)的壁上,以形成容纳钢球(202)的通道。
3.根据权利要求1所述的一种用于生物质对辊挤压成型的成型辊,其特征在于:所述上凹弧形推板(104)的底部与成型槽(101)的底部相贴合,且其长度小于等于成型槽(101)的长度。
4.根据权利要求1所述的一种用于生物质对辊挤压成型的成型辊,其特征在于:所述凹孔(103)为两段直径不同的通孔,且上部通孔的直径大于下部通孔的直径,以在两者交界处形成卡住压缩弹簧(302)的卡台。
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