A high and low voltage line insulator and its preparation process

Abstract

The present invention discloses a high- and low-voltage line insulator and a preparation process thereof, the process comprising an insulator collaborative production system and a material-energy circulation control system, the insulator collaborative production system performs collaborative production of high-voltage insulators and low-voltage insulators, utilizes waste produced by high-voltage insulator production and regulates the production ingredients of low-voltage insulators by the mass ratio of each component in the waste, and completes the production of low-voltage insulators in combination with the waste heat of high-temperature exhaust gas from high-voltage insulators, the material-energy circulation control system comprises a material circulation control module and an energy circulation control module, which respectively obtain real-time waste parameters and real-time high-temperature exhaust gas parameters generated in the production process of high-voltage insulators, and regulate the production process of the insulator collaborative production system in real time, the present invention realizes collaborative optimization production of high- and low-voltage insulators by utilizing the gradient differences in material purity, structural complexity, process accuracy and testing standards of high- and low-voltage insulators, and can significantly improve resource utilization.

Description

Technical Field

[0001] The invention relates to the technical field of insulators, and in particular to a high- and low-voltage line insulator and a preparation process thereof. Background Art

[0002] Insulators are devices installed between conductors at different potentials or between conductors and grounded structures, capable of withstanding voltage and mechanical stress. Insulators are a special type of insulation control that plays an important role in overhead transmission lines.

[0003] The difference between high-voltage insulators and low-voltage insulators is rooted in the essential differences in their application scenarios and performance requirements. As the core component of the transmission network, high-voltage insulators need to work stably at extreme voltages ranging from 35kV to thousands of volts. Their material system is mainly made of high-purity alumina, and the porosity is strictly controlled within 3% to ensure that the dielectric strength is greater than the hard indicator of 30kV / mm. The production process of high-voltage insulators usually uses high-temperature and long-term sintering at 1400℃ or above. In industrial production, it is necessary to strictly cooperate with X-rays and dielectric strength full inspections to achieve the reliability commitment of long-life operation. In contrast, low-voltage insulators are usually aimed at distribution scenarios below 1kV. On the premise of ensuring basic insulation performance (dielectric strength ≥12kV / mm), they pay more attention to economy. The production formula of low-voltage insulators allows the addition of 35% recycled waste, and ordinary kaolin is usually used. Compared with high-voltage insulators, the sintering process is more simplified. There are gradient differences between the two in terms of material purity, structural complexity, process accuracy and testing standards.

[0004] In the existing insulator preparation process, there is a lack of a coordinated production system for high and low voltage insulators, and the gradient differences in material purity, structural complexity, process accuracy and testing standards of high and low voltage insulators have not been fully utilized in process production. The present invention aims to provide a high and low voltage line insulator preparation process and corresponding high and low voltage line insulators. By utilizing the differences in material purity, structural complexity, process accuracy and testing standards of high and low voltage insulators, the coordinated optimized production of high and low voltage insulators is achieved, which significantly improves resource utilization while ensuring product quality.

[0005] The information disclosed in this background technology section is only intended to enhance the understanding of the overall background of the invention and should not be regarded as an acknowledgment or any form of suggestion that the information constitutes the prior art already known to a person skilled in the art. Summary of the invention

[0006] In order to solve the above technical problems, the purpose of the present invention is to provide a high and low voltage line insulator and a preparation process thereof. By utilizing the gradient differences in material purity, structural complexity, process accuracy and testing standards of high and low voltage insulators, the coordinated optimized production of high and low voltage insulators can be achieved, which can significantly improve resource utilization while ensuring product quality.

