An aluminum ingot uniform heating system and method based on dynamic flame and regulation

Abstract

This invention discloses a uniform heating system and method for aluminum ingots based on dynamic flame and control. It includes a furnace shell, with multiple support blocks spaced apart at the bottom of the furnace chamber within the shell. Baffles are mounted on the support blocks. Multiple heating zones are uniformly arranged at the top of the furnace shell, each with a flue gas outlet channel communicating with a baffle in its center. Circulation channels communicating with the baffles are asymmetrically arranged on both sides of the flue gas outlet channels, each containing a fan. Combustion channels communicating with the furnace chamber are symmetrically arranged on both sides of the flue gas outlet channels, each containing a burner. A sensor unit is located within the baffle. The sensor unit, burner, and fan are all electrically connected to a control unit. This invention transforms the traditional static point heat source or surface heat source flame into a dynamic volumetric heat source that can be periodically deflected and scanned on demand, achieving active flame coverage and temperature equalization of the upper and lower spaces of the furnace chamber.

Description

Technical Field

[0001] This invention relates to the field of aluminum ingot heating furnace technology, specifically to a uniform heating system and method for aluminum ingots based on dynamic flame and control. Background Technology

[0002] Rectangular aluminum ingot heating furnaces are key process equipment at the front end of aluminum alloy melting and casting production lines. Their main function is to uniformly and efficiently heat solid aluminum ingots to the target temperature required for rolling or extrusion processes. Currently, top-fired gas-fired heating furnaces are commonly used in the industry. This type of furnace places the burner at the top of the furnace, with the flame spraying downwards to directly heat the upper surface of the aluminum ingot. It features a compact structure, small footprint, and lower requirements for plant construction.

[0003] However, top-fired heating furnaces have inherent structural defects that directly affect the heating quality of aluminum ingots and the energy consumption of the equipment. Specifically, the temperature field distribution along the height of the furnace is severely uneven. Due to the natural upward movement of hot air and the direct radiation of the flame, the temperature in the upper part of the furnace and on the upper surface of the aluminum ingot is higher, while the temperature in the lower part of the furnace and on the lower surface of the aluminum ingot is lower, resulting in a large temperature gradient inside the aluminum ingot. These problems not only affect the quality of subsequent processing of the aluminum ingots but also force operators to extend the heating time to ensure that the lowest temperature point of the aluminum ingot reaches the process requirements, ultimately leading to energy waste and reduced production efficiency.

[0004] To address the problem of uneven temperature field in top-fired furnaces, those skilled in the art have made various improvement attempts, the main technical means of which are as follows: 1. Optimize the burner arrangement, such as using multi-row, zoned top-fired burners to improve temperature uniformity by dispersing the heat source. However, this method can only alleviate local overheating and cannot fundamentally change the physical law of hot air rising, nor can it eliminate the overall temperature distribution pattern of "hot at the top and cold at the bottom" in the furnace.

[0005] 2. A forced circulation fan is added inside the furnace to mix the airflow and achieve temperature mixing. However, traditional circulation fans mostly use a fixed speed and unidirectional airflow, which has a weak ability to specifically adjust the complex three-dimensional temperature field inside the furnace. In addition, the high-speed airflow directly blows on the surface of the aluminum ingot, which can easily cause local overcooling or accelerated surface oxidation of the aluminum ingot.

[0006] 3. The heating furnace control system was improved by adopting a conventional PID control algorithm to adjust the total gas supply based on single-point or multi-point temperature feedback. This control method can only regulate the total gas supply and has limited effectiveness in eliminating uneven temperature distribution within the furnace.

[0007] In summary, existing improvement technologies are all localized optimizations under static heating modes, failing to achieve dynamic, proactive, and intelligent control over the shape, spatial location, and airflow organization of heat sources within the furnace. Therefore, the industry urgently needs an innovative technological solution that can fundamentally reconstruct the heat flow field within the furnace, achieving precise and uniform heating in three-dimensional space. Summary of the Invention

[0008] To address the aforementioned problems in the prior art, this invention provides a uniform heating system and method for aluminum ingots based on dynamic flame and control, which solves the problem of uneven temperature field in existing top-fired heating furnaces.

