A manufacturing method of an all-electric float glass melting furnace

Abstract

The present invention discloses a manufacturing method of an all-electric float glass melting furnace, comprising the following steps: S1, modular prefabrication of the melting furnace structure; S2, assembly of a multi-stage electrode system; S3, integration of an intelligent temperature control system; S4, commissioning and optimization of the melting furnace. The beneficial effects of the present invention are as follows: the present invention eliminates the emission of combustion waste gas and realizes zero-carbon production; compared with traditional melting furnaces, the energy consumption is reduced by more than 40%, and the power consumption per ton of glass is ≤ 1200 kWh; 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 decay within the kiln age cycle.

Description

Technical Field

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

[0002] As the mainstream technology for flat glass manufacturing, the melting furnace system of the float glass production process has long relied on fossil fuel heating. Existing gas melting furnaces have problems such as large fluctuations in flame temperature (±15°C) and obvious temperature gradients in the hot spot area, resulting in difficulties in homogenizing the glass liquid and affecting the quality of the finished product. At the same time, the emission of nitrogen oxides generated during the combustion process is difficult to meet the increasingly strict environmental protection requirements.

[0003] Although the 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 design problem of a high-power electrode system; 2) the precise control of the longitudinal temperature curve of the melting furnace; 3) the durability of the electrode material in the high-temperature glass liquid. Summary of the Invention

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

[0005] To achieve the above purpose, the present invention provides the following technical solutions:

[0006] A manufacturing method for an all-electric float glass melting furnace includes the following steps:

[0007] S1. Modular prefabrication of the melting furnace structure: Precast the bottom module of the melting furnace using silicon nitride bonded silicon carbide material, and reserve electrode installation channels between the modules; embed water-cooled copper electrode sleeves in the side wall modules, and the sleeves are arranged at an inclination angle of 15°; integrate radiation temperature measurement windows and waste gas recovery channels in the top module;

[0008] S2. Assembly of a multi-stage electrode system: Arrange a molybdenum electrode matrix in the melting zone, using a three-phase six-point star arrangement; set tin oxide electrode pairs in the clarification zone, and the electrode spacing gradient decreases; configure a liftable zirconium electrode group in the working zone to achieve adaptive adjustment of the liquid level height;

[0009] S3. Integration of an intelligent temperature control system: Install a distributed optical fiber temperature measurement network with a measurement point density of 5 per square meter; deploy a multi-variable PID controller to establish a temperature-power coupling control model; through the digital twin system of the melting furnace, realize real-time simulation and prediction of the temperature field;

[0010] S4. Commissioning and optimization of the melting furnace: Energize and age in sections, and control the initial power at 30% of the rated value; use glass beads to simulate the charge for flow field visualization testing; optimize the electrode current phase distribution through spectral analysis.

[0011] Preferably, the bottom module of the melting furnace is prefabricated, including: a composite formula of 60% silicon nitride (Si3N4) + 40% silicon carbide (SiC) by mass percentage, adding 2% yttrium oxide (Y2O3) as a sintering aid; the module size is designed to be 1.5m × 1.2m × 0.3m, and the electrode channels are milled by a CNC machining center, with a groove width of 80 ± 0.1mm and the surface roughness Ra of the channel inner surface ≤ 1.6μm; sintering in sections, and the sintering atmosphere is nitrogen protection with a purity ≥ 99.99%.

[0012] Preferably, the side wall module is prefabricated, including: the sleeve is made of oxygen-free copper (C1020) sleeve with a wall thickness of 5mm and a spacing of 300mm; the insulation layer is composed of high-purity alumina fiber board, lightweight mullite bricks and a stainless steel shell.

[0013] Preferably, the top module is integrated, including: the radiation temperature measurement window uses a sapphire observation window with a diameter of 80mm, equipped with an automatic cleaning device; the waste gas recovery system uses a porous ceramic filter with a pore diameter of 0.5μm, and the air volume of the induced draft fan is adjustable in the range of 10 - 50m³ / min.

[0014] Preferably, a molybdenum electrode matrix is arranged in the melting zone, adopting a three-phase six-point star arrangement, specifically including: the molybdenum electrode has a diameter of Φ80 ± 0.05mm and a purity ≥ 99.95%; the center distance between adjacent electrodes is 500mm, the insertion depth is adjustable in the range of 300 - 400mm, and the current density control range is 0.8 - 1.2A / cm².