[0007] In order to achieve the above-mentioned purpose, the present invention provides a high- and low-voltage line insulator preparation process on the one hand. In the technical solution of the present invention, the high- and low-voltage line insulator preparation process includes an insulator collaborative production system and a material-energy circulation control system. The insulator collaborative production system performs collaborative production of high-voltage insulators and low-voltage insulators, mainly by utilizing high-voltage insulator production waste and regulating the production ingredients of low-voltage insulators by the mass ratio of each component in the waste, and combining the high-temperature exhaust gas waste heat of the high-voltage insulator to complete the production of low-voltage insulators. The material-energy circulation control system includes a material circulation control module and an energy circulation control module, which respectively obtain the real-time waste parameters and real-time high-temperature exhaust gas parameters generated in the high-voltage insulator production process, and regulate the production process of the insulator collaborative production system in real time. The material circulation control module is used to control the waste circulation of high-voltage insulators and low-voltage insulators in the insulator collaborative production system when they are collaboratively produced, and specifically includes:

[0008] S1-1. Calculate the waste generation rate during the production process of high-voltage insulators:

[0009] ;

[0010] Where: Expressed as the calculated waste generation rate, Expressed as the statistical production rate of high-voltage insulators, Expressed as the statistical pass rate of high-voltage insulator production, Expressed as the unit mass of the high-voltage insulator; the mass percentage of each component in the waste inherits the mass percentage of each raw material of the high-voltage insulator:

[0011] , ;

[0012] Where: Expressed as the mass proportion of each component in the waste, Represented as different components, Indicated as shared Components

[0013] S1-2. Calculate the total mass of supplementary raw materials for low voltage insulator production:

[0014] , ;

[0015] Where: It is expressed as the total mass of supplementary raw materials for low voltage insulator production. It is expressed as the mass of each raw material that needs to be supplemented. Represented as different components, Indicated as shared The mass percentage of each component meets the mass percentage of each raw material of the low-voltage insulator blank:

[0016] , ;

[0017] Where: Indicates the mass percentage of each raw material of low voltage insulator blank, Represented as different components, Indicated as shared Components

[0018] S1-3, get the calculation formula for feeding:

[0019] ;

[0020] According to the dynamic balance between raw material input and product output in the production process of low-voltage insulators, we get:

[0021] ;

[0022] Where: Expressed as the statistical production rate of low voltage insulators, Expressed as the unit mass of low voltage insulators, Expressed as loss calculation coefficient;

[0023] S1-4, calculation formula for real-time feeding:

[0024] , ;

[0025] , ;

[0026] Where: Expressed as the real-time waste generation rate, that is, the actual waste generation rate, It represents the actual total mass of raw materials supplemented for the production of low voltage insulators;

[0027] S1-5. Estimate the batching metering data of the low-voltage insulator batching module based on the calculated waste generation rate and the calculation formula for replenishment, adjust the batching metering data of the low-voltage insulator batching module based on the real-time waste generation rate and the real-time replenishment formula, and optimize the statistical qualification rate of high-voltage insulator production based on the real-time waste generation rate.

[0028] Furthermore, in the technical solution of the present invention, the insulator collaborative production system includes a high-voltage insulator batching module, a high-voltage insulator molding module, a low-voltage insulator batching module, a low-voltage insulator molding module, a pretreatment module, a drying area, a calcination area one and a calcination area two, the high-voltage insulator batching module is used for metering and mixing high-voltage insulator blank raw materials, the high-voltage insulator molding module performs high-voltage insulator molding, the low-voltage insulator batching module is used for metering and mixing low-voltage insulator blank raw materials, the low-voltage insulator molding module performs low-voltage insulator molding, and the pretreatment module The processing module performs crushing and filtering pretreatment operations on the waste generated in the production of high-voltage insulators, the drying area dries the molded bodies of high-voltage insulators and low-voltage insulators, the drying area is provided with monitoring points to detect the dried high-voltage insulator bodies, the calcining area one sinteres the molded bodies of high-voltage insulators, the calcining area two sinteres the molded bodies of low-voltage insulators, the high-temperature exhaust gas of the calcining area one is led to the calcining area two for the sintering of the low-voltage insulator bodies, and the high-temperature exhaust gas of the calcining area two is led to the drying area for drying the high-voltage insulators and low-voltage insulator bodies.