[0009] To achieve the above objectives, the technical solution adopted by the present invention is as follows: On one hand, a uniform heating system for aluminum ingots based on dynamic flame and control is provided, which includes a heating furnace shell. Multiple support blocks are evenly spaced at the bottom of the inner cavity of the heating furnace shell. Baffles are installed on the support blocks, dividing the inner cavity of the heating furnace shell into an outer combustion zone and an inner flue gas circulation zone for placing the aluminum ingots to be heated. Multiple heating zones are evenly arranged on the top of the heating furnace shell. A flue gas outlet channel communicating with the baffle is opened in the middle of each heating zone. Circulation channels communicating with the baffle are asymmetrically arranged on both sides of the flue gas outlet channel, and fans are installed in the circulation channels. Combustion channels communicating with the inner cavity of the heating furnace shell are symmetrically arranged on both sides of the flue gas outlet channel, and burners are installed in the combustion channels. Sensor units are installed in the baffles. The sensor units, burners, and fans are all electrically connected to a control unit.

[0010] This invention transforms traditional static point heat source or surface heat source flames into dynamic volume heat sources that can be periodically deflected and scanned on demand, achieving active coverage and temperature equalization of the upper and lower spaces of the furnace by the flame. At the same time, it collects three-dimensional temperature distribution information of the furnace in real time and performs coordinated dynamic adjustment of the flame operation status and auxiliary airflow based on the temperature information.

[0011] Furthermore, the burner includes a burner housing with an internal gas intake passage and an air inner cylinder with an internal air intake passage; The air inner cylinder is coaxially fitted at the bottom of the burner shell; the bottom of the air inner cylinder is connected to the refractory bricks through a fixed flange.

[0012] Furthermore, a fuel inlet is provided at the top of the burner shell, and multiple gas nozzles are evenly provided at the bottom of the burner shell through the refractory bricks; An air inlet is provided on the side wall of the air cylinder, and a cyclone separator is installed at the air inlet; multiple air nozzles are provided at the bottom of the air cylinder through the refractory brick, and the multiple air nozzles are evenly distributed around the gas nozzle.

[0013] Furthermore, multiple auxiliary nozzles are evenly distributed around the periphery of the air nozzle, penetrating the refractory brick. The axis of the auxiliary nozzle forms an angle of 10° with the axis of the gas nozzle. 30°.

[0014] Furthermore, the bottom of the gas nozzle, air nozzle, and auxiliary nozzle are all equipped with solenoid valves that are electrically connected to the control unit.

[0015] Furthermore, the sensor unit includes an oxygen content sensor, a pressure sensor, and a temperature sensor array; the temperature sensor array includes multiple rows of temperature sensor groups arranged along the length of the baffle, each row of temperature sensor groups includes two sets of upper sensors, middle sensors, and lower sensors symmetrically arranged on opposite sidewalls of the baffle; the upper sensors, middle sensors, and lower sensors are all electrically connected to the control unit.

[0016] On the other hand, a heating method based on a dynamic flame and a controlled aluminum ingot uniform heating system is provided, characterized by comprising the following steps: Step S1: The control unit starts the burner and controls the burner to switch to the basic heating mode. At the same time, the control unit starts the swirler to make the combustion air output from the air nozzle rotate at high speed for basic heating. Step S2: Data is collected in real time through the sensor unit and fed back to the control unit. The control unit constructs a three-dimensional temperature field digital model of the furnace based on the feedback data to obtain the temperature difference ΔT between the upper and lower regions of each heating zone in the furnace. Step S3: By determining the relationship between the temperature difference ΔT between the upper and lower regions of each heating zone and the set threshold, the mode is determined: when the average temperature difference |ΔT| between multiple heating zones is less than the first threshold, the control unit determines that the temperature is uniform and maintains the basic heating mode of the burner; when the temperature difference ΔT between the upper and lower regions of each heating zone is greater than the second threshold, the control unit determines that the temperature is not uniform and proceeds to the next step. Step S4: The control unit dynamically adjusts based on the determination result in step S3, switches the burner in the heating zone with uneven temperature to dynamic scanning mode, and increases the rotation speed of the cyclone separator. Step S5: After dynamic adjustment is completed, continue to monitor the change of temperature difference ΔT between the upper and lower regions of each heating zone. When the temperature difference ΔT between the upper and lower regions of each heating zone is less than the second threshold, the control unit controls the burner to switch to the basic heating mode, restores the rotation speed of the cyclone separator, and repeats steps S3 to S5 until the entire heating cycle is completed.

