Energy-saving vacuum glass production method

Abstract

The present application relates to the technical field of vacuum glass, in particular to an energy-saving vacuum glass production method, first, the adjustment influence intensity is preliminarily determined based on the change delay between the vacuum pump power and the vacuum degree;Then, after dividing the extraction stage based on the vacuum pump power, the temperature data characteristics and position distribution of different monitoring points in the current extraction stage are analyzed, and the corresponding gas precipitation residual index is calculated;Further, the vacuum degree data change characteristics of different monitoring points are analyzed, and the gas precipitation residual index is combined to evaluate the local extraction efficiency;Finally, according to the local extraction efficiency, the vacuum degree data and the adjustment influence intensity, the vacuum pump power adjustment coefficient at the current time is comprehensively evaluated, so that the vacuum pump power is more accurately adjusted in real time according to the vacuum pump power adjustment coefficient, the influence of gas precipitation after temperature rise is reduced, and the effect of air flow extraction is better.

Description

Technical Field

[0001] This invention relates to the field of vacuum glass technology, and more specifically to an energy-saving vacuum glass production method. Background Technology

[0002] Vacuum glass is a new type of deep-processed glass product, developed based on the principle of thermos flasks. While its structure is similar to that of insulated glass, the difference lies in the extremely thin gas layer within the vacuum cavity, almost approaching a vacuum. This vacuum reduces heat transfer through conduction, convection, and radiation, achieving superior thermal insulation, sound insulation, and noise reduction performance. It is considered an important material for next-generation energy-efficient doors, windows, and curtain walls.

[0003] In current vacuum glass manufacturing processes, a thermal vacuum process that matches temperature control with gas extraction is typically used for vacuum extraction. During this process, existing technologies often adjust the vacuum pump power based on subjective experience. However, this method fails to account for the impact of temperature increases in different local areas on actual gas evolution, potentially leading to uneven airflow distribution within the vacuum furnace. This results in poor extraction efficiency, preventing the timely removal of residual gas from the vacuum glass interlayer and causing insufficient vacuum in the finished product. Summary of the Invention

[0004] To address the problem that existing technologies, which typically adjust vacuum pump power based on subjective experience, fail to consider the impact of temperature increases in different local areas on actual gas evolution, resulting in poor gas extraction efficiency, this application aims to provide an energy-saving vacuum glass production method. The specific technical solution adopted is as follows:

[0005] The first aspect of this application provides a method for producing energy-saving vacuum glass, comprising:

[0006] During the vacuum extraction process in the production of vacuum glass, gas flow rate data, vacuum pump power data, vacuum degree monitoring values ​​and temperature data at each monitoring point in the vacuum furnace cavity are collected at each sampling time. The intensity of the adjustment effect is determined based on the time delay between the vacuum degree monitoring values ​​and the vacuum pump power data at each monitoring point.

[0007] Based on the changing trend of vacuum pump power data, at least two extraction stages are divided. In the extraction stage at the current moment, the degree of gas evolution residue at each monitoring point is determined according to the position distribution of each monitoring point relative to the exhaust port, the temporal rise of temperature data, and the corresponding vacuum pump power data.

[0008] Based on the current extraction stage, the local extraction efficiency of each monitoring point is determined according to the correlation between changes in vacuum pump power data, vacuum level monitoring value, and gas flow rate data, as well as the degree of gas precipitation residue. The vacuum pump power adjustment coefficient for the current moment is determined based on the local extraction efficiency of each monitoring point, the vacuum level monitoring value, and the intensity of the adjustment influence. The vacuum pump power is then adjusted in real time according to the vacuum pump power adjustment coefficient.

[0009] Furthermore, the process of obtaining the intensity of the adjustment influence includes:

[0010] The average vacuum level of all monitoring points at each sampling time is taken as the average vacuum level at each sampling time. The average vacuum level of all sampling times is arranged in chronological order and then subjected to curve fitting to obtain the curve of the change of the average vacuum level. The vacuum pump power data at all sampling times is subjected to curve fitting to obtain the curve of the change of vacuum pump power.

[0011] The optimal alignment path is obtained by matching the vacuum pump power change curve and the average vacuum level change curve using a dynamic time warping algorithm.

[0012] On the optimal alignment path, all vacuum pump power data matched to each average vacuum value data on the average vacuum value change curve are taken as the corresponding matching data;

[0013] The difference between the time-series index value of the sampling time of each vacuum degree average data and the time-series index value of the sampling time of each corresponding matching data is used as the matching delay amount of each matching data.

[0014] The average value of the matching delay of all matching data corresponding to each vacuum level average value is used as the corresponding local delay.

[0015] By performing a negative correlation mapping on the mean values ​​of all local delays corresponding to all average data of all vacuum pumps, the corresponding adjustment effect intensity is determined.

[0016] Furthermore, the acquisition process in the extraction phase includes:

[0017] Using the sampling time corresponding to each inflection point on the vacuum pump power change curve as the interval point, all sampling times are divided into at least two extraction stages.

[0018] Furthermore, the process for obtaining the degree of gas evolution residue includes:

[0019] The temperature data of each monitoring point in the current extraction phase are arranged in chronological order and then subjected to curve fitting to obtain the corresponding local temperature data curve. On the local temperature data curve, the product of the mean slope of the tangent at all sampling times and the mean temperature data is used to determine the temperature precipitation index of each monitoring point.

[0020] Each monitoring point is taken as the target point in turn; other monitoring points outside the target points are taken as reference points; the pressure influence coefficient of the target point is determined according to the position distribution of each reference point relative to the target point and the vacuum pipeline extraction port and the corresponding temperature precipitation index.

