Float glass production line simulation method and system and electronic equipment
By simulating a float glass production line using 3D modeling, the problems of high training costs, poor safety, and low efficiency in traditional training methods have been solved, achieving safe and efficient training and production optimization.
Patent Information
- Application Number
- CN202610113235.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-01-28
- Publication Date
- 2026-05-15
AI Technical Summary
Traditional float glass production line training is costly, unsafe, and inefficient. Existing training methods rely on on-site operation, which poses safety hazards and risks of equipment damage.
A simulation model is constructed using 3D modeling to simulate the batching, melting, forming, and annealing systems of a float glass production line. Simulation parameters are set, the production process is simulated, and faults are simulated to generate fault handling solutions and optimize production parameters and process flow.
Reduce training costs, improve training safety and efficiency, enhance operators' safety awareness and skill level, optimize production parameters and processes, and improve production efficiency and product quality.
Smart Images
Figure CN122046691A_ABST
Abstract
Description
Technical Field
[0001] This application relates to the field of float glass production technology, and in particular to a method, system and electronic equipment for simulating a float glass production line. Background Technology
[0002] The float glass production process is complex, involving multiple procedures and equipment, and requires a high level of technical skill from operators. Traditional training methods mainly rely on theoretical learning and hands-on practice, which has the following shortcomings: High training costs: Hands-on training requires a large amount of equipment and raw materials, resulting in high costs. Poor safety: Hands-on operation poses safety hazards, easily leading to personal injury and equipment damage. Low efficiency: Hands-on training is time-consuming and inefficient. Summary of the Invention
[0003] This application provides a simulation method, system, and electronic equipment for a float glass production line to solve the problems mentioned in the background art.
[0004] Firstly, this application provides a simulation method for a float glass production line, including: A simulation model is constructed using a three-dimensional modeling method. The simulation model is used to simulate at least one of the batching system, melting system, forming system, annealing system, and cold end system. Set simulation parameters, which include at least one of raw material ratio, melting temperature, forming speed and annealing temperature; The simulation model is run according to the simulation parameters to simulate the float glass production process, which includes at least one of the following steps: raw material intake, storage, homogenization, feeding, weighing, mixing, conveying, melting, cooling, forming, annealing, cutting, and packaging.
[0005] Furthermore, the construction of the simulation model using a three-dimensional modeling method includes: Collect relevant data from the float glass production line and establish a mathematical model based on the technological principles of the float glass production line; The mathematical model was converted into a three-dimensional simulation model using a simulation software platform, and parameters were set and debugged. The mathematical model includes at least one of the following: material balance model, energy balance model, heat transfer model, fluid flow model, and control system model.
[0006] Furthermore, after constructing the simulation model using 3D modeling, the process also includes: The simulation model is compared with actual production data to verify its accuracy and reliability, and then the simulation model is optimized and adjusted.
[0007] Furthermore, after running the simulation model according to the simulation parameters to simulate the float glass production process, the process further includes: The simulation model simulates various faults that occur during the production process, including equipment failures and / or abnormal parameters. Based on the simulation results, a fault handling solution is generated.
[0008] Furthermore, after running the simulation model according to the simulation parameters to simulate the float glass production process, the process further includes: The simulation results are analyzed and evaluated, and the production parameters and process flow of the float glass production line are adjusted based on the evaluation results.
[0009] Furthermore, after running the simulation model according to the simulation parameters to simulate the float glass production process, the process further includes: The simulation model displays its operating status and the float glass production process it simulates.
[0010] Furthermore, the simulation model includes at least one of the following modules: A fault database is used to simulate various faults that occur during the production process; The work condition library is used to store different production scenarios; The test question bank is used to generate different test questions based on the combination of the working condition database and the fault database. These test questions are used to assess the knowledge and skill level of operators. The test paper database is used to collect test questions from a test question bank to generate test papers; Training terminals are used to simulate and train operators' skill levels.
[0011] Secondly, this application provides a float glass production line simulation system, comprising: The model building module is used to build a simulation model using a three-dimensional modeling method. The simulation model is used to simulate at least one of the batching system, melting system, forming system, annealing system, and cold end system. The parameter setting module is used to set simulation parameters, which include at least one of raw material ratio, melting temperature, forming speed and annealing temperature. The production simulation module is used to run the simulation model according to the simulation parameters to simulate the float glass production process, which includes at least one of the following steps: raw material intake, storage, homogenization, feeding, weighing, mixing, conveying, melting, cooling, forming, annealing, cutting, and packaging.
[0012] Thirdly, this application provides an electronic device, including a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the float glass production line simulation method described above.
[0013] Fourthly, this application provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the float glass production line simulation method described above.
