Substrate glass production feeding system and control method

Abstract

The invention discloses a substrate glass production feeding system and a control method, and relates to the technical field of substrate glass production, and the system comprises a feeding machine, a raw material blanking weighing sensor M, a substrate glass original sheet weighing sensor G and a DCS system. M and G signals are collected through a DCS system, and the raw material blanking amount in unit time and the substrate glass output weight amp are calculated; lagging time h and a discharging coefficient X (X = amp; and / ) establishing a prediction model, and automatically adjusting the rotating speed of the batch feeder by taking the predicted output weight of the substrate glass as a feedback value of the PID controller. The system solves the problems of raw material feeding amount fluctuation and substrate glass sheet output hysteresis quality, and realizes remote automatic control. Practice verifies that the stability of the feeding amount can be improved, the deviation rate of the output weight of the substrate glass raw sheet is reduced, the digital monitoring and intelligent adjusting functions are achieved, and the production continuity and the product consistency are remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of substrate glass production technology, and in particular to a substrate glass production feeding system and control method. Background Technology

[0002] In substrate glass production, raw materials are fed into a high-temperature melting furnace via a feeding machine. However, the raw material's feed rate fluctuates greatly due to its own temperature and humidity. Previously, manual adjustment of the feeding machine's motor speed was relied upon to maintain a stable feed rate and substrate glass sheet weight. However, the raw material feed rate has a significant lag effect on the substrate glass sheet weight, making manual adjustment difficult to adapt in a timely manner. This results in poor feeding control stability, hindering production efficiency and product quality improvement. To overcome this predicament, there is an urgent need for a feeding system that integrates advanced technologies and can be remotely and automatically controlled. By leveraging the programmable configuration capabilities of a DCS control system and integrating computer, communication, electrical, and detection technologies, the feeding rate of the feeding machine can be precisely controlled, overcoming the lag problem, ensuring stable substrate glass sheet weight, and promoting high-quality development of the industry. Summary of the Invention

[0003] To address the technical problems existing in the background art, this invention proposes a substrate glass production feeding system and control method, enabling remote and stable control of the raw material feeding amount and the weight of the finished substrate glass sheet during the substrate glass production process. This invention collects the raw material feeding amount and the weight of the finished substrate glass sheet, calculates the feeding amount per unit time and the finished sheet weight per unit time, and combines this with the time lag between the finished substrate glass sheet and the raw material feeding amount to achieve remote automatic control of the substrate glass feeding system.

[0004] In a first aspect, the present invention provides a substrate glass production feeding system, comprising:

[0005] The feeding machine includes a hopper, a feeding channel, a variable frequency motor, a raw material feeding weighing sensor, a feeding channel gate, a screw feed shaft, and the feeding machine body. The raw material feeding weighing sensor is used to collect the raw material feeding weight signal.

[0006] The substrate glass sheet weighing module is used to collect the weight signal of the substrate glass sheet;

[0007] The DCS system is compatible with processor and controller functions, realizing data processing, storage, control and output, covering counting methods, execution of calculation rules, and read and write calls, and also has a host computer control screen.

[0008] Furthermore, the raw material feeding weighing sensor is located at the bottom of the raw material silo and above the screw feed inlet of the feeder. Its center is a longitudinal hole. The feeding channel connects the bottom of the silo and the screw feed inlet of the feeder through the central hole. The feeding channel gate is located inside the feeding channel. The screw feed shaft is driven by a variable frequency motor and is installed together on the feeder body.

[0009] Furthermore, the substrate glass sheet weighing module includes a substrate glass sheet weighing sensor, a substrate glass transfer trolley, and grippers. The substrate glass sheet weighing sensor is located below the substrate glass transfer trolley, and the grippers above the transfer trolley fix the substrate glass sheet, working together with the transfer trolley on the substrate glass sheet weighing sensor.

[0010] Secondly, the present invention provides a control method for a substrate glass production feeding system, comprising the following steps:

[0011] The weighing signals from the raw material feeding weighing sensor and the substrate glass sheet weighing sensor are collected, converted into standard signals, and sent to the input terminal of the DCS system.

