Energy-saving sapphire glass producing and processing system

Abstract

The invention discloses an energy-saving sapphire glass production and processing system, belongs to the field of sapphire glass production, and aims to solve the problems of insufficient data security and weak self-adaptive control capability. The multi-axis linkage diamond cutting machine is integrated with a visual positioning system, the cutting path is corrected in real time, the magneto-rheological polishing machine adopts a magnetic nano abrasive material of a core-shell structure, the abrasive material is driven to move directionally through a gradient magnetic field, nanoscale surface modification is achieved, the abrasive material can be recycled, and the production cost is reduced. Through the multi-stage centrifugal separation, electromagnetic separation and electrodialysis desorption technologies, the cutting fluid purification rate and the aluminum oxide powder grading and recycling utilization rate are improved, the cyclone separator recycles aluminum oxide powder according to particle size grading, coarse powder directly returns to the melting furnace, and fine powder is modified and then used for other industrial purposes. The block chain data management module adopts an SHA-256 encryption and distributed account book technology to ensure that process parameters and quality inspection data are not tampered, each production batch generates a unique block chain ID, and code scanning is supported to trace whole process information.

Description

Technical Field

[0001] The present invention relates to the field of sapphire glass production, and particularly to an energy-saving sapphire glass production and processing system. Background Art

[0002] Sapphire glass is an artificially synthesized single crystal alumina, prepared by high-temperature melting growth technology. Although it has "glass" in its name, its essence is a single crystal material, rather than traditional amorphous glass. It is named because its physical and chemical properties are highly similar to natural sapphire, but its cost is much lower than that of natural gemstones. It can be used as high-end mobile phone screens, smart watch lenses, and camera lens protective sheets.

[0003] The existing control system lacks a dynamic energy consumption monitoring and optimization mechanism, cannot adjust the melting power and cooling water flow in real time, and does not integrate a waste heat recovery module. The direct discharge of high-temperature waste gas leads to waste of heat energy. The uneven distribution of the thermal field in the melting furnace causes local overheating or insufficient temperature, and the longitudinal temperature gradient fluctuates too much. The graphite crucible has significant heat radiation loss due to the lack of a silicon carbide coating and a boron nitride doped thermal insulation layer. The cutting fluid and alumina powder are not recycled in a closed loop, and the pollutant separation is incomplete, resulting in waste of resources and environmental pollution. The process parameters rely on centralized storage and are easily tampered with, lacking blockchain encryption and full-life cycle traceability capabilities, without a neural network prediction model and PID algorithm support, and the parameter adjustment depends on manual experience, resulting in insufficient processing stability. Summary of the Invention

[0004] The purpose of the present invention is to provide an energy-saving sapphire glass production and processing system, which solves the problems of insufficient data security and weak adaptive control ability.

[0005] To achieve the above purpose, the present invention provides the following technical solution: An energy-saving sapphire glass production and processing system, comprising: a crystal growth unit, an integrated processing module, and an intelligent control unit.

[0006] The crystal growth unit includes a high-frequency induction melting furnace, a thermal field optimization module, and a waste heat recovery module. The high-frequency induction melting furnace adopts a layered induction coil, and the thermal field optimization module includes a graphite crucible.

[0007] The integrated processing module includes a multi-axis linkage diamond cutting machine, an adaptive polishing platform, and a closed-loop cooling system. The multi-axis linkage diamond cutting machine is configured with a diamond wire saw and a five-axis numerical control machine tool, and the adaptive polishing platform integrates a magnetorheological polishing machine.

[0008] The intelligent control unit includes a control center, an energy consumption dynamic monitoring system, a blockchain data management module, a neural network prediction model, and an adaptive adjustment module.

[0009] Furthermore, the high-frequency induction melting furnace drives the layered induction coil to generate an alternating magnetic field. The layered induction coil adopts a three-layer independent control structure to form a longitudinal temperature gradient. The waste heat recovery module is connected to the melting furnace and the heat exchanger through a high-temperature exhaust gas pipeline. The annealing furnace intake pipeline raises the temperature of the preheated gas to the required range of the annealing furnace through the heat exchanger. The finned tubes of the heat exchanger adopt a staggered arrangement and variable cross-section structure. The inner wall of the high-temperature exhaust gas pipeline is coated with a high-temperature thermal barrier coating.

[0010] Furthermore, the outer surface of the graphite crucible is coated with a silicon carbide coating. The graphite crucible is surrounded by silicon carbide heating elements in a circular distribution. A graphite heat insulation layer is provided outside the silicon carbide heating elements. The graphite heat insulation layer is doped with boron nitride particles. The silicon carbide heating elements and the graphite heat insulation layer act synergistically.

[0011] Furthermore, the visual positioning system includes a visible light camera and an infrared sensor. The visible light camera captures the surface morphology characteristics of the ingot, and the infrared sensor detects the internal temperature distribution of the ingot. After the dual-modal data fusion, a three-dimensional coordinate is generated. The control center plans the motion path of the multi-station robotic arm based on the three-dimensional coordinate. The multi-station robotic arm clamps the ingot to the diamond wire saw station, and the five-axis numerical control machine tool performs wafer cutting according to the preset cutting parameters. The robotic arm transfers the wafer to the magnetorheological polishing station.