[0029] Furthermore, in the technical solution of the present invention, the energy circulation control module is used to control the high-temperature exhaust gas circulation when high-voltage insulators and low-voltage insulators are co-produced in the insulator co-production system, which specifically includes:

[0030] S2-1, adopt two-stage heat exchange circulation system:

[0031] Primary heat exchange cycle: high temperature exhaust gas from calcining zone 1 flows to calcining zone 2;

[0032] Secondary heat exchange cycle: high temperature exhaust gas from calcining zone 2 is led to the drying zone;

[0033] S2-2. Calculate the real-time available heat energy in each stage of heat exchange cycle:

[0034] , ;

[0035] Where: It is expressed as the real-time available heat energy at each stage of heat exchange cycle. It means there are two stages of heat exchange cycle. Expressed as exhaust gas density, Expressed as the constant pressure specific heat capacity of exhaust gas, It is expressed as the temperature difference of each heat exchange level, Expressed as the exhaust gas volume flow rate at each level, It is expressed as the detection time interval;

[0036] S2-3. Calculate the heat energy demand of the second calcination zone of the first heat exchange cycle:

[0037] ;

[0038] Where: Expressed as the heat energy demand of calcination zone 2, Expressed as the mass flow rate of low voltage insulator blank, Expressed as the specific heat capacity of low voltage insulator blank, It is expressed as the target temperature of calcination zone 2, It is represented by the current temperature of calcination zone 2;

[0039] S2-4. Calculate the heat energy demand of the secondary heat exchange cycle drying zone:

[0040] ;

[0041] Where: Expressed as the heat energy demand of the drying area, Expressed as the mass flow rate of low voltage insulator wet body, Expressed as the specific heat of water, Expressed as the target temperature of green body drying, Expressed as wet body temperature, Expressed as the latent heat of water vaporization;

[0042] S2-5, auxiliary heating when heat energy is insufficient:

[0043] ;

[0044] ;

[0045] Where: Expressed as the first-level auxiliary heating power, Expressed as secondary auxiliary heating power, Expressed as heating efficiency coefficient;

[0046] S2-6, auxiliary cooling when there is excess heat energy:

[0047] ;

[0048] ;

[0049] Where: Expressed as the first-level cooling air volume, Expressed as secondary cooling air volume, Expressed as air density, Expressed as the specific heat capacity of air, Indicates the allowable temperature rise of cooling air;

[0050] S2-7. Regulate the heat exchange cycle of the calcining zone 2 and the drying zone. By calculating the heat energy requirements of the calcining zone 2 and the drying zone, make a judgment based on the real-time available heat energy of the two-stage heat exchange cycle, and assist in heating when the heat energy is insufficient, and assist in cooling when the heat energy is excessive.

[0051] Effective gain: In summary, the present invention provides a high- and low-voltage line insulator and a preparation process thereof. The present invention constructs a material and energy dual circulation system for the coordinated production of high-voltage and low-voltage insulators. During the preparation process of high-voltage insulators, monitoring points are used to detect the high-voltage insulator forming blanks to ensure the high reliability of the production of high-voltage insulators. At the same time, defective products are used as raw materials for the preparation of low-voltage insulators, thereby improving the portability of waste recycling and achieving a high waste resource utilization rate. In addition, the present invention utilizes the high-temperature exhaust gas in the high-temperature sintering of high-voltage insulators in a two-stage and three-point cascade manner, that is, the high-temperature exhaust gas sintered by the high-voltage insulator is utilized in the sintering process of the low-voltage insulator, and the high-temperature exhaust gas sintered by the low-voltage insulator is utilized in the forming and drying process of high- and low-voltage insulators and low-voltage insulators. This can effectively improve the comprehensive thermal efficiency of the system, further improve resource utilization, and achieve reduced raw material costs and energy consumption in industrial production. While reducing costs and increasing efficiency, it can also effectively reduce carbon emissions. The technical solution of the present invention reconstructs the efficient, low-carbon, and economical architecture of insulator manufacturing in a closed-loop cycle and intelligent optimization manner, providing a systematic solution for the green upgrade of power equipment.

