Refractory special-shaped parts, due to their unique structures adapted to different high-temperature equipment, require customized dimensions and shapes based on customer needs. They cover various types such as special-shaped bricks, special-shaped lining bricks, and large prefabricated blocks. Their rawmaterials are mostly high-alumina, magnesia, carbon, etc., refractory materials, mixed with binders for forming. The forming process is highly specialized - the irregular shapes lead to dispersed force application points, the diverse specifications require frequent equipment adjustments, and the complex particle size distribution of raw materials can easily result in uneven density. Moreover, the global high-temperature industry is transforming towards high-end and green, imposing increasingly strict requirements on the dimensional accuracy, density, and thermal shock resistance of refractory special-shaped parts. High density, no delamination, low porosity, and precise dimensions have become the hard standards for refractory special-shaped parts to be qualified for market release. However, the shortcomings of traditional forming equipment have become increasingly prominent, becoming a key bottleneck restricting the quality improvement, efficiency enhancement, and market expansion of refractory special-shaped parts enterprises. The core pain points are concentrated in three aspects.

 First, the pressure control is rough, making it difficult to balance dimensional accuracy and density uniformity. Traditional friction presses and ordinary hydraulic presses cannot achieve digitalized precise pressure control. The pressure application intensity and speed are fixed and cannot be flexibly adjusted according to the special-shaped structure and different force requirements of different parts of refractory special-shaped parts, easily leading to deviations such as "local overpressure and local underpressure". Due to the irregular shapes of special-shaped parts and the dispersed force application points, the uniform pressure application of traditional equipment cannot cover all parts, resulting in uneven thickness and large density differences of the green body. This not only affects the dimensional accuracy but also easily leads to cracks and peeling during subsequent drying and sintering processes, significantly reducing the erosion resistance and structural stability of refractory special-shaped parts. Data shows that the dimensional deviation rate of refractory special-shaped parts produced by traditional equipment exceeds 10%, and the density variation coefficient exceeds 2%, seriously affecting the product qualification rate and market competitiveness, especially making it difficult to meet the fitting requirements of high-end high-temperature equipment.

 Second, the force transmission is uneven, resulting in insufficient green body density and easy formation of stress cracks. The forming of refractory special-shaped parts requires the close combination of raw material particles and the elimination of internal pores, while avoiding local stress concentration caused by the special-shaped structure. The uniformity and flexibility of pressure transmission are extremely high. The transmission structure of traditional equipment is complex, with energy losses in gears, clutches, and other components. The pressure cannot be flexibly and uniformly transmitted to all special-shaped parts of the green body, resulting in significant differences in the density of the surface layer and inner layer, as well as the protruding and recessed parts of the green body, forming "false density". Under high-temperature service conditions, the internal pores of such green bodies will rapidly expand, and the local stress concentration areas are prone to cracks and damage, shortening the service life of refractory special-shaped parts and increasing the downtime and replacement costs for high-temperature enterprises at the terminal, and even potentially causing production safety hazards.

 Third, the process adaptability is poor, making it difficult to meet the multi-specification customization requirements. The core feature of refractory special-shaped parts is "non-standard customization". The dimensions, shapes, and raw material ratios required by different customers and different equipment vary greatly, requiring frequent adjustments to equipment parameters and mold changes. Traditional equipment mostly adopts a fixed forming mode, with no flexible parameter adjustment space. Mold changes are cumbersome and time-consuming, and they cannot precisely match the "exhausting - densification" requirements of different special-shaped structures - too fast pressure application can lead to residual bubbles and uneven binder distribution, while too slow pressure application can cause raw material particle settlement and delamination, further exacerbating the forming risks. At the same time, global environmental protection requirements are becoming stricter, and labor costs are rising. Refractory special-shaped parts enterprises urgently need efficient, intelligent, and flexible forming equipment to solve the forming pain points and achieve multiple goals of customized production, quality improvement, cost reduction, and efficiency enhancement. Compared with traditional forming equipment, the servo screw press, with its core advantages of digitalized precise pressure control, flexible pressure transmission, and flexible process adaptation, has become the best choice for solving the forming problems of refractory shaped parts. It can not only completely solve the shortcomings of traditional equipment such as uneven pressure application, large dimensional deviations, and incomplete exhaust, but also flexibly adapt to the multi-specification customized demands, achieving full density of the green body and precise dimensions, perfectly meeting the core requirements of refractory shaped part forming, and helping refractory shaped part enterprises break through quality bottlenecks and expand into high-end markets.

 Zhengzhou Haloong, relying on 45 years of experience in refractory forming equipment research and manufacturing, has deeply integrated the third-generation permanent magnet synchronous servo direct drive technology with the semi-dry forming process of refractory shaped parts, and combined with the core demands of refractory shaped parts such as "irregular structure, customization, and high precision", has developed a dedicated servo screw press for refractory shaped parts. It benchmarks against the global high-end equipment level, with "precise pressure control, flexible pressure transmission, and intelligent adaptation" as its core, effectively solving problems such as uneven density and stress cracks, providing a guarantee for the forming quality of refractory shaped parts, and becoming the preferred equipment for domestic and foreign refractory shaped part enterprises.

