Manufacturing method of all-electric float glass melting furnace

Abstract

The invention discloses a manufacturing method of an all-electric float glass melting furnace. The manufacturing method comprises the following steps: S1, carrying out modular prefabrication on a melting furnace structure; s2, assembling a multi-stage electrode system; s3, integrating an intelligent temperature control system; and S4, debugging and optimizing the melting furnace. The invention has the following beneficial effects: emission of combustion waste gas is eliminated, and zero-carbon production is realized; compared with a traditional melting furnace, the energy consumption is reduced by more than 40%, and the power consumption per ton of glass is less than or equal to 1200 kWh; the temperature control precision reaches + / -2 DEG C, and the bubble defect rate is reduced by 50%. The electrode replacement time is shortened by 70% through the modular design; a digital twin system can predict performance degradation within a kiln age cycle.

Description

Technical Field

[0001] The invention relates to the technical field of glass manufacturing, in particular to a method for manufacturing an all-electric float glass melting furnace. Background Art

[0002] As the mainstream technology for flat glass manufacturing, float glass production process has long relied on fossil fuels for heating in its melting furnace system. Existing gas-fired melting furnaces have problems such as large fluctuations in flame temperature (±15°C) and obvious temperature gradients in hot spots, which make it difficult to homogenize the glass liquid and affect the quality of the finished product. At the same time, the nitrogen oxide emissions generated during the combustion process are difficult to meet increasingly stringent environmental protection requirements.

[0003] Although all-electric melting technology has been applied in the field of special glass, it faces three major technical bottlenecks in large-scale float glass production: 1) the difficulty in designing high-power electrode systems; 2) precise control of the longitudinal temperature curve of the melting furnace; 3) the durability of electrode materials in high-temperature molten glass. Summary of the invention

[0004] The object of the present invention is to provide a method for manufacturing an all-electric float glass melting furnace to solve the problems raised in the above background technology.

[0005] To achieve the above object, the present invention provides the following technical solutions: A method for manufacturing an all-electric float glass melting furnace comprises the following steps: S1. Modular prefabrication of melting furnace structure: The bottom module of the melting furnace is prefabricated with silicon nitride combined with silicon carbide materials, and electrode installation grooves are reserved between modules; water-cooled copper electrode sleeves are pre-embedded in the side wall modules, and the sleeves are arranged at an angle of 15°; the top module integrates a radiation temperature measurement window and an exhaust gas recovery channel; S2. Assembly of multi-stage electrode system: a molybdenum electrode matrix is ​​arranged in the melting zone, using a three-phase six-point star arrangement; a tin oxide electrode pair is set in the clarification zone, with the electrode spacing decreasing gradually; a liftable zirconium electrode group is configured in the working zone to achieve adaptive adjustment of the liquid level height; S3, intelligent temperature control system integration: install a distributed optical fiber temperature measurement network with a measurement point density of 5 / m2; deploy a multivariable PID controller and establish a temperature-power coupling control model; realize real-time simulation and prediction of the temperature field through the melting furnace digital twin system; S4. Furnace commissioning and optimization: Segmented power-on aging, initial power controlled at 30% of rated value; flow field visualization test using glass bead simulation material; optimization of electrode current phase distribution through spectral analysis.

[0006] Preferably, the melting furnace bottom module is prefabricated, including: in terms of mass percentage, a composite formula of 60% silicon nitride (Si3N4) + 40% silicon carbide (SiC), and the addition of 2% yttrium oxide (Y2O3) as a sintering aid; the module size is designed to be 1.5m×1.2m×0.3m, and the electrode groove is milled by a CNC machining center with a groove width of 80±0.1mm and a groove inner surface roughness of Ra≤1.6μm; segmented sintering, the sintering atmosphere is nitrogen protection, and the purity is ≥99.99%.

[0007] Preferably, the side wall module is prefabricated, including: the casing is made of oxygen-free copper (C1020) casing with a wall thickness of 5 mm and a spacing of 300 mm; the insulation layer is composed of high-purity alumina fiberboard, lightweight mullite bricks and a stainless steel shell.

[0008] Preferably, the top module is integrated, including: the radiation temperature measurement window adopts a sapphire observation window with a diameter of 80 mm and is equipped with an automatic cleaning device; the exhaust gas recovery system adopts a porous ceramic filter with a pore size of 0.5 μm, and the induced draft fan air volume can be adjusted in the range of 10-50 m³ / min.

