In the refractory forming process, issues such as fluctuations in powder material properties, uneven pressure transmission, and delayed parameter response have long restricted the improvement of product quality. Traditional friction presses rely on mechanical transmission and cannot achieve precise linkage control of pressure and displacement, with fixed parameters only set based on experience. This easily leads to local overpressure and underpressure, resulting in a green body density deviation of more than 1.5% and a sharp reduction in the service life of refractory materials. Although ordinary hydraulic presses have a certain pressure adjustment capability, they suffer from shortcomings such as strong system hysteresis and low displacement control accuracy. When faced with complex working conditions such as special-shaped bricks and high-alumina refractories, they cannot adapt to the process requirements of "dynamic pressure application - real-time correction".

As the global refractory industry shifts toward high-end and refined development, developed countries have widely adopted pressure-displacement closed-loop control equipment with an automation rate of over 70%, while the average automation rate of the domestic industry is only 35%. The core gap lies in the precision stability of closed-loop control and system integration capabilities. Against this backdrop, Zhengzhou Haloong has filled the gap with technological breakthroughs and built a full-process closed-loop control system, providing refractory enterprises with forming equipment in line with international standards.

Haloong's Core Technology: Four Major Breakthroughs in Pressure-Displacement Closed-Loop Control

Zhengzhou Haloong has deeply integrated the structural advantages of servo screw presses with closed-loop control algorithms. The independently developed static pressure numerical control servo press realizes real-time linkage and dynamic correction of the three parameters of pressure, displacement and speed, forming four core technological advantages and completely subverting the traditional forming mode.

Synergy of High-Precision Sensing and Algorithms for Micron-Level Closed-Loop Regulation

Equipped with high-precision strain gauge force sensors and absolute photoelectric encoders, the press achieves a pressure sampling accuracy of ±0.2%FS, a displacement resolution of 0.01mm, and a sampling frequency increased to over 2kHz. It can capture the dynamic changes of pressure and displacement in real time during the forming process and feed them back to the control system without delay. Breaking through the limitations of traditional PID control, it adopts an improved fuzzy PID + feedforward composite control algorithm, which can adjust parameters in real time according to system errors and change rates, and compensate for interference items such as inertial force and friction in advance. This enables millisecond-level dynamic correction with a pressure repeat positioning accuracy of ±0.05N, ensuring that the overall density uniformity and dimensional accuracy of the green body are always within the preset range.

Closed-Loop Synchronization of Bidirectional Pressure Application, Adapting to Complex Refractory Forming Needs

An innovative new bidirectional pressure application closed-loop control scheme is adopted. The real-time movement speed of the upper mold is collected by sensors, and the real-time following speed of the mold frame is intelligently calculated. The precise ratio of 2:1 between the upper mold speed and the mold frame speed is strictly maintained to achieve true bidirectional synchronous pressure application. Compared with the problems of speed asynchrony and system hysteresis prone to occur in traditional bidirectional pressure application equipment, Haloong's press dynamically adjusts the speed ratio through closed-loop algorithms. Even under high-pressure forming (with a maximum pressure of 220MPa) and eccentric load working conditions of wedge-shaped bricks, it can still ensure uniform pressure transmission to all parts of the green body, significantly improving sealing performance and density consistency. At the same time, the design without a fixed bottom dead center can flexibly adapt to the forming of refractory materials of different materials and specifications, realizing flexible production of "one machine for multiple uses".

Intelligent Data Closed-Loop Management, Empowering Full-Process Quality Traceability

Integrated with Haloong's intelligent production management system, it builds a full data closed-loop link of "parameter setting - real-time collection - data analysis - automatic optimization". During the forming process, the pressure-displacement curve is displayed on the touch screen in real time, and the system can automatically judge product qualification and eliminate defective products at a 100% rate, realizing online quality management. It supports the storage of more than 100 forming programs; when replacing raw materials or product specifications, quick switching can be achieved only by calling the preset programs without repeated manual debugging. All forming data can be exported through the USB interface to realize traceability of the production process, providing accurate data support for customers to optimize processes and control quality, in line with the global demand for intelligent manufacturing and compliant production.

Low-Consumption and Stable Structural Design, Extending the Service Life of Equipment and Molds

Adopting a servo direct drive + static pressure transmission structure, it abandons redundant components such as traditional flywheels and clutches, increasing the transmission efficiency to over 90% and saving more than 55% energy compared with traditional friction presses. Moreover, there is no hydraulic oil pollution, meeting the requirements of environmental protection production. The frame adopts a four-beam and four-column prestressed structure, optimized through finite element analysis and stress testing, with extremely strong eccentric load resistance and rigidity. The deformation of the machine body during pressing is close to zero, avoiding the impact of structural deformation on closed-loop control accuracy. At the same time, the pressing path is optimized through closed-loop algorithms to reduce mold impact and wear. Combined with the technology of automatic adjustment of the pressing position of the mold frame, the service life of the mold is increased by more than three times, greatly reducing the comprehensive production cost of customers.

Relying on the core advantages of pressure-displacement closed-loop control technology, Zhengzhou Haloong's servo presses not only cover mainstream domestic refractory enterprises, but also are exported to Europe, Southeast Asia, Africa and other regions, adapting to high-end refractory production scenarios such as hydrogen metallurgical electric furnaces and cement rotary kilns, and providing customized forming solutions for global customers. From the mass production of ordinary shaped refractories to the customized processing of special refractories, Haloong's equipment helps customers improve product qualification rates and market competitiveness with stable closed-loop control performance, narrowing the gap with international high-end refractory products.