 It adopts a permanent magnet synchronous servo motor direct drive design, discarding the traditional clutch and gear transmission structure, with a short transmission chain and low energy loss. It is equipped with Haloong's independently developed intelligent pressure control system, which can precisely preset the pressure energy, speed, and frequency through digital programs, with a repeatable control accuracy of energy ≤ ±1%, far exceeding the industry average, achieving "full-field precise uniform pressure application", precisely matching the force requirements of the irregular structure of refractory shaped parts. According to the force differences of different parts of refractory shaped parts, it intelligently matches the three-stage forming process of "light pressure exhaust - medium pressure uniform material - heavy pressure densification": in the light pressure stage, it slowly applies pressure to thoroughly exhaust the internal air of the raw materials, avoiding the formation of bubbles and cracks; in the medium pressure stage, it uniformly applies pressure at a constant speed, promoting the uniform distribution of refractory particles, eliminating density differences that cause settlement and stratification; in the heavy pressure stage, it precisely controls the pressure, flexibly adjusting the pressure size according to the thickness and structure of the irregular parts, achieving full density of the green body, while ensuring precise dimensions, with an error controlled within ±0.5mm, completely eliminating defects such as dimensional deviations, stratification, and layer cracking. The product qualification rate of refractory shaped parts is stably above 99%, and the density is increased by more than 15% compared to traditional equipment, significantly enhancing product adaptability and service life.

 It breaks through the structural bottom dead center limitation of traditional equipment, adopting a step-by-step forging mode. According to the different shapes (irregular bricks, large lining bricks, special-shaped prefabricated blocks), different size specifications, and different raw material ratios of refractory shaped parts, it can flexibly adjust the stroke of the slider, the pressure angle, and the pressure size, without worrying about the problem of uneven pressure application caused by raw material size deviations or irregular structures. Whether it is large special-shaped refractory bricks for coke ovens, irregular lining bricks for glass furnaces, or high-density special-shaped prefabricated blocks for converters, it can achieve precise uniform pressure application, ensuring consistent density and precise dimensions of all irregular parts of the green body, and eliminating cracks and deformations caused by local overpressure or underpressure. At the same time, the equipment can flexibly adapt to green bodies of refractory shaped parts with different compression ratios, without frequent adjustments to the equipment structure. Combined with a rapid mold changing system, mold replacement is convenient and efficient, significantly reducing production preparation time. It can not only meet the demands of small-batch customized production but also adapt to large-scale mass production needs, helping enterprises expand the product matrix of refractory shaped parts.

 It adopts a fully enclosed static pressure screw, nut, and bearing transmission, forming a stable oil film during operation for protection, and is equipped with a fully automatic forced lubrication system, effectively reducing the wear of transmission components, ensuring continuous and stable pressure transmission without energy loss or pressure attenuation, perfectly meeting the strict requirements of refractory shaped part forming for pressure stability and flexibility. Compared with the rigid transmission of traditional equipment, the static pressure transmission of Haloong servo screw press can achieve flexible pressure transmission, avoiding local stress concentration caused by irregular structures, effectively eliminating the risks of cracks and deformation in the green body. At the same time, it has strong transmission stability and low vibration during operation, further ensuring the uniformity, consistency and dimensional accuracy of the green body of refractory shaped parts, eliminating the risks of forming from the process level. In addition, it has a short transmission chain, a simple structure, is easy to maintain and repair, and has extremely low later operation and maintenance costs, meeting the multi-specification and flexible production needs of refractory shaped parts enterprises.

 Relying on 45 years of refractory forming process experience, the servo screw press is equipped with a dedicated forming parameter database for refractory shaped parts, covering forming parameters for different materials, specifications and irregular structures. It can intelligently customize forming programs and pressure parameters based on customer customization requirements and the characteristics of refractory raw materials from different origins, without the need for frequent manual adjustments, reducing the impact of human factors on forming accuracy. For the problems of difficult exhaust and uneven force in irregular structures, the pressure speed and force can be precisely adjusted to ensure thorough exhaust and uniform pressure transmission. For multi-specification customization requirements, the equipment parameters can be adjusted conveniently, and combined with an intelligent mold positioning system, the forming efficiency and dimensional accuracy can be further improved, ensuring that each batch and each piece of refractory shaped parts can be formed without defects and with high quality, helping enterprises quickly respond to customer customization requirements and enhance market competitiveness.

 Equipped with the intelligent production management system independently developed by Zhengzhou Haloong, it is equipped with standardized industrial communication interfaces and can be seamlessly linked with the automatic feeding system, raw material proportioning system and green body detection equipment for refractory shaped parts, building an intelligent production line for the entire process of refractory shaped parts forming, achieving unmanned control from "raw material entry - proportioning - pressing - detection - storage", significantly reducing labor input and meeting the needs of rising labor costs in the industry. The system can collect real-time data on forming pressure, speed and size, and dynamically adjust the pressure process to correct pressure deviations in time, ensuring uniform pressure and ensuring the density, dimensional accuracy and consistency of the green body of refractory shaped parts. At the same time, it supports remote monitoring and parameter adjustment, facilitating domestic and foreign customers to control production remotely and in real time, and promptly identify forming risks, further ensuring product quality. In addition, the equipment adopts a "start on demand, sleep for energy saving" mode, saving more than 55% of energy compared with traditional friction presses, helping refractory shaped parts enterprises achieve multiple goals of "energy saving, cost reduction, high quality and high efficiency", in line with the global trend of green production. 

The quality of refractory shaped parts directly affects the safety and efficiency of high-temperature industry furnaces and equipment, and the forming equipment is the core guarantee of quality. With the global high-temperature industry's transformation towards high-end and green, the demand for customization of refractory shaped parts continues to grow, and the requirements for the accuracy, flexibility and intelligence of forming equipment are constantly increasing. Zhengzhou Haloong has been deeply engaged in the field of refractory forming equipment for 45 years, always adhering to the concept of "starting from design, excelling in process, focusing on processing, and achieving in assembly", relying on technological progress, with strict process regulations, complete detection means and a complete management system, continuously promoting technological innovation of servo screw presses, focusing on the core pain points of refractory shaped parts forming, and creating exclusive intelligent solutions.