Ventilation pipe sealing system and control method thereof
Through the integrated ventilation and sealing system and intelligent control method, automatic nitrogen filling and vacuum sintering in the ampoule tube are realized, which solves the shortcomings of the existing device in process requirements and equipment status adjustment, and improves production efficiency and product quality stability.
Patent Information
- Application Number
- CN202510843993.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-06-23
- Publication Date
- 2025-09-23
AI Technical Summary
Existing ventilation and pipe sealing devices lack the ability to intelligently adjust to different process requirements and equipment conditions, resulting in poor performance in complex and changeable actual production environments. Traditional manual operations are also inefficient and have unstable sealing performance.
An integrated ventilation and tube sealing system is designed, including a ventilation chamber, a sintering sealing vacuum device, and a controller. Through components such as a nitrogen charging device, a vacuum pumping device, a heating device, a clamping jaw, and a flame gun, automated nitrogen filling and vacuum sintering in the ampoule tube are achieved. The process flow is optimized by combining technical means such as adaptive vacuum pumping, intelligent heating control, and fault warning and self-diagnosis.
It improves production efficiency and product quality stability, reduces the impact of human factors, reduces energy consumption and material loss, and improves product consistency and equipment reliability.
Smart Images
Figure CN120681390A_ABST
Abstract
Description
Technical Field
[0001] The present invention relates to the technical field of tube sealing, and in particular to a ventilation tube sealing system and a control method thereof. Background Art
[0002] With the rapid development of industries like pharmaceuticals and electronics, the demand for sealing performance in various containers, especially ampoules, is increasing. As crucial containers for storing and transporting sensitive substances, the sealing performance of ampoules is directly related to the stability and safety of their contents. Traditional manual methods, such as nitrogen filling, ventilation, and vacuum sintering, suffer from low efficiency, unstable sealing performance, and susceptibility to human factors, making them unable to meet the demands of modern production for efficiency, precision, and stability.
[0003] Despite significant progress in automation, vacuum, and gas control technologies in recent years, providing technical support for the development of automated equipment, existing automated equipment still has shortcomings in structural design, operational procedures, sealing performance, and control strategies. In particular, control strategies lack the ability to intelligently adjust to varying process requirements and equipment status, resulting in poor performance in complex and changing production environments. Summary of the Invention
[0004] In response to the problem that the ventilation and tube sealing devices in the existing technology lack the ability to intelligently adjust to different process requirements and equipment status, the present invention provides a ventilation and tube sealing system and a control method thereof, which realizes nitrogen filling ventilation and vacuum automatic sintering of ampoule tubes through a controller.
[0005] To achieve the above technical objectives, the present invention provides a technical solution, which is a ventilation and sealing system, comprising: a ventilation cavity, in which a nitrogen filling device and a vacuum device are provided for realizing nitrogen filling and ventilation in the ampoule tube; A sintering and sealing vacuum device is connected to the ventilation cavity and is used to evacuate and sinter the ampoule tube after ventilation; a controller is used to control the operation of the ventilation cavity and the sintering and sealing vacuum device; Wherein, the ventilation cavity is provided with: An ampoule tube holder, used for fixing the ampoule tube; The nitrogen charging device is provided with a flow meter; The sintering sealing vacuum device comprises: The vacuum pipeline is equipped with a plug-in valve, a molecular pump, a mechanical pump, a pre-evacuation valve, a front-stage valve, an ionization gauge, a resistance gauge, an electromagnetic vent valve and a nitrogen replacement valve, which are used to realize vacuuming and nitrogen replacement of the ampoule tube; Multiple workstations, each equipped with an independent rotary motor and up and down lifting cylinder for supporting and operating ampoule tubes; A heating device, including an armored heating wire and a heating oven, for heating the ampoule tube to a predetermined temperature; The clamping jaws and flame gun are arranged on the guide rails of the workbench and can be raised and lowered and moved forward and backward to clamp the ampoule tube and perform sintering and sealing.
