A rolling control system and method for rolling glass roller conveyors

Abstract

This invention provides a roll-over monitoring and control system and method for rolled glass rollers, relating to the field of glass manufacturing technology. It includes: multiple temperature monitoring devices arranged along the length of the rolled glass rollers for real-time monitoring of the surface temperature of various areas on the rollers; and a controller that, when any surface temperature exceeds a first preset threshold, controls the roller motor to slow down, increases the cooling water flow of the roller liquid cooling device, and activates the purging device, while simultaneously issuing a roll-over alarm to on-site personnel to remind them to conduct on-site inspections and manual intervention. The beneficial effect is that the handling procedure is initiated at the nascent stage of the roll-over phenomenon, accurately controlling the "golden 5-second" window for fault handling, reserving crucial time for on-site personnel to arrive and implement subsequent manual intervention, thus suppressing the rapid spread and expansion of the roll-over defect from the source, and completely breaking the passive predicament of traditional handling schemes where the fault has already developed to a moderate stage by the time it is discovered.

Description

Technical Field

[0001] This invention relates to the field of glass manufacturing technology, and in particular to a rolling control system and method for rolling glass roller conveyors. Background Technology

[0002] In the field of rolled glass production, the calender is the core forming equipment of the rolled glass production line, playing a decisive role in processing molten glass into flat glass sheets with specific thicknesses and surface qualities. Among these, the calender roll assembly is the core working component of the calender, typically consisting of 2-4 high-precision alloy steel rolls (such as chilled cast iron rolls with high hardness and wear resistance). The upper and lower rolls are the main calendering actuators; by adjusting the gap between the rolls (the adjustment range covers from a few millimeters to tens of millimeters), the production needs of glass of different thicknesses can be met. Simultaneously, the roll body is equipped with a temperature control system including cooling channels and heating jackets. Its core function is to maintain a constant roll surface temperature, thereby avoiding product defects caused by molten glass sticking to the rolls or uneven cooling.

[0003] In actual production, "glass sticking to the rollers" (commonly known as "rolling wrapping") is a phenomenon in rolled glass production where molten glass abnormally adheres to the surface of the rolling rollers. This can cause obstruction of glass transport, damage to the roller surface, and quality problems such as surface defects and uneven thickness. It is a typical process anomaly in the rolling process. "Rolling wrapping" is a production malfunction. If it is not detected and dealt with in time, it will quickly deteriorate to a moderate stage, eventually requiring a shutdown and roller replacement. A single malfunction can cause economic losses of tens of thousands of yuan, wasting manpower and resources, severely disrupting the production process, and affecting the company's capacity and economic benefits.

[0004] Currently, the industry's approaches to dealing with rolling defects have significant limitations. Most manufacturers rely on manual inspections for fault detection and intervention, but manual inspections are limited by inspection cycles, personnel resources, and subjective judgment, often resulting in delayed detection and failure to address rolling defects in their early stages, frequently missing the optimal intervention window. Other solutions employ visual inspection equipment, using industrial cameras on the production line to capture real-time images of the glass surface and automatically warn of rolling defects by recognizing features such as continuous roller marks and adhesive marks. However, such visual inspection equipment is expensive, and for most manufacturers, the return on investment for purchasing this equipment specifically to prevent rolling defects is too low, failing to meet the balance between cost control and practicality required in engineering design, making widespread adoption in the industry difficult.

[0005] Based on the aforementioned industry pain points, existing roll-to-roll defect detection and control solutions cannot simultaneously meet the core needs of the production process: First, the timeliness of detection and handling is insufficient, making it difficult to curb the deterioration of faults; second, it cannot achieve the goal of handling issues primarily online and minimizing production stoppages, which can easily lead to capacity losses; and third, the equipment cost is mismatched with its practicality, making it difficult to adapt to the production budgets of most enterprises.

