Control system and control method of furnace bottom turn-off door

Abstract

The invention provides a control system and method for a furnace bottom shutoff door. An oil pump control module is used for directly controlling starting and stopping of an oil pump, providing hydraulic power and displaying the pressure of an oil pipe in real time so as to determine follow-up operation; the electric operation module adopts a universal change-over switch, has three positions of a shaking-up position, a stopping position and a putting-down position, and is connected with an electromagnetic coil of the manual-electric integrated operation valve to realize synchronous shaking-up and putting-down of multiple doors; the manual operation module performs manual operation through a handle of the manual-electric integrated operation valve and supports sequential operation of single doors, and the handle of each operation valve is provided with a step-shaped locking buckle consistent with a door body pressing connection form; the state monitoring module displays oil pipe pressure in real time, directly triggers an indicator light through a travel switch and is used for displaying the position state of a turn-off door. According to the invention, through dual mechanisms of a mechanical locking structure and electrical synchronous control, sequential operation and multi-door synchronous action of the furnace bottom shutoff door are realized, and a control loop is simplified to improve reliability and operation efficiency.

Description

Technical Field

[0001] The present invention relates to the technical field of industrial boiler equipment control, and in particular to a control system and a control method for a furnace bottom shutoff door. Background Art

[0002] With the continuous expansion of industrial production scale and the increasing requirements for production efficiency, energy conservation and emission reduction, the optimization of the performance and control mode of the furnace bottom shut-off door as a key equipment component has always been the focus of the industry; Early shut-off door controls used purely mechanical handles to directly operate the valves, with manual visual inspection of the door status. These systems had no electrical components and were suitable for small industrial boilers, but were extremely inefficient. Raising / lowering a single door took 5-10 minutes, and multiple door operations required manual adjustment one by one, which was time-consuming and dependent on manual experience. These systems had poor synchronization, with movement time errors of up to several seconds between multiple doors, which could easily lead to material accumulation or pressure imbalance. With advancements in technology, electromagnetic relays were introduced in this field to implement sequential control, ensuring the operating sequence through electrical circuit interlocks. These systems were suitable for medium-sized boilers, but due to the complexity of the electrical circuits, a medium-sized system required 30-50 relays, resulting in high wiring costs and frequent failure rates. Existing control systems mostly use programmable logic controllers (PLCs) instead of relays, implementing complex logic control through software algorithms. Some high-end systems introduce pressure sensors and synchronous control algorithms, which are suitable for large boilers, but the system costs are high, the circuits are more complex, and this increases the number of failure points.

[0003] It can be seen that the existing furnace bottom shut-off door control system has obvious deficiencies in loop complexity, reliability and ease of operation, and can no longer meet the current development needs of efficient, stable and automated industrial production. An innovative control system and control method are urgently needed to solve these problems. Summary of the Invention

[0004] The present invention aims to achieve sequential operation restriction of furnace bottom shut-off doors and synchronous action of multiple doors through the dual mechanism of mechanical locking structure and electrical synchronous control, while simplifying the control loop to improve reliability and operating efficiency.

[0005] In one aspect, the present invention provides a control system for a furnace bottom shutoff door, comprising: The oil pump control module, which consists of a start button, relay, emergency stop button, and mechanical pressure gauge, is used to directly control the start and stop of the oil pump, providing hydraulic power to the entire system. The mechanical pressure gauge also displays the oil pipe pressure in real time. The operator confirms that the pressure has reached the preset value based on the pressure display before proceeding with subsequent operations. The electric operation module uses a universal conversion switch with three positions: cranking position, stop position, and lowering position. It is connected to the electromagnetic coils of several manual and electric integrated operation valves that close the doors. When in the cranking position, the coils a of several manual and electric integrated operation valves are connected at the same time to achieve synchronous cranking of multiple doors; when in the lowering position, the coils b of several manual and electric integrated operation valves are connected at the same time to achieve synchronous lowering of three doors; when in the stop position, the power supply of all electromagnetic coils is cut off, the valve core automatically resets to the middle position, and the door body stops moving; The manual operation module is manually operated through the handle of the hand-operated and electric-integrated operating valve, supporting the sequential operation of a single door. Each operating valve handle is provided with a stepped locking buckle in the same form as the door body crimping. Adjacent handles are connected by sliding guide rails. During manual operation, the handles must move in a specific sequence. If the sequence is not followed, the handles cannot move or drive the adjacent handles to move in conjunction. The status monitoring module uses the mechanical pressure gauge to display the oil pipe pressure in real time and directly triggers the indicator light through the travel switch to display the position status of the shutoff door.

