Material hill eliminating device and method based on active heating

Abstract

The invention relates to the technical field of glass manufacturing, in particular to a material hill eliminating device based on active heating, which is characterized by comprising a kiln, the bottom of the front wall of the kiln is alternately provided with a plurality of groups of mounting ports and a plurality of feeding ports at intervals along the horizontal direction, and the group number of the mounting ports is one group more than that of the feeding ports; the gas devices are arranged in the mounting ports in a one-to-one correspondence mode and used for jetting heating flames into the kiln; the dust receiving brick is made of a high-temperature-resistant material, is arranged below the mounting opening in the bottommost end, and is used for receiving and collecting volatile matters or drippings from the gas device above and the mounting opening; the monitoring system is used for collecting the form and temperature information of the material mountain in the kiln in real time; the fuel gas executing mechanism is connected with the fuel gas device and used for adjusting working parameters of the fuel gas device; and the control system is in signal connection with the monitoring system and the fuel gas executing mechanism and is used for generating a control instruction according to the information collected by the monitoring system and driving the corresponding fuel gas device to act through the fuel gas executing mechanism.

Description

Technical Field

[0001] This invention relates to the field of glass manufacturing technology, and in particular to a device and method for eliminating slag based on active heating. Background Technology

[0002] In the production process of substrate glass, the furnace is the core equipment, which is used to melt the batch material into qualified glass liquid. The batch material is fed into the front area of ​​the furnace through the feeding machine. Because the temperature in this area is relatively low, it will accumulate to form a "material mountain". Ideally, the material mountain should be symmetrically distributed in a figure-eight shape. However, due to factors such as the uniformity of feeding and temperature distribution, the material mountain often has problems such as different sizes, positional deviations, and abnormal shapes.

[0003] An unstable flow of molten glass can disrupt the thermal convection and mass transfer of the glass in the furnace, causing unmelted particles, bubbles, and other defects to flow into subsequent processes. Ultimately, these defects, such as bubbles and stones, will form on the finished glass substrate, severely reducing the product yield. At the same time, abnormal flow of molten glass can also cause temperature fluctuations in the furnace, increasing energy consumption and production costs.

[0004] Currently, traditional methods mainly involve manual intervention (such as manual handling after shutdown) or indirect adjustment of feeding parameters and combustion regime; the former is inefficient and leads to production stoppage, while the latter is slow and inaccurate; therefore, there is an urgent need in this field for a technical solution that can eliminate material pile anomalies online, accurately and efficiently. Summary of the Invention

[0005] To address the technical problems existing in the background art, the present invention proposes a material pile elimination device and method based on active heating.

[0006] To achieve the above objectives, the present invention provides the following technical solution: A material pile elimination device based on active heating, characterized in that it comprises: The kiln has multiple sets of installation ports and multiple feeding ports alternately spaced along the horizontal direction at the bottom of its front wall, wherein the number of sets of installation ports is one more than the number of feeding ports; Multiple gas-fired devices are installed one-to-one in the installation port to inject heating flames into the kiln; Dust-collecting bricks, made of high-temperature resistant materials, are placed below the bottommost installation port to collect and collect volatiles or drips from the gas device and installation port above. The monitoring system is used to collect real-time information on the shape and temperature of the material pile inside the kiln; A gas actuator, connected to a gas appliance, is used to adjust its operating parameters; The control system is connected to the monitoring system and the gas actuator respectively. It is used to generate control commands based on the information collected by the monitoring system and drive the corresponding gas device to perform active heating correction of the material pile via the gas actuator.

[0007] Furthermore, the mounting opening is an flared structure with a diameter that gradually increases from the outer wall of the front wall of the kiln towards the inner wall.

[0008] Furthermore, the axial length of the gas device is less than the thickness of the front wall of the kiln, and its nozzle end face has a gap with the inner wall surface of the front wall of the kiln.

[0009] Furthermore, the width of the dust-collecting brick is greater than the maximum diameter of the installation opening it covers.