[0017] Furthermore, in step S1, the basic heating mode of the burner is as follows: the control unit opens the solenoid valves of the gas nozzle and the air nozzle to form a vertically downward main flame with the basic heat load.

[0018] Furthermore, in step S4, the dynamic scanning mode of the burner is as follows: based on the control unit opening the solenoid valves of the gas nozzle and the air nozzle, the control unit sequentially, alternately, or pulse-wise opens and closes the solenoid valves of the auxiliary nozzle.

[0019] This invention discloses a uniform heating system and method for aluminum ingots based on dynamic flame and control, the beneficial effects of which are: 1. This invention transforms the traditional static point heat source or surface heat source flame into a dynamic volume heat source that can be periodically deflected and scanned on demand, realizing active coverage and temperature equalization of the upper and lower spaces of the furnace by the flame. At the same time, it collects the three-dimensional temperature distribution information of the furnace in real time and makes coordinated dynamic adjustments to the flame operation status and auxiliary airflow based on the temperature information.

[0020] 2. The dynamic scanning mode of the burner in this invention breaks through the inherent limitations of fixed, static heating in traditional top-fired furnaces. Through active flame deflection and oscillation, dynamic redistribution of heat energy within the furnace space is achieved. This allows for direct and directional supplementary heating of low-temperature areas such as the lower and middle parts of the furnace, which are difficult to heat in traditional methods, fundamentally suppressing the "hot at the top, cold at the bottom" heat stratification phenomenon within the furnace. Numerical simulations and experimental verification show that this invention can reduce the average temperature difference between the upper and lower effective heating zones of the furnace from the traditional 80°C. 120℃ dropped to 20 Within 30℃, the uniformity of the temperature field is significantly improved.

[0021] 3. In this invention, the control unit can sense the temperature difference distribution, magnitude and position in the furnace in real time to form a three-dimensional temperature field digital model of the furnace. Based on this, it can make precise dynamic adjustments, realizing the upgrade from traditional open-loop or single-parameter closed-loop control to multi-variable, strongly coupled, adaptive intelligent closed-loop control, which significantly improves the adaptability and control accuracy of complex working conditions. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of a uniform heating system for aluminum ingots based on dynamic flame and control according to the present invention.

[0023] Figure 2 This is a cross-sectional structural diagram of a uniform heating system for aluminum ingots based on dynamic flame and control according to the present invention.

[0024] Figure 3 This is a cross-sectional structural diagram of a uniform heating system for aluminum ingots based on dynamic flame and regulation according to the present invention from another angle.

[0025] Figure 4 This is a schematic diagram of the burner structure of the present invention.

[0026] Figure 5 This is a bottom view of the burner structure of the present invention.

[0027] Figure 6 This is a cross-sectional structural diagram of the burner of the present invention.

[0028] Figure 7 This is a cross-sectional view of the burner of the present invention from another angle.

[0029] Figure 8 This is a schematic diagram illustrating the control principle of the heating method of the present invention.

[0030] Figure 9 This is a schematic diagram of the heating method of the present invention.

[0031] Figure 10 This is a schematic diagram of the structure of the cyclone separator of the present invention.

