Glass bead powder combining device and control method thereof

Abstract

The invention provides a glass bead powder combining device and a control method thereof, and relates to the technical field of glass bead powder combining, the glass bead combining device is characterized in that a containing space is formed in a bead combining bin, and the containing space comprises a reaction area and an air exhaust area which are distributed in the height direction of the bead combining bin; a flamethrower, a large-particle micro-bead powder injection pipe and a superfine glass micro-bead powder injector are mounted on the bead combining barrel; the filtering mechanism comprises a filtering bin arranged outside the bead combining bin in a surrounding manner, and the filtering bin comprises a negative pressure cavity and a filtering cavity located at the bottom of the negative pressure cavity; the negative pressure cavity is communicated with the air exhaust area through the filter screen cylinder, and the filter cavity is isolated from the accommodating space; the air exhaust assembly is arranged in the negative pressure cavity and used for feeding the airflow with the dust in the bead combining bin into the filtering cavity, and the filtering assembly is arranged in the filtering cavity and used for filtering the airflow with the dust so that the airflow with the dust can form clean air after being filtered. According to the device, gas with powder can be filtered while the normal airflow direction in the bead combining box is not influenced.

Description

Technical Field

[0001] The present invention relates to the technical field of glass bead powder bead merging, and specifically provides a glass bead powder bead merging device and a control method therefor. Background Art

[0002] Glass beads are a new type of material with a wide range of uses and special properties developed in recent years. In the manufacturing process, glass bead powder with a diameter of 38um - 80um is ejected through a microbead delivery pipe to contact with a flame, melted into a spherical shape and moved downward. Then, ultra-fine glass bead powder with a diameter less than 38um is ejected through a glass bead burner to collide with the aforementioned spherical glass bead melt and fuse with each other to form glass beads with a larger diameter. However, a large amount of dust will be generated during the bead merging process, and the waste gas of this equipment is directly discharged from the ventilation port, which is easy to cause environmental pollution.

[0003] The patent with the patent number CN218025831U sets up a filtration chamber, a negative pressure chamber, an air extractor, etc., so that the airflow carrying dust enters the water body, and the airflow filtered by the water body and the filter screen is discharged through the exhaust port, so that the dust in the airflow is filtered multiple times and meets the emission standards. However, when the air extractor extracts air from the bead merging box, it often affects the original airflow direction in the bead merging box, which may further affect the normal temperature gradient distribution formed by the flame injector in the bead merging box, or the additional suction generated by the air extractor will forcibly change the powder movement trajectory, and a large amount of powder will be prematurely extracted from the key reaction area near the flame injector and cannot complete sufficient contact and fusion in an ideal high-temperature environment, ultimately affecting the formation of glass beads. Summary of the Invention

[0004] In view of the above-mentioned defects or deficiencies in the prior art, the present invention aims to provide a glass bead powder bead merging device and a control method therefor, so as to filter the gas with powder while ensuring that the normal airflow direction in the bead merging box is not affected; In a first aspect, the present invention provides a glass bead powder bead merging device, including: A bead merging chamber, which has an accommodation space inside. The accommodation space includes a reaction area and an air extraction area distributed along the height direction of the bead merging chamber. The bead merging chamber includes a bead merging cylinder body at the bottom and a filter screen cylinder body provided on the top of the bead merging cylinder body. The air extraction area is formed inside the filter screen cylinder body, and the reaction area is formed inside the bead merging cylinder body. A flame injector, a large particle microbead powder injection pipe, and an ultra-fine glass bead powder injector are installed on the bead merging cylinder body, wherein the injection ends of the flame injector, the large particle microbead powder injection pipe, and the ultra-fine glass bead powder injector extend into the reaction area; A filtering mechanism, the filtering mechanism includes: Filter chamber, the filter chamber is disposed around the bead chamber, the filter chamber includes a negative pressure chamber and a filter chamber at the bottom of the negative pressure chamber; the negative pressure chamber is communicated with the air extraction area through the filter screen cylinder, and the filter chamber is isolated from the accommodation space; Air extraction assembly, the air extraction assembly is disposed in the negative pressure chamber for sucking the airflow carrying dust in the bead chamber into the filter chamber; Filter assembly, the filter assembly is disposed in the filter chamber for filtering the airflow carrying dust so that the airflow carrying dust forms clean gas after filtration.

[0005] According to the technical solution of the present invention, there is also a buffer area in the bead cylinder, the buffer area is disposed between the reaction area and the air extraction area, a buffer assembly is disposed in the buffer area, and a plurality of buffer holes are provided on the buffer assembly.

[0006] According to the technical solution of the present invention, the air extraction assembly includes an air extractor, the air outlet end of the air extractor is connected with an air outlet pipe, the air outlet pipe is connected with the filter assembly, the air extraction end of the air extractor is connected with an annular air extraction pipe, the air extraction pipe is disposed in the negative pressure chamber and sleeved outside the filter screen cylinder, and a plurality of air extraction holes opening towards the side of the filter screen cylinder are uniformly distributed on the air extraction pipe, and each air extraction hole is equipped with an air extraction switch for controlling its opening and closing and opening degree.

[0007] According to the technical solution of the present invention, at the boundary between the buffer area and the reaction area, there is an annular convex platform on the inner wall of the bead cylinder, the buffer assembly is a buffer block formed by elastic buffer material, and the buffer block is placed on the annular convex platform.

[0008] According to the technical solution of the present invention, a vibration assembly is further provided on the filter screen cylinder.

