Refractory hollow sphere bricks, as a core category of high-end refractory materials, are widely used in high-end fields such as metallurgy, chemical engineering, building materials, and aerospace due to their unique advantages of light weight, high strength, high temperature resistance, and low thermal conductivity. They are crucial for ensuring the energy efficiency, safety, and stable operation of high-temperature equipment. The quality of their formation directly determines the core properties of the product, such as pore distribution, compressive strength, and thermal conductivity. The special nature of the hollow sphere structure imposes far stricter requirements on the pressure control accuracy, pressure transmission stability, and process adaptability of the forming equipment than ordinary refractory materials.

Compared with ordinary refractory bricks, the forming difficulty of refractory hollow sphere bricks increases geometrically. The hollow sphere particles in their raw materials are brittle and have weak compressive strength, and the mixed materials have poor fluidity and special particle gradation. The precision requirements for the application of pressure, the speed of pressure application, and the duration of pressure maintenance are extremely high - it is necessary to achieve densification of the green body through precise pressure application to ensure that the compressive strength of the finished product is ≥ 30MPa and the volume density is controlled within 1.2-1.8g/cm³, while avoiding the damage and structural deformation of the hollow spheres caused by rigid impact, and at the same time precisely controlling the pore distribution to ensure the low thermal conductivity of the product.

Zhengzhou Haloong has deeply studied the raw material characteristics, forming process logic, and industry upgrade demands of refractory hollow sphere bricks. With the core technology of direct drive by permanent magnet synchronous servo motor + static pressure flexible pressure transmission + intelligent numerical control system, it has specially optimized the HLDS series servo screw press, comprehensively upgrading the equipment's precision, stability, and adaptability, precisely matching the forming requirements of hollow sphere bricks, and becoming the preferred equipment for mass production of high-quality hollow sphere bricks, assisting refractory material enterprises in creating high-quality products suitable for high-end fields.

Equipped with a direct drive system of permanent magnet synchronous servo motors, it completely eliminates the low-efficiency 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 fully stable and controllable throughout the process. The equipment is equipped with a hollow sphere brick-specific numerical control pressure control module independently developed by Haloong, which can digitally and precisely set the impact energy, pressure application speed, stepwise pressure application times, and pressure maintenance duration. The energy repetition control accuracy is ≤ ±1%, ensuring that the pressure applied in each forming process is highly consistent, completely eliminating the quality deviations caused by manual operation and mechanical fluctuations. In response to the poor fluidity of the hollow sphere brick mixed materials and the fragility of the hollow spheres, a customized stepwise flexible pressure application process is adopted. First, light pressure is applied to quickly expel the residual air inside the green body, then stepwise stable pressure is applied to compact it layer by layer, and finally long-term pressure maintenance is used for shaping. This ensures that all parts of the green body, including the center, edges, and corners, are uniformly stressed, and the density fluctuation is controlled within a very small range. This not only ensures the densification of the green body but also avoids the damage of the hollow spheres, perfectly balancing the core advantages of high strength and low thermal conductivity of the product, and increasing the product qualification rate to over 99%.

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 force application and pressure reduction, completely avoiding the severe impact force and stress concentration problems caused by traditional rigid pressure application. The pressure application process is smooth and gentle, with uniform and soft pressure transmission. It can not only fully expel the pores inside the green body, completely eliminating the defects of porosity and delamination, but also gently protect the hollow sphere structure, avoiding the rupture and deformation of the hollow spheres, significantly reducing the waste of high-cost raw materials, and effectively extending the service life of the molds, reducing material costs, and improving the production efficiency of enterprises.

It breaks through the structural limitation of the fixed bottom dead center of traditional equipment and adopts a stepwise forging forming mode. According to the material (alumina, zirconia, etc.), size, and structural complexity (standard bricks, special-shaped bricks) of refractory hollow sphere bricks, as well as the density requirements, the stroke of the slider, the depth of pressure application, and the application of pressure can be flexibly adjusted to precisely match the forming requirements of various hollow sphere bricks, covering the full range of high-end refractory material production scenarios. There is no need to worry about the problems of uneven pressure caused by deviations in raw material filling volume and differences in hollow sphere particle size. Combined with a rapid mold changing system, it enables convenient and efficient mold changing, perfectly adapting to the flexible production mode of multiple varieties and batch production, and meeting the batch supply demands of high-end fields.

The equipment is equipped with a dedicated forming parameter database for refractory hollow spheres, integrating the optimal forming process parameters for various specifications, different materials, and different density requirements of hollow spheres, covering the forming parameters of commonly used products such as low-density lightweight, high-strength dense, and special-shaped hollow spheres. 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 product are highly consistent, easily meeting the strict quality requirements of high-end fields at home and abroad, and helping enterprises smoothly open up overseas high-end refractory 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 over 55%, significantly reducing the electricity cost of hollow sphere brick production, and meeting the green and low-carbon development needs of the refractory industry. 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. The equipment has 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%. It comprehensively compresses 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 connected 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 refractory hollow spheres. It realizes unmanned control throughout the entire process from distribution, pressing, pressure holding, demolding to green body transfer and inspection, minimizing human intervention. This not only avoids damage to hollow spheres caused by manual operation but also ensures forming accuracy and production efficiency. At the same time, it supports remote monitoring, parameter adjustment, fault warning, and production data traceability functions, allowing domestic and foreign customers to remotely and real-time control production progress and product quality, fully aligning with the global refractory industry's trend of intelligent, digital, and green transformation, and helping enterprises build high-end hollow sphere brick intelligent production bases.

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 forming equipment for 45 years, deeply exploring the pain points of the forming process of high-end refractory products such as refractory hollow spheres, and insisting on empowering the refractory industry with customized technology. The Haloong 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 the material, specifications, production capacity, and density requirements of customers' hollow spheres, fully meeting the mass production needs of various hollow spheres and adapting to the refractory supply of different high-end fields.