[0021] The pumping coefficient at the target point is determined by taking into account the overall power data of the vacuum pump at the current extraction stage and the proximity of the vacuum pipeline extraction port at the target point.

[0022] Based on the self-temperature precipitation index of the target point, the gas pressure influence coefficient, and the extraction coefficient, the degree of gas precipitation residue at the target point in the current extraction stage is determined; wherein, the gas pressure influence coefficient and the extraction coefficient are both negatively correlated with the degree of gas precipitation residue; and the self-temperature precipitation index of the target point is positively correlated with the degree of gas precipitation residue.

[0023] Furthermore, the process of obtaining the air pressure influence coefficient includes:

[0024] In the three-dimensional space corresponding to the vacuum furnace cavity, the line segment pointing to the vacuum pipe exhaust port of each target point is taken as the reference line segment; the plane passing through the target point and perpendicular to the reference line segment is taken as the reference plane of the target point.

[0025] On both sides of the reference plane, all reference influence points on the side with the vacuum pipe extraction port are taken as the inverse influence points of the target point; other reference influence points other than the inverse influence points are taken as the forward influence points of the target point.

[0026] The negative correlation mapping value of the Euclidean distance between each reference influence point and the target point is used as the distance influence weight; the corresponding weighted temperature precipitation index is determined by multiplying the distance influence weight of each reference influence point with its corresponding self-temperature precipitation index.

[0027] The reverse influence coefficient is determined by summing the weighted temperature precipitation indices of all reverse influence points; the concordance coefficient is determined by summing the weighted temperature precipitation indices of all concordance points.

[0028] The air pressure influence coefficient of the target point is determined based on the ratio between the positive influence coefficient and the negative influence coefficient.

[0029] Furthermore, the process of obtaining the pumping coefficient includes:

[0030] The average value of the vacuum pump power data at all sampling times during the current extraction phase is taken as the current extraction power; the negative correlation mapping value of the Euclidean distance between the target point and the vacuum pipeline extraction port is taken as the extraction distance weight; the extraction coefficient of the target point is determined based on the product of the extraction distance weight and the current extraction power.

[0031] Furthermore, the process of obtaining the local extraction efficiency includes:

[0032] During the current extraction phase, the vacuum level monitoring values ​​of each monitoring point at all sampling times are arranged in chronological order and then curve-fitted to obtain a vacuum level monitoring curve. The slope of the tangent line at each sampling time on the vacuum level monitoring curve is normalized to determine the vacuum level change rate. The normalized value of the vacuum pump power data at each sampling time is used as a reference power parameter. The reference extraction efficiency is determined based on the ratio between the vacuum level change rate and the reference power parameter.

[0033] The ratio between the normalized value of the gas flow data at each sampling time and the reference power parameter is negatively correlated to determine the exhaust path obstruction.

[0034] The product of the degree of gas evolution residue and the obstruction of the exhaust path at each sampling time is negatively correlated to determine the reference compensation weight of each monitoring point at each sampling time; the product of the reference compensation weight and the reference extraction efficiency is used as the weighted extraction efficiency of each monitoring point at each sampling time.

[0035] The local extraction efficiency of each monitoring point in the current extraction phase is determined by summing the weighted extraction efficiency at all sampling times in the current extraction phase.

[0036] Furthermore, the process of obtaining the vacuum pump power adjustment coefficient includes:

[0037] The ratio between the negative correlation mapping value of the local extraction efficiency and the vacuum degree monitoring value of each monitoring point at the current time is used as the local power demand coefficient of each monitoring point at the current time; the overall power demand coefficient is determined based on the average of the local power demand coefficients of all monitoring points at the current time.

[0038] The vacuum pump power adjustment coefficient at the current moment is determined by positively mapping the product between the negative correlation mapping value of the adjustment influence intensity and the overall power demand coefficient.

[0039] Furthermore, the process of real-time adjustment of the vacuum pump power based on the vacuum pump power adjustment coefficient includes:

[0040] The vacuum pump power adjustment coefficient is used as the proportional gain coefficient of the PID controller to adjust the vacuum pump power in real time.

[0041] This application has the following beneficial effects:

[0042] This application first preliminarily determines the intensity of the adjustment effect based on the delay in the change between vacuum pump power and vacuum degree. Then, after dividing the extraction stage based on vacuum pump power, it analyzes the temperature data characteristics and location distribution of different monitoring points in the current extraction stage and calculates the corresponding gas evolution residue index. Furthermore, it analyzes the change characteristics of vacuum degree data at different monitoring points and combines them with the gas evolution residue index to evaluate the local extraction efficiency. Finally, based on the local extraction efficiency, vacuum degree data, and the intensity of the adjustment effect, it comprehensively evaluates the vacuum pump power adjustment coefficient at the current moment, thereby enabling more accurate real-time adjustment of vacuum pump power based on the vacuum pump power adjustment coefficient, reducing the impact of gas evolution after temperature rise, and improving the gas flow extraction effect. Attached Figure Description

[0043] To more clearly illustrate the technical solutions and advantages in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0044] Figure 1 A flowchart of an energy-saving vacuum glass production method provided in one embodiment of the present invention;

[0045] Figure 2 This is a schematic diagram of a vacuum glass evacuation and sealing method provided in one embodiment of the present invention. Detailed Implementation

[0046] To further illustrate the technical means and effects adopted by the present invention to achieve its intended purpose, the following, in conjunction with the accompanying drawings and preferred embodiments, details the specific implementation, structure, features, and effects of an energy-saving vacuum glass production method proposed according to the present invention. In the following description, different "one embodiment" or "another embodiment" do not necessarily refer to the same embodiment, and specific features, structures, or characteristics in one or more embodiments can be combined in any suitable form. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as implying or suggesting relative importance or implicitly indicating the number of indicated technical features. Thus, a feature defined with "first" or "second" may explicitly or implicitly include one or more of that feature.

