A heat treatment equipment for glass insulator production

Abstract

The present invention discloses a heat treatment device for producing glass insulators, which relates to the technical field of glass insulator production. The device includes a forming quality control mechanism for detecting the molten state of glass and quality data after forming, thereby improving the quality of the glass insulator before heat treatment; the temperature equalization furnace adopts a reflective furnace chamber and silicon carbide heating tubes spirally arranged in a vertical direction to reduce the temperature difference in the furnace, and makes the glass insulator rotate during the heating process, thereby reducing the temperature difference between various parts of the glass insulator itself; the cooling furnace cools the glass insulator by rotation to achieve uniform cooling of the glass insulator; the vacuum unit and the argon injection unit assist in accurately controlling the temperature in the furnace; waste heat is recovered by a heat pump unit; and the heat treatment process is feedback-regulated by a defect self-inspection mechanism; the present invention improves the quality stability, production efficiency and energy utilization rate of the heat treatment process of the glass insulator by optimizing the heating and cooling methods and controlling the process parameters and waste heat recovery through closed-loop control.

Description

Technical Field

[0001] The present invention relates to the technical field of glass insulator production, in particular to heat treatment equipment for glass insulator production. Background Art

[0002] As a key component of the high-voltage transmission system, the mechanical strength and insulation performance of glass insulators are highly dependent on their heat treatment process. The heat treatment process is crucial and can directly affect the quality of the glass insulators, thereby affecting their performance.

[0003] Currently, the heat treatment equipment commonly used in the production of glass insulators mainly includes box-type resistance furnaces, tunnel kilns, and roller annealing furnaces. The core process steps include heating, temperature equalization, and cooling. However, the existing technology has the following significant drawbacks in practical applications:

[0004] (1) Poor temperature uniformity: Traditional equipment mostly uses single-sided resistance wire radiation heating or gas flame heating. The heat in the furnace relies on natural convection to diffuse. There is a temperature difference between the surface and the core of the glass insulator. The glass insulator is heated unevenly, and there is a high difference in residual stress in various parts of the interior, resulting in uneven internal stress and affecting the quality of the glass insulator.

[0005] (2) High energy consumption. Traditional equipment mostly uses aluminum silicate fiber materials with good thermal insulation performance, but often causes heat leakage due to seams. Its high-temperature flue gas is directly discharged, resulting in large heat losses, and the waste heat recovery rate is low, resulting in low energy utilization and affecting production costs;

[0006] (3) Inefficient cooling system: Traditional cooling steps mostly use natural air cooling or water cooling coils, which results in a large fluctuation range in the cooling rate, which can easily cause internal stress rebound of glass insulators and increase the scrap rate.

[0007] (4) The degree of automation is low, and most equipment still relies on manual control, resulting in insufficient stability and consistency of the glass insulator products produced, affecting the quality of mass-produced glass insulators and low production efficiency; and quality control is stagnant, lacking online stress monitoring and closed-loop feedback mechanisms, and unable to dynamically optimize process parameters according to material properties, resulting in difficulty in improving the qualified rate of glass insulator products.

[0008] In summary, it is found that the existing technology has at least the following technical problems:

[0009] Existing glass insulator heat treatment equipment has technical problems such as poor temperature uniformity, high energy consumption, unstable cooling rate and low degree of automation, which make it difficult to improve the quality of glass insulators. Summary of the Invention

[0010] The purpose of the present invention is to provide a heat treatment equipment for glass insulator production to solve the technical problems of existing glass insulator heat treatment equipment, such as poor temperature uniformity, high energy consumption, unstable cooling rate and low degree of automation, which make it difficult to improve the quality of glass insulators.

[0011] The various technical effects that can be produced by the preferred technical solutions among the various technical solutions provided by the present invention are described in detail below.

[0012] In order to solve the above technical problems, the present invention provides the following technical solutions:

[0013] The present invention provides a heat treatment device for producing glass insulators, comprising a forming quality control mechanism, which obtains quality data by detecting the melting state and the formed glass insulators, and feeds back and regulates the feeding ratio and the melting of raw materials to form a closed-loop control; and a temperature-maintaining furnace that can be opened and closed automatically, wherein the inner wall of the temperature-maintaining furnace is paved with a reflective ceramic lining to form a reflective furnace chamber, and silicon carbide heating tubes are arranged spirally in the vertical direction under the encirclement of the reflective furnace chamber to reduce the temperature difference in the furnace; a plurality of first rotating bearing units are provided at the bottom of the reflective furnace chamber to carry glass insulators for rotational baking to reduce the temperature difference of the glass insulators; and a cooling furnace that can be opened and closed automatically, wherein a second rotating bearing unit is provided in the cooling furnace to carry glass insulators for rotational cooling; and a vacuum unit and an argon injection unit are provided outside the furnace, wherein the vacuum unit and the argon injection unit are provided. The gas injection unit is connected to the equalizing furnace and the cooling furnace through pipelines; and a handling robot for moving glass insulators into and out of the equalizing furnace and the cooling furnace; and a heat pump unit, the heat pump unit has two heat absorbing ends on its heat absorbing side, which are arranged at the exhaust end of the equalizing furnace and the cooling furnace, and the heat releasing end of the heat pump unit is arranged in the equalizing furnace, which is used to increase the cooling capacity of the cooling furnace, improve the waste heat recovery, and use the recovered heat to assist in baking the glass insulators; and a defect self-inspection mechanism, which performs online monitoring and intelligent sorting on the glass insulators output in batches from the cooling furnace, and is used to detect and record the quality data of each glass insulator and upload data to mark the glass insulators, so as to form a traceability database of the heat treatment process, and then feedback control is performed on the heat treatment process of the equalizing furnace and the cooling furnace according to the quality data, and glass insulators with quality defects are eliminated.