[0015] Preferably, tin oxide electrode pairs are set in the clarification zone, and the electrode spacing gradient decreases, specifically including: the electrode spacing gradient decreases, the first group is 800mm, the second group is 600mm, and the third group is 400mm; the electrode diameter is Φ60mm, and the thickness of the platinum plating layer on the surface is 5μm; the power supply method is DC pulse power supply, with a frequency of 50Hz and the voltage gradient ranging from 220V in the front zone to 150V in the rear zone.

[0016] Preferably, a liftable zirconium electrode group is configured in the working area to realize adaptive adjustment of the liquid level height, specifically including: driven by a servo motor, with a stroke of 200mm and a position feedback accuracy of ±0.05mm; the zirconium electrode is stabilized by zirconia, the working end taper angle is 45°, and the surface polishing Ra ≤ 0.8μm.

[0017] Preferably, a distributed optical fiber temperature measurement network is installed, and the measurement point density reaches 5 per square meter, specifically including: using armored optical fiber, with a temperature resistance of 1600℃, a longitudinal spacing of 500mm, and a transverse spacing of 200mm; the signal processing uses an FBG demodulator, with a resolution of 0.1℃ and a sampling frequency of 10Hz.

[0018] Preferably, the multi-variable PID controller is deployed to establish a temperature-power coupling control model, which specifically includes: establishing a 16-input × 12-output matrix, and the coupling coefficient is determined through orthogonal experiments; the proportional band is 2-5%, the integral time is 30-60 s, and the derivative time is 5-10 s.

[0019] Through the glass furnace digital twin system, real-time simulation prediction of the temperature field is realized, including: the grid division size ≤ 50 mm, including multi-physical field coupling of heat-electricity-current; the update period is 1 minute, and the prediction error of the electrode life is ≤ 5%.

[0020] Preferably, for the segmented power-on aging, the initial power is controlled at 30% of the rated value, which specifically includes: 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 shooting frequency is 25 fps, and the PIV analysis software processes the images; the spectral optimization uses genetic algorithm iteration, and the objective function is that the temperature uniformity index ≥ 0.95.

[0021] Compared with the prior art, the beneficial effects of the present invention are as follows: the present invention eliminates the combustion waste gas emissions and realizes zero-carbon production; compared with the traditional glass furnace, the energy consumption is reduced by more than 40%, and the power consumption per ton of glass is ≤ 1200 kWh; 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 decay within the kiln age cycle. Description of the Drawings

[0022] Figure 1 It is the method flow chart of the embodiment of the present invention;

[0023] Figure 2 It is the sub-flow chart of step S1 of the embodiment of the present invention;

[0024] Figure 3 It is the sub-flow chart of step S2 of the embodiment of the present invention;

[0025] Figure 4 It is the sub-flow chart of step S3 of the present invention embodiment;

[0026] Figure 5 It is the sub-flow chart of step S4 of the embodiment of the present invention. Detailed Embodiments

[0027] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0028] Please refer toFigure 1 The present invention provides a technical solution: a method for manufacturing an all-electric float glass melting furnace, comprising the following steps:

[0029] 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.

[0030] 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.

[0031] 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.

[0032] S4. Melting furnace commissioning and optimization: segmented power-on aging, initial power controlled at 30% of rated value; flow field visualization test using glass beads as simulated material; optimization of electrode current phase distribution through spectral analysis.

[0033] In an embodiment of the present invention, the prefabrication of the furnace bottom module in step S1 specifically includes:

[0034] 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.

[0035] 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.

[0036] 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).

[0037] In an embodiment of the present invention, the side wall modules in the melting furnace are prefabricated in step S1, and the steps include:

[0038] S1.4 Embedded water-cooled sleeve: Select an oxygen-free copper (C1020) sleeve with a wall thickness of 5 mm. Use laser positioning welding, control the welding temperature at 650 ± 10 °C, and the spacing is 300 mm. Form a thermal insulation layer for the embedded water-cooled sleeve. The construction of the thermal insulation layer: The inner layer is a 50-mm high-purity alumina fiber board, the middle layer is a 100-mm lightweight mullite brick, and the outer layer is a stainless steel shell (304L).

[0039] In this embodiment, the water-cooled copper electrode sleeve is made of oxygen-free copper (C1020) material with a wall thickness of 5 mm. It is necessary to ensure that its surface has no defects such as cracks and sand holes, 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. Conduct spot checks on each batch of sleeve and module materials entering the site, and check the material certification documents to ensure the stable and reliable quality of the materials.