[0006] Therefore, developing a roll defect detection and control system that is timely, efficient, capable of online handling, simple in structure, and low in cost has become an urgent technical problem to be solved in the current rolled glass production field. It is of great practical significance for improving production stability, reducing failure losses, and optimizing the input-output ratio. Summary of the Invention

[0007] To address the problems existing in the prior art, this invention provides a rolling control system for a rolled glass roller conveyor, wherein a roller conveyor liquid cooling device and a blowing device are provided on the side of the rolled glass roller conveyor; comprising: Multiple temperature monitoring devices are arranged along the length of the calendering glass roller conveyor to monitor the surface temperature of each area on the calendering glass roller conveyor in real time. The controller is connected to each of the temperature monitoring devices, the roller motor corresponding to the rolled glass roller, the roller liquid cooling device, and the purging device. When any of the surface temperatures exceeds a first preset threshold, the controller controls the roller motor to slow down, increases the cooling water flow of the roller liquid cooling device, and activates the purging device. At the same time, it sends a roll alarm to the on-site personnel to remind them to conduct on-site inspections and manual intervention.

[0008] Preferably, the rolling glass conveyor includes an upper roller and a lower roller arranged opposite each other, and the temperature probe of each temperature monitoring device faces the lower surface of the upper roller to monitor the surface temperature of each region of the lower surface of the upper roller.

[0009] Preferably, each of the temperature monitoring devices is disposed in the middle region and both ends region of the upper roller along the length direction of the upper roller.

[0010] Preferably, the controller includes a first control unit, configured to reduce the output frequency of the inverter associated with the roller conveyor motor when any of the surface temperatures exceeds the preset threshold, so as to control the upper roller and the lower roller to reduce their speeds simultaneously.

[0011] Preferably, the controller includes a second control unit, which is used to continuously monitor the surface temperature of each surface after issuing the roll alarm prompt to the on-site duty personnel, and when all the surface temperatures are less than a second preset threshold, first control the shutdown of the purging device, and then restore the rotation speed of the roller motor and the cooling water flow rate of the roller liquid cooling device.

[0012] Preferably, the first preset threshold is 700°C and the second preset threshold is 600°C.

[0013] Preferably, the temperature monitoring device is an infrared thermometer.

[0014] This invention also provides a method for measuring and controlling the roll wrapping of rolled glass on a rolling glass roller conveyor, applied to the aforementioned roll wrapping measurement and control system. The roll wrapping measurement and control method includes: Step S1: The roll measurement and control system monitors the surface temperature of each area on the rolling glass roller conveyor in real time; In step S2, when any of the surface temperatures exceeds the first preset threshold, the roll pack monitoring and control system controls the roller conveyor motor to slow down, increases the cooling water flow of the roller conveyor liquid cooling device, and activates the purging device. At the same time, it sends a roll pack alarm to the on-site personnel to remind them to conduct on-site inspections and manual intervention.

[0015] Preferably, the rolling glass conveyor includes an upper roller and a lower roller arranged opposite each other, and the temperature probe of each temperature monitoring device faces the lower surface of the upper roller to monitor the surface temperature of each region of the lower surface of the upper roller.

[0016] Preferably, after performing step S2, the method further includes: After issuing the roll alarm to the on-site personnel, the roll measurement and control system continuously monitors the surface temperature of each surface. When all the surface temperatures are less than the second preset threshold, it first controls the purging device to shut down, and then restores the speed of the roller motor and the cooling water flow rate of the roller liquid cooling device.

