Method for recovering and reusing heat energy of contact lens production line

Abstract

The invention provides a heat energy recycling and reusing method for a contact lens production line. The heat energy recycling and reusing method comprises the following steps that contact lens products to be extracted are placed in a Tray in a feeding and placing area; conveying the Tray filled with the product to a hydration area to carry out an extraction process; heat generated by the extraction process is collected through a heat energy collecting device arranged on the periphery of the hydration zone; the extracted product is taken out from the discharging area; the empty Tray is conveyed to a drying area to be subjected to backflow and drying treatment; collected heat is guided into a drying area through an air blowing device, and the refluxed Tray is rapidly dried. The method further comprises the steps of heat energy supplement, drying quality control, energy efficiency optimization, emergency treatment and the like, a sectional type drying method is adopted, and efficient recovery and cyclic utilization of heat generated by the hydration process are achieved through a real-time monitoring and intelligent control system. According to the method, the heat energy utilization efficiency is remarkably improved, the production energy consumption is reduced, and the good energy-saving and emission-reducing effects are achieved.

Description

Technical Field

[0001] The invention relates to the technical field of contact lens production, and in particular to a method for recovering and reusing heat energy from a contact lens production line. Background Art

[0002] As a medical device, the production process of contact lenses has strict requirements on product quality and production efficiency. In the production process of contact lenses, hydration extraction and tray drying are two key links, and these two links are usually accompanied by a large amount of heat energy consumption and heat emission. In the existing technology, the thermal energy utilization rate is low, energy waste is serious, the production cost is high, and it has a certain impact on the environment. Therefore, how to improve the efficiency of thermal energy utilization, reduce production costs, and optimize the process flow has become an urgent problem to be solved in the field of contact lens production technology.

[0003] In the hydration extraction process, the contact lens products need to be continuously heated to complete the hydration process. However, the large amount of hot air generated during the hydration process is usually directly discharged into the environment without being effectively recovered and utilized, resulting in a waste of heat energy. The drying process requires reheating, and the lack of linkage with the hydration process heat energy further increases energy consumption.

[0004] In the existing contact lens production line, each process uses heat energy independently and lacks a unified heat energy management system, resulting in low heat energy utilization efficiency. The efficiency of heat energy collection and transmission is insufficient, and energy waste is common.

[0005] The temperature control of the hydration and drying process usually relies on traditional mechanical or manual adjustment methods, which makes it difficult to dynamically adjust parameters such as temperature and wind speed. Large temperature fluctuations may affect the hydration uniformity and drying effect of the product, thereby adversely affecting product quality.

[0006] The direct emission of hot air not only wastes energy, but also causes the production environment temperature to rise, increases the burden on the air conditioning system, and affects the working comfort of employees. Heat emission does not meet the requirements of energy conservation and emission reduction policies and is not conducive to the sustainable development of enterprises. Summary of the invention

[0007] In view of the above-mentioned technical deficiencies, the purpose of the present invention is to provide a method for recovering and reusing heat energy in a contact lens production line to achieve the recycling of heat energy.

[0008] To achieve the above object, the present invention adopts the following technical solution:

[0009] A method for recovering and reusing heat energy in a contact lens production line comprises the following steps:

[0010] S1: Place the contact lens products to be extracted in the tray in the loading tray area;

[0011] S2: The tray containing the product is transported to the hydration area for extraction process, and heat is generated during the extraction process;

[0012] S3: collecting the heat generated by the extraction process through a heat energy collection device arranged around the hydration zone;

[0013] S4: taking out the extracted product from the tray in the unloading area;

[0014] S5: transporting the empty tray to the drying area for reflow and drying;

[0015] S6: The collected heat is introduced into the drying area through a blowing device to quickly dry the refluxed Tray. Preferably, the heat energy collection step S3 includes:

[0016] a) Direct the thermal flow above the hydration zone;

[0017] b) Real-time monitoring and collection of temperature data of thermal airflow;

[0018] c) adjusting the collection rate of the thermal airflow according to the temperature data;

[0019] d) Temporarily store the collected thermal airflow.

[0020] Preferably, the drying step S6 comprises:

[0021] a) Detect the position signal of the tray arriving at the drying area;

[0022] b) Start hot air supply according to the position signal;

[0023] c) Adjust the temperature, wind speed and wind direction of hot air;

[0024] d) Monitor the drying status of the tray;

[0025] e) Stop air supply after reaching the preset drying level.

