A method for recovering and reusing heat energy of a contact lens production line

Abstract

The application provides a heat energy recycling and reusing method for a contact lens production line, comprising the following steps: placing contact lens products to be extracted in a Tray in a feeding and tray arranging area; conveying the Tray containing the products to a hydration area for extraction process; collecting heat generated by the extraction process through a heat energy collecting device arranged around the hydration area; taking out the products after the extraction in a discharging area; conveying the empty Tray to a drying area for reflux and drying treatment; and introducing the collected heat into the drying area through a blowing device to quickly dry the Tray. The application further comprises steps of heat energy supplement, drying quality control, energy efficiency optimization and emergency treatment, adopts a segmented drying method, and realizes efficient recycling and recycling of heat generated by the hydration process through real-time monitoring and intelligent control system. The method significantly improves the heat energy utilization efficiency, reduces the production energy consumption, and has good energy saving and emission reduction effect.

Description

Technical Field

[0001] This invention relates to the field of contact lens manufacturing technology, specifically a method for heat recovery and reuse in a contact lens production line. Background Technology

[0002] As a medical device, contact lenses have stringent requirements for product quality and production efficiency in their manufacturing process. Hydration extraction and tray drying are two key steps in contact lens production, both of which typically involve significant heat consumption and emissions. Current technologies suffer from low heat utilization efficiency, substantial energy waste, high production costs, and environmental impact. Therefore, improving heat utilization efficiency, reducing production costs, and optimizing the process flow are urgent problems to be solved in the field of contact lens manufacturing technology.

[0003] In the hydration extraction process, contact lens products require continuous heating to complete the hydration process. However, the large amount of hot air generated during hydration is usually directly released into the environment without being effectively recovered and utilized, resulting in wasted heat energy. The drying stage requires reheating, and the lack of coordinated utilization of the heat energy from the hydration process further increases energy consumption.

[0004] In existing contact lens production lines, the utilization of heat energy in each process is independent, lacking a unified heat energy management system, resulting in low heat energy utilization efficiency. Insufficient heat collection and transmission efficiency leads to widespread energy waste.

[0005] Temperature control in hydration and drying processes typically relies on traditional mechanical or manual adjustments, making it difficult to dynamically adjust parameters such as temperature and airflow. Significant temperature fluctuations can affect the uniformity of hydration and the drying effect, thus negatively impacting product quality.

[0006] Directly releasing hot air not only wastes energy but also raises the temperature of the production environment, increasing the burden on air conditioning systems and affecting employee comfort. Heat emissions do not comply with energy conservation and emission reduction policies and are detrimental to the sustainable development of enterprises. Summary of the Invention

[0007] In view of the above-mentioned technical deficiencies, the purpose of this invention is to provide a method for heat energy recovery and reuse in contact lens production lines, so as to realize the recycling of heat energy.

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

[0009] A method for heat recovery and reuse in a contact lens production line includes the following steps:

[0010] S1: Place the contact lens product to be extracted into the tray in the loading and traying area;

[0011] S2: The tray containing the product is transported to the hydration zone for the extraction process, during which heat is generated.

[0012] S3: The heat generated during the extraction process is collected by a heat collection device set around the hydration zone;

[0013] S4: Remove the extracted product from the tray in the feeding area;

[0014] S5: Transport the empty trays to the drying area for recirculation and drying;

[0015] S6: The collected heat is introduced into the drying zone through a blower to quickly dry the returned tray. Preferably, the heat collection step S3 includes:

[0016] a) Directional guidance of the hot airflow above the hydration zone;

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

[0018] c) Adjust the collection rate of the hot gas flow based on the temperature data;

[0019] d) Temporarily store the collected hot gas stream.

[0020] Preferably, the drying process step S6 includes:

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

[0022] b) Start the hot air supply based on the location signal;

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

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

[0025] e) Stop supplying air after the preset drying level is reached.

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

[0027] First stage: High-temperature rapid preheating is used, with a temperature of 70-80℃ and a time of 10-15 seconds;

[0028] Second stage: Use medium-temperature continuous drying, with a temperature of 50-60℃ and a time of 20-30 seconds;

[0029] The third stage: Low-temperature buffer cooling is used, with a temperature of 40-45℃ and a time of 10-15 seconds.

[0030] Preferably, it further includes a heat energy replenishment step:

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

[0032] b) When the temperature is below the preset threshold, the heat energy replenishment program is activated;

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

[0034] d) Stop replenishing heat energy after the target temperature is reached.