[0010] Furthermore, the monitoring system includes an industrial camera for acquiring visual images of the material pile and a temperature sensor for detecting the temperature in the front area of ​​the kiln; the industrial camera is configured to acquire panoramic and close-up images of the material pile at a preset frequency through an observation window on the front wall of the kiln.

[0011] Furthermore, the control system is configured to perform the following operations: Based on the image and temperature data collected by the monitoring system, a two-dimensional or three-dimensional contour model of the material mountain is established. The contour model is compared with the preset standard material mountain model in real time to identify abnormal areas and abnormal types of the material mountain. Based on the anomaly type, a control command is generated that includes the identifier of the target gas device, the target intake volume, and the duration of action.

[0012] Furthermore, the control system is further configured to: When an abnormal increase in the volume of the material pile is detected, a first-type instruction is generated to increase the gas intake of the corresponding area's gas device. When a shift in the location of the material pile is detected, a set of second-class instructions is generated to adjust the intake volume of the gas devices at different locations to form a directional hot airflow to drive the material pile.

[0013] The present invention also discloses a method for eliminating material piles using a material pile elimination device, comprising the following steps: Real-time acquisition steps: Collect morphological and temperature distribution data of the material pile through the monitoring system; Analysis and judgment steps: Compare the collected real-time data with preset standard parameters to determine whether there is any abnormality in the material mountain and determine the control strategy; Active heating step: Based on the control strategy, the control system sends a command to the gas actuator to precisely adjust the gas intake of the target gas device so as to use the flame generated by it to perform targeted heating correction on the abnormal material mountain area; Recovery shutdown procedure: Continuously monitor the status of the gas storage facility. Once it returns to normal, reduce the gas intake of the target gas device to a preset safety value and then shut it off.

[0014] Furthermore, in the active heating step, a phased control strategy is adopted: firstly, the abnormal material is preliminarily heated and softened with a first air intake, and then concentrated melting correction is performed with a second air intake higher than the first air intake.

[0015] Compared with the prior art, the beneficial effects of the present invention are: Compared with existing technologies, this invention achieves technological breakthroughs in "online operation, precision, and high efficiency," while also offering multiple benefits such as cost reduction, energy saving, equipment protection, and enhanced safety. It allows for online material pile correction without downtime, avoiding production interruptions and capacity losses caused by traditional manual intervention, effectively improving production efficiency. The monitoring system collects data in real time, and the control system can quickly generate control commands to rapidly correct material pile anomalies, with response and processing efficiency far exceeding traditional indirect control methods. Based on dual-dimensional data of "morphology + temperature" and categorized control commands, the heating control achieves high precision, significantly reducing defects such as stones and bubbles in the glass substrate. This technology effectively improves product yield and completely solves the core problems of existing technologies, such as the need for downtime, slow response, and low precision. Precise heating avoids overall temperature fluctuations within the furnace, reducing unnecessary energy consumption. At the same time, optimized structure reduces the replacement frequency of components such as dust collection bricks and gas devices, thus reducing equipment maintenance costs. Optimized design of gas device spacing and wide dust collection bricks reduces wear on the furnace walls and gas devices, effectively extending the service life of the refractory materials on the kiln front wall and the gas devices. The entire process is automated, requiring no manual intervention, which reduces the labor intensity of operators and avoids the safety risks associated with high-temperature operation. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the material pile elimination device based on active heating proposed in this invention; Figure 2 This is an internal side view of the material pile elimination device based on active heating proposed in this invention; Figure 3 This is a schematic diagram of the internal structure of the material removal device based on active heating proposed in this invention.