[0014] The above-mentioned technical solution of this application has the following advantages: The float glass production line simulation method provided in the first aspect of this application constructs a simulation model using 3D modeling. This model simulates at least one of the following systems: a batching system, a melting system, a forming system, an annealing system, and a cold-end system. Simulation parameters are then set, including at least one of the following: raw material ratio, melting temperature, forming speed, and annealing temperature. Finally, the simulation model is run according to these parameters to simulate the float glass production process. This process includes at least one step from raw material intake, storage, homogenization, feeding, weighing, mixing, conveying, melting, cooling, forming, annealing, cutting, and packaging. This method enables analysis of the float glass production process, optimization of production parameters and process flow, and improvement of production efficiency and product quality. It also reduces training costs, improves training safety, and enhances operators' safety awareness. Furthermore, it shortens the training cycle and increases training efficiency.
[0015] It is understood that the beneficial effects of the second, third and fourth aspects mentioned above can be found in the relevant descriptions in the first aspect above, and will not be repeated here. Attached Figure Description
[0016] To more clearly illustrate the technical solutions in the specific embodiments of this application or the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.
[0017] Figure 1 A flowchart of the simulation method for a float glass production line provided in this application; Figure 2 This is a structural diagram of the float glass production line simulation system provided in this application; Figure 3 A structural diagram of the electronic device provided in this application. Detailed Implementation
[0018] In the following description, specific details such as particular system architectures and techniques are set forth for illustrative purposes and not for limitation, in order to provide a thorough understanding of the embodiments of this application. However, those skilled in the art will understand that this application may also be implemented in other embodiments without these specific details. In other instances, detailed descriptions of well-known systems, devices, circuits, and methods are omitted so as not to obscure the description of this application with unnecessary detail.
[0019] It should be understood that, when used in this application specification and the appended claims, the term "comprising" indicates the presence of the described features, integrals, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components and / or a collection thereof.
[0020] Furthermore, in the description of this application and the appended claims, the terms "first," "second," "third," etc., are used only to distinguish descriptions and should not be construed as indicating or implying relative importance.
[0021] References to "one embodiment" or "some embodiments" in this specification mean that one or more embodiments of this application include a specific feature, structure, or characteristic described in connection with that embodiment. Therefore, the phrases "in one embodiment," "in some embodiments," "in other embodiments," "in still other embodiments," etc., appearing in different parts of this specification do not necessarily refer to the same embodiment, but rather mean "one or more, but not all, embodiments," unless otherwise specifically emphasized. The terms "comprising," "including," "having," and variations thereof mean "including but not limited to," unless otherwise specifically emphasized. "A plurality" means "two or more."
[0022] The specific embodiments of this application will be described in further detail below with reference to the accompanying drawings and examples. The following examples are used to illustrate this application, but are not intended to limit the scope of this application.
[0023] like Figure 1 As shown in the figure, this application provides a simulation method for a float glass production line, which specifically includes the following steps: Step 1: Construct a simulation model using 3D modeling. The simulation model is used to simulate at least one of the batching system, melting system, forming system, annealing system, and cold end system of the float glass production line.
[0024] In some embodiments, the simulation model can be constructed using a three-dimensional modeling approach to realistically simulate the various processes and equipment of a float glass production line.
[0025] In some embodiments, the intelligent production simulation model of a float glass production line can be constructed in the following ways: 1. Define the simulation objectives. Clarify the purpose of the simulation model, such as: training operators; optimizing production parameters; evaluating production plans; and developing new processes.
[0026] 2. Data Collection. Collect relevant data from the float glass production line, including: process flow diagrams; equipment parameters; material parameters; production data; and case studies of malfunctions.
[0027] 3. Establish a mathematical model. Based on the collected data and the technological principles of the float glass production line, establish a mathematical model, which includes, but is not limited to, at least one of the following: material balance model; energy balance model; heat transfer model; fluid flow model; control system model.
[0028] 4. Select simulation software. Choose a suitable simulation software platform, such as Aspen Plus, gPROMS, MATLAB Simulink, etc.
[0029] 5. Establish a simulation model. Use simulation software to convert the mathematical model into a simulation model, and set and debug the parameters. Establish a three-dimensional simulation model to simulate the equipment structure and process flow of the float glass production line.
[0030] 6. Verify the simulation model. Compare the simulation model with actual production data to verify its accuracy and reliability. Optimize and adjust the simulation model to improve its precision.
[0031] 7. Develop simulation software. Develop simulation software with a user interface, including an operation interface, monitoring interface, and evaluation interface. Develop functional modules such as fault simulation, operating condition setting, test question generation, and score management.
[0032] 8. Testing and Evaluation. Test the simulation software to ensure its functionality and performance meet requirements. Evaluate the suitability and effectiveness of the simulation software.