[0006] According to the furnace bottom shut-off door control system provided by the present invention, the manual-electric integrated operating valve has two operating modes: electric and manual. In the electric mode, the electromagnetic coil is controlled by the universal conversion switch to achieve synchronous action. In the manual mode, the operation is restricted in sequence by the handle locking buckle.

[0007] According to the furnace bottom shut-off door control system provided by the present invention, the locking buckle takes effect during manual operation, forcing the operator to operate in the order of the shut-off door arrangement, that is, to follow the forward order when raising it and the reverse order when lowering it; during electric operation, the locking buckle does not participate in the control, and is used to ensure that the synchronous action is not mechanically restricted.

[0008] According to the furnace bottom shut-off door control system provided by the present invention, the universal transfer switch is directly connected to the electromagnetic coils of several doors, so as to simplify the electrical control circuit and reduce the number of electrical components.

[0009] In another aspect, the present invention provides a method for controlling a furnace bottom shutoff door, comprising the following steps: Step 1: The operator observes the mechanical pressure gauge to confirm that the oil pipe pressure reaches the preset value. If it does not meet the standard, check the oil pump and oil circuit; Step 2: Switch the universal conversion switch to the crank position, and at the same time trigger the coil a of the hand-operated integrated valve of all the shut-off doors. The hydraulic oil drives the hydraulic cylinders of each door synchronously through the main oil circuit to achieve synchronous cranking of multiple doors. Step 3: After the operation is completed, switch to the stop position, the valve core is reset, and the door body stops moving; Step 4: When the door needs to be lowered, switch to the lowering position, trigger coil b, and all doors are lowered synchronously; Step 5: In manual mode, manually operate a single shutoff door using the handle, following the order in which the doors are arranged. Among them, the swinging order is to operate the handle in the forward order of the door arrangement. After the previous door is in place, the handle of the next door can be moved; The lowering sequence is to operate the handles in the reverse order of the door arrangement. If the sequence is not followed, the locking buckle will restrict the movement of the handles or drive the adjacent handles to move in conjunction. Step 6. Confirm the door position in real time through the travel switch indicator light; if abnormal pressure or handle jam occurs during operation, immediately switch to the stop position, cut off the power supply and check for faults.

[0010] According to the furnace bottom shut-off door control method provided by the present invention, the duration of the electromagnetic coil being connected in the rocking-up position / lowering position of the universal conversion switch is pre-calculated and determined by the stroke distance of the hydraulic cylinder of each door and the flow rate of the hydraulic oil, ensuring that the valve core automatically resets to the stop position when the synchronous action ends.

[0011] According to the furnace bottom shut-off door control method provided by the present invention, in the sequential operation steps in the manual scenario: The stepped structure of the locking buckle is completely consistent with the crimping form of the closing door body, and the operating force is transmitted through a mechanical bite relationship; When manually operating a single door, you must first confirm that the adjacent doors are in a stationary state to avoid malfunction due to mechanical interlocking; the stationary state is determined by the indicator light of the travel switch.

[0012] According to the furnace bottom shut-off door control method provided by the present invention, in step six: The reading of the mechanical pressure gauge is automatically calibrated after every five operations; The limit switch indicator light adopts a three-color design, red represents fault, yellow represents action, and green represents in place. Different color combinations are used to display the collaborative status of multiple doors.

[0013] Compared with the prior art, the present invention has the following advantages: Compared with the existing technology, the furnace bottom shut-off door control system and method of the present application have the following beneficial effects: 1. Simplify the circuit. This application uses a universal transfer switch directly connected to the electromagnetic coil, reducing components such as relays, and mechanical pressure gauges instead of electronic sensors, reducing costs and failure points; 2. Easy operation. The electric mode of this application can synchronously control the raising and lowering of multiple doors with one button, which can improve efficiency. The manual mode uses a mechanical locking buckle to force sequential operation to avoid accidental touch. 3. High reliability: The hand-operated integrated valve of this application achieves electrical and mechanical redundancy. The design of the limit switch and three-color light can provide intuitive feedback on the status, and the emergency stop design ensures safety. 4. Cost advantage: This application does not require high-end PLCs and sensors, has low hardware and maintenance costs, and is adaptable to multiple scenarios.

[0014] Other features and advantages of the present invention will be described in the following description, and in part will become apparent from the description, or will be understood by practicing the present invention. The purpose and other advantages of the present invention can be realized and obtained by the structures particularly pointed out in the written description and the accompanying drawings.

