All-electric melting and electric boosting transformer configuration system and method for glass manufacturing

Abstract

The invention relates to the technical field of transformer transformation control, in particular to an all-electric melting electric boosting transformer configuration system and method for glass manufacturing. The system comprises a high-voltage input module, a transformer voltage regulation module and a kiln heating module, the high-voltage input module inputs high voltage to the transformer voltage regulation module for voltage regulation and transformation and then directly accesses a kiln heating electrode of the kiln heating module, and the transformer voltage regulation module comprises an input side winding, an iron core and an output side winding. The invention provides a configuration mode for improving the power utilization efficiency of the all-electric melting electric boosting transformer for glass manufacturing, and the configuration mode combines the characteristics of glass production and the characteristics of voltage regulation of glass electric melting power supply, so that the characteristics of effectively reducing the generation of harmonic waves, reducing the overall installed capacity, and being large in voltage regulation range and high in glass type adaptability are achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of transformer transformation control, and in particular to a configuration system and method of a full-electric melting and boosting transformer for glass manufacturing. Background Art

[0002] In the glass manufacturing industry, the electric melting process requires a stable and appropriate power supply. Electric boosting technology can enhance the quality and efficiency of glass melting, while full electric melting relies entirely on electricity to achieve glass melting. Transformers, as key power supply equipment, have a significant impact on the glass manufacturing process. As the glass industry develops, demands for glass quality, production efficiency, and energy conservation and consumption reduction continue to increase. Traditional transformer configuration methods are unable to meet these new demands, prompting the development of new transformer configuration systems and methods.

[0003] However, there are many problems with the existing technology, including

[0004] Harmonic problem: Traditional transformer configurations tend to generate more harmonics during operation. Harmonics injected into the power grid will interfere with the normal operation of other electrical equipment, reduce power quality, and may also cause grid resonance and other faults, affecting grid stability and safety.

[0005] Large installed capacity: The traditional method has a large overall installed capacity, which increases the equipment investment cost and has high energy consumption during operation, which is not conducive to energy conservation and cost control for enterprises.

[0006] Limited voltage regulation range: Traditional transformers have a narrow voltage regulation range, which makes it difficult to meet the diverse voltage requirements of different stages of glass manufacturing. This limits the optimization of glass production processes and affects the quality of glass products and production efficiency.

[0007] Poor adaptability: Traditional transformer configuration systems are not adaptable enough to different types of glass manufacturing processes and are unable to flexibly adjust power supply parameters. This results in an inability to provide appropriate power support when producing special glass or new products, restricting the company's product innovation and diversified development.

[0008] In order to improve the production efficiency of glass manufacturing, reduce energy consumption and reduce pollution to the power grid, there is an urgent need for a full electric melting and boosting transformer configuration system for glass manufacturing. Summary of the Invention

[0009] In order to solve the above-mentioned problems, the present invention provides a system and method for configuring a full-electric melting and boosting transformer for glass manufacturing.

[0010] In a first aspect, the present invention provides a fully electric melting and boosting transformer configuration system for glass manufacturing, which adopts the following technical solutions:

[0011] A fully electric melting and boosting transformer configuration system for glass manufacturing, comprising:

[0012] A high-voltage input module, a transformer voltage regulating module and a kiln heating module, wherein the high-voltage input module inputs the high voltage to the transformer voltage regulating module for voltage regulation and then directly connects to the kiln heating electrode of the kiln heating module; the transformer voltage regulating module includes an input side winding, an iron core and an output side winding.

[0013] Furthermore, the high-voltage input module includes three-phase input terminals, through which high-voltage signals of 10KV or 35KV are respectively input.

[0014] Furthermore, the high-voltage input module is connected to a monitoring unit V1 for monitoring the input high-voltage signal.

[0015] Furthermore, the input side winding adopts an adjustable primary winding-fixed primary winding combination structure, and the fixed primary winding is connected to the end of the adjustable primary winding, so as to reduce the step adjustment range of the adjustable primary winding by utilizing the fixed primary winding.

[0016] Furthermore, the adjustable primary winding is connected to a high-voltage on-load switch, and the number of turns of the adjustable primary winding is adjusted by the high-voltage on-load switch.

[0017] Furthermore, the input side winding also includes a DC excitation winding, and the magnetic field saturation of the iron core is controlled by the DC excitation winding.

[0018] Furthermore, the DC excitation winding is connected to a DC excitation power supply, and the magnitude of the magnetic field of the DC excitation winding is controlled by the magnitude of the output current of the DC excitation power supply.