[0047] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains.

[0048] The following describes in detail, with reference to the accompanying drawings, a specific scheme for an energy-saving vacuum glass production method provided by the present invention.

[0049] This application provides an energy-saving vacuum glass production method. Please refer to [link / reference]. Figure 1 The diagram illustrates a flow chart of an energy-saving vacuum glass production method according to an embodiment of the present invention, the method comprising:

[0050] Step S101: During the vacuum extraction process in the production of vacuum glass, collect the gas flow rate data, vacuum pump power data, vacuum degree monitoring value and temperature data of each monitoring point in the vacuum furnace at each sampling time; determine the adjustment influence intensity based on the time delay between the vacuum degree monitoring value and the vacuum pump power data at each monitoring point.

[0051] Before the vacuum extraction process, the vacuum glass needs to undergo pre-treatment. Specifically: First, Low-E glass is selected as the substrate, and the substrate is cut to the target production size using a fully automatic glass cutting machine. Then, an ultrasonic cleaning machine (including a pure water circulation system) is used to remove surface oil, dust, and impurities, including ultrasonic cleaning, multi-stage pure water rinsing, and hot air high-pressure drying. The glass substrate is then tempered using an adjustable-pressure tempering furnace (supporting Low-E film protection mode) to improve its mechanical strength. PLC is used to control cleaning parameters (such as water temperature and cleaning time) and the tempering furnace temperature profile (680-720℃) to ensure that the substrate surface cleanliness meets the ISO 2 standard. A fully automated support placement machine using a vision positioning system is used to place cylindrical or linear supports with a diameter of 0.3-1.0 mm and a height of 0.1-0.5 mm on the substrate to ensure that the glass does not collapse during vacuuming and to maintain the hollow sandwich structure. Another glass plate is then placed on the supports. A CNC glass drilling machine is used to achieve high-precision drilling of the glass substrate, with a hole diameter of 2-4 mm, to reserve an exhaust channel for vacuuming. The glass substrates are positioned facet to face on the worktable, and the support points and sealing solder are placed in place. The glass is aligned and positioned, and the glass substrates are assembled. Lead-free flexible metal solder (such as Sn-Ag-Cu alloy) or low-melting-point glass powder is coated on the glass edges. The glass is then heated in a pre-sealing furnace at 350-450℃ for 15-60 minutes to remove moisture and organic matter, forming a preliminary seal, which is the pretreatment for vacuum glass production.

[0052] Then, the assembled glass panes (including support points, Low-E film, vent holes, and solder sealing strips) are positioned and placed into the vacuum furnace working platform; ensuring the solder sealing strips are fully aligned and a vacuum pump port is reserved at the vent holes; the vacuum furnace door is further closed to ensure a good seal, and then the vacuum pump unit is started to begin evacuation. In a specific implementation of this invention, during the vacuum extraction process in the production of vacuum glass, monitoring points are evenly spaced at the vacuum glass placement location within the vacuum furnace cavity, with a 2cm interval between monitoring points. A vacuum gauge and a thermocouple sensor are installed at each monitoring point. The vacuum gauge collects the vacuum level at each monitoring point at each sampling time, and the thermocouple sensor collects the temperature data at each monitoring point at each sampling time. A mass flow meter is installed at the vacuum pipeline vent to collect the gas flow rate data at each sampling time, and the vacuum pump control system collects the vacuum pump power data at each sampling time. In one specific implementation of this invention, the sampling frequency is set to once per second, which can be adjusted according to the specific implementation environment. The various data acquisition methods or tools can also be selected according to the specific implementation environment, and will not be elaborated further here.

[0053] After the vacuum pump power is adjusted, the faster the vacuum level monitoring value changes, the stronger the adjustment of the vacuum pump power on the vacuum level. Therefore, the influence of the adjustment is initially determined based on the time delay between the vacuum level monitoring value and the vacuum pump power data at each monitoring point.

[0054] Preferably, in some possible implementations of the embodiments of the present invention, the process of adjusting the intensity of influence includes:

[0055] The average vacuum level of all monitoring points at each sampling time is taken as the average vacuum level at that time. The average vacuum levels at all sampling times are then arranged in chronological order and subjected to curve fitting to obtain the average vacuum level variation curve. Similarly, the vacuum pump power data at all sampling times are subjected to curve fitting to obtain the vacuum pump power variation curve. The optimal alignment path is obtained by matching the vacuum pump power variation curve and the average vacuum level variation curve using a dynamic time warping algorithm. On the optimal alignment path, all vacuum pump power data matched to each average vacuum level data point on the average vacuum level variation curve are taken as the corresponding matching data. It should be noted that curve fitting and dynamic time warping algorithms are techniques well-known to those skilled in the art and will not be further limited or elaborated upon here.

[0056] In all the matching data along the optimal alignment path, each vacuum level data point is typically directly influenced by the matching vacuum pump power data. This means there's a certain delay between the two matching data points in the optimal alignment path. The larger the delay, the faster the power adjustment affects the vacuum level, and the stronger the adjustment. Therefore, based on this characteristic, the difference between the temporal index of the sampling time of each average vacuum level data point and the temporal index of the sampling time of each matching data point is used as the matching delay for each matching data point. Considering that each data point on one curve may correspond to multiple data points on another curve, the average of the matching delays of all matching data points corresponding to each average vacuum level data point is used as the corresponding local delay. Finally, the overall delay is determined by combining the local delays of all average vacuum level data points, and a negative correlation mapping is performed on the average of all local delays corresponding to all average vacuum pump data points to determine the corresponding adjustment influence strength. In one specific implementation of this invention, the negative correlation mapping method for negatively correlated mapping of the mean of all local delay quantities corresponding to all average data of all vacuum pumps includes: calculating the normalized value after linear normalization of the mean of all local delay quantities corresponding to all average data of all vacuum pumps, and subtracting the normalized value from the real number 1 to obtain the corresponding negative correlation mapping result, that is, adjusting the influence intensity.