[0009] In a second aspect, the present invention proposes a control method for a glass microsphere powder bead device, which is implemented based on the glass microsphere powder bead device as described above, and the control method includes the following steps: After receiving the first injection signal sent by the flame injector, the temperature gradient set in the reaction area is obtained in real time, and the temperature gradient set at least includes the central temperature and the edge temperature of the reaction area; If the central temperature is within the first preset temperature range and the edge temperature is greater than the first preset temperature, the large particle microsphere powder injection pipe is opened and timing starts; When the injection duration of the large particle microsphere powder injection pipe accumulates to the first preset duration, the ultrafine glass microsphere powder injector is opened; After the injection duration of the ultrafine glass bead powder injector accumulates to the second preset duration, start the air extraction assembly at the first air extraction speed and fully open the air extraction holes to extract and filter the airflow carrying dust in the reaction zone.

[0010] According to the technical solution of the present invention, the reaction zone includes a circular central zone and a plurality of annular zones arranged in sequence and concentric with the central zone. The temperature gradient set includes temperature sequences corresponding to the central zone and each annular zone respectively. Each temperature sequence includes the point temperatures of several points; the average temperature of all points in the central zone is the central temperature, and the average temperature of all points in the annular zone farthest from the central zone is the edge temperature. After starting the air extraction assembly at the first air extraction speed, the following steps are further included: According to the temperature gradient set, determine whether the reaction temperature field in the reaction zone is disturbed by the heat flow of the air extraction assembly; the types of the heat flow disturbance include heat uniformity disturbance and heat balance disturbance. If so, according to the type of the heat flow disturbance, obtain the corresponding temperature adjustment strategy, and the temperature adjustment strategy at least includes adjusting the air extraction speed of the air extraction assembly and / or controlling the opening degree of the air extraction holes.

[0011] According to the technical solution of the present invention, determining whether the reaction temperature field in the reaction zone is disturbed by the heat flow of the air extraction assembly specifically includes the following steps: According to the temperature gradient set, obtain the actual temperature of each annular zone. According to the central temperature and the actual temperature of each annular zone, obtain an actual gradient sequence, and the actual gradient sequence includes the temperature difference between the central zone and the adjacent annular zone and the temperature difference between every two adjacent annular zones. Obtain the target gradient sequence corresponding to the current bead merging. If the first deviation degree between the actual gradient sequence and the target gradient sequence is greater than the first preset deviation degree, determine the type of the heat flow disturbance as a heat balance disturbance; if there is a non-uniform region in the central zone or any annular zone, determine the type of the heat flow disturbance as a heat uniformity disturbance; the non-uniform region is a region where there is a first proportion of abnormal points in the temperature sequence, and the abnormal point is a point where the second deviation degree between the point temperature and the average temperature corresponding to the region is greater than the first preset deviation.

[0012] According to the technical solution of the present invention, obtaining the corresponding temperature adjustment strategy according to the type of the heat flow disturbance specifically includes the following steps: If the type of the heat flux disturbance is the heat balance disturbance, an extraction speed adjustment amount is obtained according to the first deviation degree, and the first extraction speed is adjusted with the extraction speed adjustment amount; If the type of the heat flux disturbance is the heat uniformity disturbance, a target extraction hole corresponding to the non-uniform region is obtained according to the non-uniform region, and a target opening degree of the target extraction hole is obtained according to the second deviation degree.

[0013] According to the technical solution of the present invention, after adjusting the first extraction speed with the extraction speed adjustment amount, the following steps are further included: Obtain the real-time aperture of the buffer hole. If the real-time aperture is greater than or equal to the first preset aperture, the extraction speed adjustment amount is reduced according to the absolute value of the difference between the real-time aperture and the first preset aperture.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: The present invention divides the reaction area and the extraction area along the height direction of the bead storage bin. The reaction area is at the bottom, and the flame injector arranged at the bottom can concentrate heat here, so that the heat generated by the flame injector naturally forms a stable temperature gradient in the reaction area, and the bottom is relatively closed, and the heat is not easily dissipated too quickly. At the same time, the extraction area is located in the filter screen cylinder body at the top. When extracting air, the air flow is drawn away from above the reaction area, avoiding directly impacting the high-temperature core area of the reaction area, reducing the disturbance to the hot air flow, thereby maintaining a relatively stable temperature distribution in the reaction area and ensuring the formation of glass microspheres under uniform temperature conditions; the extraction area is located in the filter screen cylinder body at the top. It takes a certain time and distance for the powder to move upward from the bottom of the reaction area to the extraction area under its own gravity, natural convection and jet power, which is equivalent to a natural buffer. Compared with the structure where the extraction port and the powder injection port are in the same area in the traditional device, the structure proposed by the present invention gives the powder more opportunities to fully mix, melt and form beads in the reaction area, reducing the possibility of the powder being prematurely extracted from the key reaction area, making the air flow more inclined to take away the dust suspended after the preliminary bead formation above the reaction area, rather than forcibly extracting the reacting powder, ensuring that the powder has enough residence time in the reaction area to complete the fusion process. Description of the Drawings

[0015] Figure 1 It is a schematic structural diagram of a glass microsphere powder bead-forming device provided by the present invention; Figure 2 It is a schematic cross-sectional view of a glass microsphere powder bead-forming device provided by the present invention; Figure 3 It is a step flow chart of a control method for a glass microsphere powder bead-forming device provided by the present invention.

[0016] The text markings in the figure are indicated as: 1. Bead-joining cylinder; 2. Filter screen cylinder; 3. Negative pressure chamber; 4. Flame injector; 5. Large particle microbead powder injection pipe; 6. Ultra-fine glass microbead powder injector; 7. Air extractor; 8. Air extraction end; 9. Air extraction pipe; 10. Air extraction hole; 11. Buffer block; 12. Buffer hole; 13. Air outlet pipe; 14. Filtration chamber; 15. Filtration component; 16. Air extraction area; 17. Reaction area. Detailed implementation mode

[0017] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It can be understood that the specific embodiments described herein are only used to explain the related invention, rather than limiting the invention. In addition, it should be noted that, for the sake of convenience of description, only the parts related to the invention are shown in the drawings.