[0009] Preferably, the molybdenum electrode matrix is ​​arranged in the melting zone in a three-phase six-point star arrangement, specifically including: the diameter of the molybdenum electrode is Φ80±0.05mm, the purity is ≥99.95%; the center distance between adjacent electrodes is 500mm, the insertion depth is adjustable from 300 to 400mm, and the current density control range is 0.8-1.2A / cm².

[0010] Preferably, a tin oxide electrode pair is arranged in the clarification zone, and the electrode spacing decreases gradually, specifically including: the electrode spacing decreases gradually, 800mm for the first group, 600mm for the second group, and 400mm for the third group; the electrode diameter is Φ60mm, and the thickness of the platinum coating on the surface is 5μm; the power supply mode is DC pulse power supply, the frequency is 50Hz, and the voltage gradient is from 220V in the front zone to 150V in the rear zone.

[0011] Preferably, a liftable zirconium electrode group is arranged in the working area to realize adaptive adjustment of the liquid level height, specifically including: servo motor drive, 200mm stroke, position feedback accuracy ±0.05mm; the zirconium electrode is stabilized by zirconium oxide, the working end taper angle is 45°, and the surface polishing Ra≤0.8μm.

[0012] Preferably, the distributed optical fiber temperature measurement network is installed, and the density of measurement points reaches 5 / square meter, specifically including: using armored optical fiber, temperature resistance of 1600°C, longitudinal spacing of 500mm, and lateral spacing of 200mm; signal processing uses FBG demodulator, with a resolution of 0.1°C and a sampling frequency of 10Hz.

[0013] Preferably, the multivariable PID controller is deployed to establish a temperature-power coupling control model, specifically including: establishing a 16-input×12-output matrix, the coupling coefficient is determined by an orthogonal test; the proportional band is 2-5%, the integral time is 30-60s, and the differential time is 5-10s; The real-time simulation prediction of the temperature field is achieved through the digital twin system of the melting furnace, including: the grid division size is ≤50mm, including thermal-electrical-current multi-physical field coupling; the update cycle is 1 minute, and the electrode life prediction error is ≤5%.

[0014] Preferably, the segmented power-on aging, the initial power is controlled at 30% of the rated value, specifically including: segmented power-on aging, the initial power is controlled at 30% of the rated value; the flow field visualization test uses glass beads to simulate the material, the CCD camera shoots at a frequency of 25fps, and the PIV analysis software processes the image; the spectral optimization uses genetic algorithm iteration, and the objective function is temperature uniformity index ≥ 0.95.

[0015] Compared with the prior art, the invention has the following beneficial effects: it eliminates combustion exhaust gas emissions and achieves zero-carbon production; it reduces energy consumption by more than 40% compared with traditional melting furnaces, and the power consumption per ton of glass is ≤1200kWh; the temperature control accuracy reaches ±2°C, and the bubble defect rate is reduced by 50%. The modular design shortens the electrode replacement time by 70%; the digital twin system can predict the performance degradation within the kiln life cycle. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 is a flow chart of a method according to an embodiment of the present invention; Figure 2 This is a sub-flow chart of step S1 of an embodiment of the present invention; Figure 3 This is a sub-flow chart of step S2 of an embodiment of the present invention; Figure 4 This is a sub-flow chart of step S3 of the present embodiment; Figure 5 This is a sub-flow chart of step S4 of an embodiment of the present invention. DETAILED DESCRIPTION

[0017] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments 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.

[0018] See also Figure 1 The present invention provides a technical solution: a method for manufacturing an all-electric float glass melting furnace, comprising the following steps: S1. Modular prefabrication of melting furnace structure: The bottom module of the melting furnace is prefabricated using silicon nitride combined with silicon carbide materials, and electrode installation grooves are reserved between modules; water-cooled copper electrode sleeves are embedded in the side wall modules, and the sleeves are arranged at an inclined angle of 15°; the top module integrates a radiation temperature measurement window and an exhaust gas recovery channel.