[0052] Other features and advantages of the present invention will be set forth in the description which follows. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] In order to more clearly illustrate the embodiments of the present invention, the following briefly introduces the drawings required for use in the embodiments. Obviously, the drawings described below are only some embodiments of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0054] Figure 1 The present invention is a flow chart of a process for preparing high and low voltage line insulators. DETAILED DESCRIPTION

[0055] In order to make the purpose, features and advantages of the present invention more obvious and easy to understand, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the embodiments described below are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0056] The core of the present invention is to provide a high and low voltage line insulator and a preparation process thereof. By utilizing the gradient differences in material purity, structural complexity, process accuracy and testing standards of high and low voltage insulators, the coordinated optimized production of high and low voltage insulators can be achieved, which can significantly improve the utilization of resources while ensuring product quality.

[0057] In order to solve the above technical problems, an embodiment of the present invention proposes a high- and low-voltage line insulator preparation process. In this embodiment, the high- and low-voltage line insulator preparation process includes an insulator collaborative production system and a material-energy circulation control system. The insulator collaborative production system performs collaborative production of high-voltage insulators and low-voltage insulators. The production batching of low-voltage insulators is regulated by utilizing the waste produced by high-voltage insulators and adjusting the mass ratio of each component in the waste. The production of low-voltage insulators is completed by combining the waste heat of high-temperature exhaust gas from high-voltage insulators. The material-energy circulation control system includes a material circulation control module and an energy circulation control module. The production process of the insulator collaborative production system is regulated in real time by acquiring the real-time waste parameters and real-time high-temperature exhaust gas parameters generated in the production process of high-voltage insulators, respectively. The material circulation control module is used to control the waste circulation of high-voltage insulators and low-voltage insulators in the collaborative production of the insulator collaborative production system, that is, the waste generated in the production of high-voltage insulators is introduced into the low-voltage insulator batching module, and the low-voltage insulator batching module adjusts the overall batching according to the imported real-time waste parameters. It specifically includes the following contents:

[0058] S1-1. Calculate the waste generation rate during the production process of high-voltage insulators:

[0059] ;

[0060] Where: Expressed as the calculated waste generation rate, Expressed as the statistical production rate of high-voltage insulators, Expressed as the statistical pass rate of high-voltage insulator production, Expressed as the unit mass of high-voltage insulators; that is, the waste production rate in high-voltage insulator production is estimated by the statistical qualified rate of high-voltage insulator production, and the calculated waste generation rate is obtained , its accuracy is related to the accuracy of the statistical pass rate. It should be noted that the waste generation rate is based on data over a period of time;

[0061] The monitoring point is set in the drying area. The high-voltage insulator blank is only dried at a relatively low temperature. Since the material purity, structural complexity, process accuracy and testing standards of low-voltage insulators are lower than those of high-voltage insulators, the influence of drying on the blank raw materials is ignored. It is suitable for low-voltage insulator blank raw materials. The mass percentage of each component in the waste inherits the mass percentage of each blank raw material of the high-voltage insulator:

[0062] , ;

[0063] Where: Expressed as the mass proportion of each component in the waste, Represented as different components, Indicated as shared Components

[0064] S1-2. Calculate the total mass of supplementary raw materials required for the production of low-voltage insulators:

[0065] , ;

[0066] Where: It is expressed as the total mass of supplementary raw materials for low voltage insulator production. It is expressed as the mass of each raw material that needs to be supplemented. Represented as different components, Indicated as shared The mass percentage of each component meets the mass percentage of each raw material of the low-voltage insulator blank:

[0067] , ;

[0068] Where: Indicates the mass percentage of each raw material of low voltage insulator blank, Represented as different components, Indicated as shared Components

[0069] S1-3, get the calculation formula for feeding:

[0070] ;

[0071] According to the dynamic balance between raw material input and product output in the production process of low-voltage insulators, we get:

[0072] ;

[0073] Where: Expressed as the statistical production rate of low voltage insulators, Expressed as the unit mass of low voltage insulators, Expressed as loss calculation coefficient;

[0074] S1-4, calculation formula for real-time feeding:

[0075] , ;

[0076] , ;

[0077] Where: Expressed as the real-time waste generation rate, that is, the actual waste generation rate, It represents the total mass of raw materials actually supplemented for the production of low voltage insulators;

[0078] S1-5. Estimate the batching metering data of the low-voltage insulator batching module based on the calculated waste generation rate and the replenishment formula, adjust the batching metering data of the low-voltage insulator batching module based on the real-time waste generation rate and the real-time replenishment formula, optimize the statistical qualification rate of high-voltage insulator production based on the real-time waste generation rate, and improve the accuracy of the calculated waste generation rate and the replenishment formula.

[0079] For example, for each of the above steps, this embodiment provides a specific application scenario:

[0080] In a specific application of a high and low voltage line insulator preparation process, it includes:

[0081] High voltage insulator formula: kaolin , quartz sand , feldspar , Alumina , bentonite ;

[0082] Low voltage insulator formula: kaolin , quartz sand , feldspar , high pressure waste ≤ ;

[0083]

[0084] Statistics of qualified rate, where the qualified rate is calculated through the detection information of the monitoring points:

[0085]

[0086] Calculate the waste generation rate in the high-voltage insulator production process according to step S1-1:

[0087] ;

[0088] get:

[0089]

[0090] According to step S1-2, calculate the total mass of supplementary raw materials required for the production of low-voltage insulators:

[0091] , ;

[0092] Where: Expressed as the proportion of kaolin in the waste, Expressed as the proportion of quartz sand in the waste, Expressed as the proportion of feldspar in the waste, , , They are respectively the masses of kaolin, quartz sand and feldspar that need to be supplemented; ;

[0093] It should be noted that there is a calculation error of , i.e. other components in high voltage insulator waste;

[0094] Calculate the feed replenishment according to the feed replenishment formula in step S1-3:

[0095] , ;

[0096] Where: Expressed as the proportion of kaolin in low voltage insulator blanks, It is expressed as the proportion of quartz sand in the low voltage insulator blank. Expressed as the proportion of feldspar in the low-voltage insulator blank, we get:

[0097] ;

[0098] ;

[0099] ;

[0100] Solving for this yields:

[0101]

[0102] It should be noted that, according to steps S1-4 and S1-5, when the real-time waste generation rate deviates from the calculated waste generation rate, including the cumulative deviation caused by the unit mass of the high-voltage insulator, the mass of the supplementary raw materials is calculated according to the real-time waste generation rate, the specific process is the same as above, and the statistical qualified rate is optimized:

[0103]

[0104] In this embodiment, Figure 1 The flowchart of the process for preparing high and low voltage line insulators of the present invention is as follows: Figure 1 As shown, the insulator collaborative production system includes a high-voltage insulator batching module, a high-voltage insulator molding module, a low-voltage insulator batching module, a low-voltage insulator molding module, a pretreatment module, a drying area, a calcination area 1 and a calcination area 2. The high-voltage insulator batching module is used for metering and mixing the raw materials of the high-voltage insulator blanks, and the high-voltage insulator molding module is used for high-voltage insulator molding. The low-voltage insulator batching module is used for metering and mixing the raw materials of the low-voltage insulator blanks, and the low-voltage insulator molding module is used for low-voltage insulator molding. The pretreatment module is used for high-voltage insulator The waste generated in the production of insulators is crushed and filtered for pre-treatment. The drying area dries the molded bodies of high-voltage insulators and low-voltage insulators. Monitoring points are set in the drying area to detect the dried high-voltage insulator bodies. The calcining area one burns the molded bodies of high-voltage insulators, and the calcining area two burns the molded bodies of low-voltage insulators. The high-temperature exhaust gas from the calcining area one is led to the calcining area two for the burning of low-voltage insulator bodies, and the high-temperature exhaust gas from the calcining area two is led to the drying area for the drying of high-voltage and low-voltage insulator bodies.