[0032] The components are as follows: 1. Heating furnace shell; 2. Support block; 3. Baffle; 4. Aluminum ingot to be heated; 5. Flue gas outlet channel; 6. Fan; 7. Burner; 71. Burner shell; 711. Gas inlet channel; 712. Fuel inlet; 713. Gas nozzle; 72. Air cylinder; 721. Air inlet duct; 722. Air inlet; 723. Air nozzle; 73. Fixed flange; 74. Refractory brick; 75. Auxiliary nozzle; 81. Upper sensor; 82. Middle sensor; 83. Lower sensor. Detailed Implementation The specific embodiments of the present invention are described below to enable those skilled in the art to understand the present invention. However, it should be understood that the present invention is not limited to the scope of the specific embodiments. For those skilled in the art, various changes are obvious as long as they are within the spirit and scope of the present invention as defined and determined by the appended claims. All inventions utilizing the concept of the present invention are protected.

[0033] Example 1 refer to Figures 1-7 This embodiment provides a uniform heating system for aluminum ingots based on dynamic flame and regulation, which aims to solve the problem of uneven temperature field in existing top-fired heating furnaces. The specific structure of this embodiment will be described in detail below.

[0034] A uniform heating system for aluminum ingots based on dynamic flame and regulation, comprising a heating furnace shell 1; Among them, multiple support blocks 2 are evenly arranged at the bottom of the inner cavity of the heating furnace shell 1, and baffles 3 are provided on the multiple support blocks 2. The baffles 3 divide the inner cavity of the heating furnace shell 1 into an outer combustion zone and an inner flue gas circulation zone for placing the aluminum ingots 4 to be heated. Specifically, the top of the heating furnace shell 1 is uniformly provided with multiple heating zones, and each heating zone has a flue gas outlet channel 5 in the middle that communicates with the baffle 3; the flue gas outlet channel 5 is asymmetrically provided with circulation channels communicating with the baffle 3 on both sides, and a fan 6 is provided in the circulation channels; the flue gas outlet channel 5 is symmetrically provided with combustion channels communicating with the furnace chamber inside the heating furnace shell 3 on both sides, and a burner 7 is provided in the combustion channels; a sensor unit is provided in the baffle 3, and the sensor unit, burner 7 and fan 6 are all electrically connected to the control unit.

[0035] In this embodiment, the inner cavity of the furnace shell 1 is divided into multiple heating zones. Each heating zone is equipped with a flue gas outlet channel 5. There are two circulation channels that are not symmetrically arranged. A fan 6 is installed in the circulation channel. A combustion channel is symmetrically arranged and a burner 7 is installed in the combustion channel. The burner 7 outputs hot fluid from the outer combustion zone to the inner flue gas circulation zone to heat the aluminum ingot 4 to be heated in the inner flue gas circulation zone. The flame in the form of a traditional static point heat source or surface heat source is transformed into a dynamic body heat source that can be periodically deflected and scanned on demand, so as to achieve active coverage and temperature equalization of the upper and lower spaces of the furnace by the flame.

[0036] Specifically, the burner 7 includes a burner housing 71 with an internal gas intake passage 711 and an air inner cylinder 72 with an internal air intake passage 721; the air inner cylinder 72 is coaxially sleeved at the bottom of the burner housing 71; the bottom of the air inner cylinder 72 is connected to the refractory brick 74 through a fixed flange 73.

[0037] In this embodiment, the gas inlet passage 711 is used for fuel to pass through, the air inlet passage 721 is used for combustion air to pass through, the air inner cylinder 72 is coaxially sleeved on the bottom of the burner shell 71 and connected by welding, and then connected to the refractory brick 74 by the fixing flange 73, and finally cast into shape.

[0038] Specifically, the burner shell 71 has a fuel inlet 712 at the top and multiple gas nozzles 713 evenly distributed through the refractory brick 74 at the bottom; the air inlet 722 is provided on the side wall of the air cylinder 72, and the air inlet 722 is equipped with a cyclone separator; the air cylinder 72 has multiple air nozzles 723 evenly distributed around the gas nozzles 713 at the bottom through the refractory brick 74.