[0019] Furthermore, the output side winding includes a first output winding and a second output winding, and the first output winding and the second output winding are connected in parallel or in series. When the first output winding and the second output winding are connected in series, a high voltage and a small current are output; when the first output winding and the second output winding are connected in parallel, a small voltage and a large current are output.

[0020] Furthermore, the output side winding is also connected to a voltage measuring unit and a current measuring unit.

[0021] Furthermore, ends of the output side windings are respectively connected to three-phase loads.

[0022] In a second aspect, a method for configuring an all-electric melting and boosting transformer for glass manufacturing includes:

[0023] The high-voltage on-load switch is protected by a combination of an adjustable primary winding and a fixed primary winding.

[0024] The voltage and current variation range is controlled by connecting the first output winding and the second output winding of the output side winding. When the first output winding and the second output winding are connected in series, a high voltage and a low current are output; when the first output winding and the second output winding are connected in parallel, a low voltage and a high current are output.

[0025] In summary, the present invention has the following beneficial technical effects:

[0026] 1. The present invention provides a configuration method for improving electricity efficiency of an all-electric melting and boosting transformer for glass manufacturing. In this method, the high-voltage input of the power grid can be directly connected to the heating electrodes of the kiln after being regulated by the transformer, directly shielding the DC component and eliminating the need for a separate isolation transformer. This configuration method combines the characteristics of glass production and the voltage regulation characteristics of glass electric melting power supply, effectively reducing the generation of harmonics, reducing the overall installed capacity, and having a wide voltage regulation range and strong adaptability to various types of glass.

[0027] 2. The present invention adjusts the voltage by adjusting the DC size of the excitation coil to adjust the state of the core magnetic flux saturation. As the DC opening becomes larger, the operating efficiency of the voltage regulator will be greatly reduced, and the reactive loss will increase linearly. Combined with the structure and operating process of the glass melting furnace, the three-phase simultaneous adjustment and three-phase individual adjustment methods are selected. Under the condition of equal power consumption, the investment is reduced, the efficiency is improved, the pollution to the power grid is reduced, and the applicability of the voltage regulation equipment system is increased.

[0028] 3. The configuration of the present invention is to connect a multi-stage on-load voltage regulating switch in series on the primary side of the voltage regulator, and to perform cross-stage voltage regulation on the secondary side by changing the effective number of turns of the primary coil, and then to achieve continuous adjustment of the secondary voltage by continuous voltage regulation of the excitation part, so that the excitation voltage regulation part can operate in a high-efficiency state; at the same time, the secondary side coil is designed as a multi-winding form, and a wide range of adjustment of the secondary side voltage is achieved by changing the series and parallel connection of the windings. In addition, the primary side access voltage of this configuration can be 10kV and 35kV. Compared with the traditional 380V+thyristor voltage regulation method, the reduction of one-level connection also reduces the failure and loss of one level. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 Schematic diagram of a fully electric melting and boosting transformer configuration system for glass manufacturing according to Example 1 of the present invention.

[0030] Figure 2 Schematic diagram of a configuration method of a fully electric melting and boosting transformer for glass manufacturing according to an embodiment of the present invention. DETAILED DESCRIPTION

[0031] The present invention will be further described in detail below with reference to the accompanying drawings.

[0032] Example 1

[0033] Reference Figure 1 , a full electric melting and boosting transformer configuration system for glass manufacturing of this embodiment includes:

[0034] A high-voltage input module, a transformer voltage regulating module and a kiln heating module, wherein the high-voltage input module inputs the high voltage to the transformer voltage regulating module for voltage regulation and then directly connects to the kiln heating electrode of the kiln heating module; the transformer voltage regulating module includes an input side winding, an iron core and an output side winding.

[0035] Specifically,

[0036] The input side adopts A, B, C three-phase input, input 10KV or 35KV high voltage AC,

[0037] An input monitoring unit V1 is provided on the input side to monitor whether the input high voltage meets the standard;

[0038] The DC excitation power supply outputs current to the excitation winding, controlling the magnitude of the excitation magnetic field in the excitation winding and ultimately the magnetic field saturation of the core. The DC excitation power supply is also connected to a signal monitoring unit.

[0039] The fixed primary winding is connected to the adjustable primary winding, and the adjustable primary winding is adjusted through the high-voltage on-load switch.