[0014] In one embodiment, the forming quality control mechanism detects the flow state of the molten material when it is poured into the forming mold, the temperature, electrical conductivity and bubble distribution of the molten material after being poured into the forming mold, and the cracks and shape after forming, obtains forming quality data, and feeds back and regulates the raw material feeding ratio, melting temperature and molten material pouring speed to reduce the forming cracks, bubbles and deformation of the glass insulator.

[0015] In one embodiment, the reflective furnace is provided with a high-temperature zone and a low-temperature annealing zone in a vertical direction from bottom to top; the first rotating carrying unit carries the glass insulator upward into the high-temperature zone and rotates the glass insulator to perform a high-temperature homogenization treatment; after the high-temperature homogenization treatment, the first rotating carrying unit carries the glass insulator down to the low-temperature annealing zone to perform the first cooling.

[0016] In one embodiment, the first rotating bearing unit includes a high-temperature resistant ceramic turntable, a magnetic rotating shaft, a permanent magnet array, an electromagnetic drive group and a lifting group; the two ends of the magnetic rotating shaft are respectively a connecting end and a driving end, the connecting end is connected to the high-temperature resistant ceramic turntable, and the driving end passes through the reflective furnace chamber to the outside of the uniform temperature furnace and is connected to the lifting group for transmission; a permanent magnet array is installed on the end of the driving end; the electromagnetic drive group is arranged adjacent to the driving end and surrounds the magnetic rotating shaft; the magnetic rotating shaft is controlled to rotate by controlling the electromagnetic drive group, thereby transmitting the rotational motion to the high-temperature resistant ceramic turntable to drive the glass insulator carried by it to rotate.

[0017] In one embodiment, a ceramic insulation ring is installed between the magnetic rotating shaft and the reflective furnace; the driving end of the magnetic rotating shaft and the electromagnetic driving group are both provided with a water cooling jacket for reducing the temperature of the driving end to prevent excessive temperature from affecting the electromagnetic drive; the water cooling jacket is connected to the heat absorption side of the heat pump unit.

[0018] In one embodiment, the second rotating bearing unit includes a second rotating shaft, a second turntable and a motor drive group; the second turntable is arranged in the cooling furnace; one end of the second rotating shaft is connected to the second turntable, and the other end of the second rotating shaft is transmission-connected to the motor drive group.

[0019] In one embodiment, the heat release end of the heat pump unit is arranged at the bottom of the reflective furnace; the heat absorption end of the heat pump unit is located in the cooling furnace and is arranged at the top of the cooling furnace.

[0020] In one embodiment, the transport robot includes a first robot arranged outside the entrance of the temperature-equalizing furnace and a second robot arranged outside the exit; the first robot clamps the glass insulator through a clamp, the entrance of the temperature-equalizing furnace opens automatically, and the first robot sends the glass insulator into the first rotating bearing unit in the reflective furnace chamber; a contoured support clamp is installed on the end execution part of the second robot, and the finger shape of the contoured support clamp is consistent with the outer wall contour of the glass insulator in contact; the exit of the temperature-equalizing furnace opens automatically, and the second robot extends into the reflective furnace chamber and closes the fingers of the contoured support clamp with the outer wall of the glass insulator to support the glass insulator and move the glass insulator to the second rotating bearing unit of the cooling furnace; and a third robot arranged outside the exit of the cooling furnace is used to take out the glass insulator in the cooling furnace.

[0021] In one embodiment, the defect self-inspection mechanism includes an online monitoring unit and an intelligent sorting mechanism. The online monitoring unit uploads the collected data, and the intelligent sorting mechanism calls the data collected by the online monitoring unit to sort the glass insulators; the online monitoring unit includes a high-resolution industrial camera with an LED light source, a laser confocal microscope and a stress testing station arranged in sequence along the direction of conveying the glass insulators; the high-resolution industrial camera is used to scan obvious cracks, bubbles and scratches on the glass insulators; the laser confocal microscope is used to perform three-dimensional morphology reconstruction on the microcracks of the glass insulators and measure the crack depth and width ratio; the stress testing station uses ultrasonic equipment to scan the stress field of the glass insulator and calculates the stress data of the scanned glass insulators through stress inversion; the intelligent sorting mechanism is provided with multiple sorting robotic arms; along the direction of conveying the glass insulators, the multiple sorting robotic arms are respectively arranged behind the high-resolution industrial camera, the laser confocal microscope and the stress testing station to pick out glass insulators of unqualified quality.

