Energy-saving sapphire glass production and processing system

Abstract

The energy-saving sapphire glass production and processing system belongs to the sapphire glass production field and aims at solving 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 magnetorheological polishing machine adopts a magnetic nano abrasive with a core-shell structure, the abrasive is driven to move directionally through a gradient magnetic field, the surface is reshaped at the nanometer level, the abrasive can be recycled, the cutting fluid purification rate and the alumina powder grading recycling rate are improved through multi-stage centrifugal separation, electromagnetic separation and electrodialysis deionization technology, the cyclone separator is used for grading and recycling the alumina powder according to the particle size, the coarse powder is directly returned to the melting furnace, the fine powder is modified and used for other industrial purposes, the blockchain data management module adopts SHA-256 encryption and distributed ledger technology, the process parameters and the quality inspection data are ensured to be tamper-proof, a unique blockchain ID is generated for each production batch, and the code scanning and tracing of the whole process information are supported.

Description

Technical Field

[0001] This invention relates to the field of sapphire glass production, and in particular to an energy-saving sapphire glass production and processing system. Background Technology

[0002] Sapphire glass is a synthetic monocrystalline aluminum oxide produced through high-temperature melt growth technology. Although its name includes "glass," it is essentially a monocrystalline material, not a traditional amorphous glass. It is named for its highly similar physicochemical properties to natural sapphire, but its cost is far lower than that of natural gemstones. It can be used for high-end mobile phone screens, smartwatch glass, and camera lens protectors.

[0003] The existing control system lacks dynamic energy consumption monitoring and optimization mechanisms, cannot adjust melting power and cooling water flow in real time, and does not integrate a waste heat recovery module. Direct emission of high-temperature exhaust gas leads to heat energy waste. Uneven thermal field distribution in the melting furnace causes local overheating or insufficient temperature. The longitudinal temperature gradient fluctuates too much. The graphite crucible lacks silicon carbide coating and boron nitride doped insulation layer, resulting in significant heat radiation loss. Cutting fluid and alumina powder are not recycled in a closed loop, and pollutant separation is incomplete, leading to resource waste and environmental pollution. Process parameters rely on centralized storage and are easily tampered with. There is a lack of blockchain encryption and full life cycle traceability capabilities. There is no neural network prediction model or PID algorithm support. Parameter adjustment relies on manual experience, resulting in insufficient processing stability. Summary of the Invention

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

[0005] To achieve the above objectives, 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 uses 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 equipped with a diamond wire saw and a five-axis CNC 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 coils to generate an alternating magnetic field. The layered induction coils adopt a three-layer independent control structure to form a longitudinal temperature gradient. The waste heat recovery module connects the melting furnace and the heat exchanger through a high-temperature exhaust gas pipeline. The annealing furnace inlet 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 an alternating arrangement and variable cross-section structure. The inner wall of the high-temperature exhaust gas pipeline is coated with a high-temperature heat barrier coating.

[0010] Furthermore, the outer surface of the graphite crucible is coated with a silicon carbide coating, and silicon carbide heating elements are distributed in a ring around the graphite crucible. A graphite heat insulation layer is provided around the silicon carbide heating elements, and the graphite heat insulation layer is doped with boron nitride particles. The silicon carbide heating elements and the graphite heat insulation layer work together.

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

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

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

[0014] Furthermore, the closed-loop cooling system includes a separation device, an electrodialysis device, a circulating 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 and fine powder particles, the electromagnetic separator separates magnetic residues from non-magnetic powders, the electrodialysis module treats the centrifuged cutting fluid to remove contaminants, and the circulating pump delivers the regenerated cutting fluid to the machining area. The system has a built-in 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 heated in a gradient by a layered induction coil, with the upper, middle and lower layers operating 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 combined with the graphite insulation layer forms a temperature gradient that decreases from the center to the outside, suppressing heat diffusion.

[0019] 3. Waste heat recovery: The high-temperature waste gas emitted from the melting furnace is heat exchanged in a countercurrent heat exchanger to preheat the gas entering 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. Vision positioning and cutting: Wafer cutting, curved surface shaping and edge chamfering are completed by multi-axis linkage diamond wire saw, and the processing path is precisely controlled by vision positioning system;

[0022] 2. Adaptive polishing: The polishing slurry contains core-shell structured magnetic nano-abrasives, with iron oxide as the magnetic core and cerium dioxide as the polishing outer layer. A ring-shaped electromagnetic coil generates a gradient magnetic field, driving the abrasives to form a directional chain structure, thereby achieving nanoscale surface polishing.