[0019] S2. Assembly of multi-stage electrode system: a molybdenum electrode matrix is ​​arranged in the melting zone, using a three-phase six-point star arrangement; a tin oxide electrode pair is set in the clarification zone, with the electrode spacing decreasing gradually; a liftable zirconium electrode group is configured in the working zone to achieve adaptive adjustment of the liquid level height.

[0020] S3. Integration of intelligent temperature control system: Install a distributed fiber optic temperature measurement network with a measurement point density of 5 points per square meter; deploy a multivariable PID controller to establish a temperature-power coupling control model; and realize real-time simulation and prediction of the temperature field through the melting furnace digital twin system.

[0021] S4. Furnace commissioning and optimization: Segmented power-on aging, initial power controlled at 30% of rated value; flow field visualization test using glass bead simulation material; optimization of electrode current phase distribution through spectral analysis.

[0022] In an embodiment of the present invention, the prefabrication of the furnace bottom module in step S1 specifically includes: S1.1 Material preparation: In terms of mass percentage, a composite formula of 60% silicon nitride (Si3N4) + 40% silicon carbide (SiC) is used, and 2% yttrium oxide (Y2O3) is added as a sintering aid.

[0023] S1.2 Module processing: The size of a single module is designed to be 1.5m×1.2m×0.3m (length×width×height). The electrode groove is milled using a CNC machining center with a groove width of 80±0.1mm and a groove inner surface roughness of Ra≤1.6μm.

[0024] S1.3 Heat treatment: Sintering in stages, sintering atmosphere is nitrogen protection, purity ≥ 99.99%. Specific sintering steps are: room temperature → 800℃ (2h) → 1500℃ (4h) → 1850℃ (6h).

[0025] In an embodiment of the present invention, the side wall modules in the melting furnace are prefabricated in step S1, and the steps include: S1.4 Pre-embedded water-cooling jacket: oxygen-free copper (C1020) jacket with a wall thickness of 5mm is selected, laser positioning welding is adopted, the welding temperature is controlled at 650±10℃, and the spacing is 300mm; an insulation layer is formed on the pre-embedded water-cooling jacket, and the insulation layer is constructed: the inner layer is 50mm high-purity alumina fiberboard, the middle layer is 100mm lightweight mullite brick, and the outer layer is a stainless steel shell (304L).

[0026] In this embodiment, the water-cooled copper electrode sleeve is made of oxygen-free copper (C1020) with a wall thickness of 5 mm. It is necessary to ensure that there are no defects such as cracks and sand holes on the surface, and the material purity meets the requirements. The side wall module should be flat and free of impurities in the welding area to avoid affecting the welding quality. Each batch of sleeve and module materials entering the site is randomly inspected and the material certification documents are checked to ensure stable and reliable material quality.

[0027] In this embodiment, the laser welding equipment is selected from welding equipment suitable for oxygen-free copper welding, such as a pulse fiber laser welding machine. This equipment has the advantages of high energy density, fast welding speed, and small heat-affected zone, and can meet the high-precision welding requirements of water-cooled copper electrode sleeves. At the same time, auxiliary tools are prepared, such as high-precision positioning fixtures, which are used to fix the water-cooled copper electrode sleeves and the side wall modules to ensure the accurate relative position of the two during welding; an argon protection device is also required to provide inert gas protection during welding to prevent copper from oxidizing at high temperatures.

[0028] In this embodiment, sandpaper or mechanical grinding tools are used to pre-treat the welding parts of the water-cooled copper electrode sleeve and the welding areas of the side wall modules. Sandpaper or mechanical grinding tools are used to remove the oxide layer, oil stains and impurities on the surface, so that the welding surface reveals the metallic luster to improve the quality of the welded joint. After grinding, the welding area is cleaned with anhydrous ethanol or acetone to remove the residual grinding debris and cleaning agent to ensure that the welding area is clean and dry.

[0029] In this embodiment, a pulse fiber laser welding machine is used for pre-embedded welding of water-cooled copper electrode sleeves. Its wavelength is usually around 1064nm, which can be well absorbed by copper materials to achieve efficient welding. This equipment has the following advantages: In this embodiment, parameters such as pulse energy, pulse width and frequency can be precisely adjusted, and the welding energy input can be flexibly adjusted according to the wall thickness and welding requirements of the water-cooled copper electrode sleeve to ensure a stable welding process and avoid defects such as over-welding or incomplete welding.

