The core competitiveness of alumina hollow sphere bricks lies in their comprehensive properties of "lightweight, high strength, high temperature resistance, and insulation", which are entirely dependent on precise control during the forming stage. The forming process must meet six key requirements: "intact hollow spheres, uniform density, dense structure, no cracks, intact edges and corners, and precise dimensions". It is necessary to strictly protect the alumina hollow spheres from being crushed, keeping the breakage rate within 10% to ensure the insulation and structural strength of the finished product. At the same time, it is essential to ensure uniform density throughout the green body, ensuring stable bulk density and reasonable apparent porosity of the finished product, laying a solid foundation for subsequent high-temperature sintering. Additionally, the pressing speed and holding time must be precisely controlled to accommodate the special flowability and difficult exhaust of the alumina hollow sphere mixture, avoiding residual pores within the green body that could lead to structural failure during high-temperature service. Moreover, the forming pressure requirements for different specifications and applications of alumina hollow sphere bricks must be precisely matched to avoid over-pressing and crushing or under-pressing and looseness. Currently, the technical shortcomings of traditional forming equipment have led to common problems in the production of alumina hollow sphere bricks, such as high breakage rates of hollow spheres, uneven green body density, damaged edges and corners, large dimensional deviations, and low product qualification rates, severely restricting the industrial development of high-end alumina hollow sphere bricks. Zhengzhou Haloong, relying on the third-generation permanent magnet synchronous servo direct drive core technology, has optimized and upgraded the HLDS series of CNC servo screw presses, specifically addressing the forming challenges of alumina hollow sphere bricks and creating dedicated forming equipment. With the core advantages of flexible pressure control, precise sphere protection, and intelligent adaptability, it has established a benchmark for high-end alumina hollow sphere brick quality.

Compared to ordinary refractory bricks, the forming difficulty of alumina hollow sphere bricks is significantly increased due to the special nature of the raw materials and the strict forming process. The mixture for alumina hollow sphere bricks is centered around intact alumina hollow spheres, supplemented with a small amount of alumina micro-powder and sintering aids such as corundum. The hollow spheres are brittle and have poor impact resistance, and the flowability of the mixture is significantly different from that of ordinary refractory materials, making exhaust difficult. During the forming process, the application force, speed, and rhythm must be precisely controlled to achieve densification of the green body while strictly protecting the integrity of the hollow spheres and avoiding their breakage. Moreover, the forming pressure, pressing speed, and holding time for different specifications of products vary significantly, requiring extremely high process adaptability from the equipment.

Zhengzhou Haloong has deeply studied the raw material characteristics, forming process logic, and industry upgrade demands of alumina hollow sphere bricks. With the core technology of permanent magnet synchronous servo motor direct drive + static pressure flexible pressure transmission + intelligent CNC system, it has specifically optimized the HLDS series of servo screw presses, comprehensively upgrading the equipment's precision, stability, and adaptability. The advantages precisely match the dual forming requirements of "sphere protection and uniform densification" for alumina hollow sphere bricks, making it the preferred equipment for mass production of high-quality alumina hollow sphere bricks. It helps refractory enterprises create high-quality products suitable for high-temperature, strong thermal shock, and high insulation conditions, seizing the opportunity in the high-end market.

Equipped with a core permanent magnet synchronous servo motor direct drive system, 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 equipment is equipped with Haloong's independently developed CNC pressure control module for alumina hollow sphere bricks, which can digitally and precisely set the impact energy, pressing speed, stepwise pressing times, and holding time. The energy repetition control accuracy is ≤±1%, ensuring that the forming pressure is highly consistent in each cycle, completely eliminating quality deviations caused by manual operation and mechanical fluctuations. In response to the brittle nature of alumina hollow spheres and the difficulty in exhausting air from the mixture, a customized "light pressure exhaust - gentle pressure densification - long-term pressure maintenance" stepwise flexible pressurization process was developed. This process first applies light pressure to the loose raw materials to slowly expel the residual air inside, then gradually and steadily applies pressure layer by layer (with pressure increasing slowly to avoid impact), and finally maintains the pressure for a long time to shape the product. This approach not only strictly protects the integrity of the alumina hollow spheres, keeping the breakage rate within 10%, but also ensures uniform force application to all parts of the green body, including the center, edges, and corners, with density fluctuations controlled within a very small range. This provides a solid foundation for subsequent high-temperature sintering and increases the finished product qualification rate to over 99%.