[0018] It should be noted that, without conflict, the embodiments in the present invention and the features in the embodiments can be combined with each other. The present invention will be described in detail below with reference to the accompanying drawings and embodiments.

[0019] Embodiment 1 As mentioned in the background art, in view of the problems in the prior art, the present invention provides a glass microbead powder bead-joining device. Please refer to Figure 1 and Figure 2 as shown, including: A bead-joining bin, which has an accommodation space inside. The accommodation space includes a reaction area 17 and an air extraction area 16 distributed along the height direction of the bead-joining bin. The bead-joining bin includes a bead-joining cylinder 1 at the bottom and a filter screen cylinder 2 provided on the top of the bead-joining cylinder 1. The air extraction area 16 is formed inside the filter screen cylinder 2, and the reaction area 17 is formed inside the bead-joining cylinder 1. A flame injector 4, a large particle microbead powder injection pipe 5, and an ultra-fine glass microbead powder injector 6 are installed on the bead-joining cylinder 1. Among them, the injection ends of the flame injector 4, the large particle microbead powder injection pipe 5, and the ultra-fine glass microbead powder injector 6 extend into the reaction area 17; Specifically, the bead-joining cylinder 1 is a cylindrical structure. As the core reaction area 17 of the entire bead-joining device, the reaction area 17 is formed inside it. A flame injector 4, a large particle microbead powder injection pipe 5, and an ultra-fine glass microbead powder injector 6 are installed on the side of the cylinder at the position of the reaction area 17. The flame injector 4 is used to provide a high-temperature environment so that the glass microbead powder can be melted into spheres therein; the large particle microbead powder injection pipe 5 and the ultra-fine glass microbead powder injector 6 are respectively responsible for injecting glass microbead powders with different particle sizes into the reaction area 17 for bead-joining operations. The filter screen cylinder 2 is located on the top of the bead-joining cylinder 1 and is cylindrical. The air extraction area 16 is formed inside it. The main function of the filter screen cylinder 2 is to separate the reaction area 17 and the air extraction area 16 in the bead-joining bin, and at the same time allow the airflow carrying dust to enter the negative pressure area through the filter screen.

[0020] Specifically, inside the bead-forming box, glass microsphere powder is the main raw material for forming glass microspheres. However, during processes such as powder spraying, melting, and bead formation, some dust will inevitably be generated. This dust may come from incompletely melted powder particles, fine particles detached from the surface of glass microspheres due to collisions, and other impurities that may be mixed in. When the air flow moves inside the bead-forming box, it will carry this glass microsphere powder and impurities to form a dust-laden air flow. If there are too many dust impurities in the dust-laden air flow, they may adhere to the surface of the glass microspheres being formed, affecting quality indicators such as the sphericity and smoothness of the glass microspheres, resulting in the product not meeting the requirements. However, directly discharging the dust-laden air flow sucked out from the bead-forming box into the environment will cause air pollution and pose a hazard to the surrounding environment and the health of operators. Therefore, it is necessary to suck out the dust-laden air flow and perform filtration treatment.

[0021] A filtering mechanism, the filtering mechanism includes: A filtering chamber, the filtering chamber is disposed around the bead-forming chamber, the filtering chamber includes a negative pressure chamber 3 and a filtering chamber 14 at the bottom of the negative pressure chamber 3; the negative pressure chamber 3 is communicated with the air extraction area 16 through the filter screen cylinder 2, and the filtering chamber 14 is isolated from the accommodation space; Specifically, the negative pressure chamber 3 is communicated with the air extraction area 16 of the bead-forming chamber through the filter screen cylinder 2. Its function is to form a negative pressure environment under the action of the air extraction component, guiding the air flow carrying dust to enter the filtering chamber 14 from the bead-forming chamber; the filtering chamber 14 is isolated from the accommodation space, used to accommodate the filtering component 15, and filter the air flow entering it.

[0022] An air extraction component, the air extraction component is disposed inside the negative pressure chamber 3, and is used to suck the air flow carrying dust in the bead-forming chamber into the filtering chamber 14; A filtering component 15, the filtering component 15 is disposed inside the filtering chamber 14, and is used to filter the air flow carrying dust, so that the air flow carrying dust forms clean gas after filtration.

[0023] In a preferred embodiment, the air extraction component includes an air extractor 7. The air outlet end of the air extractor 7 is connected with an air outlet pipe 13, the air outlet pipe 13 is communicated with the filtering component 15, the air extraction end 8 of the air extractor 7 is connected with an annular air extraction pipe 9, the air extraction pipe 9 is disposed inside the negative pressure chamber 3 and sleeved outside the filter screen, and a plurality of air extraction holes 10 opening towards the side of the filter screen cylinder 2 are uniformly distributed on the air extraction pipe 9. Each air extraction hole 10 is equipped with an air extraction switch for controlling its opening and closing and opening degree.

[0024] Specifically, by controlling the opening and closing and opening degree of the air extraction switch, the air extraction flow rate of each air extraction hole 10 can be adjusted, so as to realize the air extraction control of different areas in the bead-forming chamber.

[0025] Optionally, the filtering component 15 is generally composed of filtering materials such as multi-layer filter screens, filter cotton, activated carbon, etc. The settings of a filter chamber, a negative pressure chamber 3, an air extractor 7, etc. disclosed in the patent with the patent number CN218025831U can also be used, so that the airflow carrying dust enters the water body, and the airflow filtered by the water body and the filter screen is discharged through the exhaust port, enabling the dust in the airflow to be filtered multiple times. Its function is to filter the airflow carrying dust, so that the dust in the airflow is intercepted and adsorbed on the filtering material, thereby forming clean gas after the airflow is filtered and discharging it through the exhaust port after reaching the emission standard.