[0006] In this technical solution, by integrating the ventilation chamber with the sintering and sealing vacuum device, the nitrogen filling and ventilation process within the ampoule tube and the subsequent vacuum pumping and sintering and sealing can be performed continuously, significantly improving production efficiency. The nitrogen filling and vacuum pumping devices installed within the ventilation chamber can quickly and efficiently replace the gas inside the ampoule tube, providing an optimal environment for the subsequent sintering and sealing process. A controller coordinates and controls the operation of the ventilation chamber and the sintering and sealing vacuum device. Using a flowmeter on the nitrogen filling device, the system can precisely control the nitrogen filling amount and rate, ensuring stable and consistent nitrogen concentration within the ampoule tube. Furthermore, the independent rotary motors and vertical lifting cylinders at multiple stations enable the system to process multiple ampoule tubes simultaneously, with independent control of each station's operation, achieving a high degree of automation and flexibility. The vacuum lines in the sintering and sealing vacuum device are equipped with a variety of valves and pumps, including gate valves, molecular pumps, and mechanical pumps, to precisely control the vacuum pumping process and ensure the required vacuum level within the ampoule tube. The heating device utilizes armored heating wires and a heating oven to evenly and quickly heat the ampoule tube to the desired temperature, providing ideal temperature conditions for sintering and sealing. Precise operation of the clamping jaws and flame gun ensures the stability and tightness of the ampoule tube during the sintering process, effectively preventing material leakage and external contamination. A controller controls nitrogen filling and vacuum evacuation for automated sintering.
[0007] The present invention further provides a configuration in which the portion of the vacuum line located at the front end of the workstation is equipped with a narrow 90-degree bend. One end of the bend is arranged horizontally and connected to the workstation, while the other end is arranged vertically downward and connected to the ampoule tube. This increases the free path of molecules and prevents material from being aspirated. The placement of the narrow 90-degree bend in the portion of the vacuum line located at the front end of the workstation effectively increases the free path of gas molecules. This increased free path allows gas molecules to travel a greater distance before colliding, thereby reducing the frequency of intermolecular collisions and helping to create a more stable and uniform vacuum environment around the ampoule tube. This is particularly important for processes requiring high vacuum for sintering and sealing, as it ensures that the gas inside the ampoule tube is fully extracted, reducing the impact of residual gas on the seal quality. The narrow bend, with its narrow diameter and specific angle design, effectively restricts the material flow path, reducing the risk of material aspiration. This not only ensures process safety but also improves product yield and quality stability. By optimizing the structure of the vacuum pipeline, the resistance of the gas in the pipeline is reduced, making the vacuum pump work more efficiently and shortening the vacuuming time. At the same time, it also reduces system failures and downtime caused by material being sucked out, thereby improving the reliability and continuous production capacity of the system.
[0008] In this technical solution, a workbench guide rail is provided on the workstation, and a box and a clamp are provided on the workbench guide rail; the operation process of the clamp and the flame gun includes: The clamping jaws clamp the ampoule tube after the ampoule tube is heated to a predetermined temperature; The flame gun moves forward to the center of the ampoule tube for sintering and melting; The motor drives the ampoule tube to rotate and pull it down at the same time until the upper end of the tube burns off; The flame gun returns to its original position, the clamping jaws are released, and the ampoule tube is removed.
[0009] In this technical solution, by setting a workbench guide rail on the work station and configuring a box and clamps on the guide rail, the system realizes the precise positioning and fixation of the ampoule tube. The clamp clamps the ampoule tube after the ampoule tube is heated to a predetermined temperature, ensuring the stability of the ampoule tube during the sintering process and avoiding uneven sintering or sealing failure caused by shaking or displacement. The flame gun moves forward to the center of the ampoule tube for sintering and melting, further ensuring the accuracy of sintering and the quality of sealing. The operating procedures of the clamp and the flame gun are highly automated, from clamping the ampoule tube, moving the flame gun forward for sintering, motor-driven rotation and pulling down, to resetting the flame gun and releasing the clamp to remove the ampoule tube. The entire process does not require manual intervention, which greatly improves production efficiency, reduces the impact of human factors on the production process, and improves product consistency and stability. The motor-driven rotation and simultaneous downward pull of the ampoule tube ensures uniform heating during the sintering process, preventing local overheating or under-sintering. This helps reduce material loss and improves raw material utilization. Furthermore, the improved sintering quality reduces material waste and rework costs caused by poor sealing.
[0010] Another technical solution provided by the present invention is a control method for a ventilation and tube sealing system, comprising the following steps: Adaptive vacuuming steps: Based on the vacuum data monitored in real time by the ionization gauge and resistance gauge, the working status of the molecular pump and mechanical pump are dynamically adjusted to optimize the vacuuming efficiency and avoid over-vacuuming; Intelligent heating control steps: According to the material, size and process requirements of the ampoule tube, the temperature range and heating time of the heating device are automatically adjusted to ensure that the ampoule tube is heated evenly and achieves the best sintering effect; Fault warning and self-diagnosis steps: Real-time monitoring of the equipment's operating parameters, including nitrogen inflation volume, vacuum level, and heating temperature. When the difference between the operating parameters and the preset values is greater than a certain value, an early warning is issued and the cause of the fault is automatically diagnosed. Batch processing optimization steps: Automatically adjust the equipment's operating parameters and operating procedures based on the size of the production batch, ampoule tube specifications, and process requirements.