[0023] 3. Closed-loop cooling and recovery: Multi-stage centrifugal separation of coarse and fine particles, electromagnetic separation of magnetic residue of iron oxide and non-magnetic alumina powder, application of DC electric field to remove metal ions, alumina powder air classification, coarse alumina powder returned to the melting furnace, and fine alumina powder used for other industrial applications after surface modification.

[0024] S3, Intelligent Control and Quality Management

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

[0026] 2. Blockchain data management: Raw material sources, process parameters, quality inspection results and energy consumption data are encrypted and distributed to ensure traceability throughout the entire life cycle. Each production batch generates a unique blockchain identifier, and scanning the code allows for the traceability of the entire life cycle information.

[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 provides real-time feedback on polishing fluid concentration and cutting fluid purification index to dynamically optimize 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 is preheated in the annealing furnace through a high-efficiency heat exchanger, reducing the initial heating energy consumption;

[0030] 2. Resource recycling: The cutting fluid is recycled after multi-stage separation and purification, reducing waste emissions. Alumina powder is recycled according to particle size, maximizing resource utilization.

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

[0032] 1. The dynamic energy consumption monitoring system of this invention collects data such as melting power and cooling water flow rate in real time, and optimizes the energy efficiency ratio by combining with the adaptive adjustment module to reduce energy consumption. The waste heat recovery module recovers the waste heat of the furnace exhaust gas through the countercurrent heat exchanger and preheats the annealing furnace intake gas to reduce initial heating energy consumption. The high-frequency induction melting furnace adopts a three-layer induction coil with independent current control and a silicon carbide coated graphite crucible, combined with a graphite 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 heat loss at the edge of the melting zone, and ensures the uniformity of the longitudinal temperature gradient. The graphite insulation layer is doped with boron nitride particles, which significantly improves thermal resistance and reduces axial heat loss. The high-temperature exhaust gas pipeline is coated with a yttrium oxide-stabilized zirconia coating to prevent pipeline oxidation and cracking and extend equipment life. The neural network prediction model predicts the annealing gradient optimization strategy based on historical data and adjusts the heating power in stages to avoid energy waste. The PID control algorithm adjusts the current intensity and phase difference of the layered 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 this invention integrates a vision positioning system to correct the cutting path in real time with micron-level precision. The magnetorheological polishing machine uses core-shell structured magnetic nano-abrasives, which are driven by a gradient magnetic field to achieve nanoscale surface shaping. The abrasives are recyclable. The closed-loop cooling system improves the cutting fluid purification rate and the graded recycling rate of alumina powder through multi-stage centrifugal separation, electromagnetic sorting, and electrodialysis deionization technology. The cyclone separator recovers alumina powder according to particle size. Coarse powder is directly returned to the melting furnace, while fine powder is modified for other industrial applications. The blockchain data management module uses SHA-256 encryption and distributed ledger technology to ensure that process parameters and quality inspection data are tamper-proof. Each production batch generates a unique blockchain ID, supporting QR code scanning to trace the entire process information. Attached Figure Description

[0034] Figure 1 This is a system flowchart of the present invention;

[0035] Figure 2 This is a flowchart of the crystal growth stages of the present invention;

[0036] Figure 3This is a flowchart of the sapphire glass processing stages of the present invention;

[0037] Figure 4 This is a flowchart of the intelligent control and quality management process of the present invention. Detailed Implementation