[0026] The working principle of this bead-joining device: The bead-joining chamber divides the accommodation space into a reaction zone 17 and an air extraction zone 16 in the height direction, so that the key reactions during the bead-joining process are carried out in the reaction zone 17, while the air extraction mainly occurs in the air extraction zone 16. A flame injector 4, a large particle microbead powder injection pipe 5, and an ultrafine glass microbead powder injector 6 are installed in the reaction zone 17, providing the high-temperature environment and raw material supply required for the bead-joining of glass microbeads. The air extraction zone 16 is mainly responsible for extracting the dust-containing airflow generated in the reaction zone 17. Through this zoning setting, the direct interference of the air extraction process on the reaction zone 17 is avoided, and the influence of air extraction on the temperature gradient distribution formed by the flame injector 4 and the powder movement trajectory is reduced. The filter screen cylinder 2 is located at the top of the bead-joining cylinder 1, playing a role in guiding the airflow and initially separating the dust. Under the action of the air extraction component, the airflow carrying dust moves upward from the reaction zone 17. When passing through the filter screen cylinder 2, larger particles of dust will be blocked by the filter screen, and part of the dust will adhere to the filter screen, achieving the initial separation of the dust. At the same time, it makes the flow direction of the airflow passing through the filter screen more orderly, reducing the influence of airflow disorder on the reaction zone 17. The filter chamber surrounds the bead-joining chamber, and the negative pressure chamber 3 therein is communicated with the air extraction zone 16 through the filter screen cylinder 2. The air extraction component works in the negative pressure chamber 3, and the generated negative pressure can stably draw the airflow carrying dust in the bead-joining chamber into the filter chamber, without the situation of excessive or insufficient local suction, thereby avoiding abnormal airflow direction and change of powder movement trajectory caused by uneven air extraction.

[0027] During the operation of the entire device, the bead-joining bin, the filtering bin, the air extraction component, and the filtering component 15 work together in coordination. The air extraction component stably extracts air in the negative pressure chamber 3, extracts the dust-containing air flow in the reaction zone 17 through the filter mesh cylinder 2, and discharges clean gas after being filtered by the filtering chamber 14. This stable air extraction process maintains a relatively stable air flow direction and pressure environment in the reaction zone 17, enabling the flame injector 4 to work under a normal temperature gradient distribution, providing an ideal high-temperature environment for the bead-joining of glass microspheres. At the same time, since the air extraction does not forcibly change the movement trajectory of the powder, the large-particle microsphere powder and the ultra-fine glass microsphere powder can fully contact and fuse in the key reaction zone 17 near the flame injector 4, thus ensuring the forming quality of the glass microspheres.

[0028] In a preferred embodiment, a buffer zone is further provided in the bead-joining cylinder 1. The buffer zone is arranged between the reaction zone 17 and the air extraction zone 16. A buffer component is provided in the buffer zone, and a plurality of buffer holes 12 are provided on the buffer component.

[0029] Furthermore, at the boundary between the buffer zone and the reaction zone 17, an annular boss is provided on the inner wall of the bead-joining cylinder 1. The buffer component is a buffer block 11 formed of an elastic buffer material, and the buffer block 11 is placed on the annular boss.

[0030] Specifically, the buffer block 11 formed of an elastic buffer material and adapted to the height of the buffer zone is usually a circular block structure adapted to the structure of the bead-joining cylinder 1, and is placed on the annular boss formed on the inner wall of the bead-joining cylinder 1. A plurality of buffer holes 12 are provided on the buffer block 11. These buffer holes 12 can make the air flow more evenly and slowly when passing through the buffer zone, further reducing the interference of the air extraction on the reaction zone 17, and at the same time preventing the powder from being prematurely extracted from the reaction zone 17.

[0031] Specifically, the design method of the buffer block 11 can be as follows: According to the vertical distance between the reaction zone 17 and the air extraction zone 16 in the bead-joining device, the preliminary thickness range of the honeycomb-shaped buffer block 11 is initially set. Optionally, the preliminary thickness range is 12 - 18 mm; multiple candidate thicknesses are selected from the preliminary thickness range, and computational fluid dynamics (CFD) software is used for simulation tests. In the simulation environment, parameters such as the air flow velocity, temperature, and the particle size distribution and density of the glass microsphere powder that are consistent with actual production are set. For honeycomb-shaped buffer block 11 models with different candidate thicknesses (such as 13 mm, 15 mm, 17 mm, etc.), observe the pressure change, turbulence degree, and the movement trajectory of the dust particles when the air flow passes through.

[0032] Through comparative analysis, a candidate thickness is selected that optimizes the airflow stability, has a good dust particle precipitation effect, and minimizes the interference to the airflow in the reaction zone 17. For example, if the simulation results show that at a thickness of 15 mm, the pressure loss of the airflow before and after the buffer block 11 is moderate, and the dust agglomeration and precipitation efficiency are relatively high, then the thickness of the buffer block 11 is finally determined to be 15 mm.

[0033] Optionally, regular hexagonal honeycomb holes are used as the buffer holes 12, and are evenly distributed in a concentric circular pattern with the center of the buffer block 11 as the reference point. Six honeycomb holes are arranged in the innermost ring (radius approximately 5 mm). As the ring expands outwards, a ring is added every 5 mm, and the number of honeycomb holes on each ring increases by six. Such a layout can ensure that the airflow enters evenly from all directions of the buffer block 11, avoiding excessive local airflow impact and stabilizing the buffering effect. At the same time, along the thickness direction of the buffer block 11, the honeycomb holes are kept through and parallel to each other, enabling the airflow to pass through smoothly, reducing the airflow resistance caused by the bending of the pore channels, and ensuring the smooth transition of the airflow within the buffer block 11.