[0033] 9. Operation and Maintenance. Apply the simulation software to actual production and perform regular maintenance and updates.
[0034] Key points in building a simulation model include: data accuracy, meaning the collected data must be accurate and reliable, otherwise it will affect the accuracy of the simulation model; model rationality, meaning the established mathematical model must conform to the process principles and actual conditions of the float glass production line; and software usability, meaning the developed simulation software must be easy to operate and use in order to be widely accepted and applied.
[0035] Step 2: Set simulation parameters, which include at least one of the following: raw material ratio, melting temperature, forming speed, and annealing temperature.
[0036] In some embodiments, the data sources for the simulation parameters are as follows: Production data: Collect data from the actual production process, such as temperature, pressure, flow rate, and concentration, as the basis for simulation parameters.
[0037] Equipment parameters: Collect equipment parameters, such as model, specifications, performance, etc., as input parameters for equipment modules in the simulation model.
[0038] Material parameters: Collect material parameters, such as density, viscosity, and specific heat capacity, as input parameters for the material module in the simulation model.
[0039] Reference materials: Refer to relevant literature, such as float glass production process manuals and equipment manuals, to obtain reference values for simulation parameters.
[0040] In some embodiments, parameter settings can be configured: Initial parameters: Set the initial parameters of the simulation model, such as initial temperature, initial pressure, initial flow rate, etc.
[0041] Boundary conditions: Set the boundary conditions of the simulation model, such as ambient temperature and ambient pressure.
[0042] Operating parameters: Set the operating parameters of the simulation model, such as production speed, temperature control parameters, pressure control parameters, etc.
[0043] Fault parameters: Set the fault parameters of the simulation model, such as equipment failure rate, fault type, etc.
[0044] In some embodiments, parameters can be adjusted according to actual production needs.
[0045] Parameter optimization: The simulation parameters are optimized by using optimization algorithms, such as genetic algorithms and particle swarm optimization, to improve the accuracy of the simulation results.
[0046] Parameter adjustment: Adjust parameters based on simulation results and actual production conditions, such as adjusting temperature control parameters and pressure control parameters, to achieve the expected production goals.
[0047] In some embodiments, the set parameters can be verified. The simulation results are compared with actual production data to verify the accuracy of the simulation parameters.
[0048] Step 3: Run the simulation model according to the simulation parameters to simulate the float glass production process, which includes at least one of the following processes: raw material intake, storage, homogenization, feeding, weighing, mixing, conveying, melting, cooling, forming, annealing, cutting, and packaging.
[0049] In some embodiments, the simulation model can be run according to the simulation parameters described above to simulate the intelligent production process of float glass.
[0050] In the above embodiments, by analyzing the float glass production process, production parameters and process flow can be optimized to improve production efficiency and product quality.
[0051] In some embodiments, the method may further include: simulating various faults that occur during the production process using the simulation model, the faults including equipment faults and / or parameter anomalies; and generating a fault handling plan based on the simulation results.
[0052] In some embodiments, the following fault handling solution can be generated for equipment failure: For mechanical failures, such as equipment wear, breakage, or jamming, troubleshooting solutions may include equipment repair or replacement of parts.
[0053] For electrical faults, such as short circuits, open circuits, and component damage, troubleshooting solutions can include circuit inspection and component replacement.
[0054] For control system failures, such as sensor failures, actuator failures, and control algorithm errors, troubleshooting solutions may include checking and debugging the control system.
[0055] In some embodiments, the following fault handling solutions can be generated for abnormal parameters: For abnormal temperatures, such as excessively high or low furnace temperatures or excessively high or low tin bath temperatures, troubleshooting solutions may include temperature adjustment and control.
[0056] For abnormal pressure, such as excessively high or low furnace pressure, troubleshooting solutions may include pressure adjustment and control.
[0057] For abnormal flow rates, such as excessively high or low raw material flow rates or excessively high or low fuel flow rates, troubleshooting solutions may include flow rate adjustment and control.
[0058] For abnormal concentrations, such as excessively high or low concentrations in the batch feed, troubleshooting solutions may include concentration adjustment and control.
[0059] In the above embodiments, by simulating various faults and generating fault handling solutions, the fault handling capabilities of operators can be improved, their proficiency in fault diagnosis and handling can be continuously enhanced, fault handling time in actual production processes can be reduced, and the impact of faults on production can be mitigated. Potential risks and hidden dangers that may exist in the production process can be identified, and preventive measures can be taken to avoid the occurrence of faults, thereby reducing their impact on production. Furthermore, weak links in the production process can be identified and optimized, improving production efficiency.
[0060] In some embodiments, the method may further include: analyzing and evaluating the simulation results, and adjusting the production parameters and process flow of the float glass production line based on the evaluation results.