[0105] Specifically, in this embodiment, the detection method of the monitoring points provided in the drying area includes using an X-ray density meter to detect the porosity of the high-voltage insulator blank, and the porosity of the qualified product is required to be less than , use laser profile scanner to detect the forming dimensions of high-voltage insulator blanks, and the diameter deviation of qualified products is required to be less than , the height deviation is required to be less than , the roundness error is required to be less than The high-voltage insulator blanks that do not meet the requirements are judged as unqualified products and introduced into the pre-processing module.

[0106] Specifically, in this embodiment, the energy circulation control module is used to control the high-temperature exhaust gas circulation when high-voltage insulators and low-voltage insulators are cooperatively produced in the insulator cooperative production system, which specifically includes the following contents:

[0107] S2-1, adopt two-stage heat exchange circulation system:

[0108] Primary heat exchange cycle: high temperature exhaust gas from calcining zone 1 flows to calcining zone 2;

[0109] Secondary heat exchange cycle: high temperature exhaust gas from calcining zone 2 is led to the drying zone;

[0110] S2-2. Calculate the real-time available heat energy in each stage of heat exchange cycle:

[0111] , ;

[0112] Where: It is expressed as the real-time available heat energy at each stage of heat exchange cycle. It means there are two stages of heat exchange cycle. Expressed as exhaust gas density, It is expressed as the specific heat capacity of exhaust gas at constant pressure, It is expressed as the temperature difference of each stage of heat exchange, that is, the temperature difference before and after the high-temperature exhaust gas passes through the first stage of heat exchange cycle. Expressed as the exhaust gas volume flow rate at each level, It is expressed as the detection time interval;

[0113] S2-3. Calculate the heat energy demand of the second calcination zone of the first heat exchange cycle:

[0114] ;

[0115] Where: Expressed as the heat energy demand of calcination zone 2, Expressed as the mass flow rate of low voltage insulator blank, Expressed as the specific heat capacity of low voltage insulator blank, It is expressed as the target temperature of calcination zone 2, It is represented as the current temperature of calcination zone 2;

[0116] S2-4. Calculate the heat energy demand of the secondary heat exchange cycle drying zone:

[0117] ;

[0118] Where: Expressed as the heat energy demand of the drying area, Expressed as the mass flow rate of low voltage insulator wet body, Expressed as the specific heat of water, Expressed as the target temperature of green body drying, Expressed as wet body temperature, Expressed as the latent heat of water vaporization;

[0119] S2-5, auxiliary heating when heat energy is insufficient:

[0120] , ;

[0121] Where: Expressed as the first-level auxiliary heating power, Expressed as secondary auxiliary heating power, Expressed as heating efficiency coefficient;

[0122] S2-6, auxiliary cooling when there is excess heat energy:

[0123] , ;

[0124] Where: Expressed as the first-level cooling air volume, Expressed as secondary cooling air volume, Expressed as air density, Expressed as the specific heat capacity of air, Indicates the allowable temperature rise of cooling air;

[0125] S2-7. Regulate the heat exchange cycle of the calcining zone 2 and the drying zone. By calculating the heat energy requirements of the calcining zone 2 and the drying zone, make a judgment based on the real-time available heat energy of the two-stage heat exchange cycle. When the heat energy is insufficient, assist in heating and calculate the auxiliary heating power. When the heat energy is excessive, assist in cooling and calculate the cooling air volume.

[0126] Exemplarily, for each of the above steps, this embodiment further provides a specific application scenario;

[0127] In a specific application of a high and low voltage line insulator preparation process, it includes:

[0128]

[0129] According to step S2-2, the real-time available heat energy in each stage of heat exchange cycle is calculated:

[0130] (Small tunnel kiln firing waste gas flow), ;

[0131] 0.3kg / m 3 ×1.05kJ / (kg·℃)× ×2500m 3 / h×1h;

[0132] 0.3kg / m 3 ×1.05kJ / (kg·℃)× ×2500m 3 / h×1h;

[0133] Among them, the temperature difference of each stage of heat exchange and Monitored by temperature sensor, The temperature difference before and after the high-temperature exhaust gas passes through the calcination zone 2. The temperature difference before and after the high-temperature exhaust gas passes through the drying area;