[0040] The excitation winding is sleeved on the iron core unit, and the positive and negative poles of the DC excitation unit are connected to an external power supply, 220V or 380V. The DC excitation unit converts the input high voltage on the input side into low voltage through the magnetic voltage regulation principle.

[0041] The number of turns of the input side working coil is adjusted by the high-voltage on-load switch, that is, the number of turns of the primary winding is adjustable. The adjustment parameter is set to 1-K. When the number of turns of the input side working coil is increased by the high-voltage on-load switch, the output voltage on the output side decreases.

[0042] In addition, when the input side is 10kV, due to the low input voltage, V3 is set to 0, and the output side voltage is controlled only through the adjustable primary winding.

[0043] When the high-voltage on-load switch adjustment span is too large, the failure rate increases exponentially. Therefore, by setting a fixed primary winding, the cross-stage adjustment voltage difference of the on-load switch is reduced, thereby protecting the high-voltage on-load switch.

[0044] The excitation winding on the input side adopts a triangle configuration and a star configuration. When the input side winding is connected in series, the input voltage mode of the input side is combined into a triangle connection; when the output end and the input end of the input side winding are connected in series, a star connection is adopted. Different high-voltage input modes are matched by the triangle connection and the star connection respectively.

[0045] The output side winding includes a first output winding and a second output winding. When the first output winding and the second output winding are connected in series, that is, the total number of turns is L1+L2, the output side voltage increases, and the power capacity of the output side winding is constant, so the current decreases, achieving high voltage and low current. When the first output winding and the second output winding are connected in parallel, the total number of turns remains unchanged, the current is I1+I2, and the power capacity of the output side winding is constant, the voltage decreases, and low voltage and high current can be achieved. Therefore, by series and parallel connection, a larger voltage and current range can be covered.

[0046] The output side is equipped with a voltmeter V2 and an ammeter A to monitor the output current and voltage;

[0047] The three phases on the output side are independent and can be set to work independently, in triangle mode or star mode according to needs, which increases adaptability, widens the usable range and improves economic reliability.

[0048] like Figure 2 The figure shows the voltage regulation process of the DC excitation winding, in which the magnetic regulator can be regarded as a variable reactor in series with the load. When the excitation current is 0, the core is unsaturated, the magnetic permeability is high, the reactance value is large, the power supply voltage is mostly dropped in the reactor working winding, and the load voltage drop is small; as the excitation current increases, the core saturation degree increases, the magnetic permeability decreases, the reactance value decreases, the reactor working winding voltage drop decreases, and the load voltage increases, thus achieving load voltage regulation. Load-related formulas and principles Load current formula:

[0049] I2=U 20 / ∑R2+j∑X2, ∑R2 is the total resistance of the secondary circuit (including the load resistance RL), ∑X2 is the total reactance of the secondary circuit (including the reactor reactance and leakage reactance), U 20 is the secondary no-load voltage (reduced value).

[0050] The voltage formula for a purely resistive load is: U2 = I2RL. For a given RL, the smaller ∑X2, the larger I2 and U2. ∑X2 is controlled by the DC excitation current IK; increasing IK decreases ∑X2, and I2 and U2 increase. I2 and U2 are also related to the size of RL: increasing RL decreases I2 and increases U2.

[0051] Voltage regulation range

[0052] The voltage regulation range of the magnetic regulator is for the rated load. If the actual load resistance is not equal to the rated value, the voltage regulation range will change, the actual power will increase, and the power factor will decrease. It is necessary to ensure that the load resistance matches the magnetic regulator output voltage.

[0053] Compared with ordinary electroslag furnace transformers:

[0054] Differences in voltage regulation methods: Ordinary electric slag furnace transformers achieve step-by-step voltage regulation by adjusting the input side voltage regulating switch to change the number of input coil turns; magnetic regulation achieves stepless and smooth voltage regulation by adjusting the reactance value of the saturated reactor through DC excitation.

[0055] Advantages: The internal saturated reactor provides current limiting, resulting in excellent drop-out characteristics, strong overload capacity, and robust load short-circuit resistance. As an actuator, it offers a large time constant, system stability, and high anti-interference capabilities. When used appropriately, it offers reliable and stable performance and can be considered a permanent device. Flexible control options include open-loop manual control and closed-loop automatic control based on control signals.

