Emergency treatment method for liquid level abnormality of mini LED backplane glass kiln

Abstract

The application discloses an emergency treatment method for liquid surface abnormality of a Mini LED backboard glass kiln, and belongs to the technical field of Mini LED backboard glass production. The technical scheme is as follows: S1, adjusting a feeding end; S2, adjusting a melting end, S21, adjusting a small furnace temperature; S22, adjusting a flow channel gate height; S3, adjusting a drawing end, S31, adjusting a line speed of a draw edge machine; S32, adjusting a draw edge machine indentation depth; and S33, adjusting a draw edge machine head angle. The application is combined with the actual production situation of electronic glass, analyzes various possible reasons for the liquid surface abnormality of the kiln, and can effectively solve the glass kiln liquid surface abnormality problem encountered in actual production from multiple angles, and provides a high feasibility liquid surface abnormality emergency treatment method for Mini LED backboard glass production.

Description

Technical Field

[0001] This invention relates to the field of Mini LED backplane glass production technology, specifically to an emergency handling method for abnormal liquid levels in a Mini LED backplane glass furnace. Background Technology

[0002] In the production process of Mini LED backplane glass, the hot-end melting process is particularly important, as the melting of raw materials directly affects subsequent processes such as forming and cold-end cutting. For the kiln, stability is paramount; the stability of temperature, kiln pressure, liquid level, and bubble boundary are crucial factors influencing kiln stability. Liquid level stability is particularly important, reflecting that multiple parameters within the kiln are within standard ranges. If the liquid level is too high, the large surface area of ​​the liquid will cause excessive pressure deformation of the bottom steel structure due to the weight of the molten glass. This deformation of the external steel structure leads to uneven gaps between the bricks, disrupting the originally stable structure and shortening the kiln's lifespan. Conversely, if the liquid level is too low, the remaining heat absorbed by the kiln walls and roof bricks is absorbed by the limited total heat of the raw materials, accelerating thermal erosion and aging of the bricks. Therefore, abnormal liquid levels are a challenging problem for glass production departments.

[0003] Chinese utility model patent CN208732896U discloses a glass melting furnace liquid level control device, including a glass melting furnace, a camera device, a control device, and a feeding device for feeding glass raw materials into the glass melting furnace. The feeding device is electrically connected to the control device. Marking holes and observation holes are respectively opened on two opposing inner walls of the glass melting furnace, both located above the glass molten surface. The camera device is mounted on the glass melting furnace and electrically connected to the control device. The camera of the camera device is located inside the observation hole, facing the marking hole, and is used to capture the marking hole and its reflection on the glass molten surface. This utility model's glass melting furnace liquid level control device calculates the glass molten level height by capturing the marking hole and its reflection, achieving non-contact measurement of the glass molten surface. It is simple, accurate, reliable, and precise, improving the accuracy of liquid level monitoring.

[0004] Chinese utility model patent CN213295152U discloses a glass melting furnace liquid level control device, including a glass melting furnace, a feed hopper, a solenoid valve, a floating mechanism, a floating frame, a floating rod, a support plate, a support ring, a first float, a second float, an arc-shaped support bar, and a support block. Several springs are provided between the support block and the floating rod. An auxiliary frame is provided inside the glass melting furnace above the floating frame, and a support sleeve is provided at the top center of the auxiliary frame. A rack is provided on the outer wall of the floating rod, and a gear matching the rack is provided inside the support sleeve. This utility model can achieve liquid level control in a glass melting furnace, effectively expanding the detection range of the liquid level, enabling comprehensive detection of the liquid level inside the glass melting furnace, effectively improving the accuracy of liquid level control, avoiding the influence of liquid flow on the normal monitoring and control effect of the liquid level, providing auxiliary support for the floating rod, enhancing the stability of the floating rod, and ensuring the accuracy of liquid level control.

[0005] The above patents all only control the furnace feeding through glass melting furnace liquid level control devices, thereby controlling the liquid level in the glass furnace. However, the height of the liquid level in a glass furnace is affected by many factors. In actual production, simply controlling the furnace feeding is sometimes insufficient to control the liquid level. Therefore, there is a need for an emergency handling method that addresses abnormal liquid levels in glass furnaces from multiple perspectives. Summary of the Invention

[0006] The technical problem to be solved by this invention is to overcome the shortcomings of the prior art and provide an emergency handling method for abnormal liquid level in Mini LED backplate glass furnaces. This method is tailored to the actual production situation of electronic glass, analyzes various possible causes of abnormal liquid level in furnaces, and solves the problem of abnormal liquid level in glass furnaces encountered in actual production from multiple perspectives.