[0030] By transmitting the laser beam through optical fiber, high-precision focusing can be achieved, and the spot diameter can reach the micron level, meeting the high-precision welding positioning requirements of 15° inclination angle and 300mm spacing of the center line of the water-cooled copper electrode sleeve.

[0031] Equipped with an automated control system, the welding process can be automated to improve welding efficiency and consistency. The operator only needs to set the welding parameters, and the equipment can weld according to the preset program, reducing the impact of human factors on welding quality.

[0032] In this embodiment, a high-precision positioning fixture is used to accurately fix the water-cooled copper electrode sleeve at the preset position of the side wall module, ensuring that the sleeve centerline inclination angle is 15° and the spacing is 300mm. Before welding, a laser tracker or total station or other measuring equipment is used to detect the positioning accuracy, and timely adjustments are made when the deviation exceeds the allowable range. During the welding process, the sleeve position is monitored in real time to prevent position deviation caused by welding thermal deformation.

[0033] In this embodiment, the welding temperature is strictly controlled at 650±10℃, and the temperature of the welding area is monitored in real time by the temperature monitoring system of the welding equipment and the infrared thermometer. At the same time, pay close attention to parameters such as welding current, voltage, and pulse frequency to ensure that they are stable within the set range. If abnormal fluctuations in parameters are found, stop welding immediately, check the equipment and welding process, and continue welding after troubleshooting.

[0034] In this embodiment, during the welding process, argon gas is continuously introduced as a protective gas, and the purity of argon gas is ≥99.99%. The argon gas flow rate is adjusted. At the beginning of welding, the flow rate is appropriately increased to effectively remove the air in the welding area; during welding, a stable flow rate is maintained, generally 5-10L / min, to ensure that the welding pool is in an inert gas protective atmosphere, to prevent copper from oxidizing at high temperatures, and to ensure the quality of the welded joint.

[0035] In this embodiment, after welding is completed, each weld joint is visually inspected to see whether the weld surface is smooth and uniform, and whether there are defects such as pores, cracks, and undercuts. Nondestructive testing methods such as ultrasonic testing or radiographic testing are used to inspect the internal quality of the weld joint to ensure that there are no defects such as incomplete penetration and internal cracks. For unqualified weld joints, rework is carried out in a timely manner, and quality inspection is carried out again after re-welding until the quality standards are met.

[0036] In an embodiment of the present invention, the top module integration in the melting furnace in step S1 comprises: S1.5 Radiation temperature measurement window: Sapphire observation window, 80mm in diameter, equipped with automatic cleaning device, purged with nitrogen every 2 hours.

[0037] In a specific embodiment, the automatic cleaning device is mainly composed of a nitrogen nozzle, a drive motor, a rotating arm and a controller. The nitrogen nozzle is installed at the front end of the rotating arm, which is driven by the drive motor and can rotate 360° on the surface of the sapphire observation window. The controller controls the start of the drive motor at a fixed time and starts the purge program every 2 hours. At this time, the drive motor drives the rotating arm to rotate slowly, and the nitrogen nozzle sprays nitrogen with a purity of ≥99.99% at a pressure of 0.5MPa. The nitrogen covers the surface of the observation window in a fan shape, effectively removing dust and impurities, ensuring the light transmittance of the observation window, and ensuring the accuracy of temperature measurement.

[0038] S1.6 Waste gas recovery system: adopt porous ceramic filter with pore size of 0.5μm and adjustable air volume of induced draft fan in the range of 10-50m³ / min.

[0039] Through modular prefabrication, the manufacturing and use process of the melting furnace is more efficient, stable and reliable, and can better meet the high precision, high efficiency and long life requirements of the all-electric float glass melting furnace.

[0040] In an embodiment of the present invention, the arrangement of the molybdenum electrode matrix in the melting zone in step S2 adopts a three-phase six-point star arrangement, which specifically includes: S2.1 Molybdenum electrode installation: electrode diameter Φ80±0.05mm, purity ≥99.95%, hydraulic propulsion mechanism, propulsion accuracy 0.1mm / step, three-phase power supply phase difference 120±1°.

[0041] S2.2 Star arrangement parameters: center distance between adjacent electrodes is 500mm, insertion depth is adjustable from 300 to 400mm, and current density control range is 0.8-1.2A / cm².