[0011] In this technical solution, the vacuum degree is monitored in real time by ionization gauges and resistance gauges. The system can accurately identify the current vacuum demand and dynamically switch the working modes of the molecular pump and mechanical pump (such as start and stop, speed adjustment), avoiding the energy waste of traditional fixed vacuum strategies. The system intelligently terminates the vacuum process based on real-time data, which not only ensures that the vacuum degree inside the ampoule tube meets the process requirements, but also reduces the ineffective operation time of high-energy-consuming equipment such as molecular pumps, significantly reduces energy consumption and extends equipment life. For ampoule tubes of different materials (such as glass, metal) and sizes (such as tube diameter, length), the system automatically matches the optimal heating temperature range and time curve to eliminate manual debugging errors. By controlling the output power of the heating device in a closed loop, it ensures that the temperature gradient of each part of the ampoule tube is less than the preset threshold, avoiding material denaturation or insufficient sintering caused by local overheating, and improving product yield and reliability.
[0012] The present invention is further configured such that the adaptive vacuuming step includes: Read the vacuum degree data of ionization gauge and resistance gauge in real time; Dynamically adjust the start / stop status and speed of the molecular pump and mechanical pump according to the vacuum data; When the vacuum degree reaches the preset value, the mechanical pump is turned off and only the molecular pump is kept running to keep the vacuum degree stable.
[0013] In this technical solution, by continuously reading vacuum data from the ionization gauge and resistance gauge, the system can instantly detect changes in the vacuum environment inside the ampoule tube, ensuring that the vacuum pumping process precisely matches actual requirements and avoiding process deviations caused by vacuum fluctuations. Based on real-time vacuum data, the system intelligently adjusts the start / stop status and speed of the molecular pump and mechanical pump to achieve a dynamic balance between vacuum pumping efficiency and energy consumption. When the vacuum demand is low, the pump speed is reduced to reduce energy consumption; when the vacuum demand is high, the pump speed is rapidly increased to accelerate the vacuum pumping process. When the vacuum reaches a preset value, the system automatically shuts down the mechanical pump, leaving only the molecular pump running to maintain a stable vacuum level. This reduces the mechanical pump's inefficient operating time at high vacuum levels, lowering energy consumption, minimizing wear on the mechanical pump, and extending the equipment's service life. By precisely controlling the vacuum level, the system avoids problems such as low pressure inside the ampoule tube or material degradation caused by over-vacuuming, ensuring process safety and stability.
[0014] The present invention is further configured as follows: the intelligent heating control step includes: Preset the heating temperature range and heating time according to the material and size of the ampoule tube; Monitor the temperature of the heating device in real time and dynamically adjust the heating power according to the preset value; When the heating temperature reaches the preset value, the temperature is kept constant for a period of time to ensure that the ampoule tube is heated evenly.
[0015] In this technical solution, the system presets the heating temperature range and heating time based on the specific material (e.g., glass, metal alloy) and dimensions (e.g., diameter, wall thickness, and length) of the ampoule tube. This ensures that ampoule tubes of different specifications complete the heating process under optimal process conditions, avoiding material degeneration, cracking, or poor sintering caused by excessively high or low temperatures. By replacing manual judgment with preset parameters, the system eliminates heating temperature fluctuations caused by differences in operator skills, improving process consistency and product yield. The system monitors the temperature of the heating device in real time and dynamically adjusts the heating power (e.g., adjusting the current, voltage, or starting and stopping the heating element) based on preset values to ensure that the heating process is always efficient. When the temperature approaches the preset value, the system automatically reduces the power to avoid overshoot; when the temperature is insufficient, the system quickly increases the power to shorten the heating time. This dynamic power adjustment strategy avoids the energy waste of traditional fixed-power heating methods, while also reducing the damage to the ampoule tube and heating device caused by thermal stress caused by temperature fluctuations, thereby extending the service life of the equipment. When the heating temperature reaches the preset value, the system enters the constant temperature holding phase. By precisely controlling the heating power, the temperature is maintained stable, ensuring uniform heating of all parts of the ampoule tube. This is particularly suitable for ampoule tubes with temperature-sensitive materials or complex structures, effectively avoiding sintering defects (such as cracks and pores) caused by temperature gradients. The constant temperature holding phase provides ample time for molecular diffusion and chemical reactions within the material, helping to form a dense, uniform sintering layer and improving the sealing performance and mechanical strength of the ampoule tube.
[0016] The present invention is further configured such that the fault warning and self-diagnosis steps include: Real-time monitoring of nitrogen filling volume, vacuum degree and heating temperature; When the difference between any operating parameter and the preset value is greater than a certain value, an early warning signal is issued; Based on the early warning signal, the fault cause is automatically diagnosed and maintenance measures are provided.