[0039] In this embodiment, the fuel inlet 712 is connected to a fuel pipeline, the gas nozzle 713 is used to output fuel, and the air inlet 722 is connected to a combustion air pipeline. A swirler is provided at the air inlet 722, forming a tangential swirling air intake structure at the inlet of the air inlet 722, allowing the combustion air to enter in a high-speed swirling state and mix thoroughly with the fuel. The swirler is a conventional axial blade swirler.

[0040] Optional, for reference Figure 10 The hydrocyclone includes a hydrocyclone tube, and the inner cavity of the hydrocyclone tube is uniformly equipped with several axial blades through the hydrocyclone column. The installation angle of the axial blades is about 38.6°, and the material is 310S stainless steel (high temperature resistant and oxidation resistant), thus forming an axial blade hydrocyclone with a swirl number of 0.8 (medium swirl intensity).

[0041] Optionally, cyclones can be installed on both side walls of the furnace shell 1 corresponding to each heating zone as tangential cyclone air inlet structures, connected to combustion air. This allows the combustion air to enter the combustion chamber in a high-speed cyclone state and mix thoroughly with the fuel. The high-speed cyclone can create a central negative pressure zone in the combustion area, entraining the low-temperature flue gas in the lower part of the furnace to participate in mixing and combustion, extending the flame path, allowing the high-temperature combustion zone to diffuse appropriately in space and prolonging its residence time. This avoids the flame directly impacting the aluminum ingot surface, reducing local high-temperature peaks from the source, and achieving overall uniformity of the temperature field within the furnace. The installation position of the cyclones can be set according to the actual situation.

[0042] Specifically, multiple auxiliary nozzles 75 are evenly distributed around the periphery of the air nozzle 723, penetrating the refractory brick 74; the axis of the auxiliary nozzles 75 forms an angle of 10° with the axis of the gas nozzle 713. 30°.

[0043] In this embodiment, the auxiliary nozzle 75 located outside the refractory brick 74 can independently supply fuel, combustion air, or a mixture of fuel and air. The specific connection can be made according to the actual situation. The axis of the auxiliary nozzle 75 forms an angle with the axis of the gas nozzle 713. The instrument generates a periodically changing lateral guiding force around the main flame, so that the axis of the main flame can achieve controllable, periodic conical deflection and oscillation, thereby realizing scanning heating of the furnace space.

[0044] Specifically, the bottom of the gas nozzle 713, air nozzle 723, and auxiliary nozzle 75 are all equipped with solenoid valves that are electrically connected to the control unit.

[0045] In this embodiment, the control unit adopts an existing industrial PLC or DCS with a built-in dedicated control algorithm, which can process temperature field data in real time and calculate the temperature difference ΔT between the upper and lower regions of the furnace. The solenoid valve is electrically connected to the control unit, so the control unit can control the opening and closing of the gas nozzle 713, air nozzle 723 and auxiliary nozzle 75 as needed.

[0046] Specifically, the sensor unit includes an oxygen content sensor, a pressure sensor, and a temperature sensor array; the temperature sensor array includes multiple rows of temperature sensor groups arranged along the length of the baffle 3, and each row of temperature sensor groups includes two sets of upper sensors 81, middle sensors 82, and lower sensors 83 symmetrically arranged on opposite side walls of the baffle 3; the upper sensors 81, middle sensors 82, and lower sensors 83 are all electrically connected to the control unit.

[0047] In this embodiment, the number of temperature sensor groups corresponds to the number of heating zones. Each temperature sensor group corresponding to each heating zone includes two groups of upper sensors 81, middle sensors 82 and lower sensors 83 symmetrically arranged on both sides of the baffle 3. Each group of upper sensors 81, middle sensors 82 and lower sensors 83 corresponds to one burner 7. Thus, the control unit can directionally control the corresponding burner 7 based on the data fed back by the upper sensors 81, middle sensors 82 and lower sensors 83. The upper sensors 81, middle sensors 82 and lower sensors 83 all adopt existing K-type thermocouples.