[0035] Preferably, it further includes a drying quality control step:

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

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

[0038] c) Adjust the drying time dynamically based on the test results;

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

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

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

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

[0043] c) Establish an energy consumption optimization model;

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

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

[0046] Preferably, it also includes emergency response steps:

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

[0048] b) Monitor the system's operating status in real time;

[0049] c) When an anomaly is detected, the following actions will be performed automatically:

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

[0051] e) Adjust the drying parameters;

[0052] f) Activate standby operating mode if necessary;

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

[0054] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0055] By recovering the heat generated during the hydration process and using it for drying the tray, the heat energy is recycled, significantly reducing heat energy waste.

[0056] By recovering and reusing heat energy, the use of external energy is reduced, the overall energy consumption of the production line is lowered, and thus production costs are effectively reduced.

[0057] By employing intelligent temperature control and a segmented drying method, the stability of the hydration and drying process of contact lens products is ensured, thereby improving the consistency and reliability of product quality.

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

[0059] The thermal linkage between the hydration and drying processes optimizes the process flow, shortens the production cycle, and improves the operating efficiency of the production line. Attached Figure Description

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

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

[0062] in:

[0063] 1. Feeding and traying area; 2. Drying area; 3. Discharging area; 4. Hydration area. Detailed Implementation

[0064] The invention will now be further described with reference to the accompanying drawings.

[0065] like Figure 1 , Figure 2 As shown, a method for heat recovery and reuse in a contact lens production line includes the following steps:

[0066] S1: Place the contact lens product to be extracted into the tray in the loading and traying area 1;

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

[0068] S3: The heat generated during the extraction process is collected by a heat collection device set around the hydration zone 4;

[0069] S4: Remove the extracted product from the tray in feeding area 3;

[0070] S5: Transport the empty Tray to drying zone 2 for recirculation and drying;

[0071] S6: The collected heat is introduced into drying zone 2 through a blower to quickly dry the returned tray, thereby achieving heat energy reuse and reducing additional energy consumption in drying zone 2. A fan is selected as the blower.

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

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

[0074] Food preparation and plating steps

[0075] The operator manually places the contact lens products to be extracted into a 300mm×400mm tray, each tray can hold 96 contact lenses;

[0076] The tray surface features an anti-slip design to ensure product stability during transportation.

[0077] Hydration extraction steps

[0078] The tray containing the contact lens product is transported to the hydration zone;

[0079] The water temperature in the hydration zone was set at 80±2℃, and the hydration time was 30 minutes.

[0080] During the hydration process, the generated hot airflow has a temperature of approximately 75°C, and the heat energy is released through natural convection and steam.

[0081] Thermal energy harvesting steps

[0082] A heat collection area is set up at the top of the hydration zone to collect the heat released during the hydration process;

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

[0084] The collected heat is directly transferred to the drying area for use.

[0085] Material feeding operation steps

[0086] In the unloading area, an automated robotic arm removes the hydrated contact lenses from the tray;

[0087] The feeding speed is 4 seconds per piece to ensure product integrity and avoid damage.

[0088] Tray tray recirculation and drying steps

[0089] Empty trays are conveyed to the drying area via a conveyor belt;

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

[0091] First stage: High-temperature rapid drying, temperature is 75℃, time is 15 seconds;

[0092] Second stage: continuous drying at medium temperature, at 55℃ for 20 seconds;

[0093] The third stage: slow cooling at a low temperature of 40℃ for 10 seconds;

[0094] After drying, the tray is returned to the feeding area for reuse.

[0095] Quality control steps

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

[0097] We conduct random checks every 2 hours and record the drying temperature curve to ensure process stability.

[0098] Energy efficiency optimization steps

[0099] Daily statistics are collected on the energy consumption data of the heat recovery system, and the heat utilization rate is calculated.

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

[0101] Implementation results:

[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-pass yield reached 99.9%.

[0105] Example 2: A method for large-scale heat recovery and reuse in a contact lens production line

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

[0107] Food preparation and plating steps

[0108] The fully automated feeding system loads the contact lens products into a large tray measuring 400mm×600mm, with each tray holding 192 lenses.

[0109] The feeding cycle time is 10 seconds per tray, which significantly improves feeding efficiency.

[0110] Hydration extraction steps

[0111] Two parallel hydration production lines were set up, with the hydration temperature set at 82±1℃ and the hydration time at 28 minutes.

[0112] Each production line generates approximately 15,000 kcal of heat per hour, with a hot airflow temperature of approximately 78°C.