[0038] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0039] To address the technical problems of insufficient data security and weak adaptive control capabilities, such as Figure 1-4 As 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 equipped with a diamond wire saw and a five-axis CNC 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. It uses a fixed-frequency (30kHz) AC current to drive layered induction coils, generating an alternating magnetic field. This induces eddy currents and Joule heating in the graphite crucible and raw materials, heating high-purity alumina powder to a molten state of 2050℃ at a constant power. The layered induction coils employ a three-layer independently controlled structure: the upper coil has a current intensity of 200A, the middle coil 180A, and the lower coil 170A. By adjusting the phase difference to 30°, the upper coil acts as the main driving layer of the magnetic field, generating an alternating magnetic field that interacts with the external environment of the graphite crucible. The silicon carbide heating element works synergistically to induce eddy currents in the top region of the graphite crucible, forming a central high-temperature zone that generates high-intensity Joule heating. This ensures that the high-purity alumina powder is rapidly heated to a molten state of 2050℃, maintaining a high-temperature core at the top of the molten zone and forming the starting point of the longitudinal temperature gradient. This suppresses heat loss at the edges. The middle layer coil forms a magnetic field intensity transition zone, avoiding local thermal field fluctuations caused by abrupt changes in the upper and lower magnetic fields. Combined with the upper and lower layer coils, the longitudinal temperature gradient is optimized, ensuring the uniformity of the longitudinal thermal field of the molten alumina. Through phase difference adjustment, heat loss at the bottom of the graphite crucible due to heat conduction or radiation is offset. This, along with the silicon carbide coating, further enhances the heating effect. The graphite crucible and boron nitride-doped graphite insulation layer work together to suppress temperature decay at the edge of the molten zone. Combined with a waste heat recovery module, this balances the thermal field inside the furnace with 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 loss and ensuring the stability of the longitudinal temperature gradient. Electromagnetic induction heating compensates for heat loss at the bottom of the graphite crucible due to heat conduction or radiation, maintaining the uniformity of the molten alumina and preventing bottom solidification or insufficient temperature. The lower coil, along with the upper and middle layers, forms an alternating magnetic field. Phase difference optimization of eddy current distribution reduces the interference of edge effects on thermal field uniformity. To prevent disturbances and create a longitudinal temperature gradient, the temperature difference from top to bottom should not exceed 50℃. The waste heat recovery module connects the melting furnace and the heat exchanger through a high-temperature exhaust gas pipeline. The high-temperature exhaust gas is introduced into the heat exchanger from the outlet of the melting furnace through the high-temperature exhaust gas pipeline, where it undergoes countercurrent heat exchange with the inlet gas of the annealing furnace. The inlet gas 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 energy consumption for heating in the initial stage of annealing. The finned tubes of the heat exchanger adopt a staggered arrangement and variable cross-section structure to maximize the utilization of waste heat from the exhaust gas through the countercurrent heat exchange mode, increase the heat exchange area, and improve the heat transfer efficiency by optimizing airflow disturbances. Heat exchanger heat transfer model:

[0045]

[0046] h 翅片 s is the heat transfer coefficient of the finned tube, s is the fin spacing, and d is the heat transfer coefficient of the finned tube. 管外 It is the outer diameter of the base tube, t 翅 It is the fin thickness, h 管 It is the heat transfer coefficient of the finless tube, d管内 The inner diameter of the base pipe is given, with heating fluid n = 0.4 and cooling fluid n = 0.3. ΔT eff It 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 It is the temperature at the inlet and outlet of the exhaust gas, T. 进气,出口 and T 进气,进口 The temperature at the inlet and outlet of the inlet air is ≥1200℃. The inner wall of the high-temperature exhaust gas pipeline is coated with a high-temperature thermal barrier coating. The coating material is yttrium-stabilized zirconium oxide with a thickness of 200-300μm and a temperature resistance threshold of ≥1200℃. This coating 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 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. A silicon carbide heating element is distributed in a ring around the graphite crucible. A graphite insulation layer is placed around the silicon carbide heating element. The graphite insulation layer is made of low-porosity, high-density graphite with a porosity ≤5% and a density ≥1.8g / cm3. The high-density graphite material surrounds the silicon carbide heating element and generates eddy current heating under an alternating magnetic field through the principle of electromagnetic induction. Combined 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 molten zone. The graphite insulation layer is doped with boron nitride particles at a mass ratio of 3%-5%, which improves the overall thermal resistance and further reduces axial heat loss. The silicon carbide heating element and the graphite insulation layer work together to ensure the stability of the thermal field in the molten zone through a gradient design with a high temperature at the center and a low temperature at the outer edge, avoiding local overheating or insufficient temperature.