[0017] In this technical solution, the system collects the core operating parameters of nitrogen filling volume, vacuum degree, and heating temperature in real time, covering the key nodes of the entire process of ventilation and sealing, avoiding the limitations of single parameter monitoring. By presetting the parameter difference threshold, the system can quickly identify abnormal parameter trends, trigger an early warning before a fault occurs, and leave a time window for intervention. When any parameter exceeds the threshold, the system immediately issues an audible and visual / screen warning, and simultaneously records the abnormal timestamp and parameter value to help operators quickly locate the problem. Compared with the traditional manual inspection mode, real-time early warning can shorten the fault discovery time and avoid batch product scrapping or equipment damage due to out-of-control parameters.
[0018] The present invention is further configured as follows: the batch processing optimization step includes: Preset equipment operating parameters and operating procedures based on the scale of production batches; Adjust the heating temperature and heating time according to the specifications of the ampoule tube; Adjust the order and time of vacuuming and nitrogen replacement according to process requirements.
[0019] In this technical solution, the system automatically matches the equipment operating parameters (such as vacuum pumping speed, nitrogen filling rate) and operating procedures (such as independent processing of single tubes and parallel processing of multiple tubes) according to the scale of production batches (such as small-batch R&D testing and large-scale mass production), avoiding the inefficiency and error accumulation of manual adjustments. Through the preset parameter library, standardized processes can be reused for different batches to reduce product quality fluctuations caused by operational differences and improve consistency between batches. For ampoule tubes of different specifications (such as thin tubes that need to be heated quickly and thick-walled tubes that need to extend the insulation time), the system automatically adjusts the heating temperature curve and heating time to ensure that the temperature gradient inside the material is less than the preset threshold, avoiding cracking or insufficient sintering due to uneven thermal stress.
[0020] The beneficial effects of the present invention are as follows: (1) nitrogen filling, ventilation and vacuuming for automatic sintering of the ampoule tube are realized through the controller; (2) by integrating the ventilation cavity and the sintering sealing vacuum device into one, the continuous operation of nitrogen filling, ventilation and subsequent vacuuming, sintering and sealing in the ampoule tube is realized, which significantly improves the production efficiency. The nitrogen filling device and vacuuming device arranged in the ventilation cavity can quickly and effectively complete the gas replacement in the ampoule tube, providing good environmental conditions for the subsequent sintering and sealing process. The controller is responsible for coordinating and controlling the operation of the ventilation cavity and the sintering sealing vacuum device. BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Figure 1 This is an axonometric diagram of the ventilation and sealing system of the present invention; Figure 2 This is a schematic structural diagram of the automatic proportioning equipment for steel structure fire retardant coatings of the present invention; Figure 3 Flowchart of the control method of the ventilation and tube sealing system in the present invention.
[0022] In the figure: 1. Ventilation chamber; 11. Ampoule tube; 12. Nitrogen charging device; 13. Vacuum pump; 2. Sintering seal vacuum device; 21. Gate valve; 22. Molecular pump; 23. Mechanical pump; 26. Ionization gauge; 27. Resistance gauge; 28. Solenoid vent valve; 29. Nitrogen replacement valve; 31. Work station; 32. Gripper; 33. Flame gun; 34. Ninety-degree narrow-diameter elbow. DETAILED DESCRIPTION
[0023] In order to make the objectives, technical solutions and advantages of the present invention more clear, the present invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific implementation method described herein is only an optimal embodiment of the present invention, which is only used to explain the present invention and does not limit the scope of protection of the present invention. All other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the present invention.
[0024] like Figure 1 、 Figure 2 As shown in the first embodiment of the present invention, a ventilation and tube sealing system includes: The ventilation cavity 1 is provided with a nitrogen filling device 12 and a vacuum pumping device 13 for realizing nitrogen filling and ventilation in the ampoule tube 11; The sintering and sealing vacuum device 2 is connected to the ventilation cavity 1 and is used to evacuate and sinter the ventilated ampoule tube 11; the controller is used to control the operation of the ventilation cavity 1 and the sintering and sealing vacuum device 2; Wherein, the ventilation cavity 1 is provided with: An ampoule tube 11 bracket, used for fixing the ampoule tube 11; The nitrogen charging device 12 is provided with a flow meter; The sintering sealing vacuum device 2 includes: The vacuum pipeline is provided with a plug valve 21, a molecular pump 22, a mechanical pump 23, a pre-evacuation valve, a front valve, an ionization gauge 26, a resistance gauge 27, an electromagnetic vent valve 28 and a nitrogen replacement valve 29, which are used to realize vacuuming and nitrogen replacement of the ampoule tube 11; Multiple workstations 31, each of which is equipped with an independent rotating motor and an up and down lifting cylinder for supporting and operating the ampoule tube 11; a heating device, including an armored heating wire and a heating oven, for heating the ampoule tube 11 to a predetermined temperature; The clamping jaws 32 and the flame gun 33 are arranged on the guide rails of the workbench and can be raised and lowered and moved forward and backward to clamp the ampoule tube 11 and perform sintering and sealing.