[0042] In an embodiment of the present invention, the step S2 of providing a tin oxide electrode pair in the clarification zone with a decreasing electrode spacing gradient specifically includes: S2.3 Gradient arrangement: the spacing of the first group is 800mm, the second group is 600mm, the third group is 400mm, the electrode diameter is Φ60mm, and the thickness of the platinum coating on the surface is 5μm.

[0043] S2.4 Power supply mode: DC pulse power supply, frequency 50Hz, voltage gradient from 220V in the front area to 150V in the rear area.

[0044] In an embodiment of the present invention, in step S2, a liftable zirconium electrode group is arranged in the working area to realize adaptive adjustment of the liquid level, which specifically includes: S2.5 Lifting mechanism: driven by servo motor, stroke 200mm, position feedback accuracy ±0.05mm.

[0045] S2.6 Zirconium electrode treatment: Zirconium oxide stabilization treatment (adding 8% Y2O3), working end cone angle 45°, surface polishing Ra≤0.8μm.

[0046] In an embodiment of the present invention, a distributed optical fiber temperature measurement network is installed in step S3, and the density of measurement points reaches 5 / square meter, specifically including: S3.1 Optical fiber layout: Armored optical fiber is used, with a temperature resistance of 1600℃, a longitudinal spacing of 500mm and a transverse spacing of 200mm.

[0047] S3.2 Signal processing: FBG demodulator is used with a resolution of 0.1°C and a sampling frequency of 10 Hz.

[0048] In an embodiment of the present invention, a multivariable PID controller is deployed in step S3 to establish a temperature-power coupling control model, which specifically includes: S3.3 Control model: A 16-input (temperature point) × 12-output (electrode group) matrix was established, and the coupling coefficient was determined by orthogonal test.

[0049] S3.4 parameter setting: proportional band 2-5%, integral time 30-60s, differential time 5-10s.

[0050] In an embodiment of the present invention, in step S3, a real-time simulation prediction of the temperature field is realized by using a melting furnace digital twin system, including: S3.5 Modeling elements: Mesh size ≤ 50 mm, including thermal-electrical-current multi-physics field coupling.

[0051] S3.6 Real-time prediction: update cycle 1 minute, electrode life prediction error ≤5%.

[0052] In the embodiment of the present invention, step S4 is a segmented power-on aging, where the initial power is controlled at 30% of the rated value, and specifically includes: S4.1 Start-up procedure: 0-24h: 20% rated power; 24-48h: 40% rated power; 48-72h: 60% rated power.

[0053] S4.2 Aging monitoring: electrode contact resistance change rate ≤1% / h, module expansion joint change ≤0.2mm.

[0054] In the embodiment of the present invention, in order to observe and analyze the flow field distribution in the glass melting furnace so as to optimize the process parameters, the following flow field visualization test is performed, namely step S4. Specifically, the flow field visualization test in step S4 uses glass beads as a simulated material, a CCD camera with a shooting frequency of 25fps, and PIV analysis software to process the image, including: S4.3 Simulation material configuration: glass bead particle size distribution 0.5-2mm, add 1% phosphor (YAG:Ce).

[0055] In this embodiment, the particle size of the glass beads ranges from 0.5 to 2 mm, showing a normal distribution, with an average particle size of 1.2 mm. Reasonable particle size distribution ensures that the glass beads can be evenly dispersed in the glass liquid, and the movement characteristics are similar to the glass liquid, ensuring the accuracy of the simulation results.

[0056] The shape of the glass beads is approximately spherical, with a sphericity of ≥0.95. The spherical structure can reduce resistance and irregular movement during the flow process, making it more realistic to simulate the laminar and turbulent state of glass liquid.

[0057] The density is 2.5g / cm³, which is close to the density of molten glass at working temperature (generally the density of molten glass is 2.3-2.7g / cm³), ensuring that the glass beads can be suspended in the molten glass and move with the flow of the molten glass. They will not sink to the bottom or float up due to excessive density differences, affecting flow field observation.

[0058] Glass beads have stable chemical properties. They do not react chemically with molten glass within the operating temperature range of the melting furnace (1200 - 1600°C), nor do they corrode the lining materials of the melting furnace. This ensures that no additional interference factors are introduced during the test and the reliability of the test results is ensured.