[0048] Example 2 refer to Figures 8-9 This embodiment provides a uniform heating system for aluminum ingots based on dynamic flame and regulation, which aims to solve the problem of uneven temperature field in existing top-fired heating furnaces. The specific structure of this embodiment will be described in detail below.

[0049] A heating method based on a dynamic flame and a controlled uniform heating system for aluminum ingots, comprising the following steps: Step S1: The control unit starts the burner 7 and controls the burner 7 to switch to the basic heating mode. At the same time, the control unit starts the swirler to make the combustion air output from the air nozzle 723 rotate at high speed for basic heating. Specifically, in step S1, the basic heating mode of the burner 7 is as follows: the control unit opens the solenoid valves of the gas nozzle 713 and the air nozzle 723 to form a vertically downward main flame with the basic heat load.

[0050] In this embodiment, the aluminum ingot heating furnace is started, and the control unit controls the burner 7 to switch to the basic heating mode. That is, the control unit opens the solenoid valves of the gas nozzle 713 and the air nozzle 723 to form a vertically downward main flame with the basic heat load. At the same time, the cyclone separator is started (at this time, the initial power, i.e., 50% power). The combustion air enters through the tangential cyclone air intake structure to form a high-speed cyclone. In the early stage of combustion, the fuel and air are fully mixed, and low-temperature flue gas is entrained. This initially prevents the flame from directly impacting the aluminum ingot and achieves rapid heating of the furnace.

[0051] Step S2: After the aluminum ingot surface enters the heating stage, data is collected in real time through the sensor unit and the collected data is fed back to the control unit. The control unit constructs a three-dimensional temperature field digital model of the furnace based on the feedback data to obtain the temperature difference ΔT between the upper and lower regions of each heating zone in the furnace. Step S3: By determining the relationship between the temperature difference ΔT between the upper and lower regions of each heating zone and the set threshold, the mode is determined: when the average temperature difference |ΔT| between multiple heating zones is less than the first threshold, the control unit determines that the temperature is uniform and maintains the basic heating mode of the burner 7; when the temperature difference ΔT between the upper and lower regions of each heating zone is greater than the second threshold, the control unit determines that the temperature is not uniform and proceeds to the next step. In this embodiment, through step S2, the control unit obtains the temperature difference ΔT between the upper and lower regions of each heating zone, and based on this, obtains the average temperature difference |ΔT| between multiple heating zones; When the average temperature difference |ΔT| between multiple heating zones is less than the first threshold (+10℃), the control unit determines that the temperature is uniform and maintains the basic heating mode of burner 7.

[0052] When the temperature difference ΔT between the upper and lower regions of the heating zone is greater than the second threshold (+25℃ or +30℃), the control unit determines that the temperature is uneven and proceeds to the next step for dynamic adjustment.

[0053] Step S4: The control unit dynamically adjusts the heating zone where the temperature is uneven based on the determination result in step S3, switches the burner 7 to dynamic scanning mode, and increases the rotation speed of the cyclone separator. Specifically, in step S4, the dynamic scanning mode of the burner 7 is as follows: based on the control unit opening the solenoid valves of the gas nozzle 713 and the air nozzle 723, the control unit sequentially, alternately or in a pulse manner opens and closes the solenoid valve of the auxiliary nozzle 75.

[0054] In this embodiment, when the temperature difference ΔT between the upper and lower regions of any heating zone is greater than the second threshold (+25℃ or +30℃), the control unit switches the burner 7 on the heating zone with uneven temperature to dynamic scanning mode. That is, based on the control unit opening the solenoid valves of the gas nozzle 713 and the air nozzle 723, the control unit sequentially, alternately or in a pulse manner opens and closes the solenoid valve of the auxiliary nozzle 75. At the same time, the rotation speed of the cyclone separator is increased (at this time, it is at maximum power, 100% power).