[0057] Step S102: Based on the changing trend of the vacuum pump power data, divide the process into at least two extraction stages; in the extraction stage at the current moment, determine the degree of gas evolution residue at each monitoring point based on the positional distribution of each monitoring point relative to the exhaust port, the temporal rise of the temperature data, and the corresponding vacuum pump power data.

[0058] The vacuum evacuation process in thermal vacuum glass exhibits typical nonlinear, segmented, and phased characteristics. Different phases have different physical characteristics and control requirements, often resulting in multiple evacuation stages. Analyzing all data as a whole can easily mask stage-specific anomalies, reducing monitoring sensitivity and control response accuracy. To achieve precise control of the vacuum evacuation process at any given moment, time-series segmentation is necessary, allowing for independent analysis, feature extraction, and control of each current stage. Vacuum pump power data directly reflects the operational results of each evacuation stage; therefore, based on the changing trends of the vacuum pump power data, at least two evacuation stages should be identified.

[0059] Preferably, in some possible implementations of the embodiments of the present invention, the acquisition process of the extraction stage includes: dividing all sampling times into at least two extraction stages, using the sampling time corresponding to each inflection point on the vacuum pump power change curve as an interval point. An inflection point refers to the position on the fitted curve where the curvature changes, that is, the time point when the rate of change of the vacuum pump operating power changes significantly, which can represent the transition point of the vacuum pump operating state.

[0060] During vacuum extraction, trace amounts of water vapor, adsorbed gases, and residual processing gases (such as CO2, O2, and N2) on the glass surface and in the interlayer dissipate slowly at room temperature. Therefore, it is necessary to increase the temperature inside the vacuum furnace to enhance the kinetic energy of gas molecules, increase the dissipation rate, and facilitate the rapid release of residual gases within the interlayer. Furthermore, increased temperature promotes uniform gas flow within the furnace, eliminates gas stagnation in dead zones, and improves vacuum uniformity. Therefore, it is necessary to analyze and evaluate the gas evolution caused by temperature changes at different monitoring points, using this as one of the parameters affecting the adjustment of vacuum extraction power. Higher temperatures lead to faster heat-induced gas evolution in the glass and interlayer. Simultaneously, during actual vacuum extraction, a faster temperature increase rate results in sudden and rapid gas evolution, forming instantaneous gas evolution peaks. This is especially problematic at locations far from the extraction port within the vacuum furnace, where localized gas accumulation can easily occur. If the extraction system fails to respond promptly, residual gas may remain in certain areas.

[0061] Furthermore, during the vacuum extraction process, the gas in the vacuum furnace moves towards the extraction port. Therefore, for a given monitoring point in the vacuum furnace, the actual amount of gas remaining is also affected by other monitoring points, including those between the vacuum line extraction port and the current monitoring point. For monitoring points between the vacuum line extraction port and the current monitoring point, the gas pressure at these points obstructs the extraction process, reducing the degree of gas extraction and increasing the amount of gas remaining. Conversely, for other monitoring points further back from the current monitoring point, the gas being extracted also pushes against the current monitoring point. Because the current monitoring point is further forward (relative to the vacuum line extraction port), the gas is extracted more smoothly under the pressure, increasing the extraction rate and reducing the amount of gas remaining. Therefore, in the current extraction phase, the degree of gas evolution residue at each monitoring point is determined based on the positional distribution of each monitoring point relative to the exhaust port, the temporal rise of temperature data, and the corresponding vacuum pump power data.

[0062] Preferably, in some possible implementations of the embodiments of the present invention, the process of obtaining the degree of gas evolution residue includes:

[0063] The temperature data of each monitoring point in the current extraction phase are arranged in chronological order and then subjected to curve fitting to obtain the corresponding local temperature data curve. On the local temperature data curve, the product of the mean slope of the tangent at all sampling times and the mean temperature data is used to determine the intrinsic temperature evolution index of each monitoring point. Since the higher the temperature and the faster the temperature rises, the faster the gas evolution, and the greater the impact of the evolved gas residue, the larger the intrinsic temperature evolution index, the more obvious the retention trend of the evolved gas at the corresponding monitoring point, and the greater the degree of gas evolution residue.

[0064] Each monitoring point is sequentially designated as a target point; other monitoring points besides the target points are designated as reference influence points; based on the positional distribution of each reference influence point relative to the target point and the vacuum pipeline extraction port, and their corresponding self-temperature precipitation index, the pressure influence coefficient of the target point is determined; preferably, in some possible implementations of this invention, the process of obtaining the pressure influence coefficient includes:

[0065] In the three-dimensional space corresponding to the vacuum furnace cavity, the line segment pointing from each target point to the vacuum pipe exhaust port is taken as the reference line segment; the plane passing through the target point and perpendicular to the reference line segment is taken as the reference plane of the target point; on both sides of the reference plane, all reference influence points on the side with the vacuum pipe exhaust port are taken as the inverse influence points of the target point; other reference influence points besides the inverse influence points are taken as the direct influence points of the target point; the negative correlation mapping value of the Euclidean distance between each reference influence point and the target point is taken as the distance influence weight; the corresponding weighted temperature precipitation index is determined by multiplying the distance influence weight of each reference influence point with its corresponding self-temperature precipitation index; the inverse influence coefficient is determined by summing the weighted temperature precipitation indices of all inverse influence points; the direct influence coefficient is determined by summing the weighted temperature precipitation indices of all direct influence points; and the gas pressure influence coefficient of the target point is determined by the ratio between the direct influence coefficient and the inverse influence coefficient. It should be noted that the location of the vacuum pipeline extraction port is represented by the centroid. For three-dimensional space, the implementer can also analyze it by establishing a three-dimensional coordinate system. The process of analyzing the relative position in this application depends on the relative position between the monitoring points. Therefore, the establishment of the coordinate system does not affect the analysis results and can be adjusted according to the specific implementation environment.