[0056] As a further embodiment,

[0057] 1. High voltage input module

[0058] The high-voltage input module uses three-phase input terminals, accepting either 10kV or 35kV high-voltage signals. In this embodiment, 35kV is selected based on the power requirements of the glassmaking furnace and the actual conditions of the local power grid. This module is connected to a monitoring unit V1, which monitors the input high-voltage signal in real time to ensure the stability and safety of the input voltage. If a voltage anomaly is detected, the system will promptly issue an alarm and take appropriate protective measures, such as shutting off the power supply.

[0059] 2. Transformer voltage regulation module

[0060] 1. Input side winding

[0061] Adjustable primary winding-fixed primary winding combination: The adjustable primary winding is connected to a high-voltage on-load switch (OLT), which adjusts the number of turns of the adjustable primary winding. To reduce the failure rate of the high-voltage on-load switch, a fixed primary winding is connected to the end of the adjustable primary winding. When the high-voltage on-load switch requires large voltage adjustments, the fixed primary winding can share some of the voltage variation, thereby reducing the adjustable primary winding's step adjustment range.

[0062] Among them, (1) an intelligent dynamic adjustment mechanism is introduced in the input side winding. Based on the adjustable primary winding-fixed primary winding combination structure, the system is equipped with an intelligent monitoring and dynamic adjustment module. This module collects the operating parameters of the high-voltage load switch in real time, including adjustment frequency, adjustment amplitude, current current, and winding temperature. Using this data, combined with machine learning algorithms, a prediction model is constructed to assess the failure rate risk of the high-voltage load switch under current operating conditions.

[0063] (2) When the prediction model determines that the high-voltage on-load switch may face a high failure rate risk, the intelligent dynamic regulation module automatically adjusts the connection method of the fixed primary winding. Based on the current voltage regulation requirements and system operating status, the ratio of the number of turns connected to the fixed primary winding is precisely controlled, allowing the fixed primary winding to more accurately share voltage changes. This further optimizes the step adjustment range of the adjustable primary winding, effectively reducing the failure rate of the high-voltage on-load switch.

[0064] (3) To enhance the coordinated voltage regulation capability between the fixed primary winding and the adjustable primary winding, adaptive coupling technology is introduced. Special magnetic coupling elements are set between the two windings. These elements can automatically adjust the magnetic permeability according to the changes in the winding current and voltage.

[0065] (4) When the high-voltage on-load switch is performing voltage regulation, the adaptive coupling element senses the current and voltage fluctuations of the adjustable primary winding in real time and changes the magnetic coupling strength between the fixed primary winding and the adjustable primary winding by adjusting its own magnetic permeability. When a large voltage regulation is required, the magnetic coupling is enhanced so that the fixed primary winding can more effectively share the voltage variation. When the voltage regulation amplitude is small, the magnetic coupling is appropriately reduced to ensure the flexibility and accuracy of the system voltage regulation.

[0066] (5) Considering the importance of the high-voltage on-load switch and winding system, a redundant backup and fault switching mechanism is designed. Redundant winding lines and backup high-voltage on-load switches are set at key nodes of the fixed primary winding and the adjustable primary winding.

[0067] (6) When the system detects a fault in a high-voltage on-load switch or winding, the fault switching mechanism is quickly activated, isolating the faulty part and automatically switching to the corresponding redundant backup line. At the same time, the intelligent monitoring system analyzes and diagnoses the fault and sends a detailed fault report to the operator for timely repair. This redundant backup and fault switching mechanism greatly improves the reliability and stability of the system, ensuring the continuity of power supply during the glass manufacturing process.

[0068] (7) To further improve the performance of the input side winding, the winding material and insulation design are optimized. New high-permeability, low-loss materials are used to make the winding, reducing the energy loss of the winding itself and improving the efficiency of the transformer.

[0069] In terms of insulation design, nanocomposite insulation materials and multi-layer insulation structures are utilized. Nanocomposite insulation materials have excellent electrical and mechanical properties and can effectively improve the insulation strength of the windings. The multi-layer insulation structure combines different insulation materials to form a multi-layer insulation barrier, enhancing the winding's ability to withstand high voltages and strong electric fields, and reducing the probability of failures caused by insulation problems.

[0070] 2. DC Excitation Winding: The input-side winding also includes a DC excitation winding, which is connected to a DC excitation power supply. By adjusting the output current of the DC excitation power supply, the magnetic field strength of the DC excitation winding, and thus the magnetic field saturation of the iron core, can be controlled. When different voltage outputs are required during the glass manufacturing process, continuous voltage regulation can be achieved by adjusting the DC excitation current.