[0048] The visual positioning system integrates a visible light camera and an infrared sensor, working collaboratively through multispectral imaging technology. The visible light camera captures the surface morphology features of the ingot and identifies its geometric contours, while the infrared sensor detects the internal temperature distribution of the ingot and analyzes its thermal stress state. Dual-modal data fusion generates high-precision three-dimensional coordinates, which are transmitted to the control center in real time. A 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. It supports wafer cutting, surface shaping, and edge chamfering. The diamond wire saw is precisely controlled by the machine tool; its tension, cutting speed, and feed rate are dynamically optimized according to preset parameters. The wire saw tension is controlled via a closed-loop servo motor to avoid vibration or offset during cutting. The cutting path is corrected in real time based on three-dimensional coordinates to ensure precise matching with the ingot shape. The machine tool has a built-in wear monitoring system that detects wire saw wear through optical sensors and automatically... To maintain processing accuracy, the control center plans the motion path of the multi-station robotic arm based on three-dimensional coordinates. The robotic arm clamps the ingot and positions it at the diamond wire saw station. During the cutting process, the five-axis machine tool simultaneously executes multi-axis motion to ensure that the wire saw completes high-precision cutting along the preset trajectory. After cutting, the robotic arm end integrates a force feedback sensor and a vacuum suction cup to monitor the clamping pressure and wafer stability in real time. The wafer is then safely transferred to the magnetorheological polishing station. During the transfer, 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. Cutting parameters, wire saw status, and robotic arm motion data are fed back to the control center to form a processing closed loop. In response to differences in ingot material 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 continuity and product consistency.

[0049] The control center, as the core scheduling module, coordinates the operation of the crystal growth unit, integrated processing module, and intelligent control unit. It receives and processes data from each subsystem, issues control commands, and dynamically optimizes the production process based on preset algorithms and real-time feedback data, ensuring seamless integration of all stages. The energy consumption dynamic monitoring system monitors energy consumption data in real time, collecting data on furnace power, ambient temperature, and cooling water flow. By calculating the dynamic energy efficiency ratio, it generates a dynamic energy efficiency ratio index. The dynamic energy efficiency ratio is: P 熔融 It is the effective power of the melting furnace, η 熔融 It is the thermal efficiency of the melting furnace, Q 余热 =m& 废气 c p ΔT 废气 Q 余热 It is the heat recovered from waste heat, ΔT 废气 It is the heat difference of the exhaust gas, η 换热 It is the efficiency of the heat exchanger, P 总输入This refers to the total system input power, the sum of equipment power, and the assessment of system energy efficiency. Threshold monitoring allows for timely detection of energy consumption anomalies or equipment malfunctions. Energy consumption data is transmitted to the control center in real time. Combined with algorithmic analysis of energy consumption trends, a neural network prediction model is trained based on historical data to extract temperature rise curve features and generate optimization strategies. Based on the slope changes of the annealing furnace temperature rise curve, the optimal annealing gradient is predicted. Heating power is adjusted in stages based on the prediction results to avoid energy waste. Neural network prediction model:

[0050] This represents the slope of the annealing temperature rise curve, and λ1 and λ2 are weighting coefficients set according to process requirements. It is the predicted annealing temperature rise curve. It is the historical annealing temperature rise curve. It is a predicted power. The actual optimal power is calculated using historical temperature rise curves and longitudinal temperature differences in the melting zone as input to the LSTM neural network. The blockchain data management module employs the SHA-256 hash algorithm to encrypt process parameters, quality inspection results, and energy consumption data, ensuring data immutability. A unique blockchain ID is generated for each production batch. Raw material origins, processing parameters, and test reports are traced using barcode scanning technology. Zero-knowledge proof technology verifies data correlation to prevent sensitive information leakage. Distributed ledger technology enables decentralized data storage, and encryption algorithms ensure data security and transparency. The blockchain data encryption and verification algorithm is as follows:

[0051] H 批次 =SHA256(raw material IDP process parameter P quality inspection result), C(w)=H 批次 Furthermore, R(public parameter, w) = 1, C(w) is the zero-knowledge proof commitment function, hiding private evidence w, the encrypted chip is embedded with the RFID tag of the raw material packaging, R is the verification relationship, the adaptive adjustment module is based on feedback control theory, and achieves dynamic parameter optimization through error calculation and compensation mechanism. According to real-time energy consumption data, it dynamically adjusts the crystal pulling rate to match the thermal field stability requirements. Through PID control algorithm, it accurately adjusts the current intensity and phase difference of the layered induction coil to maintain the longitudinal temperature gradient of the melting zone. Layered induction coil PID control model:

[0052] u j (t) represents the current output of the j-th layer induction coil, with 200A for the upper layer, 180A for the middle layer, and 170A for the lower layer. 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 It is the proportional gain coefficient, calibrated according to the requirements of thermal field uniformity, K i,j Integral gain coefficient, Kd,j It is the differential gain coefficient.