[0034] In a preferred embodiment, a vibration assembly is further provided on the filter screen cylinder 2.

[0035] Specifically, the vibration assembly is installed on the filter screen cylinder 2 and generally consists of a vibration motor, a transmission mechanism, and connecting components, etc. The vibration motor is connected to the filter screen cylinder 2 through the transmission mechanism, and the connecting components are used to fix and support the vibration motor and the transmission mechanism to ensure its stable operation. During the operation of the device, the vibration assembly can cause the filter screen cylinder 2 to vibrate at a certain frequency and amplitude. On the one hand, this vibration can prevent the filter screen from being blocked by dust, enabling the airflow to smoothly pass through the filter screen and enter the air extraction area 16; on the other hand, the vibration can also make the dust attached to the surface of the filter screen more likely to fall off and drop into the lower filter cavity 14, improving the filtering effect and the service life of the filter screen.

[0036] Embodiment 2 Based on Embodiment 1, this embodiment proposes a control method for a glass microsphere powder bead-making device, which is implemented based on the glass microsphere powder bead-making device described in Embodiment 1, as Figure 3 shown, and this method includes the following steps: S1. After receiving the first injection signal sent by the flame injector 4, the temperature gradient set within the reaction zone 17 is obtained in real time, and the temperature gradient set at least includes the central temperature and the edge temperature of the reaction zone 17; S2. If the central temperature is within the first preset temperature range and the edge temperature is greater than the first preset temperature, then the large particle microsphere powder injection pipe 5 is opened and timing starts; S3. After the cumulative injection duration of the large particle microbead powder injection pipe 5 reaches the first preset duration, turn on the ultrafine glass microbead powder injector 6; S4. After the cumulative injection duration of the ultrafine glass microbead powder injector 6 reaches the second preset duration, start the air extraction assembly at the first air extraction speed and fully open the air extraction holes 10 to extract and filter the airflow carrying dust in the reaction zone 17.

[0037] Specifically, a plurality of high-temperature resistant and high-precision temperature sensors are arranged at appropriate positions in the reaction zone 17. These sensors can collect temperature data in real time and transmit it to the control system. When the flame injector 4 emits the first injection signal, it means that the device is about to enter the bead coalescence process. The control system immediately activates the temperature acquisition module, receives data from each temperature sensor, and quickly integrates it to form a temperature gradient set in the reaction zone 17, covering key information such as the central temperature and the edge temperature. The control system has a comparison logic for the preset temperature range built in. Once the central temperature falls within the first preset temperature range and the edge temperature is greater than the first preset temperature, it means that the reaction zone 17 has initially reached a thermal environment suitable for the melting of large particle microbead powder. The control system immediately sends an opening instruction to the large particle microbead powder injection pipe 5 and simultaneously starts the timing module to accurately record its injection duration. The timing module cooperates closely with the control system. When the cumulative injection duration of the large particle microbead powder injection pipe 5 reaches the first preset duration, the control system turns on the ultrafine glass microbead powder injector 6 according to the preset program to ensure that the two powders enter the reaction zone 17 in sequence at appropriate time nodes and orderly start the bead coalescence process. When the injection duration of the ultrafine glass microbead powder injector 6 reaches the second preset duration, the control system drives the air extraction assembly to operate at the first air extraction speed according to the preset instruction and fully opens the air extraction holes 10. Starting the air extraction assembly in a timely manner can not only promptly remove the dust-containing airflow generated during the reaction, prevent excessive accumulation of dust in the reaction zone 17 from affecting subsequent bead coalescence, but also avoid premature air extraction from interfering with the initial melting and mixing of the powder, optimizing the stability and continuity of the entire bead coalescence process.

[0038] In a preferred embodiment, the reaction zone 17 includes a circular central area and a plurality of annular areas arranged in sequence and concentric with the central area. The temperature gradient set includes temperature sequences corresponding to the central area and each annular area respectively. Each temperature sequence includes the point temperatures of several points; the average temperature of all points in the central area is the central temperature, and the average temperature of all points in the annular area farthest from the central area is the edge temperature; Specifically, 5 sensors are evenly arranged radially in the central area, and an appropriate number of sensors are arranged in each annular area according to the area size, generally one sensor is arranged every 45 degrees.

[0039] After starting the air extraction assembly at the first air extraction speed, the following steps are further included: According to the temperature gradient set, determine whether the reaction temperature field in the reaction zone 17 is disturbed by the heat flow of the air extraction assembly; the types of the heat flow disturbance include heat uniformity disturbance and heat balance disturbance; If so, according to the type of the heat flow disturbance, obtain a corresponding temperature adjustment strategy, and the temperature adjustment strategy at least includes adjusting the air extraction speed of the air extraction assembly and / or controlling the opening degree of the air extraction holes 10.

[0040] In a preferred embodiment, the determining whether the reaction temperature field in the reaction zone 17 is disturbed by the heat flow of the air extraction assembly specifically includes the following steps: According to the temperature gradient set, obtain the actual temperature of each of the annular zones; According to the central temperature and the actual temperature of each of the annular zones, obtain an actual gradient sequence, and the actual gradient sequence includes the temperature difference between the central zone and the adjacent annular zone and the temperature difference between every two adjacent annular zones; Obtain a target gradient sequence corresponding to the current bead merging. If the first deviation degree between the actual gradient sequence and the target gradient sequence is greater than a first preset deviation degree, determine the type of the heat flow disturbance as a heat balance disturbance; if there is a non-uniform region in the central zone or any of the annular zones, determine the type of the heat flow disturbance as a heat uniformity disturbance; the non-uniform region is a region where there is a first proportion of abnormal points in the temperature sequence, and the abnormal point is a point where the second deviation degree between the point temperature and the average temperature corresponding to the region is greater than a first preset deviation.