[0017] In the diagram: 1-kiln, 11-installation port, 2-feeding port, 3-gas device, 4-dust collection brick. Detailed Implementation

[0018] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0019] like Figures 1-3 As shown, this embodiment provides a material pile elimination device based on active heating, characterized in that it includes: The kiln 1 has multiple sets of installation ports 11 and multiple feeding ports 2 alternately arranged along the horizontal direction at the bottom of its front wall. The number of sets of installation ports 11 is one more than the number of feeding ports 2. Multiple gas devices 3 are installed one-to-one in the installation port 11 for injecting heating flames into the kiln 1; The dust collection brick 4, made of high-temperature resistant material, is located below the bottom mounting port 11 and is used to receive and collect volatiles or drips from the gas device 3 above and the mounting port 11. The monitoring system is used to collect real-time information on the shape and temperature of the material pile inside kiln 1; A gas actuator, connected to the gas device 3, is used to adjust its operating parameters; The control system is connected to the monitoring system and the gas actuator respectively. It is used to generate control commands based on the information collected by the monitoring system and drive the corresponding gas device 3 to perform active heating correction of the material pile via the gas actuator.

[0020] Overall, the kiln 1 serves as the core carrier for melting the batch materials. At the bottom of its front wall, multiple sets of installation ports 11 and multiple feeding ports 2 are alternately arranged in the horizontal direction. The number of sets of installation ports 11 is one more than the number of feeding ports 2 (for example, 2 feeding ports 2 correspond to 3 sets of installation ports 11), ensuring that each feeding port 2 is covered by installation ports 11 on both sides, with no heating blind spots.

[0021] The gas device 3 uses a high-temperature resistant natural gas burner, which is assembled one-to-one with the installation port 11. Its core function is to inject directional heating flames into the kiln 1 and adjust the heating correction of the material pile in a specific area by adjusting the flame intensity.

[0022] The dust collection brick 4 is made of corundum mullite high-temperature resistant material (temperature resistance ≥1600℃) and is fixed below the bottom mounting port 11. It is used to collect volatiles (such as metal oxides) and drips of compound material generated when the gas device 3 above is working, so as to prevent impurities from contaminating the glass liquid or clogging the mounting port 11.

[0023] The monitoring system performs the "sensing" function, collecting real-time data on the shape and temperature of the material pile inside kiln 1, providing a basis for subsequent control.

[0024] Gas actuator: It adopts an electromagnetic proportional regulating valve, which is independently connected to each gas device 3. It can accurately adjust the gas intake of the gas device 3 according to the control command (the adjustment range is 0-50m³ / h), thereby controlling the flame intensity.

[0025] Control system: A PLC industrial controller is used to establish signal connections (such as RS485 communication) with the monitoring system and gas actuators respectively. The monitoring data is analyzed through preset algorithms to generate precise control commands, drive the gas actuators to act, and form a closed-loop control.

[0026] The present invention also discloses a method for eliminating material piles using a material pile elimination device, comprising the following steps: Real-time acquisition steps: Collect morphological and temperature distribution data of the material pile through the monitoring system; Analysis and judgment steps: Compare the collected real-time data with preset standard parameters to determine whether there is any abnormality in the material mountain and determine the control strategy; Active heating step: Based on the control strategy, the control system sends a command to the gas actuator to precisely adjust the gas intake of the target gas device 3 so as to use the flame it generates to perform targeted heating correction on the abnormal material mountain area; Resumption of shutdown procedure: Continuously monitor the status of the gas storage facility. Once it returns to normal, reduce the gas intake of the target gas device 3 to a preset safety value and then shut it off.

[0027] Based on the active heating method for eliminating material piles, the above-mentioned device is used to correct material pile anomalies, specifically including the following steps: Real-time acquisition steps: Start the monitoring system, the industrial camera collects panoramic and close-up images of the material pile at a preset frequency (1-5 times / second), the temperature sensor collects temperature distribution data of the front area of ​​kiln 1 simultaneously, and all data are transmitted to the control system in real time; Analysis and judgment steps: The control system compares the collected real-time data with the preset standard material pile model (such as a symmetrical "eight" shape, a height of 50-80mm, and a temperature of 1200-1300℃) to determine whether there are problems such as abnormal volume or positional displacement of the material pile, and determines the corresponding control strategy (such as local heating or directional airflow). Active heating step: The control system sends instructions to the target gas actuator according to the control strategy, precisely adjusts the gas intake of the corresponding gas device 3, and uses flames to target the abnormal material pile area (such as strengthening the flame in the area with increased volume, and adjusting the flames on both sides of the offset area to form airflow). Recovery shutdown procedure: The monitoring system continuously tracks the status of the material pile. Once its shape and temperature return to the standard range, the control system reduces the gas intake of the target gas device 3 to a preset safety value (e.g., 5 m³ / h, maintaining a weak flame to prevent blockage after cooling). After maintaining this for 3-5 minutes, the gas device 3 is shut off to complete the correction.