[0025] In this embodiment, by integrating the ventilation cavity 1 with the sintering sealing vacuum device 2, the continuous operation of nitrogen filling ventilation and subsequent vacuum sintering and sealing in the ampoule tube 11 is achieved, which significantly improves production efficiency. The nitrogen filling device 12 and vacuum pumping device 13 provided in the ventilation cavity 1 can quickly and effectively complete the gas replacement in the ampoule tube 11, providing good environmental conditions for the subsequent sintering and sealing process. The controller is responsible for coordinating and controlling the operation of the ventilation cavity 1 and the sintering sealing vacuum device 2. Through the flow meter on the nitrogen filling device 12, the system can accurately control the amount and speed of nitrogen filling to ensure the stability and consistency of the nitrogen concentration in the ampoule tube 11. At the same time, the independent rotating motors and up and down lifting cylinders of multiple workstations 31 enable the system to process multiple ampoule tubes 11 at the same time, and the operation of each workstation 31 can be independently controlled, achieving a high degree of automation and flexibility. The vacuum pipeline in the sintering sealing vacuum device 2 is equipped with a variety of valves and pump bodies such as a gate valve 21, a molecular pump 22, and a mechanical pump 23, which can accurately control the vacuuming process to ensure that the required vacuum level is achieved inside the ampoule tube 11. The heating device uses armored heating wires and a heating oven to evenly and quickly heat the ampoule tube 11 to a predetermined temperature, providing ideal temperature conditions for sintering and sealing. The precise operation of the clamping jaws 32 and the flame gun 33 ensures the stability and sealing of the ampoule tube 11 during the sintering process, effectively preventing material leakage and external contamination. The nitrogen filling, ventilation, and vacuuming of the ampoule tube 11 are automatically sintered through the controller.
[0026] In one embodiment of the present invention, the portion of the vacuum pipeline located at the front end of the workstation 31 is provided with a 90-degree narrow-diameter elbow, one end of the 90-degree narrow-diameter elbow is arranged horizontally and connected to the workstation 31, and the other end of the 90-degree narrow-diameter elbow is arranged vertically downward and connected to the ampoule tube 11, so as to increase the molecular free path and prevent the material from being sucked out. Providing a 90-degree narrow-diameter elbow at the portion of the vacuum pipeline located at the front end of the workstation 31 can effectively increase the free path of gas molecules. The increase in molecular free path means that gas molecules can move a greater distance before collision, thereby reducing the frequency of collisions between molecules and helping to form a more stable and uniform vacuum environment around the ampoule tube 11. This is particularly important for process steps that require high vacuum for sintering and sealing, and can ensure that the gas inside the ampoule tube 11 is fully extracted, reducing the impact of residual gas on the sealing quality. The narrow diameter and specific angle design of the narrow-diameter elbow effectively restricts the material flow path and reduces the risk of material being sucked out. This not only ensures process safety but also improves product yield and quality stability. By optimizing the vacuum pipeline structure, the gas resistance in the pipeline is reduced, allowing the vacuum pump to operate more efficiently and shortening the vacuum pumping time. At the same time, it also reduces system failures and downtime caused by material being sucked out, thereby improving system reliability and continuous production capacity.
[0027] It can be understood that the workstation 31 is provided with a workbench guide rail, and the workbench guide rail is provided with a box and a clamp 32; the operation process of the clamp 32 and the flame gun 33 includes: The clamping jaws 32 clamp the ampoule tube 11 after the ampoule tube 11 is heated to a predetermined temperature; The flame gun 33 moves forward to the center of the ampoule tube 11 for sintering and melting; The motor drives the ampoule tube 11 to rotate and pull down at the same time until the upper end of the tube burns off; The flame gun 33 returns to its original position, the clamping jaws 32 are released, and the ampoule tube 11 is taken out.