[0134] According to steps S2-3 and S2-4, the heat energy demand of the first heat exchange cycle calcining zone 2 and the heat energy demand of the second heat exchange cycle drying zone are calculated:

[0135] 1000kg×0.84kJ (kg·℃)×(1320℃-20℃)=1092000 kJ;

[0136] 1000kg×10%×(4.18kJ(kg·℃)×(150℃-20℃)+2260kJ / kg)=280340 kJ;

[0137] It should be noted that in the drying area, the purpose is to dry all the water, that is, 280340kJ is the total heat energy demand for 8 hours. During the time, the heat energy demand is calculated as: 280340 kJ / 8h=35042.5 kJ;

[0138] According to steps S2-5 and S2-6, the heat energy required to be supplemented in the first-stage heat exchange cycle calcining zone 2 and the heat energy required to be reduced in the second-stage heat exchange cycle drying zone are calculated, wherein the supplementary heat energy is provided by natural gas:

[0139] ;

[0140] Where: Expressed as the amount of natural gas required, Expressed as natural gas calorific value;

[0141] Use cooling air to reduce heat energy, and the cooling air allows temperature rise ;

[0142] The calculation results are:

[0143]

[0144] Specifically, the utilization of waste heat provided in the primary heat exchange cycle and the secondary heat exchange cycle can be further regarded as saving the usage of natural gas.

[0145] The above shows and describes the basic principles, main features and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited by the above embodiments. The above embodiments and descriptions are only preferred examples of the present invention and are not intended to limit the present invention. Without departing from the spirit and scope of the present invention, the present invention may have various changes and improvements, which fall within the scope of the present invention to be protected. The scope of protection of the present invention is defined by the attached claims and their equivalents.

Claims

1. A process for preparing high and low voltage line insulators, characterized in that: include: Insulator collaborative production system, which carries out collaborative production of high-voltage and low-voltage insulators, uses waste from high-voltage insulator production to control the production ingredients of low-voltage insulators by the mass ratio of each component in the waste, and completes the production of low-voltage insulators by combining the high-temperature waste gas waste heat of high-voltage insulators; A material-energy cycle control system, including a material cycle control module and an energy cycle control module, which respectively obtains real-time waste material parameters and real-time high-temperature exhaust gas parameters generated during the production process of high-voltage insulators, and controls the production process of the insulator collaborative production system in real time; The material circulation control module is used to control the waste circulation when high-voltage insulators and low-voltage insulators are produced in a coordinated production system of insulators, and specifically includes: S1-1. Calculate the waste generation rate during the production process of high-voltage insulators: ； Where: Expressed as the calculated waste generation rate, Expressed as the statistical production rate of high-voltage insulators, Expressed as the statistical pass rate of high-voltage insulator production, Expressed as the unit mass of the high-voltage insulator; the mass percentage of each component in the waste inherits the mass percentage of each raw material of the high-voltage insulator: ， ； Where: Expressed as the mass proportion of each component in the waste, Represented as different components, Indicated as shared Components S1-2. Calculate the total mass of supplementary raw materials for low voltage insulator production: ， ； Where: It is expressed as the total mass of supplementary raw materials for low voltage insulator production. It is expressed as the mass of each raw material that needs to be supplemented. Represented as different components, Indicated as shared The mass percentage of each component meets the mass percentage of each raw material of the low-voltage insulator blank: ， ； Where: Indicates the mass percentage of each raw material of low voltage insulator blank, Represented as different components, Indicated as shared Components S1-3, get the calculation formula for feeding: ； According to the dynamic balance between raw material input and product output in the production process of low-voltage insulators, we get: ； Where: Expressed as the statistical production rate of low voltage insulators, Expressed as the unit mass of low voltage insulators, Expressed as loss calculation coefficient; S1-4, calculation formula for real-time feeding: ， ； ， ； Where: Expressed as the real-time waste generation rate, that is, the actual waste generation rate, It represents the actual total mass of raw materials supplemented for the production of low voltage insulators; S1-5. Estimate the batching metering data of the low-voltage insulator batching module based on the calculated waste generation rate and the calculation formula for replenishment, adjust the batching metering data of the low-voltage insulator batching module based on the real-time waste generation rate and the real-time replenishment formula, and optimize the statistical qualification rate of high-voltage insulator production based on the real-time waste generation rate.