[0017] The above technical solution has the following advantages or beneficial effects: 1) By collecting the surface temperature of each area of ​​the roller surface in real time, when the surface temperature of any monitored area exceeds the first preset threshold, the controller immediately triggers the linkage intervention command, starts the handling procedure at the bud stage of the rolling phenomenon, accurately controls the "golden 5 seconds" window period for fault handling, and reserves key time for on-duty personnel to arrive at the scene to carry out subsequent manual intervention, suppressing the rapid spread and expansion of rolling defects from the source, and completely breaking the passive dilemma of the traditional handling plan where the fault has already developed to the moderate stage when it is discovered. 2) By reducing the speed of the roller conveyor motor, the contact pressure and residence time between the molten glass and the roller surface can be reduced, inhibiting abnormal adhesion between the two from a mechanical perspective and preventing further expansion of the rolling range; by increasing the cooling water flow rate of the roller conveyor liquid cooling device, the cooling efficiency of the roller surface is enhanced, reducing the wettability between the molten glass and the metal roller surface, weakening the adhesion basis from the material interface characteristics perspective, significantly improving the anti-adhesion ability of the molten glass on the roller surface, and further curbing the development of the rolling phenomenon; by activating the blowing device, dust, water vapor and other impurities adhering to the roller surface are blown away and cleaned in real time, avoiding impurities from catalyzing the glass sticking to the roller, while ensuring the cleanliness and temperature stability of the roller surface, providing technical support for smooth glass conveying; the simultaneous activation and synergistic effect of the above three actions can effectively prevent defects from deteriorating from the initial stage to moderate and severe levels; 3) This invention, through real-time detection and online intervention, can effectively control roll defects in their early stages without the need for emergency shutdown measures. This perfectly matches the process requirements of rolled glass production, which is mainly based on online processing and avoids production stoppages as much as possible, thus minimizing the production capacity loss caused by shutdowns. At the same time, by precisely curbing the spread of roll defects, it can effectively avoid problems such as severe roller surface damage and batch scrapping of glass products. It fundamentally eliminates major production accidents such as roller replacement and complete shutdown caused by defect deterioration, avoids economic losses of tens of thousands of yuan caused by a single accident, significantly reduces the company's production and maintenance costs and fault handling costs, and improves the stability and continuity of the production process. 4) Compared with existing expensive visual inspection equipment, this system is based on the linkage modification of existing roller conveyor motors, liquid cooling devices, and purging devices. It is equipped with multiple temperature monitoring devices and controllers to form the core measurement and control unit. There is no need to purchase additional complex and precise inspection equipment, which greatly reduces the equipment investment cost. It takes into account both technical practicality and economic rationality. It can be adapted to the efficient operation and maintenance scenarios of large-scale production enterprises, and can also meet the cost control needs of small and medium-sized enterprises. It can be widely used in various rolled glass production lines and has broad prospects for industrial promotion. Attached Figure Description

[0018] Figure 1 A schematic diagram of the structure of a rolling sheet control system for a rolled glass roller conveyor is shown in a preferred embodiment of the present invention. Figure 2 A schematic diagram showing the installation position of the temperature detection device in a preferred embodiment of the present invention; Figure 3 A side view of a calender in a preferred embodiment of the present invention; Figure 4 A schematic diagram of the detection and control process of a rolling glass roller conveyor measurement and control system is shown in a preferred embodiment of the present invention. Figure 5This is a flowchart illustrating the rolling and control method for the rolling glass roller conveyor, which is a preferred embodiment of the present invention. Detailed Implementation

[0019] The present invention will now be described in detail with reference to the accompanying drawings and specific embodiments. The present invention is not limited to this embodiment; other embodiments that conform to the spirit of the present invention may also fall within the scope of the present invention.

[0020] In a preferred embodiment of the present invention, based on the above-mentioned problems existing in the prior art, a rolling control system for a rolled glass roller conveyor is provided, wherein a roller conveyor liquid cooling device and a blowing device are provided on the side of the rolled glass roller conveyor; as shown Figures 1 to 4 As shown, it includes: Multiple temperature monitoring devices 1 are set along the length of the calendering glass roller 2 to monitor the surface temperature of each area on the calendering glass roller 2 in real time. The controller 3 is connected to each temperature monitoring device 1, the roller motor 4 corresponding to the rolling glass roller 2, the roller liquid cooling device 5, and the blowing device 6. When the temperature of any surface exceeds the first preset threshold, the controller controls the roller motor 4 to slow down, increases the cooling water flow of the roller liquid cooling device 5, and starts the blowing device 6. At the same time, it sends a rolling alarm to the on-duty personnel to remind them to conduct on-site inspection and manual intervention.

[0021] Specifically, the temperature detection device 1 is preferably an infrared thermometer, and the rolling glass roller 2 includes an upper roller 21 and a lower roller 22 arranged opposite to each other. The temperature probe of each temperature monitoring device 1 faces the lower surface of the upper roller 21 to monitor the surface temperature of each area of ​​the lower surface of the upper roller 21.