[0028] In this technical solution, by setting a workbench guide rail on the work position and configuring a box and a clamp 32 on the guide rail, the system realizes the precise positioning and fixation of the ampoule tube 11. The clamp 32 clamps the ampoule tube 11 after the ampoule tube 11 is heated to a predetermined temperature, ensuring the stability of the ampoule tube 11 during the sintering process and avoiding the problem of uneven sintering or sealing failure caused by shaking or displacement. The flame gun 33 moves forward to the center position of the ampoule tube 11 for sintering and melting, further ensuring the accuracy of sintering and the quality of sealing. The operating procedures of the clamp 32 and the flame gun 33 are highly automated, from clamping the ampoule tube 11, moving the flame gun 33 forward for sintering, motor-driven rotation and pulling down, to resetting the flame gun 33 and releasing the clamp 32 to remove the ampoule tube 11. The entire process does not require manual intervention, which greatly improves production efficiency, reduces the impact of human factors on the production process, and improves product consistency and stability. The motor-driven rotation and simultaneous downward movement of the ampoule tube 11 ensures uniform heating of the ampoule tube 11 during the sintering process, preventing local overheating or insufficient sintering. This helps reduce material loss and improves raw material utilization. Furthermore, the improved sintering quality reduces material waste and rework costs caused by poor sealing.
[0029] like Figure 3 As shown in the figure, as a second embodiment of the present invention, a control method for a ventilation and sealing tube system includes the following steps: an adaptive vacuuming step: dynamically adjusting the working states of the molecular pump 22 and the mechanical pump 23 according to the vacuum degree data monitored in real time by the ionization gauge 26 and the resistance gauge 27 to optimize the vacuuming efficiency and avoid over-vacuuming; Intelligent heating control step: automatically adjust the temperature range and heating time of the heating device according to the material, size and process requirements of the ampoule tube 11 to ensure that the ampoule tube 11 is heated evenly and achieves the best sintering effect; Fault warning and self-diagnosis steps: real-time monitoring of the operating parameters of the equipment, including nitrogen filling volume, vacuum degree, and heating temperature. When the difference between the operating parameters and the preset values is greater than a certain value, an early warning is issued and the cause of the fault is automatically diagnosed; batch processing optimization step: according to the scale of the production batch, the specifications of the ampoule tube 11 and the process requirements, the operating parameters and operating procedures of the equipment are automatically adjusted.
[0030] In this technical solution, the vacuum degree is monitored in real time by the ionization gauge 26 and the resistance gauge 27. The system can accurately identify the current vacuum demand and dynamically switch the working modes of the molecular pump 22 and the mechanical pump 23 (such as start and stop, speed adjustment), avoiding the energy waste of the traditional fixed vacuum strategy. The system intelligently terminates the vacuum process based on real-time data, which not only ensures that the vacuum degree inside the ampoule tube 11 meets the process requirements, but also reduces the ineffective operation time of high-energy consumption equipment such as the molecular pump 22, significantly reduces energy consumption and extends the life of the equipment. For ampoule tubes 11 of different materials (such as glass, metal) and sizes (such as tube diameter, length), the system automatically matches the optimal heating temperature range and time curve to eliminate manual debugging errors. By controlling the output power of the heating device in a closed loop, it ensures that the temperature gradient of each part of the ampoule tube 11 is less than the preset threshold, avoids material denaturation or insufficient sintering caused by local overheating, and improves product yield and reliability.
[0031] In one embodiment of the present invention, the adaptive vacuuming step comprises: Read the vacuum degree data of the ionization gauge 26 and the resistance gauge 27 in real time; According to the vacuum data, the start and stop status and speed of the molecular pump 22 and the mechanical pump 23 are dynamically adjusted; When the vacuum degree reaches a preset value, the mechanical pump 23 is turned off, and only the molecular pump 22 is kept running to keep the vacuum degree stable.
[0032] In this technical solution, by continuously reading vacuum data from the ionization gauge 26 and resistance gauge 27, the system can instantly detect changes in the vacuum environment within the ampoule tube 11, ensuring that the vacuuming process precisely matches actual requirements and avoiding process deviations caused by vacuum fluctuations. Based on real-time vacuum data, the system intelligently adjusts the start / stop status and speed of the molecular pump 22 and mechanical pump 23 to achieve a dynamic balance between vacuuming efficiency and energy consumption. When the vacuum demand is low, the pump speed is reduced to reduce energy consumption; when the vacuum demand is high, the pump speed is rapidly increased to accelerate the vacuuming process. When the vacuum reaches a preset value, the system automatically shuts down the mechanical pump 23, leaving only the molecular pump 22 running to maintain a stable vacuum. This reduces the inefficient operating time of the mechanical pump 23 at high vacuum levels, lowering energy consumption and minimizing wear on the mechanical pump 23, thereby extending the equipment's service life. By precisely controlling the vacuum level, the system avoids problems such as excessively low internal pressure or material deterioration within the ampoule tube 11 caused by over-vacuuming, ensuring process safety and stability.