[0041] Exemplarily, assume that the reaction zone 17 is divided into a circular central zone and two concentric annular zones, which are labeled as annular zone 1 and annular zone 2 (annular zone 2 is the farthest from the central zone). Five temperature sensors are evenly arranged radially in the central zone (the positions of the temperature sensors are the points), and the measured point temperatures (unit: °C) are successively: 1220, 1230, 1240, 1225, 1235. After calculation, the average temperature of all points in the central zone (i.e., the central temperature) is: (1220 + 1230 + 1240 + 1225 + 1235) / 5 = 1230 °C. According to the area size, one sensor is arranged every 45° in annular zone 1, and a total of 8 sensors are arranged. The measured point temperature sequence is: 1205, 1210, 1215, 1200, 1220, 1218, 1208, 1225. The average temperature of this annular zone is calculated to be 1212 °C. Similarly, one sensor is arranged every 45° in annular zone 2, and 6 sensors are arranged. The point temperature sequence is: 1190, 1195, 1185, 1180, 1198, 1188. The average temperature of all points in the annular zone farthest from the central zone (i.e., the edge temperature) is: 1190 °C. The temperature gradient set contains the temperature sequence of the central zone [1220, 1230, 1240, 1225, 1235], the temperature sequence of annular zone 1 [1205, 1210, 1215, 1200, 1220, 1218, 1208, 1225], and the temperature sequence of annular zone 2 [1190, 1195, 1185, 1180, 1198, 1188].

[0042] The target gradient sequence is the target temperature difference of the average temperature between the central zone and the adjacent concentric annular zones, and between adjacent concentric annular zones. Assume that the average temperature of the central zone is 1240 °C, the target temperature difference between annular zone 1 and the central zone is 15 °C (i.e., the average temperature is 1225 °C), and the target temperature difference between annular zone 2 and annular zone 1 is 10 °C (i.e., the average temperature is 1215 °C). The actual gradient sequence is calculated as follows: the temperature difference between the central zone and annular zone 1 is 1230 - 1212 = 18 °C, and the temperature difference between annular zone 2 and annular zone 1 is 1212 - 1190 = 22 °C. By comparing the actual gradient sequence with the target gradient sequence, the first deviation degree is calculated (optionally, the sum of the absolute values of the temperature difference differences): |18 - 15| + |22 - 10| = 3 + 12 = 15. If the preset first deviation degree is greater than 12, it is determined as a thermal equilibrium disturbance. Since 15 > 12, it can be determined as a thermal equilibrium disturbance at this time.

[0043] It is assumed that in each region, if the proportion of points where the second deviation degree between the point temperature and the average temperature corresponding to the region is greater than 15°C reaches 25% (i.e., the first ratio), then the region is determined to be a non-uniform region. In the annular region 1, after statistics, it is found that there are 2 points where the deviation degree between the point temperature and the average temperature of 1212°C is greater than 15°C, accounting for 25% of the total 8 points in the region, meeting the determination conditions for a non-uniform region. Due to the existence of a non-uniform region, it can be determined as a thermal uniformity disturbance at this time.

[0044] In summary, based on the arrangement of temperature sensors, a temperature gradient set is constructed, and then according to specific deviation degree calculation and regional non-uniform determination rules, the type of heat flux disturbance can be accurately determined, thereby providing strong support for ensuring the thermal stability of the glass bead coalescence process.

[0045] In a preferred embodiment, obtaining a corresponding temperature control strategy according to the type of the heat flux disturbance specifically includes the following steps: If the type of the heat flux disturbance is the thermal balance disturbance, then according to the first deviation degree, an air extraction speed adjustment amount is obtained, and the first air extraction speed is adjusted with the air extraction speed adjustment amount; If the type of the heat flux disturbance is the thermal uniformity disturbance, then according to the non-uniform region, a target air extraction hole 10 corresponding to the non-uniform region is obtained, and according to the second deviation degree, a target opening degree of the target air extraction hole 10 is obtained.

[0046] Exemplarily, in a glass bead production process, it is preset that the central area temperature should be maintained at 1200 - 1300°C, the edge temperature should not be lower than 1100°C, the first preset duration is 10 s, the second preset duration is 5 s, and the first air extraction speed is 5 m³ / min. When the flame injector 4 is started, the control system collects that the central temperature is 1250°C and the edge temperature is 1120°C. After meeting the conditions, the large particle microbead powder injection pipe 5 is opened and timed. After 10 s, the ultra-fine glass microbead powder injector 6 is opened, and after 5 s, the air extraction assembly is started. If during the air extraction process, it is found that the local temperature in a certain annular region drops suddenly, it is determined as a thermal uniformity disturbance. The control system quickly locates the corresponding air extraction hole 10 and adjusts its opening degree from fully open to 50%, so that the temperature in the reaction area 17 quickly returns to uniformity, ensuring the smooth progress of the glass bead coalescence. Another example is that if the overall temperature gradient deviates greatly from the target gradient, it is determined as a thermal balance disturbance, and the air extraction speed is adjusted to 4 m³ / min through calculation to rebalance the heat flux and ensure the product quality.

[0047] Specifically, because the thermal equilibrium disturbance reflects the macroscopic deviation of the temperature gradient of the entire reaction zone 17 from the ideal state, and the exhaust speed has a global impact on the heat flow distribution in the reaction zone 17, when it is determined to be a thermal equilibrium disturbance, the exhaust speed adjustment amount is determined according to the first deviation degree, which can effectively correct the temperature gradient of the reaction zone 17. For example, a larger first deviation degree means that the thermal imbalance is more serious. Correspondingly increasing the exhaust speed adjustment amount can quickly change the extraction rate of the heat flow, causing the temperature gradient of the reaction zone 17 to approach the target state again, and accurately correct the thermal imbalance. In the process of glass microbeads, the thermal equilibrium state may change at any time with the progress of the reaction, the spraying of the powder, and slight changes in the external environment. By continuously monitoring the temperature gradient set and calculating the first deviation degree in real time, the exhaust speed can be dynamically adjusted to keep the reaction zone 17 in a thermal equilibrium environment close to the ideal at all times, ensuring that the beading process is not disturbed by thermal imbalance and improving the stability of product quality.