[0071] Among them, (1) a real-time monitoring module is built on the DC excitation winding side to monitor not only the output current and voltage of the DC excitation power supply, but also the magnetic field strength, temperature, and permeability changes of the iron core, as well as key parameters in the glass manufacturing process, including the temperature, viscosity, and conductivity of the glass liquid in the kiln. These parameters are transmitted to the intelligent controller in real time using a high-precision sensor network.

[0072] (2) Based on historical operating data and real-time monitoring data, a prediction model is constructed using a deep learning algorithm, a convolutional neural network (CNN). The model predicts the transformer voltage output requirements at different stages of the glass manufacturing process and adjusts the DC excitation current in advance. In the initial stage of glass melting, the model predicts the required voltage rise curve based on the characteristics of the glass raw materials and the current environmental conditions, thereby automatically adjusting the DC excitation current to achieve precise and continuous voltage regulation.

[0073] (3) An adaptive fuzzy control algorithm is used to dynamically adjust the DC excitation current by combining real-time monitoring data with the output of the prediction model. When parameter fluctuations occur during the glass manufacturing process, the fuzzy controller quickly adjusts the control strategy based on preset fuzzy rules to ensure that the magnetic field saturation of the iron core is always at the optimal state, achieving stable and efficient voltage output.

[0074] (4) Design a multi-redundant DC excitation winding structure, that is, in addition to the main DC excitation winding, multiple backup windings are also set up. These backup windings are in hot standby state during normal operation. When the main winding fails, they can quickly and automatically switch to the backup winding to ensure the continuity of the DC excitation function.

[0075] (5) Establish a comprehensive fault diagnosis system to monitor the operating status of the DC excitation winding in real time. By analyzing the winding's current, voltage, resistance, and other parameters, and applying fault diagnosis algorithms (such as those based on wavelet transform), the fault location can be quickly and accurately located. Once a fault is detected, the fault-tolerant control system immediately activates, adjusts the operating mode of the backup winding, and simultaneously issues an alarm to the operator, providing detailed fault information.

[0076] (6) Adopt new power supply topologies, such as multi-level converter topologies, to improve the efficiency and output stability of DC excitation power supplies. Multi-level converters can reduce the harmonic content of the output voltage, reduce electromagnetic interference, and at the same time increase the power density of the power supply and reduce the size of the equipment.

[0077] (6) An energy recovery module is integrated into the DC excitation power supply. When the voltage output of the transformer needs to be reduced, the excess energy is recovered and stored in an energy storage device (such as a supercapacitor). When the voltage output needs to be increased later, the energy in the energy storage device is released to provide auxiliary energy for the DC excitation power supply, thereby improving energy utilization efficiency.

[0078] (7) Collaboration with the adjustable primary winding and fixed primary winding: The voltage regulation function of the DC excitation winding is combined with the voltage regulation method of the adjustable primary winding and fixed primary winding. The proportion of the two voltage regulation methods is dynamically allocated according to the voltage requirements at different stages of the glass manufacturing process. When adjusting the voltage within a small range, the DC excitation winding is preferred for continuous voltage regulation; when adjusting the voltage within a large range, the coarse adjustment function of the adjustable primary winding and fixed primary winding is combined to achieve fast and accurate voltage regulation.

[0079] 3. Iron core: The iron core is the core component of the transformer, which provides the magnetic circuit for the winding. In this system, the design of the iron core fully considers the magnetic saturation characteristics to ensure stable operation under different excitation currents.

[0080] 4. Output side winding:

[0081] The output windings consist of the first and second output windings, which can be connected in parallel or series. When high voltage and low current are required, the first and second output windings are connected in series; when low voltage and high current are required, they are connected in parallel. This flexible connection method covers a wider voltage and current range, meeting the needs of different stages in the glass manufacturing process.

[0082] Measurement Unit: The output winding is also connected to a voltage measurement unit and a current measurement unit to monitor the output voltage and current in real time. This measurement data can be fed back to the control system to adjust the transformer's voltage regulation parameters in a timely manner.

[0083] Among them, (1) on the basis of the original series and parallel connection, a variety of composite connection modes are designed. Part of the first output winding is connected in series with the second output winding, and then connected in parallel with the remaining first output winding or second output winding to form a hybrid connection mode. This composite connection mode can produce more different voltage-current combinations, further expanding the coverable voltage and current range. By accurately calculating the number of turns and connection ratios of different windings, more precise control of output parameters can be achieved to meet the unique requirements of voltage and current in some special process stages of the glass manufacturing process. For example, in the key link of glass forming, a specific medium voltage and medium current combination may be required, and the composite connection mode can meet such requirements.