[0012] Furthermore, the control center serves as the core scheduling module to coordinate the operation processes among the crystal growth unit, the integrated processing module, and the intelligent control unit. The energy consumption dynamic monitoring system monitors the energy consumption data in real time. The neural network prediction model trains the historical data. The blockchain data management module encrypts the process parameters, quality inspection results, and energy consumption data using the SHA-256 hash algorithm.

[0013] Furthermore, the magnetorheological polishing machine includes a circular electromagnetic coil and magnetic nano-abrasives. The magnetic nano-abrasives form a chain-like structure under the action of a magnetic field. The magnetic nano-abrasives have a core-shell structure.

[0014] Furthermore, the closed-loop cooling system includes a separation device, an electrodialysis device, a circulation pump, and a cyclone separator. The separation device includes a multi-stage centrifugal separation device and an electromagnetic separator. The multi-stage centrifugal separation device separates coarse particle powders and fine particle powders. The electromagnetic separator separates magnetic residues and non-magnetic powders. The electrodialysis module treats the centrifuged cutting fluid to remove pollutants. The circulation pump transports the regenerated cutting fluid to the processing area. The system is equipped with an abrasive concentration monitoring module based on the principle of optical scattering.

[0015] Furthermore, the process flow of an energy-saving sapphire glass production and processing system is as follows:

[0016] S1. Crystal growth stage

[0017] 1. Raw material pretreatment: High-purity alumina powder is gradient heated through a layered induction coil, and the upper, middle, and lower layers operate synchronously to reduce thermal inertia;

[0018] 2. Melting and thermal field optimization: The graphite crucible is coated with a silicon carbide coating to reduce heat radiation loss; The honeycomb structure at the bottom of the crucible enhances the uniformity of melt convection. The annular silicon carbide heating element is combined with a graphite thermal insulation layer to form a temperature gradient decreasing from the center outwards, suppressing heat diffusion;

[0019] 3. Waste heat recovery: The high-temperature waste gas discharged from the melting furnace is counter-current heat exchanged through a heat exchanger to preheat the intake gas of the annealing furnace, reducing the initial energy consumption of annealing. The inner wall of the high-temperature waste gas pipeline is coated with a high-temperature resistant coating to prevent oxidation and cracking;

[0020] S2. Ingot cutting and shaping processing

[0021] 1. Visual positioning and cutting: The wafer cutting, surface shaping, and edge chamfering are completed by a multi-axis linkage diamond wire saw, and the processing path is precisely controlled in combination with a visual positioning system;

[0022] 2. Adaptive polishing: The polishing liquid contains magnetic nano-abrasives with a core-shell structure. Ferroferric oxide is the magnetic core, and cerium dioxide is the polishing outer layer. The annular electromagnetic coil generates a gradient magnetic field to drive the abrasives to form an oriented chain structure, achieving nanoscale surface polishing;

[0023] 3. Closed-loop cooling and recycling: Coarse particles and small particles are separated by multi-stage centrifugation. The ferroferric oxide magnetic residue and non-magnetic alumina powder are separated by electromagnetic separation. Metal ions are removed by applying a DC electric field. The alumina powder is classified by air separation. The coarse alumina powder is returned to the melting furnace, and the fine alumina powder is used for other industrial purposes after surface modification;

[0024] S3. Intelligent control and quality management

[0025] 1. Dynamic energy efficiency optimization: Sensors collect real-time data on melting power, cooling water flow, and environmental data. The process parameters are adjusted through an adaptive algorithm. According to the real-time energy efficiency calculation results, the crystal pulling rate and annealing gradient are dynamically adjusted;

[0026] 2. Blockchain data management: The raw material source, process parameters, quality inspection results, and energy consumption data are encrypted and distributed for storage to ensure traceability throughout the life cycle. Each production batch generates a unique blockchain identifier, and scanning the code can trace the information throughout the life cycle;

[0027] 3. Adaptive adjustment and model prediction: The neural network prediction model predicts the annealing gradient optimization strategy based on historical data, adjusts the heating power in stages, and the concentration of the polishing liquid and the purification index of the cutting fluid are fed back in real time to dynamically optimize the centrifugal speed and compounding parameters;

[0028] S4. Waste heat and resource recycling

[0029] 1. High-temperature waste gas recovery: The waste gas from the melting furnace preheats the annealing furnace gas through an efficient heat exchanger, reducing the initial heating energy consumption.

[0030] 2. Resource recycling and utilization: The cutting fluid is recycled after multi-stage separation and purification, reducing waste emissions. The alumina powder is classified and recycled according to particle size, achieving the maximum utilization of resources.