[0026] Preferably, the drying process adopts a segmented drying method:

[0027] The first stage: high temperature rapid preheating, the temperature is 70-80℃, the time is 10-15 seconds;

[0028] The second stage: medium temperature continuous drying, the temperature is 50-60℃, the time is 20-30 seconds;

[0029] The third stage: low temperature buffer cooling is adopted, the temperature is 40-45℃, and the time is 10-15 seconds.

[0030] Preferably, the method further comprises a heat energy supplement step:

[0031] a) Real-time monitoring of the temperature of the collected heat;

[0032] b) When the temperature is lower than the preset threshold, the heat energy replenishment program is started;

[0033] c) Calculate the required additional heat based on the temperature difference;

[0034] d) Stop heat energy supplement after reaching the target temperature.

[0035] Preferably, the method further comprises a drying quality control step:

[0036] a) Set the standard parameters for tray drying;

[0037] b) Use humidity sensor to detect drying degree;

[0038] c) Dynamically adjust the drying time according to the test results;

[0039] d) Record drying quality data and establish quality traceability files.

[0040] Preferably, the method further includes an energy efficiency optimization step:

[0041] a) Collect energy consumption data during production line operation;

[0042] b) Analyze the energy utilization efficiency under different working conditions;

[0043] c) Establish energy consumption optimization model;

[0044] d) Dynamically adjust heat recovery and utilization parameters based on model results;

[0045] e) Generate energy efficiency analysis reports regularly.

[0046] Preferably, the method further includes emergency treatment steps:

[0047] a) Set safety thresholds for system operating parameters;

[0048] b) Real-time monitoring of system operation status;

[0049] c) When an abnormality is detected, the following processing is automatically performed:

[0050] d) reduce the rate of heat collection;

[0051] e) Adjust drying parameters;

[0052] f) Start the backup working mode when necessary;

[0053] g) Record abnormal conditions and generate fault analysis reports.

[0054] Compared with the prior art, the present invention has the following beneficial effects:

[0055] By recovering the heat generated in the hydration process and using it for drying the tray, the thermal energy is recycled and the waste of thermal energy is significantly reduced.

[0056] Through heat recovery and reuse, the use of external energy is reduced, the overall energy consumption of the production line is reduced, and thus production costs are effectively reduced.

[0057] The use of intelligent temperature control and segmented drying methods ensures the stability of contact lens products during hydration and drying, and improves the consistency and reliability of product quality.

[0058] It reduces the direct discharge of heat into the environment, reduces the impact of the production process on the environment, complies with the requirements of energy conservation and emission reduction policies, and has good environmental benefits.

[0059] The thermal energy linkage of the hydration and drying processes optimizes the process flow, shortens the production cycle, and improves the operating efficiency of the production line. BRIEF DESCRIPTION OF THE DRAWINGS

[0060] Figure 1 It is a flowchart of the present invention;

[0061] Figure 2 It is a schematic diagram of the layout of the production line of the present invention.

[0062] in:

[0063] 1. Loading and traying area; 2. Drying area; 3. Unloading area; 4. Hydration area. DETAILED DESCRIPTION

[0064] The present invention will be further described below in conjunction with the accompanying drawings.

[0065] like Figure 1 , Figure 2 As shown, a method for recovering and reusing heat energy from a contact lens production line comprises the following steps:

[0066] S1: placing the contact lens products to be extracted in the tray in the loading tray area 1;

[0067] S2: The tray containing the product is transported to the hydration zone 4 for extraction process, and heat is generated during the extraction process;

[0068] S3: collecting the heat generated by the extraction process through a heat energy collection device arranged around the hydration zone 4;

[0069] S4: taking out the extracted product from the tray in the unloading area 3;

[0070] S5: transporting the empty tray to the drying area 2 for reflow and drying;

[0071] S6: The collected heat is introduced into the drying area 2 through the blowing device to quickly dry the returned Tray, thereby realizing the reuse of heat energy and reducing the extra energy consumption of the drying area 2. The blowing device is a fan.

[0072] Example 1: Standard heat recovery and reuse method for contact lens production line

[0073] This embodiment is applicable to a contact lens production line with a daily output of 100,000 pieces, and adopts a single-cycle heat recovery method. The specific steps are as follows:

[0074] Steps for loading and placing the plates

[0075] The operator manually places the contact lenses to be extracted into a tray with a size of 300mm×400mm. Each tray can hold 96 contact lenses.

[0076] The surface of the tray adopts anti-slip design to ensure the stability of the product during transportation.

