Coating machine air volume control system based on glue type
The coating machine airflow control system, which identifies adhesive type and automatically adjusts airflow, solves the problem of inflexible airflow adjustment in coating machine production, optimizes safety and energy consumption, and improves production efficiency and product quality.
Patent Information
- Application Number
- CN202511317693.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-16
- Publication Date
- 2025-11-11
AI Technical Summary
In existing coating machine production systems, the exhaust volume of the oven cannot be flexibly adjusted according to the type of adhesive, resulting in insufficient safety in the production of oil-based products and excessively high energy consumption and environmental costs for water-based products.
Design a coating machine airflow control system based on adhesive type, including an oven system, an air supply system, a control system, and a heat exchanger. The system uses an adhesive identification module to determine the adhesive type, and combines a process database and an airflow calculation module to achieve automatic airflow adjustment. In case of abnormality, a safety protocol is triggered, and the waste heat of the exhaust gas is recovered using the heat exchanger.
It enables flexible adjustment of exhaust volume according to the type of adhesive, ensuring production safety, reducing energy consumption and environmental protection costs, and improving product yield and equipment adaptability.
Smart Images
Figure CN120920328A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of coating machine technology, and more specifically, to an airflow control system for a coating machine based on an adhesive type. Background Technology
[0002] A coating machine is a mechanical device used to uniformly coat the surface of materials such as paper, film, and fabric. Its core function is to form a coating with specific properties on the surface of the substrate through a specific process.
[0003] The adhesives used in coating machine production are mainly of two types: oil-based and water-based. Oil-based adhesives require the addition of toluene as a solvent during preparation, while water-based adhesives use water as a solvent. When the fabric coated with adhesive is sent into the drying oven for drying, the toluene or water in the adhesive will evaporate into gas under high temperature. Due to the flammable and explosive nature of toluene, a large exhaust volume is required when handling oil-based adhesives to ensure production safety and prevent it from accumulating in the drying oven and creating a safety hazard. In contrast, the water vapor produced by water-based adhesives does not pose a flammable or explosive risk and does not require a large exhaust volume to ensure safety. However, in existing coating machine production systems, the exhaust system of the drying oven often uses a fixed exhaust volume setting, which cannot be adjusted according to the type of adhesive used. This results in the use of the large exhaust volume required for oil-based products when producing water-based products, causing the heat in the drying oven to be carried away, resulting in unnecessary energy waste.
[0004] Therefore, how to flexibly adjust the exhaust volume of the oven to take into account the different characteristics of oil-based and water-based adhesives, so as to ensure the safety of oil-based product production while reducing the energy consumption and environmental protection costs of water-based product production, has become a technical problem that urgently needs to be solved in the current coating machine production field. Summary of the Invention
[0005] To address the shortcomings of existing technologies, the present invention aims to provide an airflow control system for coating machines based on adhesive types.
[0006] The above-mentioned technical objective of the present invention is achieved through the following technical solution: an air volume control system for a coating machine based on adhesive type, including an oven system, an air supply system, a control system and a heat exchanger, wherein the oven system includes a No. 1 line and a No. 2 line arranged in parallel, and each of the No. 1 line and the No. 2 line is independently equipped with a temperature monitoring point, a pressure detection point and an exhaust gas composition analyzer; The air supply system includes a combustion-supporting blower, an RTO blower, a backflow blower, a fresh air blower, and exhaust gas filter boxes, fresh air filter boxes, and electric regulating valve groups connected to each blower. The RTO blower has a QHZ speed regulation mode, and the air volume is adjusted according to the type of adhesive through the air supply system. The control system includes an adhesive identification module, a process database, an airflow calculation module, and a safety interlock module. The adhesive identification module is used to determine whether the adhesive used in the current production is oil-based or water-based. The process database stores the airflow adjustment curves, temperature ranges, and pressure thresholds corresponding to different JBX process numbers. The airflow calculation module automatically selects the process parameters provided by the process database according to the material type. The safety interlock module triggers a safety protocol when it detects excessive toluene concentration, abnormal pressure, or abnormal temperature. The heat exchanger is connected to the fresh air fan and the back air blower through the air supply pipe. The back air blower delivers high-temperature exhaust gas to the heat exchanger to preheat the fresh air, forming a waste heat recovery loop.