[0022] In one embodiment, the traceability database is constructed through the stress data and defect data collected by the line monitoring unit, and a glass insulator defect prediction model is formed through training and learning of the glass insulator quality data in the traceability database; through the glass insulator defect prediction model, an SPC control chart is produced in real time according to the stress data and defect data of the current batch of glass insulators, and a feedback control mechanism is automatically triggered to regulate the heat treatment parameters of the equalizing furnace and the cooling parameters of the cooling furnace to improve the heat treatment quality of the next batch of glass insulators.

[0023] The beneficial effects of the present invention are as follows:

[0024] By introducing a forming quality control mechanism, a temperature-averaging furnace, a cooling furnace, a heat pump unit, and a defect self-inspection mechanism to form a heat treatment equipment for glass insulator production, the production quality and efficiency of glass insulators have been effectively improved, which is mainly reflected in:

[0025] (1) Improve temperature uniformity, reduce internal stress of glass insulators and reduce stress differences among various parts of the surface of glass insulators: A reflective furnace chamber is constructed using a reflective ceramic lining, and the spiral arrangement of silicon carbide heating tubes is combined to evenly distribute heat in the furnace, reduce temperature differences in the furnace, and control the temperature differences of various parts of the same temperature zone in the reflective furnace chamber to at least ±3°C. Compared with traditional heating furnaces, the present invention greatly improves the heating uniformity of glass insulators in the uniform temperature furnace through the ingenious arrangement of heating elements.

[0026] The first rotating bearing unit rotates the glass insulator and cooperates with the temperature-averaging furnace to realize rotary baking of the glass insulator, ensuring that all parts of the glass insulator are heated evenly, effectively eliminating the internal stress of the glass, and improving product stability; and using the centrifugal force of rotation to homogenize the microcrystalline structure on the surface of the glass insulator, promote a smoother transition of the microcrystalline structure, reduce the stress difference between various parts of the surface of the glass insulator, and reduce the cracking of the glass insulator during cooling and tempering in the cooling furnace.

[0027] (2) Reduce energy consumption and improve heat utilization rate: Use heat pump units to perform graded waste heat recovery, use the heat absorption end to absorb the exhaust waste heat of the equalizing furnace and the heat energy of the cooling furnace, and then feed the heat back to the equalizing furnace through the heat release end, thereby improving the heat energy recovery rate and significantly reducing production energy consumption; at the same time, increase the cooling capacity of the cooling furnace and reduce the power consumption of the cooling furnace.

[0028] By reflecting the heat inside the furnace through the structure of the reflective furnace, the heat loss of the temperature-maintaining furnace can be reduced, the heating efficiency can be improved, and the heat utilization rate can be improved by coordinating the heat released by the heat release end of the heat pump unit.

[0029] (3) Optimize the cooling temperature difference and rate to prevent the glass insulator from cracking: A second rotating bearing unit is set in the cooling furnace to ensure that the glass insulator is cooled evenly during the cooling process, prevent the concentration of thermal stress caused by local excessive cooling, reduce the risk of cracking, and improve the yield rate.

[0030] The vacuum unit is used in conjunction with the argon injection unit to optimize the atmosphere in the cooling furnace, making the cooling process of the glass insulator more controllable and ensuring a stable cooling rate.

[0031] (4) Improve the level of automation and realize intelligent control: Through the forming quality control mechanism, the melting state and the quality of the glass insulator after forming can be detected in real time, and closed-loop feedback control can be performed to optimize the feeding ratio and melting process parameters, thereby improving the forming quality of the glass insulator before heat treatment.

[0032] The glass insulators are moved into and out of the temperature-averaging furnace and the cooling furnace by a provided handling robot, thereby reducing human intervention, reducing factors that interfere with the heat treatment of the glass insulators, and improving the consistency of the heat treatment of the glass insulators.

[0033] A defect self-inspection mechanism is used to conduct online monitoring and intelligent sorting of cooled glass insulators, automatically eliminating products with quality defects. At the same time, a heat treatment traceability database is established to form a closed-loop control of the glass insulator heat treatment process, thereby improving the quality management level of glass insulator products.

[0034] (5) Improve production efficiency and ensure product quality traceability: Use a temperature-averaging furnace and cooling furnace that can be opened and closed automatically to reduce heat and cold losses caused by frequent opening and closing of the furnace door, reduce uneven temperature distribution in the furnace, and cooperate with the handling robot to improve the production efficiency of the heat treatment of glass insulators; through the online monitoring of the defect self-inspection mechanism, batch inspection, marking and recording of the quality of glass insulators can be achieved, providing data support for production (heat treatment process) management, ensuring that the production data and quality data of each glass insulator are traceable.

[0035] In summary, the heat treatment equipment for glass insulator production of the present invention integrates the forming quality control, heat treatment control, waste heat recovery and quality monitoring of glass insulators before heat treatment through the cooperation of multiple mechanisms, successfully solving the technical problems of existing glass insulator heat treatment equipment such as poor temperature uniformity, high energy consumption, unstable cooling rate and low degree of automation, and significantly improving the production quality, production efficiency and energy utilization of glass insulators. BRIEF DESCRIPTION OF THE DRAWINGS

[0036] In order to more clearly illustrate the technical solution of the present invention, the following is a brief introduction to the drawings required for use in the implementation. Obviously, the drawings described below are only some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying any creative work.