[0048] Specifically, when the temperature deviation at several points in the annular area is too large and is judged as a thermal uniform disturbance, action is taken directly against the exhaust hole 10 associated with the annular area, avoiding unnecessary unified adjustments to the entire reaction area 17 and reducing interference with the normal thermal environment of the reaction area 17. The target opening of the target exhaust hole 10 is determined based on the second deviation, and fine "micro-manipulation" of the heat flow is achieved. The second deviation reflects the degree to which the temperature of the local point deviates from the average value. The precise adjustment of the opening can accurately change the heat flow rate passing through the exhaust hole 10, so that the heat in the local overheated or overcooled area is reasonably allocated, and the uniform temperature distribution is quickly restored to ensure that the powder is melted and beaded in a uniform thermal field, improve the product molding quality, and reduce the defects of glass beads caused by local temperature unevenness.

[0049] In a preferred embodiment, after adjusting the first pumping speed by the pumping speed adjustment amount, the method further includes the following steps: The real-time aperture of the buffer hole 12 is obtained. If the real-time aperture is greater than or equal to the first preset aperture, the air extraction speed adjustment amount is reduced according to the absolute value of the difference between the real-time aperture and the first preset aperture.

[0050] Specifically, at the moment when the air extraction component adjusts the air extraction speed, the air flow speed and pressure may change sharply, generating instantaneous high-pressure pulses. This high-pressure impact acts on the buffer holes 12, which may cause elastic deformation of the hole walls. When the impact intensity is large and occurs frequently, the elastic deformation of the buffer holes 12 will accumulate, resulting in a permanent expansion of the hole diameter. However, the change in the diameter of the buffer holes 12 will directly affect the air extraction resistance and the uniformity of the air flow passing through. When the real-time hole diameter is greater than the first preset hole diameter, it means that the air flow resistance during the air extraction process becomes smaller. If the air extraction speed is not adjusted, it may cause the local air flow to be too fast, thereby destroying the thermal balance and air flow stability of the reaction zone 17 and affecting the bead formation effect of the glass microspheres. By adjusting the air extraction speed adjustment amount according to the hole diameter difference, it is possible to dynamically adapt to the change in the diameter of the buffer holes 12, make the air extraction process more stable, maintain a stable thermal environment and air flow field in the reaction zone 17, and ensure the formation of glass microspheres under ideal conditions.

[0051] Specifically, a high-precision hole diameter monitoring sensor is installed in the buffer hole 12 at the center of the buffer block 11. The sensor can use laser ranging technology to accurately measure the diameter of the buffer hole 12 by emitting a laser beam and receiving the reflected light, and immediately transmit the real-time hole diameter information of the buffer hole 12 collected to the control system. After the control system calculates and executes the air extraction speed adjustment amount according to the first deviation degree based on the determination result of the thermal balance disturbance and adjusts the first air extraction speed, the hole diameter monitoring program is immediately started. The control system receives the real-time hole diameter data from the sensor and determines whether the real-time hole diameter is greater than or equal to the first preset hole diameter. If the condition is met, the algorithm module built into the control system quickly calculates the absolute value of the difference between the real-time hole diameter and the first preset hole diameter. For example, the real-time hole diameter is 3.5 mm, the first preset hole diameter is 3 mm, and the absolute value of the difference is 0.5 mm.

[0052] Based on the preset adjustment rules, the air extraction speed adjustment amount is adjusted according to this absolute value of the difference. The adjustment rule can be a linear relationship, such as for every 0.1 mm difference, the air extraction speed adjustment amount is reduced by 10%.

[0053] In this article, specific examples are used to elaborate on the principle and implementation manner of the present invention. The description of the above embodiments is only used to help understand the method and its core idea of the present invention. The above is only the preferred implementation manner of the present invention. It should be noted that due to the limited nature of the written expression, and objectively there are infinite specific structures. For those of ordinary skill in the art in this technical field, without departing from the principle of the present invention, several improvements, retouches or changes can also be made, or the above technical features can be combined in an appropriate manner; these improvements, retouches, changes or combinations, or directly applying the concept and technical solution of the invention to other occasions without improvement, should all be regarded as the protection scope of the present invention.

Claims

1. A glass microbead powder beading device, characterized in that: include: A bead combining bin, wherein the bead combining bin has a storage space therein, wherein the storage space comprises a reaction zone (17) and an exhaust zone (16) distributed along the height direction of the bead combining bin, wherein the bead combining bin comprises a bead combining cylinder (1) located at the bottom, and a filter cylinder (2) arranged at the top of the bead combining cylinder (1), wherein the exhaust zone (16) is formed in the filter cylinder (2), and the reaction zone (17) is formed in the bead combining cylinder (1), wherein a flame injector (4), a large-particle micro-bead powder injection tube (5) and an ultra-fine glass micro-bead powder injector (6) are installed on the bead combining cylinder (1), wherein the injection ends of the flame injector (4), the large-particle micro-bead powder injection tube (5) and the ultra-fine glass micro-bead powder injector (6) extend into the reaction zone (17); A filtering mechanism, the filtering mechanism comprising: A filter chamber, the filter chamber is arranged around the bead chamber, the filter chamber comprises a negative pressure chamber (3) and a filter chamber (14) located at the bottom of the negative pressure chamber (3); the negative pressure chamber (3) is connected to the air extraction area (16) through the filter cylinder (2), and the filter chamber (14) is isolated from the accommodating space; An air extraction component, the air extraction component being arranged in the negative pressure chamber (3) and being used to extract the airflow entrained with dust in the bead bin into the filter chamber (14); A filter assembly (15) is arranged in the filter cavity (14) and is used to filter the airflow entrained with dust, so that the airflow entrained with dust forms clean gas after filtering.