[0061] In some embodiments, production parameters can be optimized in the following ways: Temperature control: Based on simulation results, the impact of parameters such as furnace temperature and tin bath temperature on the production process is analyzed, and optimization adjustments are made, for example: Improving melting efficiency: Appropriately increasing the furnace temperature can accelerate the melting speed and improve melting efficiency.
[0062] Improving glass quality: Optimizing the temperature control of the tin bath can improve the surface quality and optical properties of the glass.
[0063] Pressure control: Based on simulation results, analyze the impact of parameters such as furnace pressure and tin bath pressure on the production process, and make optimization adjustments, for example: Stabilizing the production process: Properly controlling the pressure of the melting furnace and the tin bath can stabilize the production process and prevent accidents such as glass shattering.
[0064] Flow control: Based on simulation results, analyze the impact of parameters such as raw material flow rate and fuel flow rate on the production process, and make optimization adjustments, for example: Increase output: Appropriately increasing the flow rate of raw materials and fuel can increase output.
[0065] Reduce energy consumption: Optimizing fuel flow control can reduce energy consumption.
[0066] In some embodiments, process optimization can be performed in the following ways: Optimize the batching system: Based on simulation results, analyze the impact of parameters such as batching ratio and mixing method on the quality of the batching materials, and make optimization adjustments, for example: Improving the uniformity of the batch: Optimizing the batch ratio and mixing method can improve the uniformity of the batch, thereby improving the quality of the glass.
[0067] Optimize the melting system: Based on simulation results, analyze the impact of parameters such as feeding method and fuel type on the melting process, and make optimization adjustments, for example: Improving melting efficiency: Optimizing the feeding method and fuel type can improve melting efficiency and reduce energy consumption.
[0068] Optimize the forming system: Based on simulation results, analyze the impact of parameters such as solder bath temperature and edge-pulling machine position on the forming process, and make optimization adjustments, for example: Improving glass quality: Optimizing the tin bath temperature and the position of the edge-drawing machine can improve the forming quality of the glass and reduce defects.
[0069] Optimize the annealing system: Based on simulation results, analyze the impact of parameters such as annealing furnace temperature and cooling method on the annealing process, and make optimization adjustments, for example: Improving glass strength: Optimizing the annealing furnace temperature and cooling method can improve the strength of glass and reduce cracking.
[0070] The above embodiments can effectively improve the production efficiency of float glass production lines, reduce energy consumption, and improve product quality.
[0071] In some embodiments, the above method may further include: The simulation model displays its operating status and the float glass production process it simulates.
[0072] In some embodiments, the visualization process can visually demonstrate the production process, displaying the float glass production process in the form of a 3D model, allowing students to intuitively understand the overall structure of the production line and the operation of each piece of equipment.
[0073] Furthermore, visualization technology can use animation to demonstrate each step of the production process, such as raw material preparation, melting, forming, and annealing, helping to understand the production flow. Visualization technology can also display various data from the production process, such as temperature, pressure, and flow rate, in the form of charts or curves to aid in the analysis of the production process.
[0074] In addition, visualization allows operators to perform simulated operations in simulation models, such as starting equipment, adjusting parameters, and handling faults, thereby improving their operational skills.
[0075] In some embodiments, the simulation model includes at least one of the following modules: a fault database for simulating various faults that occur during the production process; a working condition database for storing different production scenarios; a test question database for generating different test questions based on a combination of the working condition database and the fault database, wherein the test questions are used to assess the knowledge and skill levels of operators; a test paper database for collecting test questions from the test question database to generate test papers; and a training terminal for conducting simulation training on the operational skills of operators.
[0076] In one example, the fault library can be used for: Fault information storage: The fault database is used to store fault information for various devices, including fault type, fault phenomenon, fault cause, and fault handling method.
[0077] Fault Setting: Instructors can select appropriate faults from the fault library according to teaching or training needs and set them in the simulation system, allowing students to practice fault diagnosis and handling.
[0078] Fault Analysis: The fault database can help instructors analyze the causes of faults and develop corresponding preventive measures to avoid their occurrence.
[0079] In one example, the load case library can be used for: Storage of operating condition information: The operating condition database is used to store information on various production operating conditions, including normal production operating conditions, fault operating conditions, and optimization operating conditions.
[0080] Working Condition Selection: Instructors can select appropriate working conditions from the working condition library according to teaching or training needs, set them in the simulation system, and allow students to practice production operations.
[0081] Operating condition analysis: The operating condition database can help instructors analyze the production process and develop corresponding optimization measures to improve production efficiency, reduce energy consumption, and improve product quality.
[0082] In one example, a question bank can be used for: Store exam question information: The exam question bank is used to store various exam question information, including theoretical questions, practical questions, and troubleshooting questions.