[0028] like Figures 2-3 As shown, in this embodiment, the mounting opening 11 is an flared structure with a diameter that gradually increases from the outer wall of the front wall of the kiln 1 to the inner wall.

[0029] Specifically, the mounting opening 11 on the front wall of the kiln 1 is designed as a "flared structure": the diameter of the mounting opening 11 gradually increases from the outer wall to the inner wall of the front wall of the kiln 1, for example, the diameter at the outer wall end is 80mm, the diameter at the inner wall end is 120mm, and the flaring angle is 15°-20°.

[0030] The flared structure reduces airflow resistance when the gas device 3 injects flame, increasing the flame diffusion range in the furnace by 15%-20% and avoiding localized heating blind spots. During installation, it facilitates the positioning and fixing of the gas device 3, while reserving sufficient space for flame direction adjustment, improving the coverage of irregular material piles. The larger diameter of the inner wall reduces the probability of high-temperature molten glass splashing onto the inner wall of the mounting port 11, reducing the risk of blockage of the mounting port 11.

[0031] like Figures 2-3 As shown, in this embodiment, the axial length of the gas device 3 is less than the thickness of the front wall of the kiln 1, and its nozzle end face has a gap with the inner wall surface of the front wall of the kiln 1.

[0032] Specifically, the axial length and nozzle position of the gas device 3 are limited: the axial length of the gas device 3 is 5-10mm smaller than the thickness of the front wall of the kiln 1 (e.g., when the thickness of the front wall is 300mm, the length of the gas device 3 is 280mm), and the nozzle end face maintains a distance of 15-18mm from the inner wall surface of the front wall of the kiln 1.

[0033] The gas device 3 does not penetrate the front wall, avoiding direct conduction of high temperature inside the furnace to the gas pipe and valve at the tail of the device, thus extending the service life of the gas device 3; the distance between the nozzle and the inner wall can prevent the molten batch material inside the furnace from directly adhering to the nozzle, avoiding abnormal flame caused by nozzle blockage, and ensuring heating stability; the spacing design creates a "buffer zone" when the flame is sprayed, reducing the direct impact of the flame on the inner wall of the furnace and reducing the wear of the refractory material of the furnace wall.

[0034] like Figure 3 As shown, in this embodiment, the width of the dust-collecting brick 4 is greater than the maximum diameter of the installation opening 11 it covers.

[0035] Specifically, the dimensions of the dust collection brick 4 are optimized: the width of the dust collection brick 4 is greater than the maximum diameter of the installation opening 11 it covers. For example, when the maximum diameter of the inner wall end of the installation opening 11 is 120mm, the width of the dust collection brick 4 is set to 180mm, and the length of the dust collection brick 4 covers the total length of all bottom installation openings 11.

[0036] The wide design can 100% collect the volatiles and drips generated by the upper installation port 11 and the gas device 3, preventing impurities from leaking into the molten glass inside the furnace from the edge of the dust collection brick 4, thus reducing stone defects; there is no need to set up a separate dust collection brick 4 for each installation port 11, simplifying the installation structure and reducing maintenance costs; the dust collection brick 4 has a wide coverage area, which can reduce the frequency of cleaning ash accumulation at the bottom of the furnace.

[0037] like Figure 1 As shown, in this embodiment, the monitoring system includes an industrial camera for acquiring visual images of the material pile and a temperature sensor for detecting the temperature of the front area of ​​the kiln 1; the industrial camera is configured to acquire panoramic and close-up images of the material pile at a preset frequency through an observation window on the front wall of the kiln 1.