[0022] The number of temperature detection devices 1 is not limited. However, considering that the glass often has a slightly thicker middle and slightly thinner sides due to the process characteristics during rolled glass production, and based on on-site production experience, 60% to 70% of the rolling phenomenon originates in the middle area of ​​the upper roller 21 and then gradually spreads to both sides. Therefore, it is necessary to align each temperature detection device 1 with the middle area and both ends of the upper roller 21 respectively.

[0023] Taking the configuration of 4 temperature detection devices 1 as an example, as follows: Figure 2The models shown are TE-101, TE-102, TE-103, and TE-104. Further, through on-site observation, in the initial, slight stage of the rolling phenomenon, the adhesion of molten glass first occurs on the lower surface of the upper roller 21, then gradually spreads to the top surface of the upper roller 21 like rolling an egg roll. Based on this, pointing the probe at the lower surface can capture the earliest sticking signal, buying time for subsequent rapid intervention. Meanwhile, the selection of infrared thermometers balances economy and practicality; the total purchase cost of four infrared thermometers is far lower than that of a single visual inspection device. Furthermore, since the surface temperature of the upper roller 21 is stable at 550℃~600℃ during normal production, while the temperature of the molten glass reaches 1000℃~1100℃, there is a temperature difference of approximately 500℃. When glass adheres to the roller surface, localized heat dissipation is hindered, leading to an abnormal increase in the roller surface temperature. Therefore, by detecting temperature abrupt changes, the initial sticking signal can be accurately identified, making this method significantly more cost-effective than existing visual inspection solutions.

[0024] Furthermore, the roller conveyor motor 4 adjusts the speed through a frequency converter to provide power to the upper roller 21 and the lower roller 22; the roller conveyor liquid cooling device 5 adjusts the cooling water flow rate through the opening of the cooling water valve to achieve precise control of the roller surface temperature; the blowing device 6 is a gas blowing device, which can blow away dust, water vapor and a small amount of glass fragments on the roller surface after being turned on.

[0025] The controller 3 mentioned above is an existing industrial-grade PLC or DCS control system. In a preferred embodiment of the present invention, the controller 3 includes a first control unit 31, which is used to reduce the output frequency of the inverter associated with the roller motor 4 when any surface temperature is greater than a preset threshold, so as to control the upper roller 21 and the lower roller 22 to reduce speed simultaneously.

[0026] In a preferred embodiment of the present invention, the controller 3 includes a second control unit 32, which is used to continuously monitor the temperature of each surface after issuing a roll alarm prompt to the on-site personnel, and when all surface temperatures are less than a second preset threshold, first control the purging device 6 to be shut down, and then restore the rotation speed of the roller motor 4 and the cooling water flow rate of the roller liquid cooling device 5.

[0027] In a preferred embodiment of the present invention, the first preset threshold is 700°C and the second preset threshold is 600°C.

[0028] The overall roll-off measurement and control process is as follows: 1. When the rolled glass production line starts and the rolling mill rollers (upper roller 21 and lower roller 22) rotate normally, four infrared thermometers TE-101~TE-104 are simultaneously activated to monitor the temperature of the middle and both ends of the lower surface of the upper roller 21 in real time. The monitoring data is transmitted to the controller 3 in real time. Under normal production conditions, the surface temperature of the upper roller 21 is stable at around 600℃, and the temperature of the molten glass is maintained at around 1050℃. The controller 3 continuously collects and analyzes the data from each temperature measuring point, keeping the system in standby monitoring mode.