[0012] Define the raw material weighing value M as a unit of time, with the current value in minutes recorded as M. t The value of the previous minute is denoted as M. t-1 ), raw material feed rate Δ per minute t =M t -M( t-1 ); Define the weight value G of the substrate glass sheet as the weight value of each sheet, and record the current weight value of the sheet as G. t The number of prints produced per minute is denoted as N, and the weight of the first N original prints is denoted as G. t-N ), the weight of substrate glass sheets produced per minute &t=G( t-1 )+……+G( t-N );

[0013] The feed coefficient X = & / Δ is determined to be the feed amount Δ and the corresponding substrate glass output weight &. X is related to the time h of the substrate glass sheet lagging behind the raw material and the melting temperature t. Through experiments, a lookup table of X for a fixed formula of raw material within a melting temperature of 1400-1700℃ and a lag time of 5-20min is obtained.

[0014] Furthermore, using the output coefficient X, the relationship between the current substrate glass sheet output weight per minute, t, and the raw material feed rate Δ(th) before the lag time is established: t = Δ( t-h )*X, and the current raw material feeding amount Δt and the weight of the substrate glass sheet after the lag time &( t+h The relationship between &( t+h )=Δt*X, which enables the prediction of the weight of the substrate glass sheet produced based on the current raw material feed rate.

[0015] Furthermore, using the proportional, integral, and derivative controllers within the DCS system, the set value for the weight of the substrate glass wafer produced per minute is input to the SP terminal of the controller, denoted as SP. t The weight of the substrate glass sheet produced per minute after the predicted lag time &( t+h ) is used as the process value feedback terminal PV, denoted as PV. t =&( t+h The controller output terminal OP is connected to the feeder frequency converter to control the feeder speed and feed rate.

[0016] Furthermore, by controlling the variable frequency motor of the feeding machine in real time, a stable amount of raw material Δ is achieved per minute. The control program calculates the predicted weight & of the substrate glass sheet produced per minute in real time and feeds it back to the controller to stabilize the current and subsequent predicted weight & of the sheet produced.

[0017] Furthermore, the host computer control screen includes SP input boxes, lag time h input boxes, discharge coefficient X input boxes, controller proportional P, integral I, derivative D input boxes, PV display value, and a control mode selection box. Users can select AUTO automatic mode or MAN manual mode. The input box parameters can be modified according to the control effect and actual situation, and the control program will adjust the calculation based on the new parameters.

[0018] The beneficial effects of this invention are:

[0019] 1. Utilize the programmable configuration capability of the DCS system to accurately process the lag data of raw material feeding and weighing and substrate glass sheet weighing, and establish a predictive model in combination with the output coefficient to achieve dynamic matching between the feeding amount control and the output weight of the substrate glass sheet, thus solving the problem of lag in traditional manual adjustment.

[0020] 2. Real-time data acquisition by sensors and linkage with PID control algorithm automatically compensate for fluctuations in feed rate caused by factors such as raw material humidity and temperature. Compared with manual control, the stability of feed rate is greatly improved, and the deviation rate of the weight of the substrate glass sheet is reduced.

[0021] 3. It integrates remote automatic control functions, allowing operators to monitor and adjust parameters in real time via a host computer, reducing the frequency of on-site intervention and lowering labor costs while achieving digital and intelligent management of the production process, significantly improving the continuity and consistency of substrate glass production. Attached Figure Description

[0022] Figure 1 This is a structural block diagram of the feeding system of the present invention;

[0023] Figure 2 This is a schematic diagram of the feeding machine in this invention;

[0024] Figure 3This is a schematic diagram of the substrate glass sheet weighing module in this invention;

[0025] Figure 4 This is a schematic diagram of data relationships in this invention;

[0026] Figure 5 This is a schematic diagram of the X lookup table data in this invention.