[0066] Since the gas path at the target point usually points towards the vacuum pipe's extraction port, after drawing a plane perpendicular to the reference line segment to obtain the reference plane, the points with the positive influence after the target point (relative to the vacuum pipe's extraction port) and the points with the negative influence before the target point can be screened using the reference plane as the boundary. Since the points with the negative influence are in front of the target point, during the exhaust process at the target point, the gas at the points with the negative influence will hinder the extraction process at the target point, while the gas at the points with the positive influence will promote the extraction process at the target point. In order to more accurately analyze the influence of each reference influence point on the extraction process at the target point, the influence of each reference influence point on the target point is further quantified. The closer a reference point is to the target point, the greater the influence of the gas pressure at that reference point on the target point. Furthermore, the higher the temperature precipitation index of the reference point, the more pronounced the retention trend of the precipitated gas, and the more easily it influences the target point. Therefore, the distance influence weight obtained by the negative correlation mapping value of the Euclidean distance between each reference point and the target point is used as the weight to weight the temperature precipitation index of each reference point, so that the resulting weighted temperature precipitation index can characterize its influence on the target point. In a specific implementation of this invention, the negative correlation mapping method for Euclidean distance includes: taking the reciprocal of the Euclidean distance between each reference point and the target point as the corresponding negative correlation mapping value, i.e., the distance influence weight. The mathematical calculation method can be selected according to the specific implementation environment, and will not be further elaborated here.

[0067] After quantifying the gas extraction impact of each reference point on the target point, it is necessary to consider that the adverse impact points hinder the gas extraction at the target point, while the favorable impact points promote it. Therefore, the weighted temperature precipitation index of all adverse impact points is further integrated, and the adverse impact coefficient, representing the hindering effect on the gas extraction at the target point, is determined by summing them up. Similarly, the weighted temperature precipitation index of all favorable impact points is integrated, and the favorable impact coefficient, representing the promoting effect on the gas extraction at the target point, is determined by summing them up. The larger the adverse impact coefficient, the greater the overall hindering effect on the gas extraction process at the target point; the larger the favorable impact coefficient, the greater the overall promoting effect on the gas extraction process at the target point. Therefore, the pressure impact coefficient of the target point is determined based on the ratio between the favorable and adverse impact coefficients. A larger pressure impact coefficient results in a smaller overall hindering effect on the gas extraction process at the target point and a smaller degree of gas precipitation residue. It should be noted that when the target point is in a specific location, the denominator may be 0, which may render the calculation meaningless. Therefore, in order to ensure that the calculation result is meaningful, in the present invention embodiment, when performing fractional operations, if the denominator is 0, a parameter adjustment factor greater than 0 needs to be added to the denominator to prevent the denominator from being 0. The value of the parameter adjustment factor is set by the implementer according to the actual situation. This application sets it to 1 for analysis, and will not be further elaborated on later.

[0068] Further, by considering the overall magnitude of the vacuum pump power data during the current extraction phase and the proximity of the vacuum pipeline extraction port to the target point, the extraction coefficient of the target point is determined. Preferably, in some possible implementations of this invention, the process of obtaining the extraction coefficient includes: taking the average value of the vacuum pump power data at all sampling times during the current extraction phase as the current extraction power; and taking the negative correlation mapping value of the Euclidean distance between the target point and the vacuum pipeline extraction port as the extraction distance weight. The method for negative correlation mapping of the Euclidean distance between the target point and the vacuum pipeline extraction port includes: taking the reciprocal of the Euclidean distance between the target point and the vacuum pipeline extraction port as the negative correlation mapping value, i.e., the extraction distance weight. The implementer may use other mathematical calculation methods according to the specific implementation environment.

[0069] For the current extraction stage, the closer the target point is to the vacuum pipeline evacuation port and the higher the overall vacuum pump power data at all sampling times, the more obvious the suction force on the target point and the lower the degree of gas precipitation residue. Therefore, the pumping coefficient of the target point is determined by the product between the extraction distance weight and the current extraction power, so that the larger the pumping coefficient, the smaller the degree of gas precipitation residue.

[0070] Finally, based on the correlation, the degree of gas evolution residue at the target point is determined in the current extraction stage according to the self-temperature evolution index, gas pressure influence coefficient, and extraction coefficient of the target point. Among them, the gas pressure influence coefficient and extraction coefficient are negatively correlated with the degree of gas evolution residue, while the self-temperature evolution index of the target point is positively correlated with the degree of gas evolution residue.

[0071] In one specific implementation of this invention, the product of the gas pressure influence coefficient and the extraction coefficient at the target point is used as the reference product; the ratio between the self-temperature precipitation index of the target point and the reference product is used as the degree of gas precipitation residue at the target point in the extraction stage at the current moment; those skilled in the art may use other basic mathematical methods to implement this, which will not be further limited or described here.