[0040] In this embodiment, the laser welding equipment selects welding equipment suitable for oxygen-free copper welding, such as a pulsed 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 the water-cooled copper electrode sleeve. At the same time, prepare auxiliary tools, such as high-precision positioning jigs, to fix the water-cooled copper electrode sleeve and the side wall module to ensure the accurate relative position of the two during the welding process; an argon protection device also needs to be prepared to provide inert gas protection during the welding process to prevent copper from oxidizing at high temperatures.

[0041] In this embodiment, use sandpaper or mechanical grinding tools to pre-treat the welding parts of the water-cooled copper electrode sleeve and the welding area of the side wall module. Use sandpaper or mechanical grinding tools to remove the oxide layer, oil stains and impurities on the surface, so that the welding surface shows metallic luster to improve the quality of the welded joint. After grinding, clean the welding area with anhydrous ethanol or acetone to remove the remaining grinding debris and cleaning agent to ensure that the welding area is clean and dry.

[0042] In this embodiment, a pulsed fiber laser welding machine is selected for the embedded welding of the water-cooled copper electrode sleeve. Its wavelength is usually around 1064 nm, which can be well absorbed by copper materials to achieve efficient welding. This equipment has the following advantages:

[0043] In this embodiment, parameters such as pulse energy, pulse width and frequency can be precisely adjusted. According to the wall thickness of the water-cooled copper electrode sleeve and the welding requirements, flexibly adjust the welding energy input to ensure the stability of the welding process and avoid defects such as over-welding or incomplete penetration.

[0044] The laser beam is transmitted through the optical fiber, which can achieve high-precision focusing. The spot diameter can reach the micron level, meeting the high-precision welding positioning requirements of the water-cooled copper electrode sleeve with a center line inclination angle of 15° and a spacing of 300 mm.

[0045] Equipped with an automated control system, it can achieve automated operation of the welding process, improving welding efficiency and consistency. The operator only needs to set the welding parameters, and the equipment can perform welding according to the preset program, reducing the influence of human factors on welding quality.

[0046] 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 inclination angle of the sleeve center line is 15° and the spacing is 300 mm. Before welding, a laser tracker or total station and other measuring equipment are used to detect the positioning accuracy, and adjustments are made in a timely manner when the deviation exceeds the allowable range. During the welding process, the position of the sleeve is monitored in real time to prevent position deviation caused by welding thermal deformation.

[0047] In this embodiment, the welding temperature is strictly controlled at 650 ± 10 °C, and the temperature of the welding area is monitored in real time through the temperature monitoring system of the welding equipment and an infrared thermometer. At the same time, parameters such as welding current, voltage, and pulse frequency are closely monitored to ensure that they are stable within the set range. If abnormal fluctuations in the parameters are found, welding is immediately stopped, the equipment and welding process are inspected, and welding is continued after troubleshooting.

[0048] In this embodiment, during the welding process, argon is continuously introduced as a shielding gas, and the argon purity ≥ 99.99%. The argon flow rate is adjusted. At the initial stage of welding, the flow rate is appropriately increased to effectively remove the air in the welding area; during the welding process, a stable flow rate is maintained, generally 5 - 10 L / min, to ensure that the welding molten pool is in an inert gas protection atmosphere, prevent copper from oxidizing at high temperatures, and ensure the quality of the welded joint.

[0049] In this embodiment, after welding is completed, the appearance of each welded joint is inspected to observe whether the weld surface is smooth and uniform, and whether there are defects such as pores, cracks, and undercut. Non-destructive testing methods such as ultrasonic testing or radiographic testing are used to detect the internal quality of the welded joint to ensure that there are no defects such as incomplete penetration and internal cracks. For unqualified welded joints, rework is carried out in a timely manner, and quality inspection is carried out again after re-welding until the quality standard is reached.

[0050] In the embodiment of the present invention, in step S1, the integration of the top module in the melting furnace includes the following steps:

[0051] S1.5 Radiation temperature measurement window: A sapphire observation window with a diameter of 80 mm is used, equipped with an automatic cleaning device, and purged with nitrogen every 2 hours.