[0055] For example, in a clockwise direction, two adjacent peripheral auxiliary nozzles 75 are opened simultaneously each time. Utilizing the offset angle of the peripheral auxiliary nozzles 75 and the momentum difference formed by the pulse jet, a periodically changing lateral guiding force is generated around the main flame, enabling the main flame axis to achieve controllable, periodic conical deflection and oscillation, thereby achieving scanning-type enhanced heating of the furnace space. The flame deflects and oscillates downwards periodically in the circumferential direction, directionally enhancing the heating of the lower and middle regions of the furnace. At the same time, the intensity of the combustion air swirl in this area is adjusted to the maximum (at which point it is at maximum power, 100% power), which enhances the flue gas entrainment effect, extends the high-temperature flame path, and promotes more complete heat diffusion to the lower part of the furnace.

[0056] After step S5 and dynamic adjustment are completed, continue to monitor the change of temperature difference ΔT between the upper and lower regions of each heating zone. When the temperature difference ΔT between the upper and lower regions of each heating zone is less than the second threshold, the control unit controls the burner 7 to switch to the basic heating mode, restores the initial rotation speed of the cyclone separator, and repeats steps S3 to S5 until the entire heating cycle is completed.

[0057] In this embodiment, after the dynamic adjustment is completed, the control unit continues to monitor the temperature difference ΔT between the upper and lower regions of each heating zone by constructing a three-dimensional temperature field digital model of the furnace. When the temperature difference ΔT between the upper and lower regions of each heating zone is less than the second threshold, the control unit controls the burner 7 to switch to the basic heating mode, restore the initial rotation speed of the cyclone separator, and maintain the initial cyclone intensity to consolidate the uniformity of the temperature field. Steps S3 to S5 are repeated. The control unit dynamically adjusts the working mode and operating parameters of the corresponding burner 7 according to the real-time temperature distribution of each region until the entire heating cycle is completed.

[0058] Finally, when the temperature at all monitoring points reaches the process setting range and the temperature uniformity (temperature difference between the top and bottom, and temperature difference along the length) meets the requirements, the system determines that the heating process has ended or has entered the heat preservation stage.

[0059] Although specific embodiments of the invention have been described in detail with reference to the accompanying drawings, this should not be construed as limiting the scope of protection of this patent. Various modifications and variations that can be made by a person skilled in the art without inventive effort within the scope described in the claims still fall within the scope of protection of this patent.

Claims

1. A uniform heating system for aluminum ingots based on dynamic flame and control, characterized in that: Including the furnace shell (1); The bottom of the inner cavity of the heating furnace shell (1) is provided with multiple support blocks (2) at even intervals. Each support block (2) is provided with a baffle (3). The baffle (3) divides the inner cavity of the heating furnace shell (1) into an outer combustion zone and an inner flue gas circulation zone for placing the aluminum ingot (4) to be heated. The top of the heating furnace shell (1) is uniformly provided with multiple heating zones, and each heating zone has a flue gas outlet channel (5) in the middle that communicates with the baffle (3); the flue gas outlet channel (5) is asymmetrically provided with circulation channels communicating with the baffle (3) on both sides, and a fan (6) is provided in the circulation channel; the flue gas outlet channel (5) is symmetrically provided with combustion channels communicating with the furnace chamber inside the heating furnace shell (3) on both sides, and a burner (7) is provided in the combustion channel. A sensor unit is provided inside the baffle (3), and the sensor unit, burner (7) and fan (6) are all electrically connected to the control unit.

2. The aluminum ingot uniform heating system based on dynamic flame and control according to claim 1, characterized in that: The burner (7) includes a burner housing (71) with a gas inlet passage (711) and an air inlet (72) with an air inlet passage (721). The air inner cylinder (72) is coaxially sleeved at the bottom of the burner shell (71); the bottom of the air inner cylinder (72) is connected to the refractory brick (74) through a fixed flange (73).