[0083] Test question generation: Coaches can select appropriate test questions from the test question bank according to teaching or training needs, generate test papers, and assess students (i.e. operators).
[0084] Assessment and evaluation: The test question bank can help coaches assess students' learning outcomes and adjust teaching or training programs based on the assessment results.
[0085] In one example, the exam paper library can be used for: Exam paper information storage: The exam paper library is used to store various exam paper information, including theory exam papers, practical exam papers, and fault diagnosis exam papers.
[0086] Test paper management: Coaches can manage test papers, such as modifying, deleting, and viewing them.
[0087] Performance Management: Coaches can view students' exam scores and analyze them to understand their learning progress.
[0088] In one example, the training terminal can be used for: Monitoring student operations: The training terminal can monitor the student's operation process, including operation steps, operation time, operation results, etc.
[0089] Setting up faults: Instructors can set up faults through the training terminal, allowing students to practice fault diagnosis and handling.
[0090] Scoring System: The training terminal can score students and provide feedback based on the scores to help students improve their operational skills.
[0091] The above process is further illustrated with examples below.
[0092] In this application embodiment, a central control simulation system and a 3D simulation system for a float glass production line are provided.
[0093] The simulation content includes: The 3D simulation system must closely match the central control simulation of the float glass enterprise. The overall structure of a float glass production line mainly consists of several major parts, including batching, melting, forming, annealing, and cold end, and includes necessary storage systems, metering systems, control systems, conveying systems, liquid supply systems, pneumatic systems, control rooms, and dust removal systems, to complete the production of float glass from raw materials to finished products. It is required to achieve a 3D stereoscopic display, be movable, separable, and highly realistic effect.
[0094] Float glass production line central control simulation system: Simulates the actual central control operating system of an enterprise, including the float glass batching system, melting system, forming system, annealing system, cold end system, etc. The simulation system is required to correspond to the production process, and the process parameters should conform to the actual situation of current glass production. It can be combined with a 3D simulation factory model to complete simulated operation items such as inspection and testing of each process, equipment inspection, adjustment of production process parameters, equipment failure handling, production accident handling, and product defect diagnosis. The results are reflected in the 3D simulated production scene. After operation, the corresponding results can be obtained, truly realizing simulated operation.
[0095] The batching system—the process includes raw material intake, storage, homogenization, feeding, weighing, mixing, and conveying. Equipment includes raw material storage silos, homogenization silos, belt conveyors, bucket elevators, screening equipment (hexagonal sieves, flat shaking sieves, etc.), silos, feeders (vibrating, screw, etc.), electronic scales, mixers, material distribution equipment, dust removal equipment, etc. Operation should include the inspection, operation, maintenance, and troubleshooting of the above equipment; the process operation should simulate all operations in the company's batching control room.
[0096] The melting system—the process includes raw material feeding, melting, cooling, fuel conveying and combustion systems, flue gas extraction, and waste heat recovery. Equipment includes the entire melting furnace, kiln head hopper, feeder, agitator, cooling water pipes, dilution air ducts, combustion system, fuel supply system, and heat storage system. Operation should include the inspection, operation, maintenance, and troubleshooting of the above equipment. Process operation should simulate all operations of the enterprise's melting central control system and necessary operations on the production line, such as furnace baking, cooling water tank replacement, etc. The forming system—the process includes forming glass of different thicknesses, clearly demonstrating the glass leveling and polishing, thinning and thickening processes, etc. Equipment includes the entire solder bath, edge-pulling machine, cooling water tank, linear motor, and all other solder bath auxiliary equipment. Operation should include the inspection, operation, maintenance, and troubleshooting of the above equipment. The process operation should simulate all operations in the enterprise's forming central control system and necessary operations on the production line, such as gate adjustment, edge-pulling machine adjustment, solder bath sealing, board drawing, and board modification.
[0097] The annealing system—the process encompasses all stages of glass annealing, categorized into two processes based on the annealing furnace structure: Straight Through Annealing (STAIN) and Curtain Annealing (CUND). The equipment includes the entire annealing furnace, clearly demonstrating both types and the upper and lower structures of each zone. Operation should include the inspection, operation, maintenance, and troubleshooting of the annealing furnace. The process operation should simulate all operations of the enterprise's annealing central control system and necessary operations on the production line, such as adjusting the airflow on and under the plates in each zone, and handling accidents such as glass breakage.
[0098] The cold end system—the process encompasses all stages from glass annealing to packaging and shipment, such as cross-cutting, slitting, sheet breaking, online inspection, powder coating, stacking, and unloading. Equipment includes cross-cutting machines, slitting machines, sheet breaking machines, online inspection equipment, powder coating equipment, and stacker cranes. Operations should include the inspection, operation, maintenance, and troubleshooting of all cold end equipment. Process operations should simulate all cold end control operations and necessary operations on the production line, such as adjusting cutting specifications, powder coating control, and stacking robot control.