[0031] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0032] 1. The dynamic energy consumption monitoring system of the present invention collects data such as melting power and cooling water flow in real time, optimizes the energy efficiency ratio in combination with the adaptive adjustment module, reduces energy consumption. The waste heat recovery module recovers the waste heat of the melting furnace exhaust gas through a countercurrent heat exchanger, preheating the intake gas of the annealing furnace, reducing the initial heating energy consumption. The high-frequency induction melting furnace adopts a three-layer independent current-controlled stratified induction coil and a silicon carbide-coated graphite crucible, combined with a graphite thermal insulation layer, to form a stable thermal field with high temperature in the center and low temperature at the outer edge. The phase difference adjustment optimizes the eddy current distribution, suppresses the heat loss at the edge of the melting zone, and ensures the uniformity of the longitudinal temperature gradient. The graphite thermal insulation layer is doped with boron nitride particles, significantly improving the thermal resistance and reducing the axial heat loss. The high-temperature waste gas pipeline is coated with a yttria-stabilized zirconia coating to prevent pipeline oxidation and cracking, extending the equipment life. The neural network prediction model predicts the annealing gradient optimization strategy based on historical data, adjusts the heating power in stages, and avoids energy waste. The PID control algorithm adjusts the current intensity and phase difference of the stratified induction coil in real time to maintain the stability of the temperature gradient in the melting zone.

[0033] 2. The multi-axis linkage diamond cutting machine of the present invention integrates a vision positioning system, which can correct the cutting path in real time with an accuracy of the micron level. The magnetorheological polishing machine uses a core-shell structured magnetic nano-abrasive, and drives the abrasive to move directionally through a gradient magnetic field to achieve nano-level surface modification. Moreover, the abrasive can be recycled. The closed-loop cooling system improves the purification rate of the cutting fluid and the classification recovery utilization rate of alumina powder through multi-stage centrifugal separation, electromagnetic separation, and electrodialysis deionization technology. The cyclone separator classifies and recovers alumina powder according to particle size. The coarse powder is directly returned to the melting furnace, and the fine powder is used for other industrial purposes after modification. The blockchain data management module uses SHA-256 encryption and distributed ledger technology to ensure that process parameters and quality inspection data cannot be tampered with. Each production batch generates a unique blockchain ID, supporting scanning the code to trace the whole process information. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 is the system flow chart of the present invention;

[0035] Figure 2 is the flow chart of the crystal growth stage of the present invention;

[0036] Figure 3Flow chart of the sapphire glass processing stage of the present invention;

[0037] Figure 4 Flow chart of the intelligent control and quality management of the present invention. Detailed implementation manners

[0038] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying 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.

[0039] To solve the technical problems of insufficient data security and weak adaptive control ability, as Figures 1-4 shown, the following preferred technical solutions are provided:

[0040] An energy-saving sapphire glass production and processing system includes: a crystal growth unit, an integrated processing module, and an intelligent control unit;

[0041] The crystal growth unit includes a high-frequency induction melting furnace, a thermal field optimization module, and a waste heat recovery module. The high-frequency induction melting furnace uses a layered induction coil, and the thermal field optimization module includes a graphite crucible;

[0042] The integrated processing module includes a multi-axis linkage diamond cutting machine, an adaptive polishing platform, and a closed-loop cooling system. The multi-axis linkage diamond cutting machine is configured with a diamond wire saw and a five-axis numerical control machine tool, and the adaptive polishing platform integrates a magnetorheological polishing machine;

[0043] The intelligent control unit includes a control center, an energy consumption dynamic monitoring system, a blockchain data management module, a neural network prediction model, and an adaptive adjustment module.

[0044] The high-frequency induction melting furnace is based on the principle of electromagnetic induction heating. A high-frequency alternating current with a fixed frequency of 30 kHz drives a layered induction coil to generate an alternating magnetic field. Eddy currents are induced in the graphite crucible and the raw materials, generating Joule heat, and heating high-purity alumina powder to a molten state at 2050°C at a constant power. The layered induction coil adopts a three-layer independent control structure. The current intensity of the upper coil is 200 A, the current intensity of the middle coil is 180 A, and the current intensity of the lower coil is 170 A. By adjusting the phase difference to 30°, the upper coil serves as the main driving layer of the magnetic field. An alternating magnetic field is generated through the high-frequency alternating current, which acts synergistically with the silicon carbide heating element outside the graphite crucible to induce eddy currents in the top area of the graphite crucible, forming a central high-temperature zone, generating high-intensity Joule heat, ensuring that the high-purity alumina powder is quickly heated to the molten state of 2050°C, maintaining the high-temperature core at the top of the molten zone, forming the starting point of the longitudinal temperature gradient, and suppressing edge heat loss. The middle coil forms a magnetic field intensity transition zone to avoid local thermal field fluctuations caused by sudden changes in the magnetic fields of the upper and lower layers. Combining the upper and lower coils, it optimizes the longitudinal temperature gradient to ensure the longitudinal thermal field uniformity of the molten alumina. Through phase difference adjustment, the heat loss caused by heat conduction or radiation at the bottom of the graphite crucible is offset. It acts synergistically with the silicon carbide-coated graphite crucible and the boron nitride-doped graphite heat insulation layer to suppress the temperature decay at the edge of the molten zone. Cooperating with the waste heat recovery module, it balances the internal thermal field of the melting furnace and the external energy recovery efficiency. The lower coil precisely controls the temperature at the bottom of the molten zone through current intensity and phase difference adjustment, suppressing heat dissipation and ensuring the stability of the longitudinal temperature gradient. The heat loss caused by heat conduction or radiation at the bottom of the graphite crucible is compensated by electromagnetic induction heating, maintaining the uniformity of the molten alumina and avoiding bottom solidification or insufficient temperature. The lower coil forms an alternating magnetic field in cooperation with the upper and middle coils, optimizing the eddy current distribution through the phase difference, reducing the interference of the edge effect on the thermal field uniformity, forming a longitudinal temperature gradient, and the temperature difference from the top to the bottom does not exceed 50°C. The waste heat recovery module is connected to the melting furnace and the heat exchanger through a high-temperature exhaust gas pipeline. The high-temperature exhaust gas is introduced from the outlet of the melting furnace into the heat exchanger through the high-temperature exhaust gas pipeline for countercurrent heat exchange with the intake air of the annealing furnace. The intake air pipeline of the annealing furnace raises the temperature of the preheated gas to the required range of the annealing furnace through the heat exchanger, reducing the heating energy consumption in the initial stage of annealing. The finned tubes of the heat exchanger adopt a staggered arrangement and variable cross-section structure, maximizing the utilization of waste heat through the countercurrent heat exchange mode, increasing the heat transfer area, and improving the heat transfer efficiency by optimizing the air flow disturbance. The heat transfer model of the heat exchanger:

[0045]

[0046] h 翅片 is the heat transfer coefficient of the finned tube, s is the fin pitch, d 管外 is the outer diameter of the base tube, t 翅 is the fin thickness, h 管 is the heat transfer coefficient of the finless tube, d管内 is the inner diameter of the base tube, heating fluid n = 0.4, cooling fluid n = 0.3, ΔT eff is the logarithmic mean temperature difference between the inlet and outlet of the heat exchanger, T 废气,进口 and T 废气,出口 are the temperatures at the inlet and outlet of the exhaust gas recirculation, T 进气,出口 and T 进气,进口 , are the temperatures at the inlet and outlet of the intake air. The inner wall of the high-temperature exhaust gas pipeline is coated with a high-temperature-resistant thermal barrier coating. The coating material is yttria-stabilized zirconia, with a thickness of 200 - 300 μm and a temperature resistance threshold ≥ 1200 °C. It is used to prevent the pipeline from cracking or corroding due to high-temperature oxidation and thermal stress, ensuring the long-term stable operation of the system. The finned tubes of the heat exchanger and the high-temperature-resistant thermal barrier coating work together to reduce energy waste and extend the service life of the equipment.

[0047] The outer surface of the graphite crucible is coated with a silicon carbide coating. The silicon carbide heating elements are distributed annularly around the graphite crucible. A graphite thermal insulation layer is provided outside the silicon carbide heating elements. The material of the graphite thermal insulation layer is low-porosity, high-density graphite, with a porosity ≤ 5% and a density ≥ 1.8 g / cm3. The high-density graphite material wraps around the outside of the silicon carbide heating elements. Eddy current heating is generated under an alternating magnetic field through the principle of electromagnetic induction. Combining with the high-temperature stability of silicon carbide, a uniform annular thermal field is formed, creating a temperature gradient that decreases from the center to the outside, suppressing the temperature decay at the edge of the melting zone. The graphite thermal insulation layer is doped with boron nitride particles, and the doping mass ratio is 3% - 5%, improving the overall thermal resistance and further reducing the axial heat loss. The silicon carbide heating elements and the graphite thermal insulation layer work together. Through the gradient design with a high temperature in the center and a low temperature at the outer edge, the thermal field stability of the melting zone is ensured, avoiding local overheating or insufficient temperature.

[0048] The vision positioning system integrates a visible light camera and an infrared sensor, which work together through multi-spectral imaging technology. The visible light camera captures the surface topography features of the ingot and identifies the geometric contour, while the infrared sensor detects the internal temperature distribution of the ingot and analyzes the thermal stress state. The dual-modal data fusion generates high-precision three-dimensional coordinates, which are transmitted to the control center in real time. The five-axis CNC machine tool serves as the core processing platform, driving the diamond wire saw to execute complex motion trajectories through multi-axis linkage, supporting wafer cutting, surface forming, and edge chamfering. The diamond wire saw is precisely regulated by the machine tool, and its tension, cutting speed, and feed rate are dynamically optimized according to preset parameters. The wire saw tension is controlled by a servo motor closed-loop to avoid vibration or deviation during cutting. The cutting path is corrected in real time based on the three-dimensional coordinates to ensure precise matching with the ingot topography. The machine tool is equipped with a wear monitoring system that detects the wire saw wear through an optical sensor and automatically compensates the cutting parameters to maintain the processing accuracy. The control center plans the motion path of the multi-station robotic arm based on the three-dimensional coordinates. The robotic arm holds the ingot and positions it at the diamond wire saw station. During cutting, the five-axis machine tool synchronously executes multi-axis motions to ensure that the wire saw completes high-precision cutting along the preset trajectory. After cutting, the end of the robotic arm is integrated with a force feedback sensor and a vacuum chuck to monitor the clamping pressure and wafer stability in real time and safely transfer it to the magnetorheological polishing station. During the transfer process, the vision system continuously monitors the ingot position. If the offset exceeds the threshold, an adaptive path correction algorithm is triggered to dynamically adjust the robotic arm trajectory. The cutting parameters, wire saw status, and robotic arm motion data are fed back to the control center to form a processing closed-loop. For different ingot materials or environmental disturbances, the multi-axis linkage diamond cutting machine automatically adjusts the cutting speed, wire saw tension, and robotic arm acceleration to ensure processing coherence and product consistency.