[0015] The technical solution of the present invention is further described in detail below through the accompanying drawings and embodiments. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The accompanying drawings are used to provide a further understanding of the present invention and constitute a part of the specification. Together with the embodiments of the present invention, they are used to explain the present invention and do not constitute a limitation of the present invention. In the accompanying drawings: Figure 1 A schematic structural diagram of a control system for a furnace bottom shut-off door provided by the present invention; Figure 2 A flow chart of a method for controlling a furnace bottom shut-off door provided by the present invention. DETAILED DESCRIPTION

[0017] The preferred embodiments of the present invention are described below with reference to the accompanying drawings. It should be understood that the preferred embodiments described herein are only used to illustrate and explain the present invention, and are not used to limit the present invention.

[0018] Example 1: This embodiment provides a control system for the furnace bottom shut-off door. Figure 1 ,include The oil pump control module, which consists of a start button, relay, emergency stop button, and mechanical pressure gauge, is used to directly control the start and stop of the oil pump, providing hydraulic power to the entire system. The mechanical pressure gauge also displays the oil pipe pressure in real time. The operator confirms that the pressure has reached the preset value based on the pressure display before proceeding with subsequent operations. The electric operation module uses a universal conversion switch with three positions: rocking position, stop position, and lowering position. It is connected to the electromagnetic coils of several manual and electric integrated operation valves that close the doors. When in the rocking position, the coils a of several manual and electric integrated operation valves are connected at the same time to achieve synchronous rocking of multiple doors; when in the lowering position, the coils b of several manual and electric integrated operation valves are connected at the same time to achieve synchronous lowering of three doors; when in the stop position, the power supply of all electromagnetic coils is cut off, the valve core automatically resets to the middle position, and the door body stops moving; The manual operation module is manually operated through the handle of the hand-operated and electric-integrated operating valve, supporting the sequential operation of a single door. Each operating valve handle is provided with a stepped locking buckle in the same form as the door body crimping. Adjacent handles are connected by sliding guide rails. During manual operation, the handles must move in a specific sequence. If the sequence is not followed, the handles cannot move or drive the adjacent handles to move in conjunction. The status monitoring module uses a mechanical pressure gauge to display the oil pipe pressure in real time and directly triggers the indicator light through the travel switch to display the position status of the shut-off door.

[0019] Among them, the hand-operated and electric-integrated valve has two operating modes: electric and manual. In the electric mode, the electromagnetic coil is controlled by the universal conversion switch to achieve synchronous action. In the manual mode, it is restricted by the handle locking buckle and operates in sequence.

[0020] The locking buckle works during manual operation, forcing the operator to follow the order of closing the doors: the forward order when raising them and the reverse order when lowering them. During electric operation, the locking buckle does not participate in the control and is used to ensure that the synchronous action is not mechanically restricted.

[0021] The universal transfer switch is directly connected to the electromagnetic coils of several doors to simplify the electrical control circuit and reduce the number of electrical components.

[0022] It should be noted that this embodiment uses a universal transfer switch to directly connect the electromagnetic coils of multiple shut-off doors, replacing the large number of relays or complex software algorithms in traditional PLC systems, and the number of electrical circuits is significantly reduced. For example, a medium-sized system can be streamlined from the traditional 30-50 relays to a small number of core components, reducing wiring costs and failure points. At the same time, complex wiring components such as pressure sensors are eliminated, and the oil pipe pressure is displayed in real time through a mechanical pressure gauge. Pressure monitoring is achieved with a low-cost mechanical device, avoiding the high failure rate of electronic components. The hydraulic cylinders of each door are driven synchronously through the main oil circuit, and there is no need to configure a separate control branch for each shut-off door, which simplifies the layout of the hydraulic pipeline and reduces the risk of leakage.

[0023] In this embodiment, the universal conversion switch has three positions: rocking position, lowering position, and stop position. When operated electrically, one button can trigger the synchronous action of all closed doors. The time for rocking / lowering a single door is shortened from 5-10 minutes of traditional manual operation to a hydraulically driven response of seconds, greatly improving efficiency.

[0024] Synchronous action determines the power-on time by pre-calculating the hydraulic flow rate and hydraulic cylinder stroke, ensuring the automatic reset of the valve core, eliminating the need for continuous manual monitoring and reducing operational intensity.

[0025] The stepped locking catch and the mechanical interlocking guide rails enforce a strict operating sequence: raising the handle in the forward direction, lowering it in the reverse direction. Irregular operations prevent the handle from moving or causing adjacent handles to move. For example, if the previous door is not in place during manual operation, the next door handle will not operate, preventing material accumulation or pressure imbalances caused by inexperienced operators.