[0099] Flue gas treatment and preheating recovery systems – including the basic principles and control of delayed desulfurization and denitrification systems and waste heat power generation systems in glass enterprises.
[0100] The simulation system can simulate modern, advanced float glass production lines, and must incorporate ultra-thin technology, annealing kiln roller conveyor technology, multi-line technology in a single kiln, energy-saving process technology, and environmental protection technology.
[0101] The simulation platform should provide a range of functions, including instructor (teacher) and operator (student) stations, fault settings, and an automated assessment system. The classroom terminal should be able to control the running status of the student-side simulation software, uniformly access student status updates, set faults, and conduct unified assessments and grade management. The simulation platform should also offer flexible grouping capabilities, allowing each computer to run the simulation system independently or in groups for collaborative operation, with no limit on the number of terminals within each group.
[0102] The assessment system can include the following modules and functions: Fault Library: Faults can be freely added or removed; it is a collection of phenomena that trigger faults.
[0103] Working condition library: You can freely add or delete working conditions, and save any working condition according to the needs of the exam.
[0104] The test question bank can combine test questions arbitrarily based on the operating condition database and the fault database. Teachers can create their own questions, set the difficulty level of the questions, and write the test question scoring criteria and test time.
[0105] Test paper bank: It can generate required questions and random questions. Questions can be combined arbitrarily and can be divided into difficulty levels.
[0106] Training terminal: This terminal displays the connection status between student and teacher computers. Teachers can control the exam and practice status of any student computer via the training terminal. After the exam, student scores are automatically sent to the training terminal.
[0107] The existing question bank can be freely expanded according to teachers' needs. The assessment criteria can be modified by teachers themselves. The assessment system must be scientific and reliable (the system should have a hiding function; the question bank and test paper bank should be invisible to the operator, visible only to the teacher's computer). Test questions should have a hint function; teachers can input textual hints or set image hints.
[0108] The simulated training projects and test questions have automatic scoring or teacher evaluation functions, and can be used for theoretical and skills examinations.
[0109] Fault Simulation Function: The simulation software can reflect abnormal and accidental operating conditions such as unit equipment failures, device damage, and automatic control function malfunctions in real time. It can simulate faults of varying degrees and gradual changes, and the simulation results should accurately reflect the actual fault process. The simulator can not only respond reasonably to faults set by the instructor, but also to naturally occurring faults and faults caused by improper operation and adjustment. The simulator should be able to simulate faults of various equipment or systems in real time, and the development process of the fault should be consistent with the reference unit. Faults are set through the fault setting function of the instructor's console. The fault trigger time and fault trigger conditions can be arbitrarily selected, and the fault degree is adjustable within the range of 0-100% (e.g., blockage, leakage). Faults can be set individually or in groups, and the number of faults set in a group is unlimited. The variable fault degree provided by the simulator should be able to increase or decrease the fault degree according to the instructor's predetermined range within a certain period of time. Because the instructor set a fault, the system is running in a fault state. When the instructor cancels the fault, the system should maintain the state before the fault was cleared, allowing the operator to continue processing until it returns to normal. The system should not immediately return to normal when the instructor clears the fault. For example, if the instructor sets a valve to close, the valve should not open automatically after the instructor clears the fault; the operator should open it manually.
[0110] System modeling software refers to a graphical modeling system for glass production processes. This system can establish high-precision mass conservation, momentum conservation, and energy conservation models and algorithms for melting, forming, and annealing processes in glass production. It can convert computer language model algorithms into graphical algorithm modules. Through graphical modeling software, process flow design, equipment parameter and operating parameter design and debugging, and simulation of on-site operating parameters and effects can be achieved. The system modeling software must be open: the model algorithm must be open, allowing for free expansion or modification of modules; the modeling environment must be open, allowing for free design or modification of the process flow. The modeling system software may also include a graphical modeling component for the control system. Copyright certificates for the graphical modeling software for control systems, thermal systems, and electrical systems must be provided.
[0111] The modeling system allows users to view the calculation methods involved in processes such as ingredient preparation, melting, forming, and annealing. These calculation methods represent a complete and systematic modeling approach, including core algorithm formulas. Interfaces for viewing, downloading, editing, and printing are provided.
[0112] The system modeling software provides a Fortran programming interface, enabling theoretical calculation methods to be programmed into a computer language, compiled into a calculation program, and then packaged into a graphical modeling program module by the modeling software. The system should have a pre-developed process modeling module library containing algorithm modules for all major equipment in the plant, and the system should be open, allowing for future expansion and upgrades.