[0049] As the core scheduling module, the control center coordinates the operation processes among the crystal growth unit, the integrated processing module, and the intelligent control unit, receives and processes data from each subsystem, and issues control instructions. Based on preset algorithms and real-time feedback data, it dynamically optimizes the production process to ensure seamless connection of each link. The energy consumption dynamic monitoring system continuously monitors the energy consumption data, collects data such as the power of the melting furnace, environmental temperature, and cooling water flow rate, and generates a dynamic energy efficiency ratio index by calculating the dynamic energy efficiency ratio. The dynamic energy efficiency ratio: P 熔融 is the effective power of the melting furnace, η 熔融 is the thermal efficiency of the melting furnace, Q 余热 =m& 废气 c p ΔT 废气 ,Q 余热 is the recovered waste heat, ΔT 废气 is the heat difference of the waste gas, η 换热 is the heat exchanger efficiency, P 总输入is the total input power of the system, which is the sum of the device powers. It evaluates the energy consumption efficiency of the system. Through threshold monitoring, it can detect energy consumption anomalies or equipment failures in a timely manner. The energy consumption data is transmitted to the control center in real time. Combining algorithm analysis of the energy consumption trend, the neural network prediction model is trained based on historical data, extracts the characteristics of the temperature rise curve and generates an optimization strategy. According to the slope change of the annealing furnace temperature rise curve, it predicts the optimal annealing gradient and adjusts the heating power in stages according to the prediction results to avoid energy waste. Neural network prediction model:

[0050] is the slope of the annealing temperature rise curve, and λ1, λ2 are weight coefficients set according to process requirements. is the predicted annealing temperature rise curve. is the historical annealing temperature rise curve. is the predicted power. The actual optimal power, the LSTM neural network inputs the historical temperature rise curve and the longitudinal temperature difference in the melting zone. The blockchain data management module uses the SHA-256 hashing algorithm to encrypt process parameters, quality inspection results, and energy consumption data to ensure the data cannot be tampered with. It generates a unique blockchain ID for each production batch, and through scanning technology, it can trace the raw material source, processing parameters, and inspection reports. It uses zero-knowledge proof technology to verify data relevance and prevent the leakage of sensitive information. The distributed ledger technology realizes the decentralized storage of data and combines encryption algorithms to ensure data security and transparency. Blockchain data encryption and verification algorithm:

[0051] H 批次 = SHA256(Raw material ID P Process parameters P Quality inspection results), C(w)=H 批次 and R(Public parameters, w)=1, C(w) is the zero-knowledge proof commitment function that hides the private evidence w. The encryption chip is embedded in the RFID tag of the raw material package. R is the verification relationship. The adaptive adjustment module is based on the feedback control theory and realizes dynamic optimization of parameters through error calculation and compensation mechanisms. According to the real-time energy consumption data, it dynamically adjusts the crystal pulling rate to match the requirements of the thermal field stability. Through the PID control algorithm, it accurately adjusts the current intensity and phase difference of the stratified induction coil to maintain the longitudinal temperature gradient in the melting zone. Stratified induction coil PID control model:

[0052] u j (t) is the current output of the j-th layer induction coil, 200A for the upper layer, 180A for the middle layer, and 170A for the lower layer. e j (t) is the difference between the set temperature and the measured value of the j-th layer, u j (t) is the current of the j-th layer coil, K p,j is the proportional gain coefficient calibrated according to the requirements of the thermal field uniformity, K i,j , the integral gain coefficient, Kd,j is the differential gain coefficient.

[0053] The magnetorheological polishing machine achieves efficient polishing through the synergistic effect of a toroidal electromagnetic coil and core-shell structured magnetic nano-abrasives. Surrounding the polishing area, a controllable radial gradient magnetic field is generated by adjusting the current intensity. The magnetic field intensity decreases from the center outwards, precisely controlling the abrasive distribution and polishing pressure. The gradient magnetic field drives the abrasives to form a chain-like structure, enhancing the local polishing pressure and material removal efficiency. The gradient magnetic field intensity distribution model of the toroidal electromagnetic coil:

[0054] B(r) is the magnetic field intensity, μ0 = 4π × 10 -7 H / m, μ0 is the magnetic permeability of vacuum, which is a physical constant, N is the number of turns of the electromagnetic coil, I is the coil current. The polishing pressure model of the core-shell abrasive chain: P 抛光 is the polishing pressure, n 磨料 is the abrasive concentration, μ 磁 is the magnetic susceptibility of magnetite, is the magnetic field gradient. At the same time, excessive wear on the workpiece surface is avoided. The core of the core-shell structure is magnetite, providing high magnetic responsiveness and quickly responding to magnetic field changes. The shell is cerium dioxide, which has high hardness and chemical stability, ensuring efficient polishing and reducing scratches. The surface of the abrasive is grafted with carboxyl functional groups, enhancing the dispersion stability in the polishing liquid through electrostatic repulsion and steric hindrance effects, preventing abrasive agglomeration and extending the service life. The polishing liquid contains magnetic nano-abrasives and a dispersion medium. By magnetically orienting and controlling the movement trajectory of the abrasives, nano-scale surface modification is achieved. After polishing, the abrasives are recovered by centrifugal separation, and the coarse particles are filtered and redispersed for reuse, reducing resource waste. The adaptive polishing platform is built-in with an abrasive concentration monitoring module, a wafer surface roughness and internal defect detection module. When the detected abrasive concentration drops to the set value, the replenishment work is started to replenish the lost abrasives in real time and maintain the consistency of the polishing liquid performance. Through the wafer surface roughness and internal defect detection module, the surface roughness of the wafer after grinding can be detected, as well as whether there are defects inside the wafer.

[0055] The closed-loop cooling system includes a separation device, an electrodialysis device, a circulation pump, and a cyclone separator. The separation device includes a multi-stage centrifugal separation device and an electromagnetic separator. The multi-stage centrifugal separation device quickly separates coarse particle powders through first-stage high-speed centrifugation and further removes small particle powders through second-stage medium-speed centrifugation, reducing the subsequent processing load. The multi-stage centrifugal separation efficiency model:

[0056] ω1, ω2 are the angular velocities of the centrifuge, r1, r2 are the centrifugal radii, ρ pThe particle density of the alumina powder is 3.95 g / cm3. d is the particle size, and μ is the viscosity of the cutting fluid. After centrifugal separation, the coarse particle powder and the fine particle powder are separated by an electromagnetic separator. The magnetic residue containing magnetite is separated from the non-magnetic alumina powder. The magnetic residue enters the abrasive recovery channel for compounding the polishing fluid. The non-magnetic alumina powder enters the melting furnace regeneration channel. The centrifuged cutting fluid enters the electrodialysis module. A DC electric field is applied to drive the migration of metal ions and salt pollutants. Pollutants are efficiently removed through a selective ion exchange membrane. The conductivity is monitored in real time to ensure that the ion concentration of the cutting fluid meets the standard. The purified cutting fluid is supplemented with corrosion inhibitors and defoamers to restore its lubricity and cooling performance. The regenerated cutting fluid is transported to the processing area through a circulation pump. The pH value and temperature of the regenerated cutting fluid are monitored in real time to ensure process stability. The separated magnetic residue undergoes a ball milling process to reduce the agglomeration rate and is mixed with cerium dioxide powder in a mass ratio of 1:2. In a high-temperature reaction kettle, a core-shell structure is formed through chemical vapor deposition. The inner core is magnetite, providing magnetic responsiveness, and the outer shell is cerium dioxide, enhancing the polishing performance and scratch resistance. Carboxyl functional groups are grafted to improve the dispersion stability of the polishing fluid. The regenerated core-shell abrasive is added to the magnetorheological polishing fluid in proportion and mixed evenly with the dispersion medium. The system is equipped with an abrasive concentration monitoring module based on the principle of optical scattering to supplement the lost abrasive in real time and maintain the consistency of the polishing fluid performance. The non-magnetic alumina powder is classified by a cyclone separator. The first-stage cyclone separation captures the coarse powder and directly returns it to the melting furnace as raw material. The second-stage cyclone separation collects the fine powder, which is used for other industrial purposes after surface modification. The closed-loop cooling system dynamically adjusts the centrifugal speed according to the powder load in the cutting fluid to cope with impurity fluctuations in different processing stages. The performance data of the polishing fluid and the purification indicators of the cutting fluid are fed back to the control center in real time, and the separation and compounding parameters are optimized through the PID algorithm.

[0057] The process flow of an energy-saving sapphire glass production and processing system is as follows:

[0058] S1. Crystal growth stage

[0059] 1. Raw material pretreatment: High-purity alumina powder is gradient heated through a layered induction coil, and the upper, middle, and lower layers operate synchronously to reduce thermal inertia;

[0060] 2. Melting and thermal field optimization: The graphite crucible is coated with a silicon carbide coating to reduce heat radiation loss; The honeycomb structure at the bottom of the crucible enhances the uniformity of melt convection. The annular silicon carbide heating element combined with the graphite heat insulation layer forms a temperature gradient decreasing from the center to the outside to inhibit heat diffusion;

[0061] 3. Waste heat recovery: The high-temperature waste gas discharged from the melting furnace undergoes countercurrent heat exchange in a heat exchanger to preheat the intake gas of the annealing furnace and reduce the initial energy consumption of annealing. The inner wall of the high-temperature waste gas pipeline is coated with a high-temperature resistant coating to prevent oxidation and cracking;

