Precision forming empowers the longevity of glass furnaces and builds a quality barrier for refractory materials. As the core equipment in glass production, glass furnaces are constantly exposed to extreme high temperatures above 1500°C, and are subject to the erosion of molten glass and frequent temperature fluctuations. The quality of the refractory bricks lining the furnaces directly affects their service life, production efficiency, and the quality of the glass products. Refractory bricks for glass furnaces (such as high-purity fused silica bricks, high-alumina bricks, and magnesia-alumina spinel bricks) are key refractory materials that must have extreme density, uniform density distribution, excellent thermal shock resistance, and erosion resistance. However, the strict requirements for their raw material properties (high purity, fine particles, and special binders) and forming processes make it difficult for traditional forming equipment to meet these demands, which has become a core bottleneck restricting the quality upgrade of refractory bricks for glass furnaces and their long-term operation.

Zhengzhou Haloong has deeply studied the raw material properties, forming process logic, and service requirements of refractory bricks for glass furnaces. It has abandoned the inherent shortcomings of traditional transmission equipment and adopted a three-in-one core technology of direct drive by permanent magnet synchronous servo motors, static pressure flexible pressure transmission, and intelligent numerical control systems to optimize the HLDS series of servo screw presses specifically for refractory bricks for glass furnaces. The equipment's precision, stability, and adaptability have been comprehensively upgraded, precisely matching the strict forming requirements of refractory bricks for glass furnaces. It has become the preferred core equipment for high-quality mass production of refractory bricks for glass furnaces, helping refractory material enterprises to create high-end refractory products suitable for the long-term operation of glass furnaces.

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, with an extremely short transmission chain and zero energy loss in energy transmission. The pressure output is stable and controllable throughout the process, in line with the core advantage of numerical control presses in precise energy control. The equipment is equipped with a Haloong self-developed numerical control pressure control module specifically for refractory bricks for glass furnaces, which can digitally and precisely set the striking energy, pressure application speed, number of stepwise pressure applications, and pressure holding time. The energy repetition control accuracy is ≤±1%, ensuring that the pressure in each forming process is highly consistent, completely eliminating quality deviations caused by manual operation and mechanical fluctuations.

In response to the fine particle characteristics of the mixed materials for refractory bricks for glass furnaces, a customized stepwise flexible pressure application process is adopted. It first applies light pressure to quickly expel the residual air inside the blank, then applies pressure stepwise and layer by layer to compact it, and finally holds the pressure for a long time to shape it. This ensures that all parts of the blank, including the center, edges, and corners, are uniformly stressed, and the density fluctuation is controlled within a very small range. The coefficient of density variation is far better than the industry standard, perfectly ensuring the uniform and dense quality of the entire blank, significantly improving the thermal shock resistance and erosion resistance of the finished product, and making it suitable for the extreme high-temperature conditions above 1500°C in glass furnaces, thereby extending the service life of the furnaces.

It adopts a fully enclosed static pressure screw, nut, and special 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. It inherits the advantage of stable operation of numerical control presses. The pressure application process is smooth and gentle, which can not only fully expel the air holes inside the blank, completely eliminating porosity and delamination defects, but also gently protect the brittle structure of the refractory brick blanks for glass furnaces, avoiding edge and corner damage and internal micro-cracks. This increases the product qualification rate to over 99%, significantly reduces the waste of high-purity raw materials, and effectively extends the service life of molds, reducing material costs and improving production efficiency for enterprises.

It breaks through the structural limitation of the fixed bottom dead center of traditional equipment and adopts a step-by-step forging forming mode. It can flexibly adjust the stroke of the slider, the depth of pressure application, and the pressure application force according to the material (high-purity fused silica, high alumina, magnesia-alumina spinel, etc.), size, and structural complexity (such as standard bricks, large arched bricks, regenerator bricks, and pool bottom lining bricks) of refractory bricks for glass furnaces, precisely matching the forming requirements of various refractory bricks for glass furnaces and covering the production scenarios of refractory materials for all parts of the furnaces. There is no need to worry about the deviation in raw material filling volume or uneven pressure caused by complex structures. Coupled with a rapid mold changing system, mold changing is convenient and efficient, perfectly adapting to the flexible production mode of multiple varieties and batches of glass kiln refractory bricks, and meeting the batch supply requirements of large-scale glass kiln projects.

The equipment is equipped with a dedicated database of forming parameters for glass kiln refractory bricks, integrating the optimal forming process parameters for various specifications and different materials of glass kiln refractory bricks, including the forming parameters of commonly used glass kiln refractory materials such as high-purity fused quartz silica bricks. Operators can retrieve them with one click, eliminating the need for repeated debugging and exploration, and 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 glass kiln refractory brick are highly consistent, easily meeting the strict quality requirements of large-scale glass kiln projects at home and abroad, and helping enterprises smoothly open up the overseas high-end glass kiln refractory materials market.

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 is completely zero energy consumption, with a comprehensive energy-saving rate of over 55%, significantly reducing the electricity cost of glass kiln refractory brick production, meeting the green and low-carbon development needs of the glass industry, and continuing the core advantage of high efficiency and energy saving of CNC presses. At the same time, the static pressure transmission structure has minimal wear, and is equipped with a fully automatic forced lubrication system and an oil shortage alarm device, achieving maintenance-free operation, with a low failure rate and a service life far exceeding that of traditional equipment, reducing the later operation and maintenance costs by more than 40%, comprehensively compressing production, operation and maintenance, and material costs, 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 glass kiln refractory bricks, achieving unmanned control throughout the process from distribution, pressing, pressure holding, demolding to green body transfer and inspection, minimizing human intervention, ensuring forming accuracy and production efficiency, and aligning with the development direction of automation and intelligence of CNC presses. 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 real-time control production progress and product quality, fully in line with the global refractory materials industry's trend of intelligence, digitalization, and green transformation, helping enterprises build an intelligent production base for high-end glass kiln refractory materials.

As a leading enterprise in the domestic electric servo screw press field, Zhengzhou Haloong Machinery Co., Ltd. has been focusing on the technological innovation of refractory material forming equipment for 45 years, deeply exploring the forming process pain points of high-end refractory materials such as glass kiln refractory bricks, and adhering to the customization of technology to empower the high-quality development of the refractory materials industry. Haloong's HLDS series CNC servo screw press covers the full tonnage range from 200T to 1600T, and can provide one-to-one customized forming solutions based on customers' material, specification, and production capacity requirements for glass kiln refractory bricks, fully meeting the mass production needs of various glass kiln refractory bricks and adapting to the refractory material supply of glass kiln projects of different scales.