The service environment of special refractory materials is often extremely harsh, such as ultra-high temperatures, strong corrosion, rapid heating and cooling, high pressure, and vacuum. The performance of the finished product is directly determined by the quality of the green body forming. Even minor density fluctuations, internal micro-cracks, or porosity can cause rapid failure of the product under extreme conditions, leading to production line malfunctions, safety hazards, and significant economic losses.

Zhengzhou Haloong has deeply studied the characteristics of special refractory raw materials and the logic of forming processes. It has abandoned the inherent shortcomings of traditional transmission equipment and adopted a core technology of a three-in-one system: direct drive by permanent magnet synchronous servo motors, static pressure flexible pressure transmission, and intelligent numerical control systems. This technology has been specially optimized for the HLDS series of servo screw presses for special refractory materials. The equipment's precision, stability, and adaptability are all benchmarked against international high-end standards, making it the preferred core equipment for high-end mass production of special refractory materials.

Equipped with a direct drive system of permanent magnet synchronous servo motors, it completely eliminates the inefficient transmission structures such as traditional friction discs and clutches. The transmission chain is extremely short, with zero energy loss during energy transmission. The pressure output is stable and controllable throughout the process. The equipment is equipped with a special refractory material-specific numerical control pressure control module independently developed by Haloong, which can digitally and precisely set the impact energy, pressure application speed, number of stepwise pressure applications, and pressure holding time. The energy repetition control accuracy is ≤±1%, ensuring that the pressure for each forming process is highly consistent, completely eliminating quality deviations caused by manual operation and mechanical fluctuations.

For the characteristics of ultra-fine powder and high viscosity of special refractory materials, a customized stepwise flexible pressure application process is adopted. It first applies light pressure to quickly expel the residual air inside the green body, then applies pressure step by step to compact each layer, and finally maintains pressure for a long time to shape. This ensures that all parts of the green body, including the center, edges, corners, and thin-walled areas, are uniformly stressed, with density fluctuations controlled within a very small range. The coefficient of density variation is far superior to the industry standards for special refractory materials, perfectly ensuring the uniform density and compactness of the entire green body.

It adopts a fully enclosed static pressure screw, nut, and dedicated heavy-duty bearing transmission structure. During operation, a stable high-pressure oil film is formed for protection, achieving flexible and uniform pressure application and completely avoiding the severe impact force and stress concentration problems caused by traditional rigid pressure application. The pressure application process is smooth and gentle, which can not only fully expel the internal pores of the green body, completely eliminating porosity and delamination defects, but also gently protect the brittle structure of the special refractory material green body, avoiding edge and corner defects and internal micro-cracks in irregular and thin-walled parts. This increases the product qualification rate to over 99%, significantly reduces the waste of high-purity special raw materials, and effectively extends the service life of molds, reducing material costs.

It breaks through the structural limitation of the fixed bottom dead center of traditional equipment and adopts a progressive forging forming mode. According to the material characteristics, size, structural complexity, and wall thickness of special refractory materials, the stroke of the slider, the depth of pressure application, and the pressure application force can be flexibly adjusted to precisely match the forming requirements of all types of special refractory materials, including magnesia-calcium-carbon bricks, zirconium refractories, silicon nitride bonded silicon carbide products, special corundum bricks, high-purity oxide refractories, large-sized special structural parts, and irregular special lining bricks. There is no need to worry about the uneven pressure application caused by raw material filling volume deviations or complex structures. Combined with a rapid mold changing system, mold changing is convenient and efficient, perfectly adapting to the flexible production mode of multiple varieties, small batches, and customization of special refractory materials, fully covering various production scenarios of special refractory materials.

The equipment is equipped with a special refractory material-specific forming parameter database, integrating the optimal forming process parameters for various high-purity raw materials, special ratios, and irregular structure products. Operators can retrieve them with one click, eliminating the need for repeated debugging and exploration, significantly reducing the interference of human factors on product quality. All forming parameters can be permanently saved and reused in batches, ensuring that the density, compactness, and dimensional accuracy of each batch and each piece of special refractory material green body are highly consistent, easily meeting the strict quality requirements of high-end industrial projects in Europe, North America, Southeast Asia, the Middle East, and other regions. This helps enterprises smoothly pass international quality certifications and open up high-end overseas markets. Compared with traditional friction presses, the Haloong servo screw press adopts an intelligent mode of on-demand start-stop and sleep energy-saving. The servo motor only operates during the pressing process, and the standby state has zero energy consumption. The comprehensive energy-saving rate is as high as over 55%, significantly reducing the electricity cost for the production of special refractory materials. At the same time, the static pressure transmission structure has minimal wear, and when combined with a fully automatic forced lubrication system, the equipment has a low failure rate and a service life far exceeding that of traditional equipment. The later maintenance and operation costs are reduced by more than 40%, comprehensively compressing production, operation, and material costs, and helping enterprises achieve a green, low-carbon, and efficient profit-making production model.

The equipment is equipped with standardized industrial communication interfaces, which can be seamlessly linked with automatic and precise feeding machines, closed-loop distribution machines, intelligent demolding machines, non-destructive testing equipment for green bodies, and constant-temperature conveyor lines, building a fully automatic and intelligent forming production line for special refractory materials. It realizes unmanned control throughout the entire process from distribution, pressing, pressure holding, demolding to green body transfer and inspection, minimizing human intervention and ensuring forming accuracy and production efficiency. At the same time, it supports remote monitoring, parameter adjustment, fault warning, and production data traceability functions, facilitating domestic and foreign customers to remotely and in real-time control production progress and product quality, fully in line with the global trend of intelligent, digital, and green transformation in the special refractory materials industry.

As a leading enterprise in the domestic electric servo screw press field, Zhengzhou Haloong Machinery Co., Ltd. has been focusing on technological innovation in refractory material forming equipment for 45 years, delving into the pain points of industry processes, and insisting on empowering the high-quality development of the special refractory materials industry with customized technologies. The Haloong HLDS series of CNC servo screw presses cover the full tonnage range from 200T to 1600T. According to the material, structure, and production capacity requirements of customers' special refractory materials, it can provide one-to-one customized forming solutions, fully meeting the mass production needs of various extreme working condition special refractory materials.