2. The glass microbead powder combining device according to claim 1, characterized in that: The bead-binding cylinder (1) also has a buffer zone, which is arranged between the reaction zone (17) and the gas extraction zone (16). A buffer component is arranged in the buffer zone, and a plurality of buffer holes (12) are provided on the buffer component.

3. The glass microbead powder combining device according to claim 2, characterized in that: The exhaust assembly comprises an exhaust fan (7), the exhaust end of the exhaust fan (7) is connected to an exhaust pipe (13), the exhaust pipe (13) is connected to the filter assembly (15), the exhaust end (8) of the exhaust fan (7) is connected to an annular exhaust pipe (9), the exhaust pipe (9) is arranged in the negative pressure chamber (3) and is sleeved outside the filter cylinder (2), and a plurality of exhaust holes (10) are evenly distributed on the exhaust pipe (9) and open toward the side of the filter cylinder (2), and each of the exhaust holes (10) is equipped with an exhaust switch for controlling its opening and closing and the opening degree.

4. The glass microbead powder combining device according to claim 3, characterized in that: At the boundary between the buffer zone and the reaction zone (17), an annular boss is provided on the inner wall of the bead-binding cylinder (1), and the buffer component is a buffer block (11) formed of an elastic buffer material, and the buffer block (11) is placed on the annular boss.

5. The glass microbead powder combining device according to claim 4, characterized in that: A vibration component is also provided on the filter cylinder (2).

6. A control method for a glass microbead powder combining device, which is implemented based on the glass microbead powder combining device according to claim 5; characterized in that: The control method comprises the following steps: After receiving a first injection signal sent by a flame injector (4), a temperature gradient set in the reaction zone (17) is acquired in real time, the temperature gradient set comprising at least a central temperature and an edge temperature of the reaction zone (17); If the center temperature is within a first preset temperature range and the edge temperature is greater than the first preset temperature, the large particle micro-bead powder injection tube (5) is turned on and timing is started; When the spraying time of the large-particle micro-bead powder spraying tube (5) reaches a first preset time, the ultra-fine glass micro-bead powder sprayer (6) is turned on; When the injection time of the ultra-fine glass microbead powder injector (6) is accumulated to a second preset time, the suction component is started at a first suction speed, and the suction holes (10) are all opened to extract and filter the airflow entrained with dust in the reaction zone (17).

7. The control method of the glass microbead powder combining device according to claim 6, characterized in that: The reaction zone (17) comprises a circular central zone and a plurality of annular zones distributed in sequence and arranged concentrically with the central zone, the temperature gradient set comprises a temperature sequence corresponding to the central zone and each of the annular zones, each of the temperature sequences comprises point temperatures of a plurality of points; the average temperature of all points in the central zone is the central temperature, and the average temperature of all points in the annular zone farthest from the central zone is the edge temperature; After starting the vacuum assembly at the first vacuum speed, the following steps are also included: According to the temperature gradient set, determining whether the reaction temperature field in the reaction zone (17) is disturbed by the heat flow of the exhaust component; the types of the heat flow disturbance include thermal uniformity disturbance and thermal equilibrium disturbance; If so, a corresponding temperature adjustment strategy is obtained according to the type of the heat flow disturbance, the temperature adjustment strategy at least comprising adjusting the exhaust speed of the exhaust component and / or controlling the opening of the exhaust hole (10).

8. The control method of the glass microbead powder combining device according to claim 7, characterized in that: The step of judging whether the reaction temperature field in the reaction zone (17) is disturbed by the heat flow of the exhaust component specifically comprises the following steps: According to the temperature gradient set, an actual temperature of each of the annular zones is obtained; According to the central temperature and the actual temperature of each of the annular zones, an actual gradient sequence is obtained, wherein the actual gradient sequence includes the temperature difference between the central zone and the annular zones adjacent thereto, and the temperature difference between every two adjacent annular zones; The target gradient sequence corresponding to this bead merging is obtained; if the first deviation between the actual gradient sequence and the target gradient sequence is greater than the first preset deviation, the type of the heat flow disturbance is determined to be a thermal equilibrium disturbance; if there is a non-uniform area in the central area or any of the annular areas, the type of the heat flow disturbance is determined to be a thermal uniform disturbance; the non-uniform area is an abnormal point with a first proportion in the temperature sequence, and the abnormal point is a point where the second deviation between the point temperature and the average temperature corresponding to the area is greater than the first preset deviation.

9. The control method of the glass microbead powder combining device according to claim 8, characterized in that: The step of obtaining a corresponding temperature adjustment strategy according to the type of the heat flow disturbance specifically includes the following steps: If the type of the heat flow disturbance is the thermal balance disturbance, obtaining a pumping speed adjustment amount according to the first deviation, and adjusting the first pumping speed by the pumping speed adjustment amount; If the type of the thermal flow disturbance is the thermal uniform disturbance, a target air extraction hole corresponding to the non-uniform area is obtained according to the non-uniform area, and a target opening of the target air extraction hole is obtained according to the second deviation.

10. The control method of the glass microbead powder combining device according to claim 9, characterized in that: After the first pumping speed is adjusted by the pumping speed adjustment amount, the following steps are also included: The real-time aperture of the buffer hole (12) is obtained, and if the real-time aperture is greater than or equal to a first preset aperture, the air extraction speed adjustment amount is reduced according to the absolute value of the difference between the real-time aperture and the first preset aperture.

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