[0033] In one embodiment of the present invention, the intelligent heating control step includes: The heating temperature range and heating time are preset according to the material and size of the ampoule tube 11; Monitor the temperature of the heating device in real time and dynamically adjust the heating power according to the preset value; When the heating temperature reaches the preset value, the temperature is kept constant for a period of time to ensure that the ampoule tube 11 is heated evenly.
[0034] In this technical solution, the system presets the heating temperature range and heating time based on the specific material (e.g., glass, metal alloy) and dimensions (e.g., diameter, wall thickness, and length) of the ampoule tube 11. This ensures that ampoule tubes 11 of varying specifications complete the heating process under optimal process conditions, avoiding material deterioration, cracking, or poor sintering caused by excessively high or low temperatures. By replacing manual judgment with preset parameters, the system eliminates heating temperature fluctuations caused by operator skill differences, improving process consistency and product yield. The system monitors the temperature of the heating device in real time and dynamically adjusts the heating power (e.g., adjusting the current, voltage, or starting and stopping the heating element) based on preset values to ensure a consistently efficient heating process. When the temperature approaches the preset value, the system automatically reduces the power to avoid overshoot; when the temperature is insufficient, the system rapidly increases the power to shorten the heating time. This dynamic power adjustment strategy avoids the energy waste of traditional fixed-power heating methods while reducing the damage to the ampoule tube 11 and heating device caused by thermal stress due to temperature fluctuations, thereby extending the service life of the equipment. Once the heating temperature reaches the preset value, the system enters the constant temperature holding phase. By precisely controlling the heating power, the temperature is maintained stable, ensuring uniform heating across the ampoule tube 11. This phase is particularly suitable for ampoule tubes 11 with temperature-sensitive materials or complex structures, effectively avoiding sintering defects (such as cracks and pores) caused by temperature gradients. The constant temperature holding phase provides ample time for molecular diffusion and chemical reactions within the material, helping to form a dense, uniform sintered layer and improving the sealing performance and mechanical strength of the ampoule tube 11.
[0035] Furthermore, the fault warning and self-diagnosis steps include: Real-time monitoring of nitrogen filling volume, vacuum degree and heating temperature; When the difference between any operating parameter and the preset value is greater than a certain value, an early warning signal is issued; Based on the early warning signal, the fault cause is automatically diagnosed and maintenance measures are provided.
[0036] In this technical solution, the system collects the core operating parameters of nitrogen filling volume, vacuum degree, and heating temperature in real time, covering the key nodes of the entire process of ventilation and sealing, avoiding the limitations of single parameter monitoring. By presetting the parameter difference threshold, the system can quickly identify abnormal parameter trends, trigger an early warning before a fault occurs, and leave a time window for intervention. When any parameter exceeds the threshold, the system immediately issues an audible and visual / screen warning, and simultaneously records the abnormal timestamp and parameter value to help operators quickly locate the problem. Compared with the traditional manual inspection mode, real-time early warning can shorten the fault discovery time and avoid batch product scrapping or equipment damage due to out-of-control parameters.
[0037] In one embodiment of the present invention, the batch processing optimization step includes: Preset equipment operating parameters and operating procedures based on the scale of production batches; Adjust the heating temperature and heating time according to the specifications of the ampoule tube 11; Adjust the order and time of vacuuming and nitrogen replacement according to process requirements.
[0038] In this technical solution, the system automatically matches the equipment operating parameters (such as vacuum pumping speed, nitrogen filling rate) and operating procedures (such as single-tube independent processing, multi-tube parallel processing) according to the scale of the production batch (such as small-batch R&D testing, large-scale mass production), avoiding the inefficiency and error accumulation of manual adjustment. Through the preset parameter library, different batches can reuse standardized processes to reduce product quality fluctuations caused by operational differences and improve consistency between batches. For ampoule tubes 11 of different specifications (such as thin tubes that need to be heated quickly and thick-walled tubes that need to extend the insulation time), the system automatically adjusts the heating temperature curve and heating time to ensure that the temperature gradient inside the material is less than the preset threshold, avoiding cracking or insufficient sintering due to uneven thermal stress.
[0039] The specific description of the present invention in the above embodiments is only used to further illustrate the present invention and cannot be understood as limiting the scope of protection of the present invention. Technical engineers in this field may make some non-essential improvements and adjustments to the present invention based on the contents of the above invention, which fall within the scope of protection of the present invention.