[0037] Figure 1 This is a schematic diagram of the overall heat treatment structure of the heat treatment equipment for producing glass insulators of the present invention;

[0038] Figure 2 The present invention is a schematic diagram of the local heat treatment structure of the heat treatment equipment for producing glass insulators. DETAILED DESCRIPTION

[0039] The technical solutions in the embodiments of the present invention will be described clearly and completely below with reference to the accompanying drawings in the embodiments of the present invention.

[0040] In a specific embodiment, a heat treatment device for glass insulator production is provided, which includes a forming quality control mechanism for detecting the molten state of glass and quality data after forming, thereby improving the quality of glass insulators before heat treatment; the temperature equalization furnace adopts a reflective furnace chamber and a silicon carbide heating tube spirally arranged in a vertical direction to reduce the temperature difference in the furnace, and causes the glass insulator to rotate during the heating process, thereby reducing the temperature difference between various parts of the glass insulator itself; the cooling furnace cools the glass insulator by rotation to achieve uniform cooling of the glass insulator; the vacuum unit and the argon injection unit assist in accurately controlling the temperature in the furnace; waste heat is recovered by a heat pump unit; and the heat treatment process is feedback-regulated by a defect self-inspection mechanism; the present invention improves the quality stability, production efficiency and energy utilization rate of the heat treatment process of glass insulators by optimizing the heating and cooling methods and by closed-loop control of process parameters and waste heat recovery; it effectively solves the technical problems of existing glass insulator heat treatment equipment, such as poor temperature uniformity, high energy consumption, unstable cooling rate and low degree of automation, which make it difficult to improve the quality and quality of glass insulators.

[0041] The first embodiment of a heat treatment apparatus for producing glass insulators is Figure 1 and Figure 2 As shown, it includes a forming quality control mechanism, which obtains quality data by detecting the melting state and the formed glass insulators, and feeds back and regulates the feeding ratio and the melting of raw materials to form a closed-loop control; and a temperature-averaging furnace that can be opened and closed automatically, the inner wall of the temperature-averaging furnace is paved with a reflective ceramic lining to form a reflective furnace chamber, and silicon carbide heating tubes are arranged in a vertical spiral around the reflective furnace chamber to reduce the temperature difference in the furnace; a plurality of first rotating bearing units are provided at the bottom of the reflective furnace chamber to carry glass insulators for rotational baking to reduce the temperature difference of the glass insulators; and a cooling furnace that can be opened and closed automatically, a second rotating bearing unit is provided in the cooling furnace to carry glass insulators for rotational cooling; and a vacuum unit and an argon injection unit are provided outside the furnace, and the vacuum unit and the argon injection unit are provided. The unit is connected to the equalizing furnace and the cooling furnace through pipes; and a handling robot for moving glass insulators into and out of the equalizing furnace and the cooling furnace; and a heat pump unit, the heat pump unit has two heat absorbing ends on the heat absorbing side, which are arranged at the exhaust end of the equalizing furnace and the cooling furnace, and the heat releasing end of the heat pump unit is arranged in the equalizing furnace, which is used to increase the cooling capacity of the cooling furnace, improve the waste heat recovery, and use the recovered heat to assist in baking the glass insulators; and a defect self-inspection mechanism, which performs online monitoring and intelligent sorting of the glass insulators output in batches from the cooling furnace, and is used to detect and record the quality data of each glass insulator and upload data to mark the glass insulators, forming a traceability database of the heat treatment process, and then feedback-controls the heat treatment process of the equalizing furnace and the cooling furnace according to the quality data, and eliminates glass insulators with quality defects.

[0042] Among them, regarding the specific structure of the above-mentioned temperature equalizing furnace, the reflective furnace is provided with a high-temperature zone and a low-temperature annealing zone in the vertical direction from bottom to top; the first rotating carrying unit carries the glass insulator to rise into the high-temperature zone, and rotates the glass insulator to perform high-temperature equalization treatment; after the high-temperature equalization treatment, the first rotating carrying unit carries the glass insulator down to the low-temperature annealing zone for the first cooling.

[0043] During application, multiple temperature sensors are arranged in the high-temperature zone and the low-temperature annealing zone to detect the temperature of the corresponding area, obtain temperature difference distribution data, and accurately control the temperature of the corresponding area by adjusting the heat release end of the silicon carbide heating tube and the heat pump unit.

[0044] Among them, the temperature of the high temperature zone is controlled at 680-750°C; the temperature of the low temperature annealing zone is controlled at 400-450°C. During the heat treatment, the specific temperature parameters of the high temperature zone and the low temperature annealing zone can be adjusted.

[0045] Furthermore, through the cooperation of the vacuum unit and the argon injection unit, the temperature in the reflective furnace can be accelerated before the heat treatment in the temperature-matching furnace, and the accuracy of controlling the rate of temperature increase or decrease in the reflective furnace during the heat treatment can be improved; and during the cooling process of the cooling furnace, the furnace atmosphere of the cooling furnace can be optimized, making the cooling process of the glass insulator more controllable and ensuring a stable cooling rate.

[0046] By introducing a forming quality control mechanism, a temperature-averaging furnace, a cooling furnace, a heat pump unit, and a defect self-inspection mechanism to form heat treatment equipment for glass insulator production, the production quality and efficiency of glass insulators have been effectively improved.