[0052] In a specific embodiment, the automatic cleaning device mainly consists of a nitrogen nozzle, a driving motor, a rotating arm, and a controller. The nitrogen nozzle is installed at the front end of the rotating arm. The rotating arm is driven by the driving motor and can rotate 360° on the surface of the sapphire observation window. The controller controls the driving motor to start at regular intervals, and the purging program is started once every 2 hours. At this time, the driving motor drives the rotating arm to rotate slowly, and the nitrogen nozzle sprays nitrogen with a purity of ≥99.99% at a pressure of 0.5 MPa. 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 guaranteeing the temperature measurement accuracy.

[0053] S1.6 Exhaust gas recovery system: A porous ceramic filter with a pore diameter of 0.5 μm is used, and the air volume of the induced draft fan can be adjusted in the range of 10 - 50 m³ / min.

[0054] Through modular prefabrication, the manufacturing and use process of the melting furnace is more efficient, stable, and reliable, and can better meet the requirements of high precision, high efficiency, and long life of the all-electric float glass melting furnace.

[0055] In the embodiment of the present invention, arranging a molybdenum electrode matrix in the melting zone in step S2, using a three-phase six-point star arrangement, specifically includes:

[0056] S2.1 Molybdenum electrode installation: The electrode diameter is Φ80 ± 0.05 mm, the purity is ≥99.95%, a hydraulic propulsion mechanism is used, the propulsion accuracy is 0.1 mm / step, and the phase difference of three-phase power supply is 120 ± 1°.

[0057] S2.2 Star arrangement parameters: The center distance between adjacent electrodes is 500 mm, the insertion depth is adjustable in the range of 300 - 400 mm, and the current density control range is 0.8 - 1.2 A / cm².

[0058] In the embodiment of the present invention, arranging tin oxide electrode pairs in the clarification zone in step S2, with the electrode spacing decreasing in a gradient, specifically includes:

[0059] S2.3 Gradient arrangement: The distance of the first group is 800 mm, the second group is 600 mm, the third group is 400 mm, the electrode diameter is Φ60 mm, and the thickness of the platinum plating layer on the surface is 5 μm.

[0060] S2.4 Power supply method: DC pulse power supply, frequency 50 Hz, and the voltage gradient ranges from 220 V in the front area to 150 V in the rear area.

[0061] In the embodiment of the present invention, configuring a liftable zirconium electrode group in the working area in step S2 to achieve adaptive adjustment of the liquid level height, specifically includes:

[0062] S2.5 Lifting mechanism: Driven by a servo motor, the stroke is 200 mm, and the position feedback accuracy is ±0.05 mm.

[0063] S2.6 Zirconium electrode treatment: Zirconia stabilization treatment (adding 8% Y2O3), working end taper angle 45°, surface polished Ra ≤ 0.8μm.

[0064] In the embodiment of the present invention, in step S3, a distributed optical fiber temperature measurement network is installed, and the measurement point density reaches 5 per square meter, specifically including:

[0065] S3.1 Optical fiber arrangement: Use armored optical fiber, temperature resistant up to 1600°C, longitudinal spacing 500mm, transverse spacing 200mm.

[0066] S3.2 Signal processing: Use an FBG demodulator, resolution 0.1°C, sampling frequency 10Hz.

[0067] In the embodiment of the present invention, in step S3, a multivariable PID controller is deployed to establish a temperature-power coupling control model, specifically including:

[0068] S3.3 Control model: Establish a 16-input (temperature points) × 12-output (electrode groups) matrix, and the coupling coefficient is determined through orthogonal experiments.

[0069] S3.4 Parameter tuning: Proportional band 2 - 5%, integral time 30 - 60s, derivative time 5 - 10s.

[0070] In the embodiment of the present invention, in step S3, through the glass furnace digital twin system, real-time simulation prediction of the temperature field is realized, including:

[0071] S3.5 Modeling elements: Mesh division size ≤ 50mm, including multi-physical field coupling of heat - electricity - current.

[0072] S3.6 Real-time prediction: Update period 1 minute, electrode life prediction error ≤ 5%.

[0073] In the embodiment of the present invention, in step S4, sectional power-on aging is carried out, and the initial power is controlled at 30% of the rated value, specifically including:

[0074] S4.1 Startup program: 0 - 24h: 20% rated power; 24 - 48h: 40% rated power; 48 - 72h: 60% rated power.

[0075] S4.2 Aging monitoring: Electrode contact resistance change rate ≤ 1% / h, module expansion joint change ≤ 0.2mm.