[0113] Within the system modeling software's modeling environment, graphical modules from the module library can be dragged and dropped into the modeling diagram for design and modeling according to process requirements. Modules can be connected via flow lines, and each module can have its rated equipment parameters set. After modeling is complete, it can be directly compiled and run, with the runtime parameters clearly visible in the modeling environment.
[0114] Simulation software should possess task-driven training capabilities. In a task-driven teaching simulation system, the instructor breaks down the simulated teaching content into multiple representative tasks, with task completion as the central focus of the teaching activity. Driven by the motivation to complete the tasks, trainees analyze and discuss them to clarify the knowledge involved, the problems to be solved, and identify which knowledge is prior to their knowledge and which is new. Under the guidance and assistance of the instructor, trainees actively apply learning resources and, through independent exploration and collaborative learning, discover methods to complete the tasks. Task-driven training includes the following functional modules: It allows simultaneous or separate selection and saving of operating conditions for multiple simulation systems running within a local area network; It allows setting faults simultaneously or separately for multiple simulation systems running within a local area network; It can simultaneously or separately accelerate and decelerate multiple simulation systems running within a local area network; It allows simultaneous or individual selection of rollback functionality for multiple simulation systems running within a local area network; It can simultaneously or separately evaluate multiple simulation systems within a local area network online and automatically generate evaluation results; It can randomly test any simulation system within a local area network, generate test papers, and automatically generate test results.
[0115] The 3D simulation model allows users to freely enter the glass production line 3D virtual system, visiting the production process and major equipment from any angle and along any route, showcasing the overall layout and equipment structure. Major buildings and equipment must include at least: factory buildings, float glass combined workshop, nitrogen and hydrogen station, substation, raw material storage system, waste heat power generation (boiler), desulfurization and denitrification system, batch preparation system, melting furnace and its auxiliary equipment, tin bath and its auxiliary equipment, annealing furnace, cold end and its auxiliary equipment, etc. It should also indicate the name of the equipment, its main working content, and the job responsibilities of key positions.
[0116] The simulation system supports three operating modes: standalone operation, LAN authorized operation, and Internet authorized operation. The number of authorized computers is unlimited. All computers in the simulation room can run the simulation system standalone, or they can be arbitrarily grouped and operated collaboratively by multiple users. The number of computers within each group is unlimited.
[0117] Corresponding to the float glass production line simulation method described in the above embodiments, this application also provides a float glass production line simulation system, such as... Figure 2 As shown, the float glass production line simulation system includes: The model building module is used to build a simulation model using a three-dimensional modeling method. The simulation model is used to simulate at least one of the batching system, melting system, forming system, annealing system, and cold end system. The parameter setting module is used to set simulation parameters, which include at least one of raw material ratio, melting temperature, forming speed and annealing temperature. The production simulation module is used to run the simulation model according to the simulation parameters to simulate the float glass production process, which includes at least one of the following steps: raw material intake, storage, homogenization, feeding, weighing, mixing, conveying, melting, cooling, forming, annealing, cutting, and packaging.
[0118] It should be noted that the information interaction and execution process between the above modules / units are based on the same concept as the method embodiments of this application. For details on their specific functions and technical effects, please refer to the method embodiments section, and they will not be repeated here.
[0119] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional units and modules is merely an example. In practical applications, the above functions can be assigned to different functional units and modules as needed, that is, the internal structure of the system can be divided into different functional units or modules to complete all or part of the functions described above. The functional units and modules in the embodiments can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit. The integrated unit can be implemented in hardware or as a software functional unit. Furthermore, the specific names of the functional units and modules are only for easy differentiation and are not intended to limit the scope of protection of this application. The specific working process of the units and modules in the above system can be referred to the corresponding process in the foregoing method embodiments, and will not be repeated here.
[0120] This application also provides an electronic device, such as... Figure 3 As shown, it includes a memory, a processor, and a computer program stored in the memory and executable on the processor. When the processor executes the computer program, it implements the steps of the float glass production line simulation method provided in the first aspect.
[0121] In applications, electronic devices may include, but are not limited to, processors and memory. Figure 3This is merely an example of an electronic device and does not constitute a limitation on the device. It may include more or fewer components than illustrated, or combinations of certain components, or different components, such as input / output devices, network access devices, etc. Input / output devices may include cameras, audio capture / playback devices, displays, etc. Network access devices may include network modules for wireless network communication with external devices.
[0122] In applications, the processor can be a Central Processing Unit (CPU), but it can also be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. A general-purpose processor can be a microprocessor or any conventional processor.