[0047] (1) Improve temperature uniformity, reduce internal stress of glass insulators and reduce stress differences among various parts of the surface of glass insulators: A reflective furnace chamber is constructed using a reflective ceramic lining, and the spiral arrangement of silicon carbide heating tubes is combined to evenly distribute heat in the furnace, reduce temperature differences in the furnace, and control the temperature differences of various parts of the same temperature zone in the reflective furnace chamber to at least ±3°C. Compared with traditional heating furnaces, the present invention greatly improves the heating uniformity of glass insulators in the uniform temperature furnace through the ingenious arrangement of heating elements.

[0048] The first rotating bearing unit rotates the glass insulator and cooperates with the temperature-averaging furnace to realize rotary baking of the glass insulator, ensuring that all parts of the glass insulator are heated evenly, effectively eliminating the internal stress of the glass, and improving product stability; and using the centrifugal force of rotation to homogenize the microcrystalline structure on the surface of the glass insulator, promote a smoother transition of the microcrystalline structure, reduce the stress difference between various parts of the surface of the glass insulator, and reduce the cracking of the glass insulator during cooling and tempering in the cooling furnace.

[0049] (2) Reduce energy consumption and improve heat utilization rate: Use heat pump units to perform graded waste heat recovery, use the heat absorption end to absorb the exhaust waste heat of the equalizing furnace and the heat energy of the cooling furnace, and then feed the heat back to the equalizing furnace through the heat release end, thereby improving the heat energy recovery rate and significantly reducing production energy consumption; at the same time, increase the cooling capacity of the cooling furnace and reduce the power consumption of the cooling furnace.

[0050] By reflecting the heat inside the furnace through the structure of the reflective furnace, the heat loss of the temperature-maintaining furnace can be reduced, the heating efficiency can be improved, and the heat utilization rate can be improved by coordinating the heat released by the heat release end of the heat pump unit.

[0051] (3) Optimize the cooling temperature difference to prevent the glass insulator from cracking: A second rotating bearing unit is set in the cooling furnace to ensure that the glass insulator is cooled evenly during the cooling process, prevent the concentration of thermal stress caused by local excessive cooling, reduce the risk of cracking, and improve the yield rate.

[0052] (4) Improve the level of automation and realize intelligent control: Through the forming quality control mechanism, the melting state and the quality of the glass insulator after forming can be detected in real time, and closed-loop feedback control can be performed to optimize the feeding ratio and melting process parameters, thereby improving the forming quality of the glass insulator before heat treatment.

[0053] The glass insulators are moved into and out of the equalizing furnace and the cooling furnace by a set handling robot, which reduces human intervention, reduces factors that interfere with the heat treatment of the glass insulators, and improves the consistency of the heat treatment of the glass insulators.

[0054] A defect self-inspection mechanism is used to conduct online monitoring and intelligent sorting of cooled glass insulators, automatically eliminating products with quality defects. At the same time, a heat treatment traceability database is established to form a closed-loop control of the glass insulator heat treatment process, thereby improving the quality management level of glass insulator products.

[0055] (5) Improve production efficiency and ensure product quality traceability: Use a temperature-averaging furnace and cooling furnace that can be opened and closed automatically to reduce heat and cold losses caused by frequent opening and closing of the furnace door, reduce uneven temperature distribution in the furnace, and cooperate with the handling robot to improve the production efficiency of the heat treatment of glass insulators; through the online monitoring of the defect self-inspection mechanism, batch inspection, marking and recording of the quality of glass insulators can be achieved, providing data support for production (heat treatment process) management, ensuring that the production data and quality data of each glass insulator are traceable.

[0056] The heat treatment equipment for glass insulator production integrates the forming quality control, heat treatment control, waste heat recovery and quality monitoring of glass insulators before heat treatment through the cooperation of multiple mechanisms. It successfully solves the technical problems of existing glass insulator heat treatment equipment such as poor temperature uniformity, high energy consumption, unstable cooling rate and low degree of automation, and significantly improves the production quality, production efficiency and energy utilization of glass insulators.

[0057] As an optional implementation method

[0058] Regarding the specific closed-loop control method of the above-mentioned forming quality control mechanism, the forming quality control mechanism detects the flow state of the molten material when it is poured into the forming mold, the temperature, electrical conductivity and bubble distribution of the molten material after being poured into the forming mold, and the cracks and shape after forming, obtains forming quality data, and feeds back and controls the raw material feeding ratio, melting temperature and pouring speed of the molten material in the forming mold to reduce the forming cracks, bubbles and deformation of the glass insulator.

[0059] During application, an industrial camera is used to capture images of the molten material flow state, and an algorithm is used to analyze the current state of the molten material to generate molten material pouring flow state data. An infrared thermal imager is used to monitor the temperature of the molten material after it is poured into the forming mold, and a zirconia solid electrolyte probe is inserted to measure the conductivity of the molten material after it is poured into the forming mold. A microfocus X-ray source is used to penetrate the molten glass layer and a high-speed CMOS camera is used to capture and detect bubbles and their distribution. A high-resolution industrial camera (5μm pixels) is used in combination with a ring-shaped LED light source to capture and detect cracks after forming. A blue light laser scanner is used to reconstruct the three-dimensional model of the insulator to obtain a rough shape, and the deformation is obtained by comparing it with the drawing model.