[0026] Manual mode and electric mode can be switched independently. The locking buckle does not participate in the control during electric operation, ensuring that the synchronous action is not restricted by mechanical constraints, and taking into account flexibility and safety.

[0027] This embodiment retains the integrated manual and electric operation valve, which can be switched to manual mode when the electric system fails, and the operation is completed by a mechanical handle to avoid production line stagnation due to electrical failure.

[0028] The travel switch directly triggers the indicator light and uses mechanical contacts to feedback the door position. Compared with traditional electronic sensors, it is more resistant to interference and reduces the false alarm rate.

[0029] This embodiment requires no PLC, pressure sensors, or complex software. Its core components are low-cost devices like universal transfer switches, relays, and mechanical pressure gauges, making it suitable for upgrades and retrofits for small and medium-sized enterprises. Simplified electrical and hydraulic circuits reduce installation and maintenance costs.

[0030] Example 2: This embodiment provides a method for controlling the furnace bottom shutoff door. Figure 2 , including the following steps: Step 1: The operator observes the mechanical pressure gauge to confirm that the oil pipe pressure reaches the preset value. If it does not meet the standard, check the oil pump and oil circuit; Step 2: Switch the universal conversion switch to the crank position, and at the same time trigger the coil a of the hand-operated integrated valve of all the shut-off doors. The hydraulic oil drives the hydraulic cylinders of each door synchronously through the main oil circuit to achieve synchronous cranking of multiple doors. Step 3: After the operation is completed, switch to the stop position, the valve core is reset, and the door body stops moving; Step 4: When the door needs to be lowered, switch to the lowering position, trigger coil b, and all doors are lowered synchronously; Step 5: In manual mode, manually operate a single shutoff door using the handle, following the order in which the doors are arranged. Among them, the swinging order is to operate the handle in the forward order of the door arrangement. After the previous door is in place, the handle of the next door can be moved; The lowering sequence is to operate the handles in the reverse order of the door arrangement. If the sequence is not followed, the locking buckle will restrict the movement of the handles or drive the adjacent handles to move in conjunction. Step 6. Confirm the door position in real time through the travel switch indicator light; if abnormal pressure or handle jam occurs during operation, immediately switch to the stop position, cut off the power supply and check for faults.

[0031] The duration of the electromagnetic coil connection in the rocking / lowering position of the universal switch is pre-calculated and determined by the stroke distance of the hydraulic cylinder of each door and the flow rate of the hydraulic oil, ensuring that the valve core automatically returns to the stop position when the synchronous action is completed; In the manual operation sequence: The stepped structure of the locking buckle is exactly the same as the crimping form of the closing door body, and the operating force is transmitted through the mechanical bite relationship; When manually operating a single door, you must first confirm that the adjacent doors are in a stationary state to avoid malfunction due to mechanical interlocking; the stationary state is determined by the indicator light of the travel switch.

[0032] In step six: The reading of the mechanical pressure gauge is automatically calibrated after every five operations; The limit switch indicator light adopts a three-color design, red represents fault, yellow represents action, and green represents in place. Different color combinations are used to display the collaborative status of multiple doors.

[0033] It should be noted that, in addition to the information disclosed in Example 1, Example 2 uses a three-color indicator light to display door status in real time (red for fault, yellow for operation, and green for position). The coordinated status of multiple doors is intuitively displayed through color combinations, facilitating quick judgment by the operator. The mechanical pressure gauge automatically calibrates after every five operations to ensure accurate pressure monitoring. The emergency stop button and stop position design immediately cut off power in the event of abnormal pressure or jamming, shortening troubleshooting time.

[0034] The electric mode is suitable for efficient synchronous operation of large boilers, and the manual mode meets the sequential control requirements of small systems or emergency scenarios. One system is compatible with multiple scenarios, avoiding duplicate investment.

[0035] This embodiment uses a minimalist design that combines mechanical and electrical elements to significantly improve operational convenience and efficiency while ensuring reliability, while reducing cost and complexity. It provides a cost-effective solution for industrial furnace bottom shut-off door control and is particularly suitable for small and medium-sized enterprises and scenarios with high requirements for synchronization and stability.

[0036] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or make equivalent replacements for some of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the various embodiments of the present invention.