[0007] Preferably, the glue type identification module obtains glue type information through at least one of the following methods; A. Receive order information issued by production management; B. Manual input by the operator; C. The toluene content in the exhaust gas is detected using an exhaust gas composition analyzer.
[0008] Preferably, the air volume calculation module uses the following formula to calculate the exhaust volume of oil-based adhesives: Q_oil-based = k1 × V × C_toluene, and the air volume calculation module uses the following formula to calculate the exhaust volume of water-based adhesives: Q_water-based = k2 × V × H2O, where k1 and k2 are correction coefficients, V is the oven volume, C_toluene is the toluene concentration, and H2O is the water vapor concentration.
[0009] Preferred: The security protocol is activated when any of the following conditions are detected; A. The oven temperature is maintained at >500℃ or <450℃ for 2 minutes; B. The oven pressure deviates from the range of -15Pa to -25Pa for 2 minutes. C. Compressed air pressure value remains <0.6MPa for 2 minutes; D. The concentration of toluene in the exhaust gas is ≥ 20% of the lower explosive limit; Preferably, the security protocol includes at least one of the following operations; Level 1 response: Issues an audible and visual alarm and adjusts the opening of the electric regulating valve; Level 2 response: Reduce the speed of the combustion fan and RTO fan; Level 3 Response: Cut off the heating source and activate the emergency plan corresponding to the JBX number.
[0010] Preferred: Includes the following control steps; S1. Start the system and retrieve the production instruction with the JBX process number; S2. Identify the type of adhesive currently used on the production line; S3. Select the high or low exhaust mode according to the type of adhesive. S4. Adjust the opening of several electric exhaust valves and the speed of the combustion fan, RTO fan, backflow fan, and fresh air fan to the target value; S5. Dynamically adjust the exhaust volume based on monitoring data, and monitor combustion temperature, exhaust temperature and pressure parameters in real time; S6. When parameters are abnormal, trigger the safety protocol; otherwise, continue running and stop after the set processing time.
[0011] Preferably, the electric regulating valve is electrically connected to the air volume calculation module, and the air volume calculation module sends an opening adjustment signal to the electric regulating valve based on the real-time calculated air volume value.
[0012] Preferably, the process database stores historical optimal process parameters for different types of adhesives, including airflow adjustment curves, temperature variation ranges, and pressure control thresholds for different production stages.
[0013] Preferred settings: When processing oil-based adhesives, the electric regulating valve opening is 80-100%, the exhaust volume is 8000-12000 m³ / h, the combustion fan and RTO fan are running at full speed, and the oven temperature is 480-490℃. When processing water-based adhesives, the electric regulating valve opening is 20-50%, the exhaust volume is 3000-5000 m³ / h, the combustion fan and RTO fan are reduced to 50-70%, and the oven temperature is 460-470℃.
[0014] Preferably, the temperature monitoring point and pressure detection are formed by setting temperature sensors and pressure sensors in the inlet section, middle section and outlet section along the length of the oven.
[0015] In summary, the present invention has the following beneficial effects: 1. The glue identification module accurately determines the type of glue. For oil-based glues, a high exhaust volume mode is adopted, and a safety interlock module monitors toluene concentration, temperature and pressure parameters in real time. When abnormal conditions occur, a multi-level safety protocol is triggered, which can effectively avoid flammable and explosive risks and ensure the safety and stability of the production process. For water-based glues, a low exhaust volume mode is adopted, and an electric regulating valve is used to reduce heat loss from the oven. At the same time, a waste heat recovery loop is formed through a heat exchanger to preheat fresh air with high-temperature waste gas, thereby reducing heating energy consumption. 2. Based on the historical optimal parameters of JBX process numbers stored in the process database, the system can automatically match the air volume curve and temperature threshold with one click. Combined with the dynamic calculation formula of the air volume calculation module, the system can automatically adjust the air volume according to the real-time monitored concentration, temperature and pressure data, solving the adaptability problem of the traditional fixed air volume mode. The system is easy to operate, the processing is stable, and the product yield is improved. 3. The low exhaust volume during water-based adhesive processing can reduce the amount of gas entering the waste gas treatment system, adaptively adjust and reduce the operating load of each piece of equipment, and at the same time, the historical optimal parameters of the process database can optimize the waste gas treatment efficiency and reduce the investment and operation and maintenance costs of environmental protection equipment.