Claims
1. A ventilation and sealing system, characterized in that: include: The ventilation cavity is provided with a nitrogen filling device and a vacuum pumping device for realizing nitrogen filling and ventilation in the ampoule tube; The sintering sealing vacuum device is connected to the ventilation cavity and is used to evacuate the ampoule tube after ventilation and sinter and seal it; A controller for controlling the operation of the ventilation cavity and the sintering sealing vacuum device; Wherein, the ventilation cavity is provided with: An ampoule tube holder, used for fixing the ampoule tube; The nitrogen charging device is provided with a flow meter; The sintering sealing vacuum device comprises: The vacuum pipeline is equipped with a plug-in valve, a molecular pump, a mechanical pump, a pre-evacuation valve, a front-stage valve, an ionization gauge, a resistance gauge, an electromagnetic vent valve and a nitrogen replacement valve, which are used to realize vacuuming and nitrogen replacement of the ampoule tube; Multiple workstations, each equipped with an independent rotary motor and up and down lifting cylinder for supporting and operating ampoule tubes; A heating device, including an armored heating wire and a heating oven, for heating the ampoule tube to a predetermined temperature; The clamping jaws and flame gun are arranged on the guide rails of the workbench and can be raised and lowered and moved forward and backward to clamp the ampoule tube and perform sintering and sealing.
2. A ventilation and sealing system according to claim 1, characterized in that: The part of the vacuum pipeline located at the front end of the workstation is provided with a 90-degree thin-diameter elbow, one end of the 90-degree thin-diameter elbow is arranged horizontally and connected to the workstation, and the other end of the 90-degree thin-diameter elbow is arranged vertically downward and connected to the ampoule tube to increase the molecular free path and prevent the material from being sucked out.
3. A ventilation and sealing system according to claim 2, characterized in that: The workstation is provided with a workbench guide rail, and the workbench guide rail is provided with a box and a clamping claw; The operation process of the clamping jaws and the flame gun includes: The clamping jaws clamp the ampoule tube after the ampoule tube is heated to a predetermined temperature; The flame gun moves forward to the center of the ampoule tube for sintering and melting; The motor drives the ampoule tube to rotate and pull it down at the same time until the upper end of the tube burns off; The flame gun returns to its original position, the clamping jaws are released, and the ampoule tube is removed.
4. A method for controlling a ventilation and sealing system, for implementing the ventilation and sealing system according to any one of claims 1 to 3, characterized in that: The following steps are involved: Adaptive vacuuming steps: Based on the vacuum data monitored in real time by the ionization gauge and resistance gauge, the working status of the molecular pump and mechanical pump are dynamically adjusted to optimize the vacuuming efficiency and avoid over-vacuuming; Intelligent heating control steps: According to the material, size and process requirements of the ampoule tube, the temperature range and heating time of the heating device are automatically adjusted to ensure that the ampoule tube is heated evenly and achieves the best sintering effect; Fault warning and self-diagnosis steps: real-time monitoring of the equipment's operating parameters, including nitrogen filling volume, vacuum degree, and heating temperature. When the difference between the operating parameters and the preset values is greater than a certain value, an early warning is issued and the cause of the fault is automatically diagnosed; Batch Processing Optimization Steps: Automatically adjust equipment operating parameters and operating procedures based on production batch size, ampoule tube specifications, and process requirements.
5. The control method of the ventilation and sealing system according to claim 4, characterized in that: The adaptive vacuuming step comprises: Read the vacuum degree data of ionization gauge and resistance gauge in real time; Dynamically adjust the start / stop status and speed of the molecular pump and mechanical pump according to the vacuum data; When the vacuum degree reaches the preset value, the mechanical pump is turned off and only the molecular pump is kept running to keep the vacuum degree stable.
6. The control method of the ventilation and sealing system according to claim 5, characterized in that: The intelligent heating control step includes: Preset the heating temperature range and heating time according to the material and size of the ampoule tube; Monitor the temperature of the heating device in real time and dynamically adjust the heating power according to the preset value; When the heating temperature reaches the preset value, the temperature is kept constant for a period of time to ensure that the ampoule tube is heated evenly.
7. The control method of the ventilation and sealing system according to claim 6, characterized in that: The fault warning and self-diagnosis steps include: Real-time monitoring of nitrogen filling volume, vacuum degree and heating temperature; When the difference between any operating parameter and the preset value is greater than a certain value, an early warning signal is issued; Based on the early warning signal, the fault cause is automatically diagnosed and maintenance measures are provided.
8. A method for controlling a ventilation and sealing tube system according to claim 4, 5, 6 or 7, characterized in that: The batch processing optimization step comprises: Preset equipment operating parameters and operating procedures based on the scale of production batches; Adjust the heating temperature and heating time according to the specifications of the ampoule tube; Adjust the order and time of vacuuming and nitrogen replacement according to process requirements.