[0062] S2, Ingot Cutting and Forming Processing

[0063] 1. Visual Positioning and Cutting: The wafer cutting, surface forming and edge chamfering are completed by a multi-axis linkage diamond wire saw, and the processing path is accurately controlled in combination with a visual positioning system;

[0064] 2. Adaptive Polishing: The polishing liquid contains core-shell structured magnetic nano-abrasives, with magnetite as the magnetic core and cerium dioxide as the polishing outer layer. Functional groups are modified on the surface to improve dispersion. An annular electromagnetic coil generates a gradient magnetic field to drive the abrasives to form a directional chain structure, achieving nano-level surface polishing;

[0065] 3. Closed-loop Cooling and Recycling: Coarse particles and fine particles are separated by multi-stage centrifugation, magnetite magnetic residues and non-magnetic alumina powder are separated by electromagnetic separation, metal ions are removed by applying a DC electric field, corrosion inhibitors and defoamers are added to the purified cutting fluid to restore its lubricating performance. The alumina powder is classified by air separation. The coarse alumina powder is returned to the melting furnace, and the fine alumina powder is used for other industrial purposes after surface modification;

[0066] S3, Intelligent Control and Quality Management

[0067] 1. Dynamic Energy Efficiency Optimization: Sensors collect real-time data on melting power, cooling water flow and environmental data, adjust process parameters through an adaptive algorithm, and dynamically adjust the crystal pulling rate and annealing gradient according to the real-time energy efficiency calculation results;

[0068] 2. Blockchain Data Management: The raw material source, process parameters, quality inspection results and energy consumption data are encrypted and stored distributively to ensure traceability throughout the life cycle. Each production batch generates a unique blockchain identifier, and scanning the code can trace the information throughout the life cycle;

[0069] 3. Adaptive Regulation and Model Prediction: The neural network prediction model predicts the annealing gradient optimization strategy based on historical data, adjusts the heating power in stages, and the polishing liquid concentration and cutting fluid purification index are fed back in real time to dynamically optimize the centrifugal speed and compounding parameters;

[0070] S4, Waste Heat and Resource Recycling

[0071] 1. High-temperature Exhaust Gas Recovery: The exhaust gas from the melting furnace preheats the gas in the annealing furnace through a high-efficiency heat exchanger, reducing the initial heating energy consumption;

[0072] 2. Resource Recycling and Utilization: The cutting fluid is recycled after multi-stage separation and purification, reducing waste emissions. The alumina powder is recycled by particle size classification to achieve maximum resource utilization.

[0073] It should be noted that in this document, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprising", "including" or any other variant thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements not only includes those elements, but also includes other elements not expressly listed, or further includes elements inherent to such process, method, article or device.

[0074] As described above, the above is only a preferred specific embodiment of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention, according to the technical solution and inventive concept of the present invention, making equivalent substitutions or changes, shall be covered by the protection scope of the present invention.

Claims

1. An energy-saving sapphire glass production and processing system, characterized in that, Including: A crystal growth unit, an integrated processing module, and an intelligent control unit, The crystal growth unit includes a high-frequency induction melting furnace, a thermal field optimization module, and a waste heat recovery module. The high-frequency induction melting furnace adopts a layered induction coil. The thermal field optimization module includes a graphite crucible; The integrated processing module includes a multi-axis linkage diamond cutting machine, an adaptive polishing platform, and a closed-loop cooling system. The multi-axis linkage diamond cutting machine is configured with a diamond wire saw and a five-axis numerical control machine tool. The adaptive polishing platform integrates a magnetorheological polishing machine; The intelligent control unit includes a control center, an energy consumption dynamic monitoring system, a blockchain data management module, a neural network prediction model, and an adaptive adjustment module.

2. The energy-saving sapphire glass production and processing system according to claim 1, characterized in that: The high-frequency induction melting furnace drives the layered induction coil to generate an alternating magnetic field. The layered induction coil adopts a three-layer independent control structure to form a longitudinal temperature gradient. The waste heat recovery module is connected to the melting furnace and the heat exchanger through a high-temperature exhaust gas pipeline. The intake pipeline of the annealing furnace raises the temperature of the preheated gas to the required range of the annealing furnace through the heat exchanger. The finned tubes of the heat exchanger adopt a staggered arrangement and variable cross-section structure. The inner wall of the high-temperature exhaust gas pipeline is coated with a high-temperature thermal barrier coating.

3. An energy-saving sapphire glass production and processing system according to claim 1, characterized in that: The outer surface of the graphite crucible is coated with a silicon carbide coating. The graphite crucible is surrounded by a silicon carbide heating element. A graphite heat insulation layer is provided outside the silicon carbide heating element. The graphite heat insulation layer is doped with boron nitride particles. The silicon carbide heating element and the graphite heat insulation layer act synergistically.