[0077] Hydration Extraction Step

[0078] Transport the tray containing contact lens products to the hydration area;

[0079] The water temperature in the hydration zone was set at 80 ± 2 °C, and the hydration time was 30 min;

[0080] During the hydration process, the temperature of the hot air flow generated is about 75°C, and the heat energy is released through natural convection and in the form of steam.

[0081] Thermal Energy Collection Steps

[0082] A heat energy collection area is set on the top of the hydration area to collect the heat released during the hydration process;

[0083] The collection temperature of the hot air flow is controlled at 65-70℃ and the collection rate is 2m 3 / min;

[0084] The collected heat is directly transported to the drying area for utilization.

[0085] Cutting operation steps

[0086] In the unloading area, an automatic robot arm is used to take the hydrated contact lenses out of the tray;

[0087] The unloading speed is 4 seconds per piece, ensuring product integrity and avoiding damage.

[0088] Tray reflow and drying steps

[0089] The empty tray is transported to the drying area via a conveyor belt;

[0090] In the drying area, a three-stage drying process is adopted:

[0091] The first stage: high temperature rapid drying, the temperature is 75℃, the time is 15 seconds;

[0092] The second stage: medium temperature continuous drying, the temperature is 55℃, the time is 20 seconds;

[0093] The third stage: slow cooling at low temperature, the temperature is 40℃, the time is 10 seconds;

[0094] After drying, the tray returns to the loading area for recycling.

[0095] Quality Control Steps

[0096] After drying, the moisture content of the tray is detected by the humidity sensor to ensure that its moisture content is ≤0.1%;

[0097] Conduct random inspections every 2 hours and record the drying temperature curve to ensure process stability.

[0098] Energy efficiency optimization steps

[0099] Collect statistics on the energy consumption data of the heat recovery system every day and calculate the heat energy utilization rate;

[0100] Based on the data analysis results, the heat collection and drying parameters are dynamically optimized to ensure maximum energy efficiency.

[0101] Implementation effect:

[0102] Thermal energy utilization rate reaches 85%;

[0103] Energy consumption in the drying area is reduced by 40%;

[0104] Product production efficiency increased by 15%, and the first-time pass rate reached 99.9%.

[0105] Example 2: Large-scale heat recovery and reuse method for contact lens production line

[0106] This embodiment is applicable to a contact lens production line with a daily output of 300,000 pieces. A double-cycle heat recovery method is used to further improve the heat energy utilization efficiency. The specific steps are as follows:

[0107] Steps for loading and placing the plates

[0108] A fully automatic loading system is used to load contact lenses into large trays with a size of 400mm×600mm. Each tray can hold 192 lenses.

[0109] The loading cycle time is 10 seconds / tray, which significantly improves the loading efficiency.

[0110] Hydration Extraction Step

[0111] Two parallel hydration production lines were set up, the hydration temperature was set at 82±1°C, and the hydration time was 28 minutes;

[0112] A single production line generates about 15,000 kcal of heat per hour, and the temperature of the hot air flow is about 78°C.

[0113] Thermal Energy Collection Steps

[0114] Adopt double cycle heat energy collection system:

[0115] Main circulation: collect high temperature hot air flow with a temperature of 70-75℃ and a collection rate of 4m 3 / min, used for drying of trays;

[0116] Secondary circulation: collect medium temperature hot air flow with a temperature of 60-65℃ and a collection rate of 2m 3 / min, used for preheating system of hydration area;

[0117] The thermal energy collection system monitors the temperature of the thermal gas flow in real time and dynamically adjusts the collection rate according to production needs.

[0118] Cutting operation steps

[0119] In the unloading area, dual robotic arms are used for synchronous operation, and the unloading speed of each robotic arm is 2 seconds per piece;

[0120] Equipped with a visual inspection system to detect the integrity of contact lenses in real time, ensuring the qualified rate of the blanking process is ≥99.95%.

[0121] Tray reflow and drying steps

[0122] Using a double-track conveying system, the tray is transported to the drying area at a speed of 0.8m / s;

[0123] The drying area adopts an optimized four-stage drying process:

[0124] The first stage: preheating stage, the temperature is 45℃, the time is 10 seconds;

[0125] The second stage: rapid heating stage, temperature is 78℃, time is 12 seconds;

[0126] The third stage: constant temperature stage, the temperature is 58℃, the time is 25 seconds;

[0127] The fourth stage: cooling stage, the temperature is 40℃, the time is 15 seconds;

[0128] After drying, the tray returns to the loading area for continued use.

[0129] Quality Control Steps

[0130] The online humidity sensor monitors the drying status of the tray in real time;

[0131] Sample products every hour and record drying temperature and humidity data to ensure the stability of the drying process;

[0132] Establish batch traceability files to facilitate subsequent quality management.

