Using new technology to improve the production efficiency of zirconia sand
In the zirconia sand workshop, the huge electric furnace swallowed up suffocating energy. Master Wang frowned and stared at the scorching flames at the furnace mouth: “Every kilowatt-hour of electricity seems to be eating money!” He sighed softly, and his voice was mostly swallowed by the noisy roar of the machine. On the other side, in the crushing workshop, the masters were busy around the grading equipment, with sweat and dust mixed on their faces. They carefully sifted, their eyes focused and anxious-a slight fluctuation in the particle size of the product may make the entire batch of finished products become defective. Such scenes, day after day, struggle in the shackles of traditional crafts, as if tightly bound by invisible ropes.
However, the arrival of microwave sintering technology has finally cut through the thick cocoon of traditional high energy consumption. Once upon a time, electric furnaces were energy-intensive, and huge currents were continuously injected into the furnace, but the energy efficiency was heartbreakingly low. Today, microwave energy is accurately injected into the interior of zircon sand, and the molecules are “awakened” to generate heat evenly from the inside out. This is like using a microwave to heat food, eliminating the preheating time of traditional stoves, and the energy goes directly to the core. I have seen the comparison of workshop data with my own eyes: the energy consumption index of the old electric furnace is staggering, while the energy consumption of the new microwave oven has been reduced by nearly half! Zhang Gong, a master who has been guarding the electric furnace for many years, was also skeptical at first: “Can you really burn good things just by relying on invisible “waves”?” But when he turned on the button of the new equipment himself, looked at the temperature curve jumping steadily on the screen, and touched the evenly warm zirconium sand after it came out of the furnace, he finally smiled: “Hey, this “wave” is really good! Not only does it save electricity, but the side of the furnace doesn’t look like a steamer anymore!”
The innovation of the crushing and grading links is also exciting. In the past, the internal conditions of the crusher seemed to be a “black box”, and the operator relied entirely on experience and was often “blind”. The new system cleverly implants sensors into the crusher cavity to monitor material flow and crushing intensity in real time. Operator Xiao Liu pointed to the intuitive data flow on the screen and told me: “Look, look at this load value. Once it turns red, it will immediately remind me to adjust the feed speed or blade gap. I no longer have to grope around like before, afraid of blocking the machine or over-crushing. I feel more confident!” The introduction of the laser particle size analyzer has completely overturned the old tradition of “looking at particle size” based on the experience of the master. High-speed laser accurately scans every flying zircon sand, instantly depicting the “portrait” of particle size distribution. Engineer Li smiled and said: “In the past, no matter how good the master’s eyesight was, he couldn’t stand the dust and long time. Now the instrument “looks” in a few seconds, the data is clear, and the error? Almost no!” – Precise crushing and real-time monitoring have significantly improved the yield rate and greatly reduced the defective rate. Technological innovation has really turned into benefits.
Our workshop has also quietly implanted the “brain” of the intelligent control system. It is like a tireless conductor, accurately dispatching the “symphony” of the entire production line from raw material ratio, microwave power to crushing intensity, classification parameters, etc. The system compares and analyzes the massive data collected in real time with the preset process model. Once a slight deviation occurs in a certain link (such as fluctuations in raw material moisture, abnormal increase in crushing chamber temperature), the relevant parameters will be automatically adjusted to compensate. Director Wang sighed: “In the past, when there was a small problem, by the time we discovered, found the cause, and adjusted it, the waste might have piled up into a small mountain. Now the system reacts much faster than people, and many small fluctuations are quietly “settled” before they cause big problems.” The entire workshop runs more smoothly, and the differences between product batches are compressed to an unprecedented level.
New technology is not a simple superposition of cold machinery, but a profound reshaping of the way and connotation of our work. Master Lao Wang’s main “battlefield” has now shifted from the front of the furnace to the bright control room screen, and his work clothes are neat and new. He skillfully called up the real-time data curve and explained to me the meaning of each parameter. When asked about his work experience, he raised his mobile phone and said humorously: “I used to sweat while watching the furnace, but now I sweat while looking at the data – sweating while thinking! However, I feel comfortable when I see the energy consumption dropping and the output rising!” What is even more gratifying is that while the production capacity has been greatly improved, the personnel structure of the workshop has become more efficient. Those positions that were once occupied by heavy physical labor and repetitive operations have been efficiently replaced by automated equipment and intelligent systems, and the released manpower has been assigned to more valuable positions such as equipment maintenance, process optimization and quality analysis. Technology, after all, serves people and makes people’s wisdom shine at a higher level.
When the giant microwave oven in the workshop runs smoothly, the crushing equipment roars under intelligent scheduling, and the laser particle size analyzer scans silently, we know that this is not just the equipment running, but also a road to more efficient, cleaner and smarter zirconia sand production is extending under our feet. The light of technology penetrates the fog of high energy consumption in the past, and also illuminates the new and possible faces of every operator in the workshop – in the arena of time and efficiency, we finally rely on the power of innovation to win more relaxed dignity and value for every precious zirconia sand and the wisdom and sweat of every worker.
This silent innovation tells us: In the world of materials, what is more precious than gold is always the time that we constantly take back from the constraints of tradition.
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