4. An energy-saving sapphire glass production and processing system as claimed in claim 1, characterized in that: The vision positioning system includes a visible light camera and an infrared sensor. The visible light camera captures the surface topography features of the ingot. The infrared sensor detects the internal temperature distribution of the ingot. After the dual-modal data fusion, a three-dimensional coordinate is generated. The control center plans the movement path of the multi-station robotic arm based on the three-dimensional coordinate. The multi-station robotic arm clamps the ingot to the diamond wire saw station. The five-axis numerical control machine tool performs wafer cutting according to the preset cutting parameters. The robotic arm transfers the wafer to the magnetorheological polishing station.

5. The energy-saving sapphire glass production and processing system according to claim 4, characterized in that: The control center serves as the core scheduling module to coordinate the operation processes among the crystal growth unit, the integrated processing module, and the intelligent control unit. The energy consumption dynamic monitoring system monitors the energy consumption data in real time. The neural network prediction model trains historical data. The blockchain data management module encrypts the process parameters, quality inspection results, and energy consumption data using the SHA-256 hash algorithm.

6. The energy-saving sapphire glass production and processing system according to claim 4, characterized in that: The magnetorheological polishing machine includes a circular electromagnetic coil and magnetic nano-abrasives. The magnetic nano-abrasives form a chain-like structure under the action of a magnetic field. The magnetic nano-abrasives have a core-shell structure.

7. An energy-saving sapphire glass production and processing system according to claim 1, characterized in that: The closed-loop cooling system includes a separation device, an electrodialysis device, a circulation pump, and a cyclone separator. The separation device includes a multi-stage centrifugal separation device and an electromagnetic separator. The multi-stage centrifugal separation device separates coarse particle powders and fine particle powders. The electromagnetic separator separates magnetic residues and non-magnetic powders. The electrodialysis module processes the centrifuged cutting fluid to remove pollutants. The circulation pump transports the regenerated cutting fluid to the processing area. The system is built-in with an abrasive concentration monitoring module based on the principle of optical scattering.

8. An energy-saving sapphire glass production and processing system according to claim 1, characterized in that: The process of an energy-saving sapphire glass production and processing system is as follows: S1. Crystal growth stage 1). Raw material pretreatment: High-purity alumina powder is gradient heated through a layered induction coil, and the upper, middle, and lower layers operate synchronously to reduce thermal inertia; 2). Melting and thermal field optimization: The graphite crucible is coated with a silicon carbide coating to reduce heat radiation loss; The honeycomb structure at the bottom of the crucible enhances the uniformity of melt convection. The annular silicon carbide heating element combined with the graphite thermal insulation layer forms a temperature gradient decreasing from the center to the outside, suppressing heat diffusion; 3). Waste heat recovery: The high-temperature exhaust gas discharged from the melting furnace exchanges heat countercurrently through a heat exchanger to preheat the intake gas of the annealing furnace, reducing the initial energy consumption of annealing. The inner wall of the high-temperature exhaust gas pipeline is coated with a high-temperature resistant coating to prevent oxidation and cracking; S2. Ingot cutting and shaping processing 1). Visual positioning and cutting: The wafer cutting, surface forming, and edge chamfering are completed by a multi-axis linkage diamond wire saw, and the processing path is accurately controlled in combination with the visual positioning system; 2). Adaptive polishing: The polishing liquid contains magnetic nano-abrasives with a core-shell structure. Ferroferric oxide is the magnetic core, and cerium dioxide is the polishing outer layer. The annular electromagnetic coil generates a gradient magnetic field to drive the abrasives to form a directional chain structure, achieving nano-level surface polishing; 3). Closed-loop cooling and recycling: Coarse particles and small particles are separated by multi-stage centrifugation. The ferroferric oxide magnetic residue and non-magnetic alumina powder are separated by electromagnetic separation. Metal ions are removed by applying a DC electric field. The alumina powder is classified by air separation. The coarse alumina powder is returned to the melting furnace, and the fine alumina powder is used for other industrial purposes after surface modification; S3. Intelligent control and quality management 1). Dynamic energy efficiency optimization: Sensors collect melting power, cooling water flow, and environmental data in real time, adjust process parameters through an adaptive algorithm, and dynamically adjust the crystal pulling rate and annealing gradient according to the real-time energy efficiency calculation results; 2). Blockchain data management: The raw material source, process parameters, quality inspection results, and energy consumption data are encrypted and stored distributively to ensure traceability throughout the life cycle. Each production batch generates a unique blockchain identifier, and scanning the code can trace the information throughout the life cycle; 3). Adaptive adjustment and model prediction: The neural network prediction model predicts the annealing gradient optimization strategy based on historical data, adjusts the heating power in stages, and the polishing liquid concentration and cutting fluid purification index are fed back in real time to dynamically optimize the centrifugal speed and compounding parameters; S4. Waste heat and resource recycling 1). High-temperature exhaust gas recovery: The exhaust gas from the melting furnace preheats the gas in the annealing furnace through an efficient heat exchanger, reducing the initial heating energy consumption; 2). Resource recycling and utilization: The cutting fluid is recycled after multi-stage separation and purification to reduce waste emissions. The alumina powder is classified and recycled according to particle size to achieve the maximum utilization of resources.

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