[0084] (2) Construct an automatic switching module based on a microprocessor and power electronic switches to automatically determine and switch the connection mode of the first and second output windings according to the real-time requirements of the glass manufacturing process. The microprocessor receives instructions from the glass manufacturing equipment and process control system, combines the current voltage and current measurement data, and quickly calculates the optimal winding connection mode through a built-in algorithm. The power electronic switch quickly and reliably completes the switching of the winding connection mode according to the instructions of the microprocessor. The entire process is completed in a short time, achieving a seamless transition and ensuring the continuity and stability of the glass manufacturing process.

[0085] (3) Adaptive Adjustment Measurement Unit and Feedback Control

[0086] The voltage and current measurement units have been upgraded to incorporate high-precision, wide-range sensors. These not only accurately measure output voltage and current in real time, but also monitor other relevant parameters such as power factor and harmonic content. These multi-parameter measurement data provide a more comprehensive picture of the transformer's output power quality, providing richer information for subsequent precise control.

[0087] (4) After feeding the data acquired by the measurement unit back to the control system in real time, the control system uses advanced intelligent optimization algorithms, such as particle swarm optimization (PSO) or genetic algorithm (GA). These algorithms can quickly optimize and adjust the transformer's voltage regulation parameters, including DC excitation current and adjustable primary winding turns, based on the current measurement data and the target parameters of the glass manufacturing process. At the same time, the control system can also perform predictive control based on historical data and real-time measurement results, adjusting the voltage regulation parameters in advance to cope with possible process changes and interference during the glass manufacturing process, ensuring that the output voltage and current always meet the process requirements.

[0088] (5) A health status monitoring module is integrated into the output side winding to evaluate the health status of the winding in real time by monitoring parameters such as winding temperature, insulation resistance, and partial discharge. Machine learning algorithms, such as support vector machines (SVM), are used to analyze and process the monitoring data and establish a fault diagnosis model. Once an abnormality in the winding is detected, such as insulation aging or overheating, the system can issue an alarm in a timely manner and take appropriate measures based on the severity of the fault, such as automatically adjusting the winding connection method and reducing the output power, to prevent the fault from further expanding and ensure the safe and reliable operation of the transformer and the smooth progress of the glass manufacturing process.

[0089] 3. Kiln heating module

[0090] The high-voltage input module transmits high voltage to the transformer voltage regulator module for voltage regulation, and then directly connects to the furnace heating electrodes of the furnace heating module. The furnace heating electrodes generate heat through the current, heating the glass raw material to a molten state. In this embodiment, the furnace heating module utilizes advanced heating technology, ensuring uniform heating of the glass raw material and improving glass quality.

[0091] Among them, (1) a new composite material is used to make the furnace heating electrode, combining high-temperature resistant and highly conductive ceramic materials with high-purity metal materials. This composite electrode not only has good conductivity and can effectively generate heat, but also has stable chemical properties under high temperature environments and is not easily corroded by glass liquid, which greatly extends the service life of the electrode. In terms of electrode structure, it is designed to be porous or hollow. Without affecting the conductivity and strength of the electrode, the contact area between the electrode and the glass liquid is increased, so that heat is transferred to the glass liquid more evenly and local temperature differences are reduced.

[0092] (2) Abandoning the traditional fixed electrode layout method, a device is designed to adjust the electrode position in real time according to the characteristics of the glass raw materials and the temperature distribution in the kiln. By installing multiple temperature sensors in the kiln, temperature data from different areas are collected and fed back to the control system. The control system uses an intelligent algorithm to calculate the optimal electrode layout plan and drive the mechanical device to adjust the electrode position. In the early stage of melting the glass raw materials, the electrodes are placed close to the raw material accumulation area to concentrate heat and accelerate melting; in the later stage of melting, the electrode position is adjusted to make the heat more evenly distributed throughout the kiln to ensure the temperature uniformity of the glass liquid.