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

[0054] B(r) is the magnetic field strength, μ0 = 4π × 10⁻⁶ -7 H / m, μ0 is the vacuum permeability, a physical constant, N is the number of turns of the electromagnetic coil, I is the coil current, core-shell abrasive chain polishing pressure model: P 抛光 It is the polishing pressure, n 磨料 It refers to the abrasive concentration, in μ. 磁 It is the magnetic susceptibility of iron(III) oxide. It features a magnetic field gradient while avoiding excessive wear on the workpiece surface. The core of the core-shell structure is made of iron(III) oxide, providing high magnetic responsiveness and rapid response to changes in the magnetic field. The outer shell is made of cerium dioxide, which has high hardness and chemical stability, ensuring efficient polishing and reducing scratches. Carboxyl functional groups are grafted onto the abrasive surface, which enhances the dispersion stability in the polishing slurry through electrostatic repulsion and steric hindrance effects, preventing abrasive agglomeration and extending service life. The polishing slurry contains magnetic nano-abrasives and a dispersion medium. The movement trajectory of the abrasives is controlled by magnetic field orientation to achieve nanoscale surface shaping. After polishing, the abrasives are centrifuged and recovered. Coarse particles are filtered and then re-dispersed for reuse, reducing resource waste. The adaptive polishing platform has a built-in abrasive concentration monitoring module and a wafer surface roughness and internal defect detection module. When the detected abrasive concentration drops to a set value, a replenishment process is initiated to replenish the worn abrasives in real time and maintain the consistency of the polishing slurry performance. The wafer surface roughness and internal defect detection module can detect the surface roughness of the wafer after polishing and whether there are defects inside the wafer.

[0055] The closed-loop cooling system includes a separation unit, an electrodialysis unit, a circulating pump, and a cyclone separator. The separation unit includes a multi-stage centrifugal separator and an electromagnetic separator. The multi-stage centrifugal separator rapidly separates coarse powder particles through a first-stage high-speed centrifugation, and further removes fine powder particles through a second-stage medium-speed centrifugation, reducing the load on subsequent processing. The efficiency model for multi-stage centrifugal separation is as follows:

[0056] ω1, ω2 are the centrifuge angular velocities, r1, r2 are the centrifuge radii, and ρ is the centrifuge radius. pThe particle density of alumina powder is 3.95 g / cm³, d is the particle size, and μ is the cutting fluid viscosity. After centrifugation, coarse and fine powder particles are separated by an electromagnetic separator. Magnetic residue containing iron(III) oxide is separated from non-magnetic alumina powder. The magnetic residue enters the abrasive recovery channel for polishing fluid recombination, while the non-magnetic alumina powder enters the melting furnace regeneration channel. The centrifuged cutting fluid enters the electrodialysis module, where a DC electric field is applied to drive the migration of metal ions and salt contaminants. Contaminants are efficiently removed through a selective ion exchange membrane. Conductivity is monitored in real time to ensure the cutting fluid ion concentration meets standards. 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 via a circulating pump. The pH and temperature of the regenerated cutting fluid are monitored in real time to ensure process stability. The separated magnetic residue undergoes ball milling to reduce agglomeration and is then mixed with cerium dioxide powder according to mass... The materials are mixed in a 1:2 ratio and deposited in a high-temperature reactor to form a core-shell structure via chemical vapor deposition. The core is iron(III) oxide, providing magnetic responsiveness, while the outer shell is cerium(II) oxide, enhancing polishing performance and scratch resistance. Grafting carboxyl functional groups improves the dispersion stability of the polishing slurry. Regenerated core-shell abrasives are added to the magnetorheological polishing slurry in proportion and mixed evenly with the dispersion medium. The system has a built-in abrasive concentration monitoring module based on the principle of optical scattering, which replenishes the lost abrasives in real time to maintain the consistency of the polishing slurry performance. Non-magnetic alumina powder is classified by a cyclone separator. The first-stage cyclone separator captures coarse powder, which is directly returned to the melting furnace as raw material. The second-stage cyclone separator collects fine powder, which is then surface modified for other industrial applications. The closed-loop cooling system dynamically adjusts the centrifugal speed according to the powder load in the cutting fluid to cope with impurity fluctuations at different processing stages. Polishing slurry performance data and cutting fluid purification indicators are fed back to the control center in real time, and separation and compounding parameters are optimized through a 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 heated in a gradient by a layered induction coil, with the upper, middle and lower layers operating 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 insulation layer forms a temperature gradient that decreases from the center to the outside, suppressing heat diffusion.