[0113] Thermal energy harvesting steps

[0114] A dual-cycle thermal energy harvesting system is adopted:

[0115] Main circulation: Collects high-temperature hot airflow at a temperature of 70-75℃, with a collection rate of 4m / s. 3 / min, used for drying trays;

[0116] Secondary circulation: Collects medium-temperature hot airflow at a temperature of 60-65℃, with a collection rate of 2m / s. 3 / min, used for the preheating system in the hydration zone;

[0117] The heat collection system monitors the temperature of the hot airflow in real time and dynamically adjusts the collection rate according to production needs.

[0118] Material feeding operation steps

[0119] In the unloading area, dual robotic arms operate synchronously, with each robotic arm unloading at a speed of 2 seconds per piece;

[0120] Equipped with a visual inspection system, it monitors the integrity of contact lenses in real time, ensuring a pass rate of ≥99.95% during the material preparation process.

[0121] Tray tray recirculation and drying steps

[0122] A dual-track conveyor system is used, with the trays conveyed to the drying area at a speed of 0.8 m / s;

[0123] The drying zone employs an optimized four-stage drying process:

[0124] First stage: Preheating section, temperature 45℃, time 10 seconds;

[0125] Second stage: rapid heating section, temperature 78℃, time 12 seconds;

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

[0127] Fourth stage: Cooling section, temperature 40℃, time 15 seconds;

[0128] After drying, the trays are returned to the feeding area for continued use.

[0129] Quality control steps

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

[0131] Products are sampled every hour, and drying temperature and humidity data are recorded to ensure the stability of the drying process;

[0132] Establish batch traceability records 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] The heat energy distribution ratio is dynamically adjusted according to the production load to ensure the heat energy utilization efficiency of the main circulation and the auxiliary circulation.

[0136] Weekly energy efficiency analysis reports are generated to optimize the parameters of the heat recovery system.

[0137] Implementation results:

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

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

[0140] Production efficiency increased by 25%;

[0141] The first-pass yield rate of the products reached 99.98%.

[0142] Summarize

[0143] Example 1 is applicable to small and medium-sized contact lens production lines. It adopts a single-cycle heat recovery method, which is simple in process and has significant energy-saving effect.

[0144] Example 2 is applicable to large-scale production lines and adopts a dual-cycle heat recovery system, which further improves heat utilization efficiency and meets high production capacity requirements;

[0145] Both embodiments achieved the goals of energy conservation, reduced consumption, improved production efficiency, and guaranteed product quality by optimizing the heat collection and drying processes.

Claims

1. A method for heat recovery and reuse in a contact lens production line, characterized in that, Includes the following steps: S1: Place the contact lens product to be extracted into the tray in the loading and traying area (1); S2: The tray containing the product is transported to the hydration zone (4) for extraction. Heat is generated during the extraction process. S3: The heat generated by the extraction process is collected by a heat collection device set around the hydration zone (4), specifically including: a) directional guidance of the hot airflow above the hydration zone (4); b) real-time monitoring of the temperature data of the collected hot airflow; c) adjustment of the collection rate of the hot airflow according to the temperature data; d) temporary storage of the collected hot airflow. S4: In the feeding area (3), the extracted product is removed from the tray; S5: The empty Tray is transported to the drying area (2) for recirculation and drying. S6: The collected heat is introduced into the drying zone (2) through the blower to quickly dry the returned tray. Specifically, this includes: a) detecting the position signal of the tray reaching the drying zone (2); b) starting the hot air supply according to the position signal; c) adjusting the temperature, speed and direction of the hot air; d) monitoring the drying status of the tray; e) stopping the air supply after the preset drying degree is reached.

2. The method for heat recovery and reuse in a contact lens production line as described in claim 1, characterized in that, The drying process employs a segmented drying method: First stage: High-temperature rapid preheating is used, with a temperature of 70-80℃ and a time of 10-15 seconds; Second stage: Use medium-temperature continuous drying, with a temperature of 50-60℃ and a time of 20-30 seconds; The third stage: Low-temperature buffer cooling is used, with a temperature of 40-45℃ and a time of 10-15 seconds.

3. The method for heat recovery and reuse in a contact lens production line as described in claim 1, characterized in that, It also includes the heat replenishment step: a) Real-time monitoring of the temperature at which heat is collected; b) When the temperature is below the preset threshold, the heat energy replenishment program is activated; c) Calculate the required additional heat based on the temperature difference; d) Stop replenishing heat energy after the target temperature is reached.

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

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

6. The method for heat recovery and reuse in a contact lens production line as described in claim 1, characterized in that, It also includes emergency response steps: a) Set safety thresholds for system operating parameters; b) Monitor the system's operating status in real time; c) When an anomaly is detected, the following actions will be performed automatically: reduce the heat collection rate; adjust drying parameters; activate standby working mode; record the anomaly and generate a fault analysis report.

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