[0007] The technical solution of this invention is as follows:

[0008] Emergency handling methods for abnormal liquid levels in the glass furnace of Mini LED backplates include the following steps:

[0009] S1 Adjust the feeding end

[0010] S11: If the ultrasonic detector detects insufficiently sintered clumps at the bottom of the kiln, causing the kiln liquid level to be too high, reduce the feeding frequency of all feeders until the liquid level drops to the set range; during the later kiln combustion process, the clumps at the bottom of the kiln will gradually melt, causing the liquid level to be too low. At this time, increase the feeding frequency of all feeders to the set frequency.

[0011] In actual production, uneven mixing of the materials at the batching end can cause lumps to form on the feeder's material blanket. When the mixture enters the kiln, these lumps are not fully sintered, leading to an accumulation that causes the kiln's liquid level to rise. In this case, it is necessary to reduce the feeding frequency using the methods described above to control the mixing uniformity of the materials. Once the lumps are completely sintered, the feeding frequency can be adjusted back to the set value to resolve the problem.

[0012] S12: If the ultrasonic detector does not detect insufficiently sintered clumps at the bottom of the kiln, and the kiln liquid level is too high or too low, check if it is caused by the feeding frequency of one or more feeders being too high or too low. If so, it will cause the raw material to be fed too quickly or too slowly. In this case, the increase or decrease value of the feeding frequency is evenly distributed to other feeders to reduce or increase the feeding frequency of other feeders to ensure that the total feeding amount remains unchanged. Then, repair the feeders with excessively high or low feeding frequencies. When the kiln liquid level returns to the set range, restore the feeding frequency of all feeders to the set value. If not, adjust the height of the flow channel gate.

[0013] S2 Adjusting the flow channel gate height: As the channel between the furnace and the tin bath, the degree of erosion of the flow channel gate significantly affects the liquid level. Check the erosion level of the flow channel gate. If the erosion at the bottom exceeds 1cm, the abnormal furnace liquid level is determined to be caused by flow channel gate erosion. In this case, if the furnace liquid level is too high, raise the flow channel gate to improve the fluidity of the molten glass and lower the liquid level; if the furnace liquid level is too low, lower the flow channel gate to reduce the fluidity of the molten glass and ensure the liquid level returns to the set range. If the erosion at the bottom of the flow channel gate does not exceed 1cm, adjust the pull end.

[0014] S3 Adjustment of the Pulling End: As molten glass enters the tin bath, it is pulled thinner and flattened by the pulling action of the edge-pulling machine head. Therefore, the linear speed, indentation depth, and angle between the machine head and the tin bath wall of the edge-pulling machine all significantly affect the liquid level. A higher linear speed means a faster flow of molten glass from the melting furnace to the tin bath, resulting in a lower liquid level in the furnace. The depth to which the edge-pulling machine head is pressed into the molten tin is closely related to the edge-pulling efficiency. A deeper indentation depth results in greater friction between the machine head gears and the liquid surface, leading to a greater traction force and a stronger tendency for the molten glass to flow from the melting furnace to the tin bath, thus lowering the liquid level in the furnace. The angle between the edge-pulling machine head and the tin bath wall, which is partially immersed in the molten glass, is also closely related to the pulling amount. A larger angle results in a greater outward thinning force and a smaller pulling force towards the end of the tin bath, effectively raising the liquid level in the furnace. If the linear speed, indentation depth, and angle between the machine head and the solder bath wall of the edge-pulling machine are not at the set values, adjust them to the set values; if the linear speed, indentation depth, and angle between the machine head and the solder bath wall of the edge-pulling machine are not abnormal, adjust the furnace temperature.

[0015] S4 Adjusting the furnace temperature: Based on the principle of high-temperature imaging for determining glass density, it was concluded that within the temperature range of 1200-1500℃, the density of the molten glass decreases as the temperature increases. When the furnace liquid level is too high, lowering the temperature of each furnace increases the density of the molten glass, reduces the overall volume of the molten glass, and slowly lowers the liquid level to the set range. Conversely, when the furnace liquid level is too low, raising the temperature of each furnace slowly reduces the density of the molten glass, increases its volume, and slowly raises the liquid level to the set range.

[0016] Preferably, in step S11, for every 0.1 Hz increase in the frequency of each feeder, the liquid level in the kiln rises by 0.3 mm.

[0017] Preferably, in step S2, for every 5mm decrease in the gate, the liquid level in the kiln increases by 0.3mm.

[0018] Preferably, in step S4, the temperature of each small furnace is adjusted by adjusting the gas injection flow rate of the natural gas lances in each small furnace. For every 0.1 Nm increase in the natural gas injection flow rate... 3 / h, the temperature rises by 0.1℃, and the liquid level in the kiln rises by 0.3mm.