[0061] 3. Waste heat recovery: The high-temperature waste gas emitted from the melting furnace is heat exchanged in a countercurrent heat exchanger to preheat the gas entering 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.

[0062] S2, Ingot Cutting and Shaping Processing

[0063] 1. Vision positioning and cutting: Wafer cutting, curved surface shaping and edge chamfering are completed by multi-axis linkage diamond wire saw, and the processing path is precisely controlled by vision positioning system;

[0064] 2. Adaptive polishing: The polishing slurry contains core-shell structured magnetic nano-abrasives, with iron oxide as the magnetic core and cerium dioxide as the polishing outer layer. Surface-modified functional groups enhance dispersibility, and a ring-shaped electromagnetic coil generates a gradient magnetic field to drive the abrasives to form a directional chain structure, achieving nanoscale surface polishing.

[0065] 3. Closed-loop cooling and recovery: Multi-stage centrifugal separation of coarse and fine particles, electromagnetic separation of magnetic residues of iron oxide and non-magnetic alumina powder, application of DC electric field to remove metal ions, purification of cutting fluid to replenish corrosion inhibitors and defoamers to restore lubrication performance, alumina powder air classification, coarse alumina powder returned to the melting furnace, and fine alumina powder used for other industrial applications after surface modification.

[0066] S3, Intelligent Control and Quality Management

[0067] 1. Dynamic energy efficiency optimization: Sensors collect melting power, cooling water flow rate and environmental data in real time, and adjust process parameters through adaptive algorithms. Based on the real-time energy efficiency calculation results, the crystal pulling rate and annealing gradient are dynamically adjusted.

[0068] 2. Blockchain data management: Raw material sources, process parameters, quality inspection results and energy consumption data are encrypted and distributed to ensure traceability throughout the entire life cycle. Each production batch generates a unique blockchain identifier, and scanning the code allows for the traceability of the entire life cycle information.

[0069] 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 provides real-time feedback on polishing fluid concentration and cutting fluid purification index to dynamically optimize centrifugal speed and compounding parameters.

[0070] S4, Waste Heat and Resource Recycling

[0071] 1. High-temperature waste gas recovery: The waste gas from the melting furnace is preheated in the annealing furnace through a high-efficiency heat exchanger, reducing the initial heating energy consumption;

[0072] 2. Resource recycling: The cutting fluid is recycled after multi-stage separation and purification, reducing waste emissions. Alumina powder is recycled according to particle size, maximizing resource utilization.

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

[0074] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An energy-saving sapphire glass production and processing system, characterized in that, include: Crystal growth unit, integrated processing module, vision positioning system and 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, which adopts a three-layer independent control structure to form a longitudinal temperature gradient. 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 equipped with a diamond wire saw and a five-axis CNC machine tool. The adaptive polishing platform integrates a magnetorheological polishing machine. The closed-loop cooling system includes a separation device, an electrodialysis device, a circulating pump, and a cyclone separator. The centrifuged cutting fluid enters the electrodialysis module, where a DC electric field is applied to drive the migration of metal ions and salt contaminants, which are then efficiently removed through a selective ion exchange membrane. 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; The visual positioning system includes a visible light camera and an infrared sensor. The visible light camera captures the surface morphology features of the ingot, and the infrared sensor detects the internal temperature distribution of the ingot. After the dual-modal data is fused, three-dimensional coordinates are generated. The control center plans the motion path of the multi-station robotic arm based on the three-dimensional coordinates. The multi-station robotic arm clamps the ingot to the diamond wire saw station. The five-axis CNC machine tool performs wafer cutting according to preset cutting parameters. The robotic arm transfers the wafer to the magnetorheological polishing station. The control center, as the core scheduling module, coordinates the operation process between the crystal growth unit, the integrated processing module and the intelligent control unit. The energy consumption dynamic monitoring system monitors energy consumption data in real time. The neural network prediction model trains historical data. The blockchain data management module uses the SHA-256 hash algorithm to encrypt process parameters, quality inspection results and energy consumption data. The magnetorheological polishing machine includes a ring-shaped 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. The process flow 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 heated in a gradient by a layered induction coil, with the upper, middle and lower layers operating synchronously to reduce thermal inertia; 2. Optimization of melting and thermal field: 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, and the annular silicon carbide heating element combined with the graphite insulation layer forms a temperature gradient that decreases from the center to the outside, thus suppressing heat diffusion.