[0027] In the diagram: 1. Hopper; 2. Feeding channel; 3. Variable frequency motor; 4. Raw material feeding weighing sensor; 5. Feeding channel gate; 6. Screw feed shaft; 7. Feeding machine body; 8. Substrate glass sheet weighing sensor; 9. Substrate glass sheet; 10. Substrate glass transfer trolley; 11. Gripper. Detailed Implementation

[0028] Reference Figure 1-5 This invention proposes a substrate glass production feeding system, mainly composed of a hopper 1, a feeding channel 2, a variable frequency motor 3, a raw material feeding weighing sensor 4, a feeding channel gate 5, a spiral feeding shaft 6, a feeding machine body 7, a substrate glass sheet weighing sensor 8, a substrate glass transfer trolley 10, and grippers 11. The hopper 1 is used to temporarily store raw materials to be fed; the feeding channel 2 is the channel for conveying raw materials from the hopper 1 to the melting furnace; the variable frequency motor 3 provides power for the rotation of the spiral feeding shaft 6, and the speed can be adjusted by changing the motor frequency, thereby controlling the feeding amount; the raw material feeding weighing sensor 4 is installed at the bottom of the hopper 1 and above the spiral feeding inlet to collect raw material feeding weight data in real time; the feeding channel gate 5 can control the opening and closing of the feeding channel, facilitating equipment maintenance or handling of abnormal situations; the spiral feeding shaft 6 pushes the raw materials in the hopper to subsequent equipment such as the melting furnace by rotation; the feeding machine body 7 provides the mounting support structure for each component;

[0029] The raw material feeding weighing sensor 4 accurately collects the weight signal during the raw material feeding process, converting the physical quantity (raw material weight) into an electrical signal or other signal form that can be recognized by the DCS system, providing basic data for subsequent raw material feeding quantity calculation and control;

[0030] Place the substrate glass sheet weighing sensor 8 stably under the corresponding position on the running track of the substrate glass transfer trolley 10. Assemble the grippers 11 on the substrate glass transfer trolley 10 to ensure that the substrate glass sheet 9 is firmly fixed by the grippers 11, and that the transfer trolley 10, together with the substrate glass sheet weighing sensor 8, can stably act on the substrate glass sheet weighing sensor 8. Connect the signal output terminal of the substrate glass sheet weighing sensor 8 to the DCS system signal acquisition module to realize the acquisition of the substrate glass sheet weight signal.

[0031] The DCS system possesses powerful integrated functions, compatible with both processor and controller functionalities. On one hand, it realizes data calculation, storage, control, and output, and can perform data read, write, and retrieval operations based on preset counting methods (such as counting raw material feeding quantity and substrate glass sheet output quantity in minutes) and calculation rules (such as calculating the feeding quantity based on the difference in weighing values ​​of raw materials at different times). On the other hand, it builds a host computer control screen, providing operators with an interactive interface for parameter setting, operation status monitoring, control mode switching, and other operations, serving as the "brain" of the entire feeding system's intelligent control.

[0032] The operating procedure for the feeding system includes the following:

[0033] 1. Parameter Input: On the DCS system's host computer control screen, input relevant parameters based on production requirements and previous experimental / experience data. For example, input the set value SP for the weight of substrate glass sheets produced per minute. Combined with raw material characteristics and production process requirements, fill in the lag time t (e.g., based on historical production data, determine the lag time of the impact of raw material feeding on the weight of substrate glass sheets produced, assumed to be 10 minutes), and the output coefficient X (the ratio of raw material feeding amount to substrate glass sheet weight obtained through experiments; different melting temperatures and raw material formulations correspond to different values. If the melting temperature is 1500℃ and a specific raw material formulation is used, X is determined to be a constant through experiments, as shown in the attached figure). Figure 5 As shown), and the initial values ​​of the controller's proportional P, integral I, and derivative D (e.g., proportional P is set to 2, integral I to 0.5, and derivative D to 0.1, which can be adjusted later according to the control effect);

[0034] 2. Control mode selection: In the initial stage of production, the MAN manual mode can be selected first, which is convenient for operators to manually intervene and debug; after the system is running stably, it can be switched to the AUTO automatic mode to achieve automatic control.