[0133] Energy efficiency optimization steps

[0134] Real-time monitoring of the operating status of the dual-cycle heat recovery system;

[0135] Dynamically adjust the heat energy distribution ratio according to production load to ensure the heat energy utilization efficiency of the main cycle and the secondary cycle;

[0136] Generate energy efficiency analysis reports every week to optimize the parameters of the heat recovery system.

[0137] Implementation effect:

[0138] Thermal energy utilization rate increased to 92%;

[0139] Energy costs in the drying area were reduced by 45%;

[0140] Production efficiency increased by 25%;

[0141] The first-time qualified rate of products reaches 99.98%.

[0142] Summarize

[0143] Embodiment 1 is suitable for small and medium-sized contact lens production lines, adopts a single-cycle heat recovery method, has a simple process, and has significant energy-saving effects;

[0144] Embodiment 2 is suitable for large-scale production lines, and adopts a double-cycle heat recovery system to further improve the efficiency of heat energy utilization and meet high production capacity requirements;

[0145] Both embodiments achieve the goals of energy saving and consumption reduction, improving production efficiency and ensuring product quality by optimizing the heat collection and drying process.

Claims

1. A method for recovering and reusing heat energy in a contact lens production line, characterized in that: The following steps are involved: S1: placing the contact lens products to be extracted in the tray in the loading tray area (1); S2: The tray containing the product is transported to the hydration zone (4) for extraction process, during which heat is generated; S3: collecting heat generated by the extraction process through a heat collection device arranged around the hydration zone (4); S4: taking out the extracted product from the tray in the unloading area (3); S5: transporting the empty tray to the drying area (2) for reflow and drying; S6: The collected heat is introduced into the drying area (2) through the blowing device to quickly dry the refluxed Tray.

2. The method for heat recovery and reuse of a contact lens production line according to claim 1, characterized in that: The heat energy collection step S3 comprises: a) directing the hot air flow above the hydration zone (4); b) Real-time monitoring and collection of temperature data of thermal airflow; c) adjusting the collection rate of the thermal airflow according to the temperature data; d) Temporarily store the collected thermal airflow.

3. The method for heat recovery and reuse of a contact lens production line according to claim 1, characterized in that: The drying step S6 comprises: a) detecting the position signal of the tray reaching the drying area (2); b) Start hot air supply according to the position signal; c) Adjust the temperature, wind speed and wind direction of hot air; d) Monitor the drying status of the Tray; e) Stop air supply after reaching the preset drying degree.

4. The method for heat recovery and reuse of a contact lens production line according to claim 1, characterized in that: The drying process adopts a segmented drying method: The first stage: high temperature rapid preheating, the temperature is 70-80℃, the time is 10-15 seconds; The second stage: medium temperature continuous drying, the temperature is 50-60℃, the time is 20-30 seconds; The third stage: low temperature buffer cooling is adopted, the temperature is 40-45℃, and the time is 10-15 seconds.

5. The method for heat recovery and reuse of a contact lens production line according to claim 1, characterized in that: It also includes the heat energy replenishment step: a) Real-time monitoring of the temperature of the collected heat; b) When the temperature is lower than the preset threshold, the heat energy replenishment program is started; c) Calculate the required additional heat based on the temperature difference; d) Stop heat energy supplement after reaching the target temperature.

6. The method for heat recovery and reuse of a contact lens production line according to claim 1, characterized in that: It also includes drying quality control steps: a) Set the standard parameters for tray drying; b) Use humidity sensor to detect drying degree; c) Dynamically adjust the drying time according to the test results; d) Record drying quality data and establish quality traceability files.

7. The method for heat recovery and reuse of a contact lens production line according to claim 1, characterized in that: It also includes energy efficiency optimization steps: a) Collect energy consumption data during production line operation; b) Analyze the energy utilization efficiency under different working conditions; c) Establish energy consumption optimization model; d) Dynamically adjust heat recovery and utilization parameters based on model results; e) Generate energy efficiency analysis reports regularly.

8. The method for heat recovery and reuse of a contact lens production line according to claim 1, characterized in that: It also includes emergency response steps: a) Set safety thresholds for system operating parameters; b) Real-time monitoring of system operation status; c) When an abnormality is detected, the following processing is automatically performed: d) reduce the rate of heat collection; e) Adjust drying parameters; f) Start the backup working mode when necessary; g) Record abnormal conditions and generate fault analysis reports.

Images