3. Waste heat recovery: The high-temperature waste gas emitted from the melting furnace is heat exchanged in a countercurrent heat exchanger to preheat the gas entering 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. S2, Ingot Cutting and Shaping Processing 1. Vision positioning and cutting: Wafer cutting, curved surface shaping and edge chamfering are completed by multi-axis linkage diamond wire saw, and the processing path is precisely controlled by vision positioning system; 2. Adaptive polishing: The polishing slurry contains core-shell structured magnetic nano-abrasives, with iron oxide as the magnetic core and cerium dioxide as the polishing outer layer. A ring-shaped electromagnetic coil generates a gradient magnetic field, driving the abrasives to form a directional chain structure, thereby achieving nanoscale surface polishing.

3. Closed-loop cooling and recovery: Multi-stage centrifugal separation of coarse and fine particles, electromagnetic separation of magnetic residue of iron oxide and non-magnetic alumina powder, application of DC electric field to remove metal ions, alumina powder air classification, coarse alumina powder returned to the melting furnace, and fine alumina powder used for other industrial applications after surface modification. S3, Intelligent Control and Quality Management 1. Dynamic energy efficiency optimization: Sensors collect melting power, cooling water flow rate and environmental data in real time, and adjust process parameters through adaptive algorithms. Based on the real-time energy efficiency calculation results, the crystal pulling rate and annealing gradient are dynamically adjusted.

2. Blockchain data management: Raw material sources, process parameters, quality inspection results and energy consumption data are encrypted and distributed to ensure traceability throughout the entire life cycle. Each production batch generates a unique blockchain identifier, and scanning the code allows for the traceability of the entire life cycle information.

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 provides real-time feedback on polishing fluid concentration and cutting fluid purification index to dynamically optimize centrifugal speed and compounding parameters. S4, Waste Heat and Resource Recycling 1. High-temperature waste gas recovery: The waste gas from the melting furnace is preheated in the annealing furnace through a high-efficiency heat exchanger, reducing the initial heating energy consumption; 2. Resource recycling: The cutting fluid is recycled after multi-stage separation and purification, reducing waste emissions. Alumina powder is recycled according to particle size, maximizing resource utilization.

2. The energy-saving sapphire glass production and processing system as described in claim 1, characterized in that: The high-frequency induction melting furnace drives the layered induction coils to generate an alternating magnetic field. The layered induction coils adopt a three-layer independent control structure to form a longitudinal temperature gradient. The waste heat recovery module connects the melting furnace and the heat exchanger through a high-temperature waste gas pipeline. The annealing furnace inlet 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 an alternating arrangement and variable cross-section structure. The inner wall of the high-temperature waste gas pipeline is coated with a high-temperature heat barrier coating.

3. The energy-saving sapphire glass production and processing system as described in claim 1, characterized in that: The outer surface of the graphite crucible is coated with a silicon carbide coating. A silicon carbide heating element is distributed in a ring around the graphite crucible. A graphite heat insulation layer is provided around 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 work together.

4. The energy-saving sapphire glass production and processing system as described in claim 1, characterized in that: The closed-loop cooling system includes a separation device, an electrodialysis device, a circulating 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 and fine powder particles, the electromagnetic separator separates magnetic residues from non-magnetic powders, the electrodialysis module treats the centrifuged cutting fluid to remove contaminants, and the circulating pump delivers the regenerated cutting fluid to the machining area. The system has a built-in abrasive concentration monitoring module based on the principle of optical scattering.

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