Claims

1. A control system for a furnace bottom shut-off door, characterized in that: include The oil pump control module, which consists of a start button, relay, emergency stop button, and mechanical pressure gauge, is used to directly control the start and stop of the oil pump, providing hydraulic power to the entire system. The mechanical pressure gauge also displays the oil pipe pressure in real time. The operator confirms that the pressure has reached the preset value based on the pressure display before proceeding with subsequent operations. The electric operation module uses a universal conversion switch with three positions: cranking position, stop position, and lowering position. It is connected to the electromagnetic coils of several manual and electric integrated operation valves that close the doors. When in the cranking position, the coils a of several manual and electric integrated operation valves are connected at the same time to achieve synchronous cranking of multiple doors; when in the lowering position, the coils b of several manual and electric integrated operation valves are connected at the same time to achieve synchronous lowering of three doors; when in the stop position, the power supply of all electromagnetic coils is cut off, the valve core automatically resets to the middle position, and the door body stops moving; The manual operation module is manually operated through the handle of the hand-operated and electric-integrated operating valve, supporting the sequential operation of a single door. Each operating valve handle is provided with a stepped locking buckle in the same form as the door body crimping. Adjacent handles are connected by sliding guide rails. During manual operation, the handles must move in a specific sequence. If the sequence is not followed, the handles cannot move or drive the adjacent handles to move in conjunction. The status monitoring module uses the mechanical pressure gauge to display the oil pipe pressure in real time and directly triggers the indicator light through the travel switch to display the position status of the shutoff door.

2. The furnace bottom shut-off door control system according to claim 1, characterized in that: The hand-operated integrated valve has two operating modes: electric and manual. In the electric mode, the electromagnetic coil is controlled by the universal conversion switch to achieve synchronous action. In the manual mode, the valve is restricted by the handle locking buckle and operates in sequence.

3. The furnace bottom shut-off door control system according to claim 1, characterized in that: The locking buckle works during manual operation, forcing the operator to operate in the order of closing the doors, that is, in the forward order when raising them and in the reverse order when lowering them; during electric operation, the locking buckle does not participate in the control, and is used to ensure that the synchronous action is not mechanically restricted.

4. The furnace bottom shut-off door control system according to claim 1, characterized in that: The universal transfer switch is directly connected to the electromagnetic coils of several doors, so as to simplify the electrical control circuit and reduce the number of electrical components.

5. A method for controlling a furnace bottom shut-off door, characterized in that: The following steps are involved: Step 1: The operator observes the mechanical pressure gauge to confirm that the oil pipe pressure reaches the preset value. If it does not meet the standard, check the oil pump and oil circuit; Step 2: Switch the universal conversion switch to the crank position, and at the same time trigger the coil a of the hand-operated integrated valve of all the shut-off doors. The hydraulic oil drives the hydraulic cylinders of each door synchronously through the main oil circuit to achieve synchronous cranking of multiple doors. Step 3: After the operation is completed, switch to the stop position, the valve core is reset, and the door body stops moving; Step 4: When the door needs to be lowered, switch to the lowering position, trigger coil b, and all doors are lowered synchronously; Step 5: In manual mode, manually operate a single shutoff door using the handle, following the order in which the doors are arranged. Among them, the swinging order is to operate the handle in the forward order of the door arrangement. After the previous door is in place, the handle of the next door can be moved; The lowering sequence is to operate the handles in the reverse order of the door arrangement. If the sequence is not followed, the locking buckle will restrict the movement of the handles or drive the adjacent handles to move in conjunction. Step 6. Confirm the door position in real time through the travel switch indicator light; if abnormal pressure or handle jam occurs during operation, immediately switch to the stop position, cut off the power supply and check for faults.

6. The furnace bottom shut-off door control method according to claim 5, characterized in that: The duration of the electromagnetic coil being connected in the rocking-up position / lowering position of the universal conversion switch is pre-calculated and determined by the stroke distance of the hydraulic cylinder of each door and the flow rate of the hydraulic oil, ensuring that the valve core automatically resets to the stop position when the synchronous action ends.

7. The furnace bottom shut-off door control method according to claim 5, characterized in that: In the manual operation steps described above: The stepped structure of the locking buckle is completely consistent with the crimping form of the closing door body, and the operating force is transmitted through a mechanical bite relationship; When manually operating a single door, you must first confirm that the adjacent doors are in a stationary state to avoid malfunction due to mechanical interlocking; the stationary state is determined by the indicator light of the travel switch.

8. The furnace bottom shut-off door control method according to claim 5, characterized in that: In the step six: The reading of the mechanical pressure gauge is automatically calibrated after every five operations; The limit switch indicator light adopts a three-color design, red represents fault, yellow represents action, and green represents in place. Different color combinations are used to display the collaborative status of multiple doors.

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