[0093] (3) Introducing microwave-assisted heating technology: Based on traditional resistance heating, microwave-assisted heating technology is introduced. A microwave generator is installed in the kiln to emit microwaves to the glass raw materials. Microwaves can directly interact with the polar molecules in the glass raw materials, causing the molecules to vibrate rapidly to generate heat and achieve internal heating. This method, combined with traditional resistance heating, can, on the one hand, accelerate the melting speed of the glass raw materials, and on the other hand, further improve the temperature uniformity of the glass liquid. By precisely controlling the microwave power and heating time, the heating strategy is adjusted according to the different stages of the glass manufacturing process. In the glass clarification stage, the microwave power is appropriately increased to promote the discharge of bubbles; in the glass homogenization stage, the microwave power is reduced to maintain temperature stability.

[0094] (4) Use the technology of induction heating and resistance heating in synergy: Using the principle of electromagnetic induction, an induction coil is set around the kiln. When an alternating current passes through the induction coil, an alternating magnetic field is generated in the kiln, causing an induced current to be generated inside the glass raw material, thereby generating heat. Induction heating and resistance heating are used in synergy, and the power ratio of induction heating and resistance heating is dynamically adjusted according to the temperature and electromagnetic characteristics of the glass liquid. In the early stage of glass melting, induction heating is mainly used to quickly increase the temperature; after the glass liquid reaches a certain temperature, the proportion of resistance heating is gradually increased to accurately control the temperature and achieve a more efficient and accurate heating process.

[0095] (5) A high-density, high-precision temperature monitoring network is constructed inside the kiln. Multiple high-precision temperature sensors are installed at different locations and depths to collect temperature data from various areas within the kiln in real time. These sensors use wireless transmission technology to transmit data to the control system in real time, ensuring a comprehensive and accurate understanding of the temperature distribution within the kiln.

[0096] (6) Using an adaptive fuzzy-neural network control algorithm, the voltage and current output by the transformer are adjusted in real time based on temperature monitoring data to precisely control the heating electrode's heat output. This algorithm can automatically adjust control parameters based on the temperature variation trend within the kiln and process requirements, achieving dynamic and precise control of the kiln temperature. When the temperature deviation is large, the algorithm quickly adjusts the heating power; when the temperature approaches the set value, a fine-tuning strategy is adopted to avoid temperature overshoot, ensuring that the glass manufacturing process is carried out in a stable temperature environment.

[0097] Example 2

[0098] The difference between this embodiment and embodiment 1 is that this embodiment provides a configuration method of a full electric melting and boosting transformer for glass manufacturing, including the following aspects:

[0099] 1. The present invention improves the power efficiency of the all-electric melting and boosting transformer used in glass manufacturing. The high-voltage input from the power grid can be directly connected to the heating electrodes of the kiln after being regulated by the transformer, directly shielding the DC component and eliminating the need for a separate isolation transformer.

[0100] 2. The all-electric melting and boosting transformer for glass manufacturing of the present invention is configured to improve power efficiency, wherein continuous voltage regulation is performed with load, small step-over adjustment is performed on the high-voltage on-load switch, and continuous adjustment is performed on the series magnetic voltage regulation, thereby ensuring that the magnetic voltage regulation part is always in a high-efficiency operating range.

[0101] 3. Configuration method for improving power efficiency of all-electric melting and boosting transformers used in glass manufacturing. Among them, the most suitable voltage standards V1 on the input side are 10kv and 35kv. At 10kv, V3 can be zero; at 35kv, the voltage carried by V3 does not exceed 30% of the full load on the input side.

[0102] 4. Configuration method for improving power efficiency of all-electric melting and boosting transformers used in glass manufacturing. The input side can be connected in delta or star, with delta connection being the preferred option.

[0103] 5. A configuration method for improving power efficiency of all-electric melting and boosting transformers used in glass manufacturing. This method is characterized by having multiple independent windings on the output side, preferably 2-3 independent windings, which can be connected in series or parallel, thus expanding the voltage adjustment range and enhancing practicality.

[0104] 6. All-electric melting and boosting transformers for glass manufacturing improve power efficiency. The overall design can be tailored to rated capacity, with each phase core utilizing a high-voltage conductor wrapped around a low-voltage conductor, which is more conducive to reducing investment, ensuring operational safety, and improving efficiency.

[0105] 7. Configuration method for improving power efficiency of all-electric melting and boosting transformers used in glass manufacturing. The upper limit of the on-load switch level K is 13 for 10 kV, preferably 11, and 17 for 35 kV, preferably 15.

[0106] 8. Configuration method for improving power efficiency of all-electric melting and boosting transformers used in glass manufacturing. The transformer cooling system is oil-immersed, and water cooling is used for capacity above 3000kVA.