[0016] 4. The system adopts a parallel configuration with independent control architecture for lines 1 and 2. Each production line can independently identify the type of adhesive and adjust the parameters, supporting the simultaneous production of products with different types of adhesives. The RTO blower features a QHZ speed regulation mode and a modular design, which facilitates the expansion or upgrading of equipment according to capacity requirements in the future. Attached Figure Description
[0017] Figure 1 This is a control panel diagram of the present invention; Figure 2 This is a control system diagram of the present invention. Detailed Implementation
[0018] The present invention will now be described in detail with reference to the accompanying drawings and embodiments.
[0019] Example: An airflow control system for a coating machine based on adhesive type, such as Figures 1-2 As shown, the system includes an oven system, an air supply system, a control system, and a heat exchanger. The oven system includes two parallel lines, No. 1 and No. 2. Both lines are independently equipped with temperature monitoring points, pressure detection points, and exhaust gas composition analyzers. The temperature monitoring points and pressure detection points are established by installing temperature and pressure sensors at the inlet, middle, and outlet sections along the length of the oven. The temperature sensors are PT100 temperature sensors with a measurement range of 0-600℃, which monitor the temperature of each area of the oven in real time. The pressure sensors are micro-pressure sensors with a measurement range of -50Pa to 50Pa, which are used to monitor the micro-negative pressure environment inside the oven in real time. The exhaust gas analyzer uses infrared spectroscopy to detect the toluene concentration in the exhaust gas, with a detection range of 0-20000ppm and a response time ≤5 seconds. It is installed in the main exhaust ducts of lines No. 1 and No. 2.
[0020] like Figures 1-2As shown, the air supply system includes a combustion air blower, an RTO blower, a backflow fan, a fresh air blower, and exhaust gas filter boxes, fresh air filter boxes, and electric regulating valve groups connecting each blower. The combustion air blower has a power of 7.5kW and an air volume adjustment range of 2000-15000m³ / h, providing combustion air to the burner. The air volume is controlled by frequency conversion speed regulation. The RTO blower has a power of 15kW, a QHZ speed regulation mode, supports 0-100% stepless speed regulation, and an air pressure ≥2500Pa. It is used to transport exhaust gas to the regenerative thermal oxidizer for treatment. The backflow fan has a power of 5.5kW and an air pressure of 1500Pa. It is used to send the high-temperature exhaust gas discharged from the oven into the heat exchanger. The fresh air blower has a power of 3kW and an air volume of 3000-8000m³ / h, used to introduce outside air to the heat exchanger. The air is preheated within the heat exchanger via heat transfer before being sent into the oven. The exhaust gas filter box contains an activated carbon adsorption layer, while the fresh air filter box uses a combination of G4 primary filters and F7 medium-efficiency filters to ensure gas cleanliness. An electric regulating valve is electrically connected to an airflow calculation module to receive opening signals. The airflow calculation module sends opening adjustment signals to the electric regulating valve based on real-time calculated airflow values. The air supply system can adjust the airflow according to the type of adhesive: a high exhaust volume mode for oil-based adhesives and a low exhaust volume mode for water-based adhesives. This, combined with the electric regulating valve, reduces heat loss from the oven. The heat exchanger is connected to a fresh air fan and a backflow fan via a gas pipe. The backflow fan delivers high-temperature exhaust gas to the heat exchanger to preheat the fresh air, forming a waste heat recovery loop. Utilizing the high-temperature exhaust gas to preheat the fresh air reduces heating energy consumption. like Figures 1-2 As shown, the low exhaust volume during water-based adhesive processing can reduce the amount of gas entering the waste gas treatment system, adaptively adjusting to reduce the operating load of each piece of equipment. At the same time, the historical optimal parameters in the process database can optimize waste gas treatment efficiency, reducing the investment and maintenance costs of environmental protection equipment. Lines 1 and 