2. A process for preparing high and low voltage line insulators according to claim 1, characterized in that: The insulator collaborative production system comprises: High-voltage insulator batching module, used for metering and mixing high-voltage insulator blank raw materials; High-voltage insulator molding module, for molding high-voltage insulators; Low-voltage insulator batching module, used for metering and mixing low-voltage insulator blank raw materials; Low voltage insulator molding module, for molding low voltage insulators; The pre-treatment module performs crushing and filtering pre-treatment operations on the waste generated in the production of high-voltage insulators; Drying area, drying the formed blanks of high-voltage insulators and low-voltage insulators; Calcination zone 1, sintering the formed green body of the high voltage insulator; Calcination zone 2 is used to sinter the formed green body of the low voltage insulator.

3. A process for preparing high and low voltage line insulators according to claim 2, characterized in that: The drying area is provided with monitoring points to detect the dried high-voltage insulator blanks; The high temperature exhaust gas from the calcining zone 1 is led to the calcining zone 2 for sintering the low voltage insulator blank, and the high temperature exhaust gas from the calcining zone 2 is led to the drying zone for drying the high voltage insulator and the low voltage insulator blank.

4. A process for preparing high and low voltage line insulators according to claim 3, characterized in that: The energy circulation control module is used to control the high-temperature exhaust gas circulation when high-voltage insulators and low-voltage insulators are produced in a coordinated production system of insulators, and specifically includes: S2-1, adopt two-stage heat exchange circulation system: Primary heat exchange cycle: high temperature exhaust gas from calcining zone 1 flows to calcining zone 2; Secondary heat exchange cycle: high temperature exhaust gas from calcining zone 2 is led to the drying zone; S2-2. Calculate the real-time available heat energy in each stage of heat exchange cycle: ， ； Where: It is expressed as the real-time available heat energy at each stage of heat exchange cycle. It means there are two stages of heat exchange cycle. Expressed as exhaust gas density, Expressed as the constant pressure specific heat capacity of exhaust gas, It is expressed as the temperature difference of each heat exchange level, Expressed as the exhaust gas volume flow rate at each level, It is expressed as the detection time interval; S2-3. Calculate the heat energy demand of the second calcination zone of the first heat exchange cycle: ； Where: Expressed as the heat energy demand of calcination zone 2, Expressed as the mass flow rate of low voltage insulator blank, Expressed as the specific heat capacity of low voltage insulator blank, It is expressed as the target temperature of calcination zone 2, It is represented as the current temperature of calcination zone 2; S2-4. Calculate the heat energy demand of the secondary heat exchange cycle drying zone: ； Where: Expressed as the heat energy demand of the drying area, Expressed as the mass flow rate of low voltage insulator wet body, Expressed as the specific heat of water, Expressed as the target temperature of green body drying, Expressed as wet body temperature, Expressed as the latent heat of water vaporization; S2-5, auxiliary heating when heat energy is insufficient: ； ； Where: Expressed as the first-level auxiliary heating power, Expressed as secondary auxiliary heating power, Expressed as heating efficiency coefficient; S2-6, auxiliary cooling when there is excess heat energy: ； ； Where: Expressed as the first-level cooling air volume, Expressed as secondary cooling air volume, Expressed as air density, Expressed as the specific heat capacity of air, Indicates the allowable temperature rise of cooling air; S2-7. Regulate the heat exchange cycle of the calcining zone 2 and the drying zone. By calculating the heat energy requirements of the calcining zone 2 and the drying zone, make a judgment based on the real-time available heat energy of the two-stage heat exchange cycle, and assist in heating when the heat energy is insufficient, and assist in cooling when the heat energy is excessive.

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