[0072] Step S103: Based on the current extraction stage, determine the local extraction efficiency of each monitoring point according to the correlation between changes in vacuum pump power data, vacuum degree monitoring value, and gas flow rate data, as well as the degree of gas precipitation residue; determine the vacuum pump power adjustment coefficient at the current moment based on the local extraction efficiency, vacuum degree monitoring value, and adjustment influence intensity of each monitoring point; and adjust the vacuum pump power in real time according to the vacuum pump power adjustment coefficient.

[0073] Vacuum degree can reflect the actual extraction process and level of local gas. That is, the vacuum degree change characteristics of a certain monitoring point during the operation of the vacuum pump can reflect the gas extraction efficiency of that monitoring point. However, at different times, when the degree of gas evolution residue at the current monitoring point is different, the gas extraction efficiency reflected by the unit increase in vacuum degree at the monitoring point due to the increase in vacuum pump power is different. Therefore, it is necessary to analyze the gas evolution residue index at different times in the extraction stage at the current time point.

[0074] Preferably, in some possible implementations of the embodiments of the present invention, the process of obtaining local extraction efficiency includes:

[0075] In the current extraction phase, the vacuum level monitoring values ​​at each monitoring point are arranged chronologically and curve-fitted to obtain a vacuum level monitoring curve. The slope of the tangent at each sampling time on the vacuum level monitoring curve is normalized to determine the vacuum level change rate. The normalized value of the vacuum pump power data at each sampling time is used as a reference power parameter. The reference extraction efficiency is determined based on the ratio between the vacuum level change rate and the reference power parameter. The ratio between the normalized value of the gas flow rate data at each sampling time and the reference power parameter is negatively correlated to determine the exhaust path obstruction. It should be noted that, unless otherwise specified, all normalization methods in this application use linear normalization and can be adjusted according to the specific implementation environment. Specifically, the negative correlation mapping between the normalized value of the gas flow rate data at each sampling time and the reference power parameter determines the exhaust path obstruction. It should be noted that, unless otherwise specified, all normalization methods in this application employ the following approach: taking the negative of the ratio between the normalized value of the gas flow data at each sampling time and the reference power parameter as the power of an exponential function with the natural constant as the base, the output of the exponential function is the result after negative correlation mapping, i.e., exhaust path obstruction. Those skilled in the art can use other basic mathematical methods to implement this, which are not limited or elaborated here.

[0076] Regarding reference extraction efficiency, if a monitoring point experiences a large rate of vacuum increase at a relatively low vacuum pump power, it indicates a higher extraction efficiency at that point. Therefore, a larger ratio between the vacuum change rate and the reference power parameter signifies a higher reference extraction efficiency. Conversely, regarding exhaust path obstruction, if a monitoring point experiences a low gas flow rate at a relatively high vacuum pump power, it indicates stronger obstruction to the exhaust process during the current extraction phase, increasing the likelihood of exhaust blockage and resulting in lower extraction efficiency.

[0077] The greater the degree of gas evolution residue, the greater the impact of the evolved gas, and the lower the extraction efficiency. Therefore, by further combining the relationship between the reference extraction efficiency, exhaust path obstruction, and the degree of gas evolution residue and the overall extraction efficiency, a negative correlation mapping is performed on the product of the degree of gas evolution residue and the exhaust path obstruction at each sampling time to determine the reference compensation weight of each monitoring point at each sampling time. The product of the reference compensation weight and the reference extraction efficiency is used as the weighted extraction efficiency of each monitoring point at each sampling time. In a specific implementation of this invention, the method for negatively mapping the product of the degree of gas evolution residue and the exhaust path obstruction at each sampling time is as follows: the normalized value of the product of the degree of gas evolution residue and the exhaust path obstruction at each sampling time is calculated and linearly normalized. The difference between the real number 1 and the normalized value is used as the result of the negative correlation mapping, that is, the reference compensation weight of each monitoring point at each sampling time. Those skilled in the art can use other basic mathematical methods to implement this, which are not limited or elaborated here.

[0078] Furthermore, by comprehensively considering the weighted extraction efficiency of each monitoring point at all sampling times in the current extraction phase, and based on the cumulative value of the weighted extraction efficiency of each monitoring point at all sampling times in the current extraction phase, the local extraction efficiency of each monitoring point in the current extraction phase is determined. This ensures that the higher the local extraction efficiency, the stronger the gas extraction influence on the corresponding monitoring point at the current time, and the higher the vacuum extraction efficiency.

[0079] After determining the local extraction efficiency corresponding to each monitoring point, the extraction power of the vacuum pump can be further adjusted by combining the influence intensity and the vacuum monitoring value of each monitoring point at the current moment. The smaller the overall local extraction efficiency and vacuum level, the greater the extraction power of the vacuum pump should be, so as to reduce the influence of gas evolution after the temperature rises, improve the system response efficiency, reduce the possibility of exhaust blockage, and improve exhaust efficiency.

[0080] Preferably, in some possible implementations of the embodiments of the present invention, the process of obtaining the vacuum pump power adjustment coefficient includes: taking the ratio between the negative correlation mapping value of the local extraction efficiency and the vacuum degree monitoring value of each monitoring point at the current moment as the local power demand coefficient of each monitoring point at the current moment; determining the overall power demand coefficient based on the average of the local power demand coefficients of all monitoring points at the current moment; in a specific implementation of the embodiments of the present invention, the method of negatively mapping the local extraction efficiency includes: linearly normalizing the local extraction efficiency to obtain the corresponding normalized value, subtracting the normalized value from the real number 1 to obtain the value after negative correlation mapping. Those skilled in the art can choose other basic mathematical methods to implement this, which are not limited or elaborated here.