2 share the same exhaust pipe, which is connected to the waste gas purification device for purification before discharge. The historical optimal parameters in the process database are key parameters continuously recorded for each production cycle, including temperature, pressure, air volume, toluene concentration, and energy consumption data. After accumulating 1000 complete production cycles, an initial dataset is generated. A genetic algorithm is used with the minimum energy consumption as the objective function, with the constraints being: temperature fluctuation ≤ ±5℃, pressure deviation ≤ ±3 Pa, and toluene concentration ≤ 10% of the lower explosive limit. The final output is the Pareto optimal solution set as the historical optimal parameters. The optimization algorithm is rerun after every 100 new production data cycles to update the database parameters.
[0021] like Figures 1-2 As shown, the control system includes an adhesive identification module, a process database, an air volume calculation module, and a safety interlock module. The adhesive identification module is used to determine whether the type of adhesive currently used in production is oil-based or water-based. The adhesive type identification module obtains adhesive type information through at least one of the following methods. A. Receive order information from production management, including JBX process number and adhesive type; B. The operator manually selects oil-based or water-based on the touchscreen; C. When the toluene concentration detected by the exhaust gas composition analyzer is ≥5ppm, it is determined to be oily; otherwise, it is watery. The process database stores the air volume adjustment curves, temperature ranges and pressure thresholds corresponding to different JBX process numbers. The air volume adjustment curves corresponding to the JBX numbers are defined using piecewise functions. JBX101 (Standard Curve for Oil-Based Adhesives): 8000 + 2000 · t / 30 (0 ≤ t < 30 min) Q(t) = 10000 (30≤t≤120min) 10000-3000·t-120 / 20 (120<t≤140min) JBX202 (Water-based adhesive energy-saving curve): Q(t)=3000+1500·sin(πt / 180)(0≤t≤180min) When processing oil-based adhesives, the RTO fan operates at full speed, with an exhaust volume of 8000-12000 m³ / h, a temperature of 480-490℃, a pressure of -20±5 Pa, and an electric regulating valve opening of 80-100%. When processing water-based adhesives, the electric regulating valve opening is 20-50%, with an exhaust volume of 3000-5000 m³ / h, a temperature of 460-470℃, and a pressure of -20±5 Pa. The system also includes airflow adjustment curves for the heating, constant temperature, and cooling stages. The airflow calculation module automatically selects process parameters from the process database based on the material type and the adhesive. The air volume is calculated using the corresponding formula based on the type of adhesive. For oil-based adhesives, the air volume calculation formula is Q_oil-based = k1 × V × C_toluene; for water-based adhesives, it is Q_water-based = k2 × V × H2O. Here, k1 and k2 are correction coefficients, V is the oven volume, C_toluene is the toluene concentration, and H2O is the water vapor concentration. The calculation results are converted into signals for the electric regulating valve opening and fan speed. For example, an air volume of 10000 m³ / h corresponds to an electric regulating valve opening of 90% and the RTO fan at full speed, relying on the JBX data stored in the process database. The historical optimal parameters of the process number can be retrieved with one click and automatically matched with the airflow curve and temperature threshold. Combined with the dynamic calculation formula of the airflow calculation module, the glue identification module accurately determines the glue type. For oil-based glues, a high exhaust airflow mode is adopted, and the safety interlock module monitors toluene concentration, temperature and pressure parameters in real time. When abnormal conditions occur, multi-level safety protocols are triggered, which can effectively avoid flammable and explosive risks and ensure the safety and stability of the production process. For water-based glues, a low exhaust airflow mode is adopted, and the electric regulating valve reduces heat loss from the oven. The airflow can be automatically adjusted according to the real-time monitored concentration, temperature and pressure data, solving the compatibility problem of the traditional fixed airflow mode. It is easy to operate, the processing process is stable, and the product yield is improved.