[0076] In an embodiment of the present invention, in order to observe and analyze the flow field distribution in the glass melting furnace for optimizing process parameters, the following flow field visualization test, i.e., step S4, is carried out. Specifically, in step S4, the glass beads are used as the simulation material in the flow field visualization test, the shooting frequency of the CCD camera is 25fps, and the PIV analysis software processes the images, including:

[0077] S4.3 Simulation material configuration: The particle size distribution of the glass beads is 0.5 - 2mm, and 1% phosphor (YAG:Ce) is added.

[0078] In this embodiment, the particle size range of the glass beads is 0.5 - 2mm, showing a normal distribution, and the average particle size is 1.2mm. A reasonable particle size distribution ensures that the glass beads can be evenly dispersed in the glass liquid, and their motion characteristics are similar to those of the glass liquid, guaranteeing the accuracy of the simulation results.

[0079] The shape of the glass beads is approximately spherical, and the sphericity ≥ 0.95. The spherical structure can reduce the resistance and irregular motion during the flow process, making it more realistically simulate the laminar and turbulent states of the glass liquid.

[0080] The density is 2.5g / cm³, which is close to the density of the glass liquid at the working temperature (generally, the density of the glass liquid is in the range of 2.3 - 2.7g / cm³), ensuring that the glass beads can be suspended in the glass liquid and move along with the flow of the glass liquid, without sinking to the bottom or floating due to excessive density difference, which may affect the observation of the flow field.

[0081] The glass beads have stable chemical properties and do not react with the glass liquid within the working temperature range of the melting furnace (1200 - 1600°C), nor will they erode the lining material of the melting furnace, ensuring that no additional interference factors are introduced during the test and guaranteeing the reliability of the test results.

[0082] 1% phosphor (YAG:Ce) is added. Under the excitation of a light source with a specific wavelength (such as green light with a wavelength of 520nm), the glass beads can emit bright fluorescence, which is convenient for highlighting the position of the glass beads during the shooting by the CCD camera, improving the image contrast, and enabling the PIV analysis software to more accurately identify and track the motion trajectory of the glass beads.

[0083] S4.4 Test method: The shooting frequency of the CCD camera is 25fps, and the PIV analysis software processes the images to identify and track the motion trajectory of the glass beads.

[0084] In an embodiment of the present invention, in this step, the spectral optimization adopts genetic algorithm iteration, and the objective function is the temperature uniformity index ≥ 0.95, specifically including:

[0085] S4.5 Test point arrangement: 3 spectral probes are set in each zone, and the wavelength range for collection is 380 - 780nm.

[0086] S4.6 Phase optimization: Iterate using the genetic algorithm, with the objective function being the temperature uniformity index ≥ 0.95.

[0087] In this embodiment, the shooting frequency of the CCD camera is 25 fps, and 25 frames of images are captured per second, which can effectively capture the movement trajectory of the glass beads in the molten glass and provide continuous image data for subsequent analysis.

[0088] The shooting resolution of the CCD camera is 5120×3840 pixels. The high resolution can clearly present the details of the glass beads, enabling the PIV analysis software to more accurately identify and track the glass beads, thereby improving the accuracy of the flow field analysis.

[0089] The shooting of the CCD camera is adjusted according to the light source intensity and the fluorescence brightness of the glass beads, generally between 1 / 100 - 1 / 1000 s. A reasonable exposure time can ensure that the fluorescence of the glass beads is clearly presented in the image and avoid overexposure or underexposure from affecting the image quality.

[0090] The camera is installed on the side of the melting furnace at a height of 50 cm from the liquid surface, and the optical axis of the lens forms a 45° angle with the liquid surface, ensuring that the shooting field of view covers the entire test area (about 1 m×1 m range) and comprehensively capturing the movement of the glass beads in the flow field.

[0091] In this embodiment, the PIV analysis software processes the images to identify and track the movement trajectory of the glass beads, including:

[0092] Distinguish the glass bead particles from the background image through the particle image gray threshold. If the threshold is set too low, background noise will be misjudged as particles, resulting in the appearance of false vectors; if set too high, some particles may be missed, making the analysis result incomplete. Generally, according to the overall gray distribution of the image, through multiple experiments, adjust the gray threshold slider in the software to find the value that can clearly separate the particles from the background, usually in the gray value range of 100 - 200 (the specific value depends on the actual image).

[0093] Verify the parameters through the conditions for judging the vector validity, 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 taking values between 0.7 - 0.9. Vectors with values lower than this will be marked as invalid; the maximum allowable speed is set according to the actual flow velocity range of the molten glass 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 incorrect matching.