The equipment 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 without sudden force or stress concentration issues associated with traditional rigid pressurization. The pressurization process is smooth and even, effectively expelling internal pores in the green body to ensure its density and completely eliminate defects such as porosity, delamination, and micro-cracks. It also gently protects the alumina hollow spheres from being crushed, preventing green body cracking and edge damage, significantly reducing the waste of high-cost raw materials. At the same time, it effectively extends the service life of the mold, reduces material costs, and enhances the production efficiency of the enterprise, solving the core problem of "high breakage rate and high scrap rate" in traditional equipment.

Breaking through the structural limitation of the fixed bottom dead center in traditional equipment, a step-by-step forging forming mode is adopted. The stroke of the slider, the depth of pressurization, and the applied pressure can be flexibly adjusted according to the material, size, structural complexity (irregular structural components, lining bricks, insulating bricks), density requirements, and raw material ratio (different particle sizes of hollow spheres) of the alumina hollow sphere bricks. This precisely meets the forming needs of various types of alumina hollow sphere bricks, covering the full range of production for high-end alumina hollow sphere bricks. There is no need to worry about uneven pressurization or sphere breakage caused by variations in raw material filling volume, hollow sphere particle size, and the fluidity of the mixture. Combined with a rapid mold change system, mold changes are convenient and efficient, perfectly adapting to the flexible production mode of multiple varieties and batches, meeting the batch supply demands of high-end fields such as metallurgy, petrochemicals, and aerospace, while also accommodating the forming requirements of both lightweight insulating bricks and high-strength structural components.

The equipment is equipped with a dedicated database of forming parameters for alumina hollow sphere bricks, integrating the optimal forming process parameters for various specifications, different raw material ratios, different hollow sphere particle sizes, and different density requirements of alumina hollow sphere bricks. It covers the forming parameters of common products such as standard alumina hollow sphere lining bricks, irregular lightweight structural components, and high-strength corrosion-resistant hollow sphere bricks. Operators can retrieve these parameters with a single 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 product are highly consistent, with the alumina hollow spheres remaining intact. This easily meets the strict quality requirements of high-end fields at home and abroad, helping enterprises smoothly open up overseas markets for high-end alumina hollow sphere bricks.

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, with zero energy consumption in the standby state, achieving a comprehensive energy-saving rate of over 55%. This significantly reduces the electricity cost of alumina hollow sphere brick production, aligning with the green and low-carbon development needs of the refractory materials 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 maintenance cost by more than 40%. This comprehensively compresses production, maintenance, and material costs, helping enterprises achieve a green, low-carbon, and efficient profit-making production model, solving the core problems of "high energy consumption and complex maintenance" in traditional forming equipment. The equipment is equipped with standardized industrial communication interfaces, which can be seamlessly integrated with automatic and precise feeding machines, closed-loop distribution machines, intelligent demolding machines, non-destructive testing equipment for green bodies, and constant-temperature conveying lines to build a fully automatic and intelligent production line for alumina hollow sphere bricks. This enables unmanned control throughout the entire process from distribution, pressing, pressure holding, demolding to green body transportation and inspection, minimizing human intervention. It not only avoids damage to the green bodies caused by manual operation and reduces the risk of hollow sphere breakage, but also ensures the 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 the production progress and product quality. It fully conforms to the global trend of intelligent, digital, and green transformation in the refractory materials industry, helping enterprises build high-end intelligent production bases for alumina hollow sphere bricks and enhance large-scale mass production capabilities.

Zhengzhou Haloong Machinery Co., Ltd., as a leading enterprise in the domestic electric servo screw press field, has been focusing on technological innovation in refractory material forming equipment for 45 years. It has been deeply engaged in solving the forming process pain points of high-end refractory materials such as alumina hollow sphere bricks, and has been committed to empowering industrial upgrading with customized technologies. The Haloong HLDS series of CNC servo screw presses cover the full tonnage range from 200T to 1600T. According to the customer's requirements for the material, specifications, capacity, density, and raw material ratio (hollow sphere particle size combination) of alumina hollow sphere bricks, it can provide one-to-one customized forming solutions, fully meeting the mass production needs of various types of alumina hollow sphere bricks, and adapting to the supply of refractory materials in different high-end high-temperature, strong thermal shock, and high-temperature insulation fields. It solves the problems of low efficiency and uneven density in traditional vibration forming.