[0022] like Figures 1-2 As shown, a safety protocol is triggered when toluene concentration exceeds the standard, pressure is abnormal, or temperature is abnormal. By collecting detection data from temperature and pressure sensors in real time, the corresponding response is triggered when the following conditions occur. Level 1 response: When the toluene concentration is 10000-12000ppm, the pressure deviation is within ±3Pa, and the temperature fluctuation is within ±10℃, an audible and visual alarm will be issued with a sound pressure level of 90dB, a flashing red light, and the opening of the electric regulating valve will be finely adjusted. Secondary response: Toluene concentration 12000-15000ppm, pressure deviation ±5Pa, temperature fluctuation ±20℃. At this time, reduce the speed of the combustion fan and RTO fan to 70%. Level 3 Response: Toluene concentration ≥15000ppm, temperature exceeding range for 2 minutes, pressure exceeding range for 2 minutes, compressed air pressure <0.6MPa for 2 minutes. At this time, the gas solenoid valve closes and the corresponding emergency plan (JBX number) is activated, and the equipment operation procedure is stopped immediately. The JBX emergency plan includes starting the nitrogen storage tank to input nitrogen into the oven, with a purging flow rate of 500m³ / h for 10 minutes to quickly reduce the toluene concentration, automatically closing the fireproof roller shutters at the oven inlet and outlet to isolate the hazardous area, and turning on the workshop explosion-proof exhaust fan with an air volume ≥20000m³ / h to reduce the risk of toluene accumulation in the workshop. The equipment manager must arrive on site within 5 minutes and confirm the concentration is <1000ppm with a toluene detector before the emergency state can be lifted.
[0023] like Figures 1-2 As shown, an airflow control system for a coating machine based on an adhesive type includes the following control steps; S1. Start the system and retrieve the production instruction with the JBX process number; S2. Identify the type of adhesive currently used on the production line; S3. Select the high or low exhaust mode according to the type of adhesive. S4. Adjust the opening of several electric exhaust valves and the speed of the combustion fan, RTO fan, backflow fan, and fresh air fan to the target value; S5. Dynamically adjust the exhaust volume based on monitoring data, and monitor combustion temperature, exhaust temperature and pressure parameters in real time; S6. When parameters are abnormal, trigger the safety protocol; otherwise, continue running and stop after the set processing time.
[0024] The system employs a parallel configuration with independent control architecture for lines 1 and 2. Each production line can individually identify the type of adhesive and adjust its parameters, supporting the simultaneous production of products with different types of adhesives. The RTO blower features a QHZ speed regulation mode and a modular design, facilitating future expansion or upgrades based on production capacity requirements.
[0025] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.
Claims
1. A coating machine airflow control system based on adhesive type, comprising an oven system, an air supply system, a control system, and a heat exchanger, characterized in that: The oven system includes two parallel lines, Line 1 and Line 2, each independently equipped with a temperature monitoring point, a pressure detection point, and an exhaust gas composition analyzer. The air supply system includes a combustion-supporting blower, an RTO blower, a backflow blower, a fresh air blower, and exhaust gas filter boxes, fresh air filter boxes, and electric regulating valve groups connected to each blower. The RTO blower has a QHZ speed regulation mode, and the air volume is adjusted according to the type of adhesive through the air supply system. The control system includes an adhesive identification module, a process database, an airflow calculation module, and a safety interlock module. The adhesive identification module is used to determine whether the adhesive used in the current production is oil-based or water-based. The process database stores the airflow adjustment curves, temperature ranges, and pressure thresholds corresponding to different JBX process numbers. The airflow calculation module automatically selects the process parameters provided by the process database according to the material type. The safety interlock module triggers a safety protocol when it detects excessive toluene concentration, abnormal pressure, or abnormal temperature. The heat exchanger is connected to the fresh air fan and the back air blower through the air supply pipe. The back air blower delivers high-temperature exhaust gas to the heat exchanger to preheat the fresh air, forming a waste heat recovery loop.