[0019] Compared with the prior art, the present invention has the following advantages:

[0020] The emergency handling method of this invention is tailored to the actual production conditions of electronic glass. It analyzes various possible causes of abnormal liquid levels in the kiln and, from multiple perspectives, can effectively solve the problem of abnormal liquid levels in glass kilns encountered in actual production. It provides a highly feasible emergency handling method for abnormal liquid levels in Mini LED backplane glass production. Detailed Implementation

[0021] To enable those skilled in the art to better understand the technical solutions of this invention, the technical solutions of this invention will be clearly and completely described below.

[0022] In electronic glass kilns, the standard liquid level is 1100mm ± 0.3mm as measured by the level gauge. Within this range, no adjustments to the parameters are required. However, if the liquid level exceeds this range, the process will classify this as an abnormality and require adjustment to restore it to the set range.

[0023] Example 1

[0024] During production in the first quarter of 2021, the kiln inspector noticed the liquid level was 1100.4 mm. This was reported to management, and the melting and processing department analyzed the excessively high liquid level. They discovered that the ultrasonic detector had not detected any insufficiently sintered clumps at the kiln bottom. Subsequently, they checked the feeding frequency of the feeders and found that, with the feeding frequencies of feeders 1-4 set to 20.8Hz, 23.0Hz, 22.8Hz, and 20.9Hz respectively, the feeding frequency of feeder 1 had increased to 21.4Hz, exceeding the set frequency by 0.6Hz. The melting and processing department then reduced the feeding frequencies of feeders 2-4 by 0.2Hz each and notified the technical equipment department to conduct emergency repairs on feeder 1. After a period of time, the kiln liquid level returned to the set range. Electrical engineers in the Technical Equipment Department discovered a problem with the frequency converter of the motor of Feeder No. 1. After repair, the feeding frequency of Feeder No. 1 was restored to the set value of 20.8Hz, and the feeding frequencies of the other three feeders were also restored to the set values. After two days of observation, the kiln liquid level remained within the set range, and the abnormal kiln liquid level problem was resolved.

[0025] Example 2

[0026] In the second quarter of 2022, during a glass production model change on the production line, it was discovered that the furnace liquid level was consistently too low. Daily monitoring records showed liquid levels mostly at 1099.8mm and 1099.7mm, but the production line recorded a liquid level of 1099.6mm three to five times per week. This situation was promptly reported to management, who determined there might be an abnormal liquid level trend. Analysis revealed that the ultrasonic detector did not detect any insufficiently sintered clumps at the bottom of the furnace, the feeding machine frequency was normal, and observation of the flow channel gate revealed that the erosion height at the bottom of the gate did not exceed 1cm, indicating no significant erosion, which could be disregarded. Subsequently, adjustments were made to the drawing end. The set values ​​for the linear speed, indentation depth, and angle between the machine head and the tin bath wall of the 19th pair of drawing machines on production line are shown in Table 1. In this abnormal incident, it was observed that the pressing depth of machine head No. 1 increased by 0.2mm and the pressing depth of machine head No. 3 increased by 0.3mm. However, the linear speed of the edge-pulling machine and the angle between the machine head and the tin bath wall were normal. Therefore, the pressing depth of these two abnormal machine heads was adjusted to the set value. After observing for 3 days, it was found that the liquid level in the kiln gradually approached 1100.0mm and then returned to normal. The abnormal liquid level problem in the kiln was resolved.

[0027] Table 1. Linear speed, indentation depth, and angle settings between the machine head and the solder bath wall for 19 pairs of edge-pulling machines.

[0028] Line speed of edge trimmer (m / h) Indentation depth of edge trimmer (mm) Angle between head and tin bath wall (°) Edge trimmer No. 1 17 -24.3 0.1° Edge trimmer No. 2 19 -16.1 3.2° Edge trimmer No. 3 22.5 -9.7 6.0° Edge trimmer No. 4 28.9 -35.3 9.6° Edge trimmer No. 5 38.8 -30.5 11.2° Edge trimmer No. 6 50.0 -26.5 11.0° Edge trimmer No. 7 60.7 -4.8 11.0° Edge trimmer No. 8 69.9 -7.1 10.9° Edge trimmer No. 9 78.0 -0.1 10.3° Edge trimmer No. 10 82.0 -2.3 9.9° Edge trimmer No. 11 82.0 -12.7 7.9° Edge trimmer No. 12 92.2 -1.7 6.1° Edge trimmer No. 13 101.4 4.3 5.1° Edge trimmer No. 14 110.1 57.1 0.0° Edge trimmer No. 15 120.0 -5.2 0.0° Edge trimmer No. 16 150.0 42.0 0.0° Edge trimmer No. 17 150.0 15.1 0.0° Edge trimmer No. 18 50.0 36.7 0.0° Edge trimmer No. 19 50.0 35.3 0.0°