[0094] When the calculated vector distribution is uneven or there are missing values, an interpolation algorithm needs to be used for supplementation. Common interpolation methods include linear interpolation, bilinear interpolation, etc. Parameters such as the interpolation grid size and interpolation weight can be set in the software. The grid size determines the fineness of the interpolation. A smaller grid can provide more accurate interpolation results but will increase the computational amount; the interpolation weight affects the contribution degree of adjacent vectors to the interpolation point. Reasonably setting these parameters can make the flow field velocity vector diagram and streamline diagram smoother and more continuous.

[0095] Input the time interval parameter. Since the CCD camera shoots at 25fps, there is a time interval between two adjacent frames of images. In the PIV analysis software, this time interval needs to be accurately input (for shooting at 25fps, the time interval is 0.04s). The software calculates the displacement of particles per unit time based on this and then obtains the velocity. If the time interval is input incorrectly, it will cause deviations in the calculated velocity results.

[0096] To remove abnormal vectors and noise from the analysis results through data filtering parameters, the software provides various filtering methods, such as mean filtering, median filtering, etc., and the filtering window size can be set. If the filtering window is too large, it may oversmooth the data and lose the details of the flow field; if the window is too small, the filtering effect is not good. Generally, according to the complexity of the flow field and the noise level, select the appropriate filtering method and window size. Usually, the filtering window size is between 3×3 - 5×5 pixels.

[0097] In this embodiment, a genetic iterative algorithm is used to optimize the key parameters in the PIV analysis software to improve the accuracy and efficiency of flow field analysis. It includes:

[0098] Determine the key parameters of the PIV analysis software and their value ranges, such as the interrogation window size, overlap rate, etc. Randomly generate multiple groups of parameter combinations within the value range to form an initial population containing 50 - 200 individuals;

[0099] Apply the parameter combinations of the initial population to the PIV analysis software to process the flow field image, and calculate the fitness value of each combination according to the objective function to quantify the individual performance;

[0100] Randomly select two individuals from the next-generation population as parents, and with a probability of 0.6 - 0.9, exchange parameters through single-point crossover, multi-point crossover, or uniform crossover to generate offspring individuals; at the same time, with a probability of 0.01 - 0.1, perform small-scale random mutations on the individual parameters to increase the population diversity and explore better parameter combinations;

[0101] Repeat the fitness evaluation, selection, crossover, and mutation operations, and continuously iterate to update the population. Set stop conditions such as the maximum number of iterations (e.g., 500 times) or the convergence threshold of the objective function. When the conditions are met, obtain the parameter combination corresponding to the individual with the highest fitness in the current population, which is the optimized parameter solution;

[0102] Apply the optimized parameter combination to the PIV analysis software, reprocess the flow field image, and obtain more accurate and reliable flow field analysis results to provide data support for the optimization of the glass melting furnace process.

[0103] In the embodiments of the present invention, the key process control points include: coaxiality of electrode installation: ≤Φ0.1mm. Module splicing seam: ≤1mm, filled with high-temperature sealant. Initial heating rate: ≤5°C / h (below 800°C). Oxygen content control in the working area: ≤50ppm. Cooling water flow rate: ≥3m³ / h (single electrode).

[0104] In the embodiments of the present invention, the quality inspection standards include: temperature uniformity: temperature difference between any two points ≤15°C. Energy consumption index: electricity consumption per ton of glass ≤1200kWh. Glass quality: number of bubbles ≤0.1 per kg, stripe grade ≤ Grade A (ISO 9385). Electrode life: molybdenum electrode ≥12 months. Emission index: dust ≤10mg / Nm³.

[0105] Through the above refined step control, the all-electric float glass melting furnace has achieved the following effects: eliminating combustion exhaust gas emissions and realizing carbon-free production. Reducing energy consumption by more than 40% compared with traditional melting furnaces, and electricity consumption per ton of glass ≤1200kWh. 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 decay within the kiln age cycle.

[0106] Although the embodiments of the present invention have been shown and described, for those of ordinary skill in the art, it can be understood that various changes, modifications, substitutions, and variations can be made to these embodiments without departing from the principles and spirit of the present invention. The scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A manufacturing method of 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. Melting furnace commissioning and optimization: segmented power-on aging, initial power controlled at 30% of rated value; flow field visualization test using glass beads as simulated material; optimization of electrode current phase distribution through spectral analysis.

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

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

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

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