2. The airflow control system for a coating machine based on adhesive type according to claim 1, characterized in that: The adhesive type identification module obtains adhesive type information through at least one of the following methods; A. Receive order information issued by production management; B. Manual input by the operator; C. The toluene content in the exhaust gas is detected using an exhaust gas composition analyzer.
3. The device according to claim 2, a coating machine airflow control system based on adhesive type, characterized in that: The air volume calculation module uses the following formula to calculate the exhaust volume of oil-based adhesives: Q_oil-based = k1 × V × C_toluene. The air volume calculation module uses the following formula to calculate the exhaust volume of water-based adhesives: Q_water-based = k2 × V × H2O. Where k1 and k2 are correction coefficients, V is the oven volume, C_toluene is the toluene concentration, and H2O is the water vapor concentration.
4. The device according to claim 3, a coating machine airflow control system based on adhesive type, characterized in that: The security protocol will be activated if any of the following conditions are detected; A. The oven temperature is maintained at >500℃ or <450℃ for 2 minutes; B. The oven pressure deviates from the range of -15Pa to -25Pa for 2 minutes. C. Compressed air pressure value remains <0.6MPa for 2 minutes; D. The concentration of toluene in the exhaust gas is ≥ 20% of the lower explosive limit.
5. The device according to claim 4, a coating machine airflow control system based on adhesive type, characterized in that: The security protocol includes at least one of the following operations; Level 1 response: Issues an audible and visual alarm and adjusts the opening of the electric regulating valve; Level 2 response: Reduce the speed of the combustion fan and RTO fan; Level 3 Response: Cut off the heating source and activate the emergency plan corresponding to the JBX number.
6. The device according to claim 5, a coating machine airflow control system based on adhesive type, characterized in that: Includes the following control steps; S1. Start the system and retrieve the production instruction with the JBX process number; S2. Identify the type of adhesive currently used on the production line; S3. Select the high or low exhaust mode according to the type of adhesive. S4. Adjust the opening of several electric exhaust valves and the speed of the combustion fan, RTO fan, backflow fan, and fresh air fan to the target value; S5. Dynamically adjust the exhaust volume based on monitoring data, and monitor combustion temperature, exhaust temperature and pressure parameters in real time; S6. When parameters are abnormal, trigger the safety protocol; otherwise, continue running and stop after the set processing time.
7. The device according to claim 1, a coating machine airflow control system based on adhesive type, characterized in that: The electric regulating valve is electrically connected to the air volume calculation module, and the air volume calculation module sends an opening adjustment signal to the electric regulating valve based on the real-time calculated air volume value.
8. The device according to claim 1, a coating machine airflow control system based on adhesive type, characterized in that: The process database stores historical optimal process parameters for different types of adhesives, including airflow adjustment curves, temperature variation ranges, and pressure control thresholds for different production stages.
9. The device according to claim 8, a coating machine airflow control system based on adhesive type, characterized in that: When processing oil-based adhesives, the electric regulating valve is opened to 80-100%, the exhaust volume is 8000-12000 m³ / h, the combustion fan and RTO fan are running at full speed, and the oven temperature is 480-490℃. When processing water-based adhesives, the electric regulating valve is opened to 20-50%, the exhaust volume is 3000-5000 m³ / h, the combustion fan and RTO fan are reduced to 50-70%, and the oven temperature is 460-470℃.
10. The airflow control system for a coating machine based on adhesive type according to claim 1, characterized in that: The temperature monitoring points and pressure detection are achieved by setting temperature sensors and pressure sensors in the inlet, middle, and outlet sections along the length of the oven.