[0060] Regarding the specific structure of the above-mentioned first rotating bearing unit, the first rotating bearing unit includes a high-temperature resistant ceramic turntable, a magnetic rotating shaft, a permanent magnet array, an electromagnetic drive group and a lifting group; the two ends of the magnetic rotating shaft are respectively a connecting end and a driving end, the connecting end is connected to the high-temperature resistant ceramic turntable, and the driving end passes through the reflective furnace chamber to the outside of the uniform temperature furnace and is connected to the lifting group for transmission; a permanent magnet array is installed on the end of the driving end; the electromagnetic drive group is arranged adjacent to the driving end and surrounds the magnetic rotating shaft; the rotation of the magnetic rotating shaft is controlled by controlling the electromagnetic drive group, thereby transmitting the rotational motion to the high-temperature resistant ceramic turntable to drive the glass insulator carried by it to rotate.

[0061] During application, a ceramic insulation ring is installed between the magnetic rotating shaft and the reflective furnace; the driving end of the magnetic rotating shaft and the electromagnetic driving group are both provided with a water cooling jacket to reduce the temperature of the driving end and avoid demagnetization caused by excessive temperature, thereby affecting the electromagnetic drive; the water cooling jacket is connected to the heat absorption side of the heat pump unit, and the heat pump unit recovers the heat emitted from the uniform temperature furnace by the magnetic rotating shaft, and cools the driving end of the magnetic rotating shaft at the same time.

[0062] Regarding the specific structure of the above-mentioned second rotating bearing unit, the second rotating bearing unit includes a second rotating shaft, a second turntable and a motor drive group; the second turntable is arranged in the cooling furnace; one end of the second rotating shaft is connected to the second turntable, and the other end of the second rotating shaft is transmission connected to the motor drive group.

[0063] Regarding the location of the heat release end and the suction end of the above-mentioned heat pump unit, the heat release end of the heat pump unit is set at the bottom of the reflective furnace; the heat absorption end of the heat pump unit is located in the cooling furnace and is arranged at the top of the cooling furnace.

[0064] During application, the positions of the heat release end and the suction end of the heat pump unit are set according to the principle that hot air rises and cold air floats down, which can make the released heat rise evenly in the temperature-averaging furnace and the released cold fall evenly in the cooling furnace, further reducing the temperature difference between the temperature-averaging furnace and the cooling furnace. At the same time, it can also quickly increase the temperature of the temperature-averaging furnace and quickly reduce the temperature of the cooling furnace.

[0065] The specific setting of the above-mentioned handling robot is that the handling robot includes a first robot arranged outside the entrance of the equalizing furnace and a second robot arranged outside the exit; the first robot clamps the glass insulator through a clamp, the entrance of the equalizing furnace opens automatically, and the first robot sends the glass insulator into the first rotating bearing unit in the reflective furnace; a contoured supporting clamp is installed on the end execution part of the second robot, and the shape of the fingers of the contoured supporting clamp is consistent with the outer wall contour of the glass insulator in contact with; the exit of the equalizing furnace opens automatically, and the second robot extends into the reflective furnace and closes the fingers of the contoured supporting clamp with the outer wall of the glass insulator to support the glass insulator and move the glass insulator to the second rotating bearing unit of the cooling furnace; and a third robot arranged outside the exit of the cooling furnace is used to take out the glass insulator in the cooling furnace.

[0066] During application, by setting the first manipulator, the second manipulator and the third manipulator, the automatic transportation of the glass insulator between the equalizing furnace and the cooling furnace is realized, the production efficiency is improved, the stability of the glass insulator during the transportation process is ensured, and the interference factors exerted on the glass insulator during manual transportation are reduced. Specifically: the degree of automation is improved and manual intervention is reduced: the first manipulator is used to automatically clamp the glass insulator and send it into the equalizing furnace, avoiding the instability caused by manual operation and reducing the scrap rate of the glass insulator; the second manipulator is equipped with a contoured supporting fixture to ensure that the finger shape of the fixture is consistent with the outer wall contour of the glass insulator, making the clamping more stable. At the same time, the clamping method of supporting the glass insulator can reduce the pressure exerted by the fixture on the surface of the glass insulator, avoiding surface damage of the glass insulator that has just been heat-treated due to improper clamping; the third manipulator automatically takes out the cooled glass insulator, realizing full-process automated transportation, reducing manual operation and improving production efficiency.

[0067] Optimize the heat treatment process and improve product quality: The first manipulator cooperates with the automatically opened and closed temperature-maintaining furnace inlet to reduce heat loss when the glass insulator enters the furnace, thereby improving heating efficiency and temperature uniformity.

[0068] The contoured support fixture of the second manipulator provides stable support for the glass insulator when it comes out of the furnace, preventing thermal stress concentration or deformation caused by uneven force, thereby improving product quality.

[0069] The third robot takes out the glass insulator at the exit of the cooling furnace and places it on the conveyor line, realizing the full-process automated handling of the glass insulator, preventing damage to the surface of the glass insulator caused by human operation, and reducing the risk of cracking.

[0070] Improve handling accuracy and reduce losses: Use automated manipulators to precisely control the clamping force, effectively reducing breakage of glass insulators caused by uneven clamping force or vibration, and improving the yield of glass insulators.