[0081] A larger local power demand coefficient indicates a lower extraction efficiency and a smaller vacuum level at the corresponding monitoring point at the current moment. In this case, a larger vacuum pump power is needed to reduce the impact of gas evolution after temperature rise and improve exhaust efficiency. Therefore, the corresponding local power demand coefficient is calculated, and based on this, combined with the local power demand coefficients of all monitoring points at the current moment, the overall power demand coefficient is determined by averaging. The larger the overall power demand coefficient, the greater the demand for vacuum pump power, and the larger the vacuum pump power adjustment coefficient should be.

[0082] The smaller the adjustment influence intensity, the smaller the rate of change in vacuum pump power adjustment. Therefore, to reduce the impact of gas evolution after temperature rise and improve exhaust efficiency, a larger vacuum pump power is needed to compensate for the overall power demand, minimizing the impact of gas evolution after temperature rise and improving exhaust efficiency. Thus, this embodiment of the invention further performs a positive correlation mapping between the negative correlation mapping value of the adjustment influence intensity and the overall power demand coefficient to determine the vacuum pump power adjustment coefficient at the current moment. In a specific implementation of this embodiment, the method for negatively mapping the adjustment influence intensity includes: using the negative of the adjustment influence intensity as the power of an exponential function with the natural constant as the base, and the output of this exponential function is the value after negative correlation mapping; wherein, the method for positive correlation mapping includes: linearly normalizing the product between the negative correlation mapping value of the adjustment influence intensity and the overall power demand coefficient, and using the sum of the normalized value and the real number 1 as the result of positive correlation mapping, i.e., the vacuum pump power adjustment coefficient at the current moment.

[0083] After determining the vacuum pump power adjustment coefficient, this coefficient is used as the proportional gain coefficient of the PID controller for real-time adjustment of the vacuum pump power. It should be noted that the proportional gain coefficient of the PID controller is a well-known technical term in the field of PID control, and will not be further defined or elaborated upon here.

[0084] The vacuum extraction process continues with adaptively adjusted vacuum pump power until the target vacuum level is achieved. The two glass panes are then pressed together, and the sealing solder at the glass edges is melted by high-frequency induction heating, completing the sealing of the vacuum glass. Further, laser sealing is used to soften the sealing solder at the evacuation port, sealing the evacuation port of the vacuum glass. Please refer to [link to relevant documentation]. Figure 2 The diagram shows a vacuum glass evacuation and sealing method according to an embodiment of the present invention, including a glass surface, an evacuation pipe and a protective cap; when the furnace chamber is cooled to below 100°C, the furnace door is opened and the finished vacuum glass is taken out.

[0085] In summary, an energy-saving vacuum glass production method first preliminarily determines the intensity of adjustment influence based on the change delay between vacuum pump power and vacuum degree. Then, after dividing the extraction stage based on vacuum pump power, it analyzes the temperature data characteristics and location distribution of different monitoring points within the current extraction stage, calculating the corresponding gas evolution residue index. Further analysis of the vacuum degree data change characteristics at different monitoring points, combined with the gas evolution residue index, is used to evaluate the local extraction efficiency. Finally, based on the local extraction efficiency, vacuum degree data, and the intensity of adjustment influence, the vacuum pump power adjustment coefficient at the current moment is comprehensively evaluated. This allows for more accurate real-time adjustment of the vacuum pump power based on the adjustment coefficient, reducing the impact of gas evolution after temperature rise and resulting in better gas flow extraction.

[0086] It should be noted that the order of the above embodiments of the present invention is merely for descriptive purposes and does not represent the superiority or inferiority of the embodiments. The processes depicted in the accompanying drawings do not necessarily require a specific or sequential order to achieve the desired result. In some embodiments, multitasking and parallel processing are also possible or may be advantageous.

[0087] The various embodiments in this specification are described in a progressive manner. The same or similar parts between the various embodiments can be referred to each other. Each embodiment focuses on describing the differences from other embodiments.

Claims

1. A method for producing energy-saving vacuum glass, characterized in that, The method includes: During the vacuum extraction process in the production of vacuum glass, gas flow rate data, vacuum pump power data, vacuum degree monitoring values ​​and temperature data at each monitoring point in the vacuum furnace cavity are collected at each sampling time. The intensity of the adjustment effect is determined based on the time delay between the vacuum degree monitoring values ​​and the vacuum pump power data at each monitoring point. Based on the changing trend of vacuum pump power data, at least two extraction stages are divided. In the extraction stage at the current moment, the degree of gas evolution residue at each monitoring point is determined according to the position distribution of each monitoring point relative to the exhaust port, the temporal rise of temperature data, and the corresponding vacuum pump power data. Based on the current extraction stage, the local extraction efficiency of each monitoring point is determined according to the correlation between changes in vacuum pump power data, vacuum level monitoring value, and gas flow rate data, as well as the degree of gas precipitation residue. The vacuum pump power adjustment coefficient for the current moment is determined based on the local extraction efficiency of each monitoring point, the vacuum level monitoring value, and the intensity of the adjustment influence. The vacuum pump power is then adjusted in real time according to the vacuum pump power adjustment coefficient.

