Compared with regular shaped refractories, special-shaped refractories impose more stringent requirements on forming equipment due to their irregular structures, significant dimensional differences, uneven wall thickness, and the special design requirements of some products such as complex curved surfaces and special-shaped holes. The prominent forming pain points prevalent in the current industry are as follows: Traditional friction presses rely on mechanical transmission with low pressure control accuracy, which easily causes local overpressure and underpressure of special-shaped green bodies, leading to uneven density, corner collapse, and a forming qualification rate of less than 85%; ordinary hydraulic presses have slow response and cannot adapt to the process requirements of "stage-by-stage pressure application and precise pressure compensation" for special-shaped forming, making it difficult to control the forming accuracy of complex parts and resulting in dimensional deviations exceeding industry standards; meanwhile, traditional equipment features low automation, requiring skilled operators to manually adjust parameters with large human errors, which not only affects production efficiency but also restricts the upgrading of special-shaped refractories to high specifications and high quality.

With over 40 years of deep cultivation in the press industry, Zhengzhou Haloong Machinery Co., Ltd. has always taken technological innovation as its core driving force – from the successful R&D of the J67 series double-disk friction press in 1989 to the mass launch of the third-generation servo numerical control electric screw press in 2009. The independently developed static pressure numerical control servo screw press covers various tonnages from 200T to 1600T, and is suitable for more than 100 types of special-shaped refractory products such as special-shaped bricks, honeycomb checker bricks, and burner composite bricks. Relying on the advantages of precise pressure control, intelligent adaptation, high efficiency and stability, it has become the preferred equipment for special-shaped refractory enterprises at home and abroad.

Servo Direct Drive for Pressure Control, Precisely Adapting to Special-Shaped Forming Needs

Adopting a direct drive design with a permanent magnet synchronous servo motor and abandoning the traditional clutch structure, the equipment features fast operation response speed without the reaction time of the clutch, with a rotational speed error as low as 0.0001/rpm. The pressing energy can be precisely preset through digital programs, and the repeat accuracy error of energy per stroke is close to zero. Aiming at the characteristics of uneven wall thickness and complex corners of special-shaped refractories, the stage-by-stage striking force, frequency and speed can be flexibly set to realize a stepped process of "light pressing for air exhaust first, then heavy striking for forming", which precisely compensates for the pressure loss at special-shaped parts, ensures uniform density and compact structure in every corner of the green body, and effectively avoids defects such as corner collapse and internal pores. The forming qualification rate is increased to more than 99%, far exceeding the industry average.

Design without Fixed Bottom Dead Center, Eliminating Jamming and Adapting to Complex Special-Shaped Forming

Breaking through the structural bottom dead center limitation of traditional equipment, the non-fixed bottom dead center structure eliminates the risk of jamming, and avoids the problem of overload jamming caused by dimensional deviation of special-shaped green bodies or uneven raw material temperature. Through the progressive forging mode, the special-shaped green body is subjected to multiple rounds of precise pressing, which can flexibly adapt to the forming needs of refractory materials of different types such as high-alumina, magnesia and carbon, as well as special-shaped products with various complex curved surfaces and special-shaped holes. It ensures uniform stress on the green body during deformation, accurately reproduces the mold contour, and strictly controls the dimensional deviation within ±0.1mm, perfectly meeting the dimensional accuracy requirements of high-end special-shaped refractories.

Intelligent Integrated Control, Reducing Human Dependence and Ensuring Forming Consistency

Equipped with Haloong's intelligent production management system and a user-friendly human-machine interface, the touch screen can digitally control the entire process according to the forming process requirements of different special-shaped products, display the working status in real time, monitor the production process, and automatically detect and report equipment faults. It supports one-button operation, eliminating the need for skilled press operators – the entire striking process can be completed automatically with a single button press, saving labor costs; at the same time, it can link with equipment such as automatic feeding, mold release agent spraying, and part picking and conveying to build a fully automated production line, reducing the impact of human factors on forming accuracy, ensuring the consistency of size and density of special-shaped refractories in the same batch and different batches, and meeting the mass production needs of high-end customers at home and abroad.

Static Pressure Transmission Structure, Stable and Durable, Reducing Comprehensive Production Costs

Adopting a fully enclosed static pressure screw, nut and bearing transmission, a stable oil film is formed for protection during operation. Combined with a program-controlled grease lubrication system, it realizes maintenance-free operation, effectively avoiding wear caused by inadequate manual refueling, and doubling the service life of the equipment compared with ordinary screw presses. With a short transmission chain and simple structure, there are no vulnerable parts such as friction disks and gearboxes, few vulnerable and consumable parts, convenient later maintenance and extremely low maintenance costs; at the same time, the slider speed is extremely fast when the equipment approaches the bottom dead center, enabling the forming process to be completed in an instant before the raw materials cool down. The short contact time with the mold results in small temperature fluctuations of the mold, extending its service life by 30% and further compressing the comprehensive production costs of enterprises.

High-Efficiency and Energy-Saving Operation, Conforming to the Trend of Green Production

The servo motor adopts an on-demand start mode, operating only during forming operations and entering hibernation during processes such as feeding, demolding and mold cleaning with no power consumption. It saves more than 55% energy compared with traditional friction presses, and some models can save more than 60% energy. Meanwhile, it features a small starting current with no impact on the power grid and strong overload capacity, allowing a load twice the nominal pressure, which expands the application range of the equipment. It not only reduces the energy consumption costs of enterprises, but also conforms to the development trend of global industrial green transformation and adapts to the environmental protection production standards at home and abroad.

Multiple Safety Protections, Reliable Operation, Ensuring Production Safety

Equipped with dual protection devices of motor self-braking and mechanical braking, through zero-speed and torque braking of the servo motor, combined with the cylinder pushing the friction plate to generate mechanical braking on the flywheel, the slider stops immediately in case of power supply abnormality; an emergency stop button is also set to realize emergency braking at any time, and the slider will rise to the top dead center to eliminate safety accidents. In addition, an infrared safety light curtain can be optionally configured to form a safety screen, ensuring personnel safety during the striking and forming process. The equipment operates with low vibration and low noise, which not only ensures the safety of operators but also avoids green body density deviation caused by vibration, providing double protection for the stable production of special-shaped refractories.

Customized Adaptation Capability, Covering the Special-Shaped Forming Needs of All Scenarios

Relying on rich R&D and production experience, we can provide customized equipment solutions according to customers' requirements for the size, material and output of special-shaped refractories, and flexibly adjust the equipment tonnage, mold adaptation structure and process parameters. At the same time, optional configurations are provided – static pressure type (fully enclosed), dual motor, multi-output from one machine, safety light curtain, automatic mold release agent spraying and other configurations can be freely selected according to the requirements of different products, which can take into account the needs of small-batch customization and mass production. It can not only meet the production of ordinary special-shaped refractories, but also adapt to the high-end customized processing of special special-shaped refractories, helping enterprises expand their product matrix and improve market competitiveness.

From the precise forming of special-shaped refractories to the construction of fully automated production lines, from the continuous iteration of technological R&D to the continuous improvement of customized services, Zhengzhou Haloong has always been customer demand-oriented and technology innovation-driven, deeply cultivating the field of refractory forming equipment. With professionalism and reliability, we help global refractory enterprises break through forming bottlenecks and realize quality upgrading and efficiency improvement.