[0059] By adding 1% phosphor (YAG:Ce), the glass beads can emit bright fluorescence when excited by a light source of a specific wavelength (such as green light with a wavelength of 520nm), which makes it easier to highlight the position of the glass beads when shooting with a CCD camera, improve image contrast, and enable the PIV analysis software to more accurately identify and track the movement trajectory of the glass beads.

[0060] S4.4 Test method: The CCD camera captures images at 25fps and the PIV analysis software processes the images to identify and track the movement of the glass beads.

[0061] In the embodiment of the present invention, the spectrum optimization in this step adopts genetic algorithm iteration, and the objective function is temperature uniformity index ≥ 0.95, which specifically includes: S4.5 Test point arrangement: 3 spectrum probes are set in each area, and the collection wavelength range is 380-780nm.

[0062] S4.6 Phase optimization: Genetic algorithm iteration is used, and the objective function is temperature uniformity index ≥ 0.95.

[0063] In this embodiment, the CCD camera takes pictures at a frequency of 25fps, taking 25 frames of images per second, which can effectively capture the movement trajectory of the glass beads in the glass liquid and provide continuous image data for subsequent analysis.

[0064] The CCD camera has a shooting resolution of 5120×3840 pixels. The high resolution can clearly present the details of the glass beads, allowing the PIV analysis software to more accurately identify and track the glass beads, thereby improving the accuracy of flow field analysis.

[0065] The CCD camera shooting is adjusted according to the light source intensity and the fluorescence brightness of the glass beads, generally between 1 / 100 - 1 / 1000s. Reasonable exposure time can ensure that the fluorescence of the glass beads is clear in the image and avoid overexposure or underexposure that affects the image quality.

[0066] The camera is installed on the side of the melting furnace at a height of 50 cm from the liquid surface, with the optical axis of the lens forming a 45° angle with the liquid surface, ensuring that the shooting field of view covers the entire test area (approximately 1m×1m) and fully captures the movement of the glass beads in the flow field.

[0067] In this embodiment, the PIV analysis software processes the image to identify and track the motion trajectory of the glass bead, including: The grayscale threshold of the particle image is used to distinguish the glass bead particles from the background image. If the threshold is set too low, the background noise will be misjudged as particles, resulting in the appearance of false vectors; if it is set too high, some particles may be missed, making the analysis results incomplete. Generally, according to the overall grayscale distribution of the image, through multiple experiments, the grayscale threshold slider is adjusted in the software to find the value that can clearly separate the particles from the background, usually in the range of 100 - 200 grayscale values ​​(the specific value depends on the actual image).

[0068] The parameters are verified by the conditions for judging the validity of the vector, such as the minimum correlation coefficient, the maximum allowable speed, etc. The minimum correlation coefficient is used to measure the credibility of the particle matching in two adjacent frames of images, usually between 0.7 and 0.9. Vectors below this value will be marked as invalid; the maximum allowable speed is set according to the actual flow rate range of the glass liquid in the melting furnace. If the calculated particle speed exceeds this value, the corresponding vector will also be regarded as abnormal and discarded to prevent unreasonable results caused by noise or wrong matching.

[0069] When the calculated vectors are unevenly distributed or missing, an interpolation algorithm is required to supplement them. Common interpolation methods include linear interpolation and bilinear interpolation. The software can set parameters such as the interpolation grid size and interpolation weight. The grid size determines the precision of the interpolation. A smaller grid can provide more accurate interpolation results, but it will increase the amount of calculation. The interpolation weight affects the contribution of adjacent vectors to the interpolation point. Reasonable setting of these parameters can make the flow field velocity vector diagram and streamline diagram smoother and more continuous.

[0070] Enter the time interval parameter. Since the CCD camera shoots at 25fps, there is a time interval between two adjacent frames. In the PIV analysis software, you need to accurately enter this time interval (for 25fps shooting, the time interval is 0.04s), and the software calculates the displacement of the particle per unit time and then derives the velocity. If the time interval is entered incorrectly, the velocity calculation result will be biased.