[0123] In applications, memory can be an internal storage unit of an electronic device in some embodiments, such as a hard drive or RAM. In other embodiments, memory can be an external storage device of the electronic device, such as a plug-in hard drive, Smart Media Card (SMC), Secure Digital (SD) card, or Flash Card. Memory can also include both internal and external storage units of the electronic device. Memory is used to store operating systems, applications, bootloaders, data, and other programs, such as program code for computer programs. Memory can also be used to temporarily store data that has been output or will be output.
[0124] This application also provides a computer-readable storage medium storing a computer program, which, when executed by a processor, can implement the steps in the above-described method embodiments.
[0125] This application implements all or part of the processes in the methods of the above embodiments, which can be accomplished by a computer program instructing related hardware. The computer program can be stored in a computer-readable storage medium, and when executed by a processor, it can implement the steps of the various method embodiments described above. The computer program includes computer program code, which can be in the form of source code, object code, executable file, or some intermediate form. The computer-readable medium can at least include: any entity or device capable of carrying the computer program code to an electronic device, a recording medium, a computer memory, a read-only memory (ROM), a random access memory (RAM), an electrical carrier signal, a telecommunication signal, and a software distribution medium, such as a USB flash drive, a portable hard drive, a magnetic disk, or an optical disk.
[0126] Those skilled in the art will recognize that the device and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.
[0127] In the embodiments provided in this application, it should be understood that the disclosed devices and methods can be implemented in other ways. For example, the device embodiments described above are merely illustrative. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interface, or the device may be indirectly coupled or communicated, and may be electrical, mechanical, or other forms.
[0128] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.
Claims
1. A simulation method for a float glass production line, characterized in that, include: A simulation model is constructed using a three-dimensional modeling method. The simulation model is used to simulate at least one of the batching system, melting system, forming system, annealing system, and cold end system. Set simulation parameters, which include at least one of raw material ratio, melting temperature, forming speed and annealing temperature; The simulation model is run according to the simulation parameters to simulate the float glass production process, which includes at least one of the following steps: raw material intake, storage, homogenization, feeding, weighing, mixing, conveying, melting, cooling, forming, annealing, cutting, and packaging.
2. The float glass production line simulation method as described in claim 1, characterized in that, The simulation model constructed using 3D modeling includes: Collect relevant data from the float glass production line and establish a mathematical model based on the technological principles of the float glass production line; The mathematical model was converted into a three-dimensional simulation model using a simulation software platform, and parameters were set and debugged. The mathematical model includes at least one of the following: material balance model, energy balance model, heat transfer model, fluid flow model, and control system model.
3. The float glass production line simulation method as described in claim 1, characterized in that, After constructing the simulation model using 3D modeling, the following is also included: The simulation model is compared with actual production data to verify its accuracy and reliability, and then the simulation model is optimized and adjusted.
4. The float glass production line simulation method as described in claim 1, characterized in that, After running the simulation model according to the simulation parameters to simulate the float glass production process, the process further includes: The simulation model simulates various faults that occur during the production process, including equipment failures and / or abnormal parameters. Based on the simulation results, a fault handling solution is generated.
5. The float glass production line simulation method as described in claim 1, characterized in that, After running the simulation model according to the simulation parameters to simulate the float glass production process, the process further includes: The simulation results are analyzed and evaluated, and the production parameters and process flow of the float glass production line are adjusted based on the evaluation results.
6. The simulation method for a float glass production line as described in claim 1, characterized in that, After running the simulation model according to the simulation parameters to simulate the float glass production process, the process further includes: The simulation model displays its operating status and the float glass production process it simulates.
7. The float glass production line simulation method as described in claim 1, characterized in that, The simulation model includes at least one of the following modules: A fault database is used to simulate various faults that occur during the production process; The work condition library is used to store different production scenarios; The test question bank is used to generate different test questions based on the combination of the working condition database and the fault database. These test questions are used to assess the knowledge and skill level of operators. The test paper database is used to collect test questions from a test question bank to generate test papers; Training terminals are used to simulate and train operators' skill levels.
8. A simulation system for a float glass production line, characterized in that, include: The model building module is used to build a simulation model using a three-dimensional modeling method. The simulation model is used to simulate at least one of the batching system, melting system, forming system, annealing system, and cold end system. The parameter setting module is used to set simulation parameters, which include at least one of raw material ratio, melting temperature, forming speed and annealing temperature. The production simulation module is used to run the simulation model according to the simulation parameters to simulate the float glass production process, which includes at least one of the following steps: raw material intake, storage, homogenization, feeding, weighing, mixing, conveying, melting, cooling, forming, annealing, cutting, and packaging.
9. An electronic device comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the float glass production line simulation method as described in any one of claims 1 to 7.
10. A computer-readable storage medium storing a computer program, characterized in that, When the computer program is executed by the processor, it implements the float glass production line simulation method as described in any one of claims 1 to 7.