[0035] 3. Raw material feeding start-up: In MAN manual mode, the operator starts the feeder variable frequency motor and sets the initial speed through the upper computer control screen or the on-site operation unit. The screw feed shaft rotates, and the raw material is transported from the hopper to the melting furnace through the feeding channel and the screw feed shaft. After switching to AUTO automatic mode, the DCS system automatically adjusts the speed of the variable frequency motor according to the control logic to control the raw material feeding.

[0036] 4. Real-time data acquisition: The raw material feeding weighing sensor (M) continuously acquires the raw material feeding weight signal and records the raw material feeding weight value M at different times, in minutes. t (t represents the current time), M (t-1) Data such as (t-1) representing the previous moment are transmitted to the DCS system; the substrate glass sheet weighing sensor (G) synchronously collects the weight signal of the substrate glass sheet and obtains the weight value G of each sheet. tThe system calculates the number of films produced per minute (N) and transmits the data to the DCS system.

[0037] 5. Data Calculation: The DCS system processes data according to preset rules and calculates the raw material feeding rate Δ per minute. t Through the formula Δt=M t -M (t-1) The difference between the current and previous time step is obtained, i.e., the current minute's raw material feed rate; the weight of the substrate glass sheet produced per minute, &t, is calculated using &t = G( t-1 )+……+G( t-N (Add up the weights of the previous N substrate glass sheets) to get the weight of the substrate glass sheet produced in the current minute;

[0038] 6. Discharge weight prediction: Call the stored discharge coefficient X, combined with the formula &( t+h )=Δ t *X (h is the lag time, such as 10 minutes), based on the current raw material feed rate Δt, predict the weight of substrate glass sheets produced per minute after a lag of h minutes &( t+h The predicted value is then used as the process value feedback terminal PV (i.e., PVt = & (t+h) );

[0039] 7. Control Output: The proportional, integral, and derivative regulators within the DCS system receive the set value SP for the weight of the substrate glass wafers produced per minute. t and predicted feedback value PV t After calculation, a control signal OP is generated, which is transmitted to the frequency converter of the feeding machine to adjust the frequency of the frequency converter motor, thereby changing the speed of the screw feed shaft and realizing the adjustment of the feeding amount of the feeding machine, so that the weight of the substrate glass sheet output is as close as possible to the set value SP, ensuring stable production.

[0040] 8. Operation Monitoring: The system's operating status is monitored in real time on the DCS system's host computer control screen, including real-time data on raw material feeding quantity, substrate glass sheet output weight, feeder motor speed, and the signal status of each sensor. Simultaneously, the system has an anomaly detection function. If the signals from the raw material feeding weighing sensor or the substrate glass sheet weighing sensor are interrupted, fluctuate beyond the normal range, or the substrate glass sheet output weight deviates significantly from the set value (e.g., exceeding ±10% of the set value), the system automatically triggers an alarm, alerting the operator to the type of anomaly (e.g., signal loss alarm, weight deviation exceeding limit alarm) and its approximate location.

[0041] 9. Optimization and Adjustment: In MAN manual mode, operators can manually adjust the frequency and control parameters of the feeder inverter based on alarm information and monitoring data. After switching to AUTO automatic mode, if the characteristics of the raw materials (such as fluctuations in the raw material feed rate due to humidity changes) or the production environment (such as slight fluctuations in the melting furnace temperature) change during production, parameters such as SP, lag time h, discharge coefficient X, and controller P, I, and D can be modified in the control screen. The DCS system recalculates and adjusts the control strategy based on the new parameters, optimizes the feeding control effect, ensures stable output weight of the substrate glass sheet, and adapts to production changes.

[0042] Through the above usage process, the substrate glass production feeding system can realize the entire process of operation from raw material feeding and data acquisition and processing to automatic control and adjustment and operation optimization, effectively solving problems such as fluctuations in raw material feeding and lag in the weight of substrate glass sheets, and helping to stabilize the production of substrate glass.