[0071] Improve production efficiency and optimize production processes: The coordinated cooperation of the manipulators makes the transfer of glass insulators between the equalizing furnace and the cooling furnace smoother, improving the continuity of the heat treatment process of glass insulators and reducing waiting time; the automatic opening and closing structure of the equalizing furnace and the cooling furnace, and the coordinated handling manipulators quickly pick up and place glass insulators, reduce heat and cold loss in the furnace, improve energy efficiency, and avoid the safety hazards caused by manual operation of the furnace door.

[0072] Regarding the specific structure and control method of the above-mentioned defect self-inspection mechanism, the defect self-inspection mechanism includes an online monitoring unit and an intelligent sorting mechanism. The online monitoring unit uploads the collected data, and the intelligent sorting mechanism calls the data collected by the online monitoring unit to sort the glass insulators; the online monitoring unit includes a high-resolution industrial camera with an LED light source, a laser confocal microscope and a stress testing station arranged in sequence along the direction of conveying the glass insulators; the high-resolution industrial camera is used to scan the obvious cracks, bubbles and scratches on the glass insulators; the laser confocal microscope is used to perform three-dimensional morphology reconstruction on the microcracks of the glass insulators and measure the crack depth and width ratio; the stress testing station uses ultrasonic equipment to scan the stress field of the glass insulator, and calculates the stress data of the scanned glass insulators through stress inversion; the intelligent sorting mechanism is provided with multiple sorting robotic arms; along the direction of conveying the glass insulators, multiple sorting robotic arms are respectively arranged behind the high-resolution industrial camera, the laser confocal microscope and the stress testing station to pick out glass insulators of unqualified quality.

[0073] During application, the unqualified glass insulators are sorted and stacked in the defective area; the qualified glass insulators will continue to be conveyed by the conveyor line to the finished product area for stacking.

[0074] Specifically, a high-resolution industrial camera collects data on obvious cracks, bubbles, and scratches on glass insulators, and a laser confocal microscope collects data on the depth and width ratio of microcracks on glass insulators, which together constitute the defect data of glass insulators.

[0075] The second embodiment of the heat treatment equipment for glass insulator production is different from the first embodiment in that the quality of the heat treatment and cooling processes of glass insulators is improved in an intelligent and automated manner, thereby improving the yield of glass insulators and improving the quality of finished products of glass insulators. The specific control method is: using the stress data and defect data collected by the line monitoring unit to build a traceability database, and forming a glass insulator defect prediction model through training and learning of the glass insulator quality data in the traceability database; through the glass insulator defect prediction model, according to the stress data and defect data of the current batch of glass insulators, an SPC control chart is produced in real time, and the feedback control mechanism is automatically triggered to adjust the heat treatment parameters of the equalizing furnace and the cooling parameters of the cooling furnace to improve the heat treatment quality of the next batch of glass insulators.

[0076] When applied, after the feedback control mechanism is triggered, it is used to control the equalization temperature, annealing time and rotation speed in the heat treatment parameters of the equalizing furnace, and the cooling temperature and rotation speed in the cooling parameters of the cooling furnace, so as to optimize the quality of the heat treatment and cooling processes of the glass insulator.

[0077] The technical features of the above embodiments may be arbitrarily combined. To simplify the description, not all possible combinations of the technical features in the above embodiments are described.