[0029] 2. Controller 3 compares the real-time temperature of each temperature measuring point with the first preset threshold (700℃). If the temperature detected by all infrared thermometers is less than 700℃, the roller conveyor is determined to be operating normally, and all equipment parameters (roller speed, cooling water flow rate, and purging device status) remain unchanged under the existing production conditions. If roller sticking occurs, molten glass at around 1050℃ will locally adhere to the lower surface of the upper roller 21. Due to localized heat dissipation obstruction, the temperature at the corresponding temperature measuring point will rapidly and abruptly rise. When the temperature detected by any infrared thermometer exceeds 700℃, controller 3 immediately executes three linked actions: 2.1) Alarm prompt: Controller 3 sends a rolling alarm signal (audible and visual alarm) to the on-site duty room and control panel to remind the on-duty personnel to rush to the scene for inspection and secondary handling in a timely manner; 2.2) Speed ​​regulation: The controller 3 reduces the output frequency of the inverter associated with the roller motor 4 through the first control unit 31, and controls the upper roller 21 and the lower roller 22 to reduce their speed synchronously, thereby reducing the contact pressure and residence time between the molten glass and the roller surface, and suppressing the expansion of the roller sticking range from a mechanical point of view. 2.3) Temperature and Cleanliness Control: Simultaneously increase the opening of the cooling water valve of the roller conveyor liquid cooling device 5 to increase the cooling water flow rate, thereby enhancing the cooling effect of the roller surface, reducing the wettability of the molten glass and the metal roller surface, and weakening the basis for their adhesion; at the same time, turn on the blowing device 6 to blow away dust and water vapor that may adhere to the roller surface, so as to avoid impurities catalyzing the roller sticking reaction and help curb the development of the roll.

[0030] All the aforementioned automatic intervention actions are completed within the "golden 5 seconds" after the temperature anomaly is detected. Field tests show that it takes only 5 seconds for the rolling defect to develop from a slight initial stage to a moderate stage, and approximately 15-20 seconds to develop from a moderate stage to a severely deteriorated stage. After the moderate stage, manual intervention has extremely limited effectiveness and cannot prevent the fault from worsening. This system, through rapid automatic intervention within 5 seconds, can effectively control the expansion of the rolling defect before manual intervention arrives on-site, buying crucial time for subsequent handling. This is the core guarantee for avoiding roll replacement and production stoppage accidents.

[0031] 3. Upon receiving the alarm signal, the on-duty operator rushes to the scene and determines the level of defect in the rolling package based on on-site observations: 3.1) If the roller is slightly or moderately sticky, an online treatment method can be adopted. A handheld blowing device can be used to precisely blow away a small amount of glass fragments on the roller surface, or a scraper, brush or other cleaning device can be used to clean the roller surface online. The treatment can be completed without stopping production, minimizing economic losses. 3.2) If the defect has developed to a serious stage, it is necessary to coordinate the shutdown and disposal in conjunction with the production plan. However, in such cases, the losses from failure can be greatly reduced due to automatic intervention in the early stage.

[0032] It should be noted that reducing the pressure between the rollers can be used as an auxiliary control measure to further reduce the occurrence of rolling phenomenon. However, the pressure between the rollers directly affects the glass thickness and forming quality. The relevant parameters can only be adjusted after the process personnel and operators have comprehensively evaluated the production conditions. Therefore, this system has not included it in the automatic intervention process, leaving room for flexible manual adjustment.

[0033] 4. After issuing an alarm, controller 3 continuously monitors the temperature at each measuring point. When the temperature detected by all infrared thermometers drops below the second preset threshold (600℃), it is determined that the rolling defect has been effectively controlled and the roller surface temperature has returned to normal. At this time, controller 3 executes a reset procedure through the second control unit 32: First, control the shutdown of the purging device 6. After the purging action stops, gradually restore the inverter output frequency of the roller motor 4 and the opening of the cooling water valve of the roller liquid cooling device 5 to the initial production parameters, or have the operator readjust the parameters according to the actual working conditions. The system returns to the normal monitoring state to ensure the stable operation of the production line.

[0034] This invention also provides a method for measuring and controlling the rolling of rolled glass on roller conveyors, applicable to the aforementioned rolling measurement and control system, such as... Figure 4 As shown, the roll-off measurement and control method includes: Step S1: The roll control system monitors the surface temperature of each area on the rolling glass roller conveyor in real time. In step S2, when the temperature of any surface exceeds the first preset threshold, the roll pack monitoring and control system controls the roller conveyor motor to slow down, increases the cooling water flow of the roller conveyor liquid cooling device, and starts the purging device. At the same time, it sends a roll pack alarm to the on-duty personnel to remind them to conduct on-site inspection and manual intervention.

[0035] In a preferred embodiment of the present invention, the rolling glass conveyor includes an upper roller and a lower roller arranged opposite to each other, and the temperature probes of each temperature monitoring device face the lower surface of the upper roller to monitor the surface temperature of each region of the lower surface of the upper roller.