[0029] Example 3

[0030] During production in the fourth quarter of 2021, the hot-end melting and processing department found that the furnace liquid level was consistently at 1099.7 mm, sometimes even reaching 1099.6 mm, occurring almost weekly. The melting and processing department analyzed this situation, first checking the ultrasonic detector, which did not detect any insufficiently sintered clumps at the kiln bottom. The feeding machine frequency was normal, the flow channel gate showed no obvious erosion, and the drawing end was normal. Subsequently, the temperature of the small furnaces was adjusted. The temperatures of furnaces 1-5 before the adjustment are shown in Table 2. The jet flow rate of the natural gas lance in each small furnace was increased by 0.1 Nm³. 3 / h, the temperature increased by 0.1℃, and the adjusted temperatures of each small furnace are shown in Table 2. The furnace liquid level was then observed. After the liquid level rose to 1100.0 mm, it was observed for a period of time, and the liquid level remained between 1099.9 and 1100.1 mm, indicating that the abnormal furnace liquid level problem had been resolved.

[0031] Table 2 Temperatures of Furnaces 1-5 before and after adjustment

[0032] Small furnace No. 1 Small furnace No. 2 Small furnace No. 3 Small furnace No. 4 Small furnace No. 5 Temperature before adjustment (℃) 1268.3 1271.4 1290.3 1456.2 1425.6 Temperature after adjustment (℃) 1268.4 1271.5 1290.4 1456.3 1425.7

Claims

1. An emergency handling method for abnormal liquid level in a Mini LED backplate glass furnace, characterized in that, Includes the following steps: S1 Adjust the feeding end S11: If the ultrasonic detector detects insufficiently sintered clumps at the bottom of the kiln, causing the kiln liquid level to be too high, reduce the feeding frequency of all feeders until the liquid level drops to the set range; during the later kiln combustion process, the clumps at the bottom of the kiln will gradually melt, causing the liquid level to be too low. At this time, increase the feeding frequency of all feeders to the set frequency. S12: If the ultrasonic detector does not detect insufficiently sintered clumps at the bottom of the kiln, and the kiln liquid level is too high or too low, check whether it is caused by the feeding frequency of one or more feeders being too high or too low. If so, distribute the increase or decrease value of the feeding frequency to the other feeders to reduce or increase the feeding frequency of the other feeders to ensure that the total feeding amount remains unchanged. Then repair the feeders with excessively high or low feeding frequencies. After the kiln liquid level returns to the set range, restore the feeding frequency of all feeders to the set value. If not, adjust the height of the flow channel gate. S2 Adjust the flow channel gate height: Check the degree of erosion of the flow channel gate. If the erosion height of the lower part exceeds 1cm, it is determined that the abnormal kiln liquid level is caused by the erosion of the flow channel gate. At this time, if the kiln liquid level is too high, raise the flow channel gate; if the kiln liquid level is too low, lower the flow channel gate until the kiln liquid level returns to the set range; if the erosion height of the lower part of the flow channel gate does not exceed 1cm, adjust the pull end. S3 Adjust the drawing end: If the linear speed, indentation depth, and angle between the drawing head and the solder bath wall of the edge-drawing machine are not at the set values, adjust them to the set values; if the linear speed, indentation depth, and angle between the drawing head and the solder bath wall of the edge-drawing machine are not abnormal, adjust the furnace temperature. S4 Adjusts the temperature of each small furnace: When the liquid level in the kiln is too high, the temperature of each small furnace is reduced; when the liquid level in the kiln is too low, the temperature of each small furnace is increased until the liquid level returns to the set range.

2. The emergency handling method for abnormal liquid level in a Mini LED backplate glass furnace as described in claim 1, characterized in that, In step S11, for every 0.1 Hz increase in the frequency of each feeder, the liquid level in the kiln rises by 0.3 mm.

3. The emergency handling method for abnormal liquid level in a Mini LED backplate glass furnace as described in claim 1, characterized in that, In step S2, for every 5mm decrease in the gate, the liquid level in the kiln rises by 0.3mm.

4. The emergency handling method for abnormal liquid level in a Mini LED backplate glass furnace as described in claim 1, characterized in that, In step S4, for every 0.1℃ increase in temperature of each small furnace, the liquid level in the kiln rises by 0.3mm.