Claims

1. A heat treatment equipment for glass insulator production, characterized in that: It includes a forming quality control mechanism, which obtains quality data by detecting the melting state and the formed glass insulator, and provides feedback and regulates the feeding ratio and raw material melting to form a closed-loop control; and a temperature-scaling furnace that can be opened and closed automatically. The inner wall of the temperature-scaling furnace is paved with a reflective ceramic lining to form a reflective furnace chamber. Silicon carbide heating tubes are arranged in a vertical spiral around the reflective furnace chamber to reduce the temperature difference in the furnace. A plurality of first rotating bearing units are provided at the bottom of the reflective furnace chamber to carry glass insulators for rotational baking to reduce the temperature difference of the glass insulators. and a cooling furnace that can be opened and closed automatically, wherein a second rotating bearing unit is provided in the cooling furnace for bearing the glass insulator for rotational cooling; and a vacuum unit and an argon injection unit provided outside the furnace, wherein the vacuum unit and the argon injection unit are respectively connected to the temperature-sparing furnace and the cooling furnace through pipelines; and a handling robot for moving glass insulators into and out of the temperature-sparing furnace and the cooling furnace; and a heat pump unit, wherein the heat absorbing side of the heat pump unit is provided with two heat absorbing ends arranged at the exhaust end of the temperature-averaging furnace and the cooling furnace, and the heat releasing end of the heat pump unit is arranged in the temperature-averaging furnace, so as to increase the cooling capacity of the cooling furnace, improve waste heat recovery, and use the recovered heat to assist in baking glass insulators; and a defect self-inspection mechanism, which performs online monitoring and intelligent sorting of the glass insulators output in batches from the cooling furnace, is used to detect and record the quality data of each glass insulator and upload the data to mark the glass insulators, thereby forming a traceability database for the heat treatment process. The heat treatment process of the temperature-saturating furnace and the cooling furnace is then feedback-controlled based on the quality data, and glass insulators with quality defects are eliminated; The reflective furnace is vertically provided with a high-temperature zone and a low-temperature annealing zone from top to bottom; the first rotating bearing unit carries the glass insulator upward into the high-temperature zone and rotates the glass insulator to perform a high-temperature homogenization treatment; after the high-temperature homogenization treatment, the first rotating bearing unit carries the glass insulator downward into the low-temperature annealing zone to perform a first cooling process; The first rotating bearing unit includes a high-temperature resistant ceramic turntable, a magnetic rotating shaft, a permanent magnet array, an electromagnetic drive group and a lifting group; the two ends of the magnetic rotating shaft are respectively a connecting end and a driving end, the connecting end is connected to the high-temperature resistant ceramic turntable, and the driving end passes through the reflective furnace chamber to the outside of the temperature-averaging furnace and is transmission-connected to the lifting group; a permanent magnet array is installed on the end of the driving end; the electromagnetic drive group is arranged adjacent to the driving end and surrounds the magnetic rotating shaft; the magnetic rotating shaft is controlled to rotate by controlling the electromagnetic drive group, thereby transmitting the rotational motion to the high-temperature resistant ceramic turntable to drive the glass insulator carried by it to rotate; A ceramic heat-insulating ring is installed between the magnetic rotating shaft and the reflective furnace; the driving end of the magnetic rotating shaft and the electromagnetic drive group are both provided with a water-cooling jacket for reducing the temperature of the driving end to prevent excessive temperature from affecting the electromagnetic drive; the water-cooling jacket is connected to the heat-absorbing side of the heat pump unit; The heat pump unit's heat release end is located at the bottom of the reflective furnace; the heat pump unit's heat absorption end is located in the cooling furnace and is arranged at the top of the cooling furnace. The defect self-inspection mechanism includes an online monitoring unit and an intelligent sorting mechanism. The online monitoring unit uploads the collected data, and the intelligent sorting mechanism uses the data collected by the online monitoring unit to sort the glass insulators. The online monitoring unit includes a high-resolution industrial camera with an LED light source, a laser confocal microscope, and a stress testing station arranged in sequence along the direction of conveying the glass insulator; The high-resolution industrial camera is used to scan the glass insulator for obvious cracks, bubbles and scratches; The laser confocal microscope is used to reconstruct the three-dimensional morphology of microcracks in glass insulators and measure the ratio of crack depth to width; The stress testing station scans the stress field of the glass insulator using ultrasonic equipment and calculates the stress data of the scanned glass insulator through stress inversion; The intelligent sorting mechanism is provided with a plurality of sorting robotic arms; along the direction of conveying the glass insulators, the plurality of sorting robotic arms are respectively arranged behind the high-resolution industrial camera, the laser confocal microscope and the stress testing station, and are used to pick out glass insulators of unqualified quality.

2. The heat treatment equipment for producing glass insulators according to claim 1, characterized in that: The forming quality control mechanism detects the flow state of the molten material when it is poured into the forming mold, the temperature, electrical conductivity and bubble distribution of the molten material after being poured into the forming mold, and the cracks and shape after forming, obtains forming quality data, and provides feedback and regulates the raw material feeding ratio, melting temperature and pouring speed of the molten material in the forming mold to reduce forming cracks, bubbles and deformation of the glass insulator.

3. The heat treatment equipment for producing glass insulators according to claim 1, characterized in that: The second rotating bearing unit includes a second rotating shaft, a second turntable and a motor drive group; the second turntable is arranged in the cooling furnace; one end of the second rotating shaft is connected to the second turntable, and the other end of the second rotating shaft is transmission-connected to the motor drive group.

4. The heat treatment equipment for producing glass insulators according to claim 1, characterized in that: The transport robot comprises a first robot arranged outside the inlet of the temperature-maintaining furnace and a second robot arranged outside the outlet; The first manipulator clamps the glass insulator through a clamp, the entrance of the temperature-maintaining furnace is automatically opened, and the first manipulator delivers the glass insulator to the first rotating bearing unit in the reflective furnace chamber; A contoured support fixture is installed on the end effector of the second manipulator, and the shape of the fingers of the contoured support fixture is consistent with the contour of the outer wall of the glass insulator in contact; The outlet of the temperature-maintaining furnace is automatically opened, and the second manipulator extends into the reflective furnace chamber and closes the fingers of the contoured support fixture on the outer wall of the glass insulator to support the glass insulator and move the glass insulator to the second rotating bearing unit of the cooling furnace; And a third manipulator is arranged outside the outlet of the cooling furnace and is used for taking out the glass insulator in the cooling furnace.

5. The heat treatment equipment for producing glass insulators according to claim 1, characterized in that: The traceability database is constructed through the stress data and defect data collected by the online monitoring unit, and a glass insulator defect prediction model is formed through training and learning of the glass insulator quality data in the traceability database; through the glass insulator defect prediction model, an SPC control chart is produced in real time according to the stress data and defect data of the current batch of glass insulators, and a feedback control mechanism is automatically triggered to adjust the heat treatment parameters of the temperature-maintaining furnace and the cooling parameters of the cooling furnace to improve the heat treatment quality of the next batch of glass insulators.

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