2. The method for producing energy-saving vacuum glass according to claim 1, characterized in that, The process of obtaining the intensity of the adjustment influence includes: The average vacuum level of all monitoring points at each sampling time is taken as the average vacuum level at each sampling time. The average vacuum level of all sampling times is arranged in chronological order and then subjected to curve fitting to obtain the curve of the change of the average vacuum level. The vacuum pump power data at all sampling times is subjected to curve fitting to obtain the curve of the change of vacuum pump power. The optimal alignment path is obtained by matching the vacuum pump power change curve and the average vacuum level change curve using a dynamic time warping algorithm. On the optimal alignment path, all vacuum pump power data matched to each average vacuum value data on the average vacuum value change curve are taken as the corresponding matching data; The difference between the time-series index value of the sampling time of each vacuum degree average data and the time-series index value of the sampling time of each corresponding matching data is used as the matching delay amount of each matching data. The average value of the matching delay of all matching data corresponding to each vacuum level average value is used as the corresponding local delay. By performing a negative correlation mapping on the mean values ​​of all local delays corresponding to all average data of all vacuum pumps, the corresponding adjustment effect intensity is determined.

3. The method for producing energy-saving vacuum glass according to claim 2, characterized in that, The extraction phase includes the following acquisition process: Using the sampling time corresponding to each inflection point on the vacuum pump power change curve as the interval point, all sampling times are divided into at least two extraction stages.

4. The method for producing energy-saving vacuum glass according to claim 1, characterized in that, The process for obtaining the degree of gas evolution residue includes: The temperature data of each monitoring point in the current extraction phase are arranged in chronological order and then subjected to curve fitting to obtain the corresponding local temperature data curve. On the local temperature data curve, the product of the mean slope of the tangent at all sampling times and the mean temperature data is used to determine the temperature precipitation index of each monitoring point. Each monitoring point is taken as the target point in turn; other monitoring points outside the target points are taken as reference points; the pressure influence coefficient of the target point is determined according to the position distribution of each reference point relative to the target point and the vacuum pipeline extraction port and the corresponding temperature precipitation index. The pumping coefficient at the target point is determined by taking into account the overall power data of the vacuum pump at the current extraction stage and the proximity of the vacuum pipeline extraction port at the target point. Based on the self-temperature precipitation index of the target point, the gas pressure influence coefficient, and the extraction coefficient, the degree of gas precipitation residue at the target point in the current extraction stage is determined; wherein, the gas pressure influence coefficient and the extraction coefficient are both negatively correlated with the degree of gas precipitation residue; and the self-temperature precipitation index of the target point is positively correlated with the degree of gas precipitation residue.

5. The method for producing energy-saving vacuum glass according to claim 4, characterized in that, The process of obtaining the air pressure influence coefficient includes: In the three-dimensional space corresponding to the vacuum furnace cavity, the line segment pointing to the vacuum pipe exhaust port of each target point is taken as the reference line segment; the plane passing through the target point and perpendicular to the reference line segment is taken as the reference plane of the target point. On both sides of the reference plane, all reference influence points on the side with the vacuum pipe extraction port are taken as the inverse influence points of the target point; other reference influence points other than the inverse influence points are taken as the forward influence points of the target point. The negative correlation mapping value of the Euclidean distance between each reference influence point and the target point is used as the distance influence weight; the corresponding weighted temperature precipitation index is determined by multiplying the distance influence weight of each reference influence point with its corresponding self-temperature precipitation index. The reverse influence coefficient is determined by summing the weighted temperature precipitation indices of all reverse influence points; the concordance coefficient is determined by summing the weighted temperature precipitation indices of all concordance points. The air pressure influence coefficient of the target point is determined based on the ratio between the positive influence coefficient and the negative influence coefficient.

6. The method for producing energy-saving vacuum glass according to claim 4, characterized in that, The process of obtaining the pumping coefficient includes: The average value of the vacuum pump power data at all sampling times during the current extraction phase is taken as the current extraction power; the negative correlation mapping value of the Euclidean distance between the target point and the vacuum pipeline extraction port is taken as the extraction distance weight; the extraction coefficient of the target point is determined based on the product of the extraction distance weight and the current extraction power.

7. The method for producing energy-saving vacuum glass according to claim 3, characterized in that, The process of obtaining the local extraction efficiency includes: During the current extraction phase, the vacuum level monitoring values ​​of each monitoring point at all sampling times are arranged in chronological order and then curve-fitted to obtain a vacuum level monitoring curve. The slope of the tangent line at each sampling time on the vacuum level monitoring curve is normalized to determine the vacuum level change rate. The normalized value of the vacuum pump power data at each sampling time is used as a reference power parameter. The reference extraction efficiency is determined based on the ratio between the vacuum level change rate and the reference power parameter. The ratio between the normalized value of the gas flow data at each sampling time and the reference power parameter is negatively correlated to determine the exhaust path obstruction. The product of the degree of gas evolution residue and the obstruction of the exhaust path at each sampling time is negatively correlated to determine the reference compensation weight of each monitoring point at each sampling time; the product of the reference compensation weight and the reference extraction efficiency is used as the weighted extraction efficiency of each monitoring point at each sampling time. The local extraction efficiency of each monitoring point in the current extraction phase is determined by summing the weighted extraction efficiency at all sampling times in the current extraction phase.

8. The method for producing energy-saving vacuum glass according to claim 1, characterized in that, The process of obtaining the vacuum pump power adjustment coefficient includes: The ratio between the negative correlation mapping value of the local extraction efficiency and the vacuum degree monitoring value of each monitoring point at the current time is used as the local power demand coefficient of each monitoring point at the current time; the overall power demand coefficient is determined based on the average of the local power demand coefficients of all monitoring points at the current time. The vacuum pump power adjustment coefficient at the current moment is determined by positively mapping the product between the negative correlation mapping value of the adjustment influence intensity and the overall power demand coefficient.

9. The method for producing energy-saving vacuum glass according to claim 1, characterized in that, The process of real-time adjustment of vacuum pump power based on the vacuum pump power adjustment coefficient includes: The vacuum pump power adjustment coefficient is used as the proportional gain coefficient of the PID controller to adjust the vacuum pump power in real time.

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