[0071] In order to remove abnormal vectors and noise in the analysis results through data filtering parameters, the software provides a variety of filtering methods, such as mean filtering, median filtering, etc., and the filter window size can be set. If the filter window is too large, the data may be over-smoothed and the flow field details may be lost; if the window is too small, the filtering effect will be poor. Generally, according to the complexity of the flow field and the noise level, the appropriate filtering method and window size are selected. Usually, the filter window size is between 3×3 and 5×5 pixels.

[0072] In this embodiment, a genetic iterative algorithm is used to optimize key parameters in the PIV analysis software to improve the accuracy and efficiency of flow field analysis. It includes: Determine the key parameters of the PIV analysis software and their value ranges, such as interrogation window size, overlap rate, etc., and randomly generate multiple sets of parameter combinations within the value range to form an initial population of 50-200 individuals; The parameter combinations of the initial population are applied to the PIV analysis software to process the flow field images, and the fitness values ​​of each combination are calculated according to the objective function to quantify the individual performance; Randomly select two individuals from the next generation population as parents, and exchange parameters through single-point crossover, multi-point crossover or uniform crossover with a probability of 0.6-0.9 to generate offspring individuals; at the same time, perform small random mutations on individual parameters with a probability of 0.01-0.1 to increase population diversity and explore better parameter combinations; Repeat fitness evaluation, selection, crossover and mutation operations to continuously iterate and update the population. Set the maximum number of iterations (such as 500 times) or the objective function convergence threshold and other stopping conditions. When the conditions are met, obtain the parameter combination corresponding to the individual with the highest fitness in the current population, that is, the optimized parameter solution; The optimized parameter combination is applied to the PIV analysis software to reprocess the flow field image to obtain more accurate and reliable flow field analysis results, providing data support for the optimization of the glass melting furnace process.

[0073] In the embodiment of the present invention, the key process control points include: electrode installation coaxiality: ≤Φ0.1mm. Module joint seam: ≤1mm, filled with high-temperature sealant. Initial heating rate: ≤5℃ / h (below 800℃). Oxygen content control in the working area: ≤50ppm. Cooling water flow: ≥3m³ / h (single electrode).

[0074] In the embodiment of the present invention, the quality inspection standards include: temperature uniformity: the temperature difference between any two points is ≤15°C. Energy consumption index: electricity consumption per ton of glass is ≤1200kWh. Glass quality: bubble number is ≤0.1 / kg, streak grade is ≤A grade (ISO 9385). Electrode life: molybdenum electrode is ≥12 months. Emission index: dust is ≤10mg / Nm³.

[0075] Through the above-mentioned refined step control, the all-electric float glass melting furnace achieves the following effects: eliminate combustion exhaust gas emissions and achieve zero-carbon production. Compared with traditional melting furnaces, energy consumption is reduced by more than 40%, and the power consumption per ton of glass is ≤1200kWh. The temperature control accuracy reaches ±2℃, and the bubble defect rate is reduced by 50%. The modular design shortens the electrode replacement time by 70%. The digital twin system can predict the performance degradation during the kiln life cycle.

[0076] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for manufacturing an all-electric float glass melting furnace, characterized in that: The steps include: S1. Modular prefabrication of melting furnace structure: The bottom module of the melting furnace is prefabricated with silicon nitride combined with silicon carbide materials, and electrode installation grooves are reserved between modules; water-cooled copper electrode sleeves are pre-embedded in the side wall modules, and the sleeves are arranged at an angle of 15°; the top module integrates a radiation temperature measurement window and an exhaust gas recovery channel; S2. Assembly of multi-stage electrode system: a molybdenum electrode matrix is ​​arranged in the melting zone, using a three-phase six-point star arrangement; a tin oxide electrode pair is set in the clarification zone, with the electrode spacing decreasing gradually; a liftable zirconium electrode group is configured in the working zone to achieve adaptive adjustment of the liquid level height; S3, intelligent temperature control system integration: install a distributed optical fiber temperature measurement network with a measurement point density of 5 / m2; deploy a multivariable PID controller and establish a temperature-power coupling control model; realize real-time simulation and prediction of the temperature field through the melting furnace digital twin system; S4. Furnace commissioning and optimization: Segmented power-on aging, initial power controlled at 30% of rated value; flow field visualization test using glass bead simulation material; optimization of electrode current phase distribution through spectral analysis.