3. The aluminum ingot uniform heating system based on dynamic flame and control according to claim 1, characterized in that: The burner housing (71) has a fuel inlet (712) at the top and multiple gas nozzles (713) evenly distributed through the refractory brick (74) at the bottom. An air inlet (722) is provided on the side wall of the air inner cylinder (72), and a cyclone separator is provided in the air inlet (722); a plurality of air nozzles (723) are provided at the bottom of the air inner cylinder (72) through the refractory brick (74), and the plurality of air nozzles (723) are evenly distributed in the circumferential direction of the gas nozzle (713).

4. The aluminum ingot uniform heating system based on dynamic flame and control according to claim 3, characterized in that: Multiple auxiliary nozzles (75) are evenly provided around the periphery of the air nozzle (723) through the refractory brick (74). The axis of the auxiliary nozzle (75) forms an angle of 10° with the axis of the gas nozzle (713). 30°.

5. The aluminum ingot uniform heating system based on dynamic flame and control according to claim 4, characterized in that: The bottom ends of the gas nozzle (713), air nozzle (723) and auxiliary nozzle (75) are all equipped with solenoid valves electrically connected to the control unit.

6. The aluminum ingot uniform heating system based on dynamic flame and control according to claim 1, characterized in that: The sensor unit includes an oxygen content sensor, a pressure sensor, and a temperature sensor array; the temperature sensor array includes multiple rows of temperature sensor groups arranged along the length of the baffle (3), each row of temperature sensor groups includes two sets of upper sensors (81), middle sensors (82), and lower sensors (83) symmetrically arranged on opposite sidewalls of the baffle (3); the upper sensors (81), middle sensors (82), and lower sensors (83) are all electrically connected to the control unit.

7. A heating method for a uniform heating system for aluminum ingots based on dynamic flame and control according to any one of claims 1-6, characterized in that, Includes the following steps: Step S1: The control unit starts the burner (7) and controls the burner (7) to switch to the basic heating mode. At the same time, the control unit starts the swirler to make the combustion air output from the air nozzle (723) rotate at high speed for basic heating. Step S2: Data is collected in real time through the sensor unit and fed back to the control unit. The control unit constructs a three-dimensional temperature field digital model of the furnace based on the feedback data to obtain the temperature difference ΔT between the upper and lower regions of each heating zone in the furnace. Step S3: By determining the relationship between the temperature difference ΔT between the upper and lower regions of each heating zone and the set threshold, the mode is determined: when the average temperature difference |ΔT| between multiple heating zones is less than the first threshold, the control unit determines that the temperature is uniform and maintains the basic heating mode of the burner (7); when the temperature difference ΔT between the upper and lower regions of each heating zone is greater than the second threshold, the control unit determines that the temperature is not uniform and proceeds to the next step. Step S4: The control unit dynamically adjusts based on the determination result in step S3, switches the burner (7) on the heating zone with uneven temperature to dynamic scanning mode, and increases the rotation speed of the cyclone separator at the same time. After step S5 and dynamic adjustment are completed, continue to monitor the change of temperature difference ΔT between the upper and lower regions of each heating zone. When the temperature difference ΔT between the upper and lower regions of each heating zone is less than the second threshold, the control unit controls the burner (7) to switch to the basic heating mode, restore the rotation speed of the cyclone separator, and repeat steps S3 to S5 until the entire heating cycle is completed.

8. The heating method of the aluminum ingot uniform heating system based on dynamic flame and control according to claim 7, characterized in that, The basic heating mode of the burner (7) in step S1 is as follows: the control unit opens the solenoid valves of the gas nozzle (713) and the air nozzle (723) to form a vertically downward main flame with the basic heat load.

9. The heating method of the aluminum ingot uniform heating system based on dynamic flame and control according to claim 7, characterized in that: In step S4, the dynamic scanning mode of the burner (7) is as follows: based on the control unit opening the solenoid valves of the gas nozzle (713) and the air nozzle (723), the control unit sequentially, alternately or in a pulse manner opens and closes the solenoid valve of the auxiliary nozzle (75).

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