[0036] In a preferred embodiment of the present invention, after performing step S2, the method further includes: After issuing a roll alarm to the on-site personnel, the roll measurement and control system continuously monitors the temperature of each surface. When the temperature of all surfaces is less than the second preset threshold, it first controls the purging device to shut down, and then restores the speed of the roller conveyor motor and the cooling water flow of the roller conveyor liquid cooling device.

[0037] The above description is merely a preferred embodiment of the present invention and does not limit the implementation and protection scope of the present invention. Those skilled in the art should realize that any equivalent substitutions and obvious changes made using the content of this specification and illustrations should be included within the protection scope of the present invention.

Claims

1. A rolling control system for a rolled glass roller conveyor, wherein a roller conveyor liquid cooling device and a blowing device are provided on the side of the rolled glass roller conveyor; characterized in that, include: Multiple temperature monitoring devices are arranged along the length of the calendering glass roller conveyor to monitor the surface temperature of each area on the calendering glass roller conveyor in real time. The controller is connected to each of the temperature monitoring devices, the roller motor corresponding to the rolled glass roller, the roller liquid cooling device, and the purging device. When any of the surface temperatures exceeds a first preset threshold, the controller controls the roller motor to slow down, increases the cooling water flow of the roller liquid cooling device, and activates the purging device. At the same time, it sends a roll alarm to the on-site personnel to remind them to conduct on-site inspections and manual intervention.

2. The rolling package measurement and control system according to claim 1, characterized in that, The rolling glass conveyor includes an upper roller and a lower roller arranged opposite each other, and the temperature probes of each temperature monitoring device face the lower surface of the upper roller to monitor the surface temperature of each region of the lower surface of the upper roller.

3. The rolling ball measurement and control system according to claim 2, characterized in that, Each of the temperature monitoring devices is respectively located in the middle region and both ends region of the upper roller along the length direction of the upper roller.

4. The rolling package measurement and control system according to claim 2, characterized in that, The controller includes a first control unit, which reduces the output frequency of the inverter associated with the roller conveyor motor when any of the surface temperatures exceeds the preset threshold, so as to control the upper roller and the lower roller to reduce their speeds simultaneously.

5. The rolling bag measurement and control system according to claim 1, characterized in that, The controller includes a second control unit, which is used to continuously monitor the surface temperature after issuing the roll alarm prompt to the on-site duty personnel, and when all the surface temperatures are less than a second preset threshold, first control the shutdown of the purging device, and then restore the speed of the roller motor and the cooling water flow rate of the roller liquid cooling device.

6. The roll-up measurement and control system according to claim 5, characterized in that, The first preset threshold is 700℃, and the second preset threshold is 600℃.

7. The rolling bag measurement and control system according to claim 1, characterized in that, The temperature monitoring device is an infrared thermometer.

8. A method for measuring and controlling the rolling of rolled glass on a rolling mill, characterized in that, The rolling ballast measurement and control system as described in any one of claims 1-7, wherein the rolling ballast measurement and control method comprises: Step S1: The roll measurement and control system monitors the surface temperature of each area on the rolling glass roller conveyor in real time; In step S2, when any of the surface temperatures exceeds the first preset threshold, the roll pack monitoring and control system controls the roller conveyor motor to slow down, increases the cooling water flow of the roller conveyor liquid cooling device, and activates the purging device. At the same time, it sends a roll pack alarm to the on-site personnel to remind them to conduct on-site inspections and manual intervention.

9. The rolling package measurement and control method according to claim 8, characterized in that, The rolling glass conveyor includes an upper roller and a lower roller arranged opposite each other, and the temperature probes of each temperature monitoring device face the lower surface of the upper roller to monitor the surface temperature of each region of the lower surface of the upper roller.

10. The rolling package measurement and control method according to claim 8, characterized in that, After performing step S2, the method further includes: After issuing the roll alarm to the on-site personnel, the roll measurement and control system continuously monitors the surface temperature of each surface. When all the surface temperatures are less than the second preset threshold, it first controls the purging device to shut down, and then restores the speed of the roller motor and the cooling water flow rate of the roller liquid cooling device.

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