[0043] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A substrate glass production feeding system, characterized in that, include: The feeding machine includes a hopper, a feeding channel, a variable frequency motor, a raw material feeding weighing sensor, a feeding channel gate, a screw feed shaft, and the feeding machine body. The raw material feeding weighing sensor is used to collect the raw material feeding weight signal. The substrate glass sheet weighing module is used to collect the weight signal of the substrate glass sheet; The DCS system is compatible with processor and controller functions, realizing data processing, storage, control and output, covering counting methods, execution of calculation rules, and read and write calls, and also has a host computer control screen.

2. The substrate glass production feeding system according to claim 1, characterized in that, The raw material feeding weighing sensor is located at the bottom of the raw material silo and above the screw feed inlet of the feeder. Its center is a longitudinal hole. The feeding channel connects the bottom of the silo and the screw feed inlet of the feeder through the central hole. The feeding channel gate is located inside the feeding channel. The screw feed shaft is driven by a variable frequency motor and is installed on the feeder body.

3. The substrate glass production feeding system according to claim 1, characterized in that, The substrate glass sheet weighing module includes a substrate glass sheet weighing sensor, a substrate glass transfer trolley, and grippers. The substrate glass sheet weighing sensor is located below the substrate glass transfer trolley, and the grippers above the transfer trolley fix the substrate glass sheet, working together with the transfer trolley on the substrate glass sheet weighing sensor.

4. A control method for the substrate glass production feeding system according to any one of claims 1-3, characterized in that, Includes the following steps: The weighing signals from the raw material feeding weighing sensor and the substrate glass sheet weighing sensor are collected, converted into standard signals, and sent to the input terminal of the DCS system. Define the raw material weighing value M as a unit of time (in minutes), with the current value in minutes denoted as M( t The value of the previous minute is denoted as M. t-1 The current raw material feed rate Δ( t ) = M( t )-M( t-1 ); Define the weight value G of the substrate glass sheet as the weight value of each sheet, and record the current weight value of the sheet as G( t The number of prints produced per minute is denoted as N, and the weight of the first N original prints is denoted as G. t-N ), the weight of substrate glass sheets produced per minute &t=G( t-1 )+……+G( t-N ); The feed coefficient X = & / Δ is determined to be the feed amount Δ and the corresponding substrate glass output weight &. X is related to the time h of the substrate glass sheet lagging behind the raw material and the melting temperature t. Through experiments, a lookup table of X for a fixed formula of raw material within a melting temperature of 1400-1700℃ and a lag time of 5-20min is obtained.

5. The control method according to claim 4, characterized in that, Using the output coefficient X, establish the relationship between the current substrate glass wafer output weight per minute (t) and the raw material feed rate Δ before the lag time. ( The relationship between th and t: &t = Δ (t-h) *X, and the current raw material feed rate Δ ( t) and the weight of the substrate glass sheet after lag time & (t+h) Relationship: & (t+h) =Δ (t) *X enables the prediction of the weight of the substrate glass sheet to be produced based on the current raw material feed rate.

6. The control method according to claim 5, characterized in that, Using the proportional, integral, and derivative controllers within the DCS system, the set value for the weight of substrate glass wafers produced per minute is input to the SP terminal of the controller, and recorded as SP. t The weight of the substrate glass sheet produced per minute after the predicted lag time is... (t+h) As the process value feedback terminal PV, denoted as PV t =&( t+h) The controller output terminal OP is connected to the feeder frequency converter to control the feeder speed and feed rate.

7. The control method according to claim 6, characterized in that, By controlling the variable frequency motor of the feeder in real time, a stable amount of raw material Δ is achieved per minute. The control program calculates the predicted weight of the substrate glass sheet produced per minute in real time and feeds it back to the controller to stabilize the current and subsequent predicted weight of the sheet produced.

8. The control method according to claim 6, characterized in that, The host computer control screen includes SP input boxes, lag time h input boxes, discharge coefficient X input boxes, controller proportional P, integral I, derivative D input boxes, PV display value, and control mode selection boxes. Users can select AUTO automatic mode or MAN manual mode. The input box parameters can be modified according to the control effect and actual situation, and the control program will adjust the calculation based on the new parameters.

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