[0107] The above are all preferred embodiments of the present invention, and are not intended to limit the scope of protection of the present invention. Therefore, any equivalent changes made based on the structure, shape, and principle of the present invention should be included in the scope of protection of the present invention.

[0108] As a further embodiment,

[0109] This embodiment proposes a control strategy for a fully electric melting and boosting transformer configuration system for glass manufacturing, including the following:

[0110] (1) Control of high-voltage on-load switches

[0111] To protect the high-voltage on-load switch, a combination of an adjustable primary winding and a fixed primary winding is employed for position limiting protection. Simultaneously, the control system precisely controls the high-voltage on-load switch based on the glass manufacturing process requirements and output voltage and current feedback. For example, during the initial glass melting process, when a high power input is required, the control system gradually adjusts the high-voltage on-load switch to increase the output voltage and current.

[0112] (2) Control of output side winding connection method

[0113] The control system automatically switches the connection between the first and second output windings based on the voltage and current requirements at different stages of the glassmaking process. For example, during the glass clarification stage, a higher voltage is required to expel bubbles from the glass, so the control system connects the first and second output windings in series. During the glass forming stage, a higher current is required to maintain the fluidity of the glass, so the control system connects them in parallel.

[0114] (3) Control of DC excitation power supply

[0115] The output current of the DC excitation power supply is precisely controlled by the control system based on the core's magnetic field saturation and the output voltage requirements. By adjusting the DC excitation current, the output voltage can be continuously adjusted, allowing the system to maintain a stable voltage output under varying load conditions.

Claims

1. A fully electric melting and boosting transformer configuration system for glass manufacturing, characterized in that: include: A high-voltage input module, a transformer voltage regulating module and a kiln heating module, wherein the high-voltage input module inputs the high voltage to the transformer voltage regulating module for voltage regulation and then directly connects to the kiln heating electrode of the kiln heating module; the transformer voltage regulating module includes an input side winding, an iron core and an output side winding.

2. A fully electric melting and boosting transformer configuration system for glass manufacturing according to claim 1, characterized in that: The high-voltage input module includes three-phase input terminals, through which 10KV or 35KV high-voltage signals are respectively input; the high-voltage input module is connected to a monitoring unit V1 for monitoring the input high-voltage signal.

3. A fully electric melting and boosting transformer configuration system for glass manufacturing according to claim 2, characterized in that: The input side winding adopts an adjustable primary winding-fixed primary winding combination structure. By connecting the fixed primary winding to the end of the adjustable primary winding, the fixed primary winding is used to reduce the step adjustment range of the adjustable primary winding.

4. A fully electric melting and boosting transformer configuration system for glass manufacturing according to claim 3, characterized in that: The adjustable primary winding is connected to a high-voltage on-load switch, and the number of turns of the adjustable primary winding is adjusted by the high-voltage on-load switch.

5. A full electric melting and boosting transformer configuration system for glass manufacturing according to claim 4, characterized in that: The input side winding also includes a DC excitation winding, which controls the magnetic field saturation of the iron core.

6. A fully electric melting and boosting transformer configuration system for glass manufacturing according to claim 5, characterized in that: The DC excitation winding is connected to a DC excitation power supply, and the magnitude of the magnetic field of the DC excitation winding is controlled by the magnitude of the output current of the DC excitation power supply.

7. A fully electric melting and boosting transformer configuration system for glass manufacturing according to claim 6, characterized in that: The output side winding includes a first output winding and a second output winding, and the first output winding and the second output winding are connected in parallel or in series. When the first output winding and the second output winding are connected in series, a high voltage and a small current are output; when the first output winding and the second output winding are connected in parallel, a small voltage and a large current are output.

8. A full electric melting and boosting transformer configuration system for glass manufacturing according to claim 7, characterized in that: The output side winding is also connected to a voltage measuring unit and a current measuring unit.

9. A fully electric melting and boosting transformer configuration system for glass manufacturing according to claim 8, characterized in that: Ends of the output side winding are respectively connected to three-phase loads.

10. A method for configuring a fully electric melting and boosting transformer for glass manufacturing, characterized in that: include: The high-voltage on-load switch is protected by a combination of an adjustable primary winding and a fixed primary winding. The voltage and current variation range is controlled by connecting the first output winding and the second output winding of the output side winding. When the first output winding and the second output winding are connected in series, a high voltage and a low current are output; when the first output winding and the second output winding are connected in parallel, a low voltage and a high current are output.

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