2. The method for manufacturing an all-electric float glass melting furnace according to claim 1, characterized in that: The prefabrication of the bottom module of the melting furnace includes: in terms of mass percentage, a composite formula of 60% silicon nitride + 40% silicon carbide is used, and 2% yttrium oxide is added as a sintering aid; the module size is designed to be 1.5m×1.2m×0.3m, and the electrode groove is milled by a CNC machining center, the groove width is 80±0.1mm, and the groove inner surface roughness Ra≤1.6μm; segmented sintering, the sintering atmosphere is nitrogen protection, and the purity is ≥99.99%.

3. The method for manufacturing an all-electric float glass melting furnace according to claim 2, characterized in that: The side wall module is prefabricated, including: the casing adopts oxygen-free copper casing with a wall thickness of 5mm and a spacing of 300mm; the insulation layer is composed of high-purity alumina fiberboard, lightweight mullite bricks and a stainless steel shell.

4. The method for manufacturing an all-electric float glass melting furnace according to claim 3, characterized in that: The top module integration includes: the radiation temperature measurement window adopts a sapphire observation window with a diameter of 80mm and is equipped with an automatic cleaning device; the exhaust gas recovery system adopts a porous ceramic filter with a pore size of 0.5μm, and the induced draft fan air volume can be adjusted in the range of 10-50m³ / min.

5. The method for manufacturing an all-electric float glass melting furnace according to claim 1, characterized in that: The molybdenum electrode matrix is ​​arranged in the melting zone, and a three-phase six-point star arrangement is adopted, specifically including: the diameter of the molybdenum electrode is Φ80±0.05mm, the purity is ≥99.95%; the center distance between adjacent electrodes is 500mm, the insertion depth is adjustable from 300 to 400mm, and the current density control range is 0.8-1.2A / cm².

6. The method for manufacturing an all-electric float glass melting furnace according to claim 5, characterized in that: The tin oxide electrode pair is arranged in the clarification zone, and the electrode spacing gradually decreases, specifically including: the electrode spacing gradually decreases, 800mm for the first group, 600mm for the second group, and 400mm for the third group; the electrode diameter is Φ60mm, and the thickness of the platinum coating on the surface is 5μm; the power supply mode is DC pulse power supply, the frequency is 50Hz, and the voltage gradient is from 220V in the front zone to 150V in the rear zone.

7. The method for manufacturing an all-electric float glass melting furnace according to claim 6, characterized in that: The working area is provided with a liftable zirconium electrode group to realize adaptive adjustment of the liquid level height, specifically including: servo motor drive, 200mm stroke, position feedback accuracy ±0.05mm; the zirconium electrode is stabilized by zirconium oxide, the working end cone angle is 45°, and the surface polishing Ra≤0.8μm.

8. The method for manufacturing an all-electric float glass melting furnace according to claim 7, characterized in that: The distributed optical fiber temperature measurement network is installed, and the density of measurement points reaches 5 / square meter, specifically including: using armored optical fiber, temperature resistance of 1600°C, longitudinal spacing of 500mm, and transverse spacing of 200mm; signal processing uses FBG demodulator, with a resolution of 0.1°C and a sampling frequency of 10Hz.

9. The method for manufacturing an all-electric float glass melting furnace according to claim 8, characterized in that: The multivariable PID controller is deployed to establish a temperature-power coupling control model, specifically including: establishing a 16-input×12-output matrix, the coupling coefficient is determined by orthogonal test; the proportional band is 2-5%, the integral time is 30-60s, and the differential time is 5-10s; Through the digital twin system of the melting furnace, real-time simulation prediction of the temperature field is realized, including: grid division size ≤50mm, including thermal-electrical-current multi-physical field coupling; update cycle 1 minute, electrode life prediction error ≤5%.

10. The method for manufacturing an all-electric float glass melting furnace according to claim 9, characterized in that: The segmented power-on aging, the initial power is controlled at 30% of the rated value, specifically including: segmented power-on aging, the initial power is controlled at 30% of the rated value; the flow field visualization test uses glass beads to simulate the material, the CCD camera shoots at a frequency of 25fps, and the PIV analysis software processes the image; the spectrum optimization uses genetic algorithm iteration, and the objective function is a temperature uniformity index ≥ 0.95.

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