[0038] Specifically, the monitoring system consists of two industrial CCD cameras (one for panoramic acquisition and one for close-up acquisition) and four thermocouple temperature sensors (evenly distributed on both sides and in the middle of the front area of ​​kiln 1). The industrial cameras acquire images through the pre-set high-temperature resistant quartz observation window on the front wall of kiln 1, while the close-up cameras can focus on the top and edge of the material pile (resolution ≥1920×1080). The temperature sensors have an acquisition range of 1000-1500℃.

[0039] The combination of panoramic and close-up cameras can simultaneously capture the overall shape and local details of the quarry, avoiding the omission of minor anomalies (such as local protrusions) due to a single perspective, thus improving the accuracy of anomaly identification; multi-point temperature sensors can accurately locate the low-temperature areas (unmelted areas) of the quarry, providing the control system with dual-dimensional data of "shape + temperature", avoiding insufficient or excessive heating caused by adjusting only based on shape; the high-temperature resistant quartz observation window can withstand temperatures above 1600℃, eliminating the need for frequent replacement and ensuring the long-term stable operation of the monitoring system.

[0040] like Figures 2-3 As shown, in this embodiment, the control system is configured to perform the following operations: Based on the image and temperature data collected by the monitoring system, a two-dimensional or three-dimensional contour model of the material mountain is established. The contour model is compared with the preset standard material mountain model in real time to identify abnormal areas and abnormal types of the material mountain. Based on the anomaly type, a control command is generated that includes the identifier of the target gas device 3, the target air intake volume, and the duration of action.

[0041] When generating control commands, the control system is further configured to: When an abnormal increase in the volume of the material pile is detected, a first type of instruction is generated to increase the air intake of the corresponding area's gas device 3. When a shift in the location of the material pile is detected, a set of second-class instructions is generated to adjust the intake volume of the gas device 3 at different locations to form a directional hot airflow to drive the material pile.

[0042] Specifically, the core algorithms and functions of the optimized control system are as follows: The control system has a built-in 2D / 3D contour modeling module for the material pile, which can generate a real-time contour of the material pile based on camera images; at the same time, it presets three types of anomaly judgment logic: "volume anomaly", "positional offset", and "shape irregularity", and generates corresponding control commands. When the volume of the material pile exceeds the standard value by 20% (abnormal volume increase), a "Type I instruction" is generated: increase the air intake of the gas device 3 corresponding to the abnormal area (e.g., from 20m³ / h to 40m³ / h), with an action time of 5-8 minutes; when the center of the material pile deviates from the standard position by more than 100mm (position deviation), a "Type II instruction" is generated: increase the air intake of the gas device 3 on the opposite side of the deviation direction (e.g., increase the air intake of the right device if the material pile is to the left), while reducing the air intake of the device on the deviation side, forming a directional hot airflow to push the material pile back to its original position.

[0043] The contour modeling module can quantify the degree of anomalies in the material pile (such as volume increase and offset distance), avoiding errors in human judgment and improving control accuracy; the classification control command can accurately implement measures for different anomaly types, avoiding "one-size-fits-all" heating and reducing energy consumption; the command includes clear gas device identification, air intake and action time, requiring no manual intervention, realizing fully automated control and further shortening the response time.

[0044] like Figures 2-3 As shown, in this embodiment, a phased control strategy is adopted in the active heating step: firstly, the abnormal material is preliminarily heated and softened with a first air intake, and then concentrated melting correction is performed with a second air intake that is higher than the first air intake.

[0045] Specifically, a phased control strategy is adopted in the "active heating step": First stage (softening stage): The control system sends a command to the target gas device 3 to heat the material pile with the "first intake air volume" (60% of the standard heating volume, such as 24m³ / h) for 3-5 minutes to soften the surface material of the material pile (the temperature rises to 1250℃). The second stage (melting correction stage): switch to "second air intake" (90% of the standard heating capacity, such as 36m³ / h), concentrate the heating on the abnormal area of ​​the material pile for 2-4 minutes, so that the softened batch material melts quickly and restores the standard shape.

[0046] Staged heating avoids instantaneous high temperatures that can cause air bubbles to form inside the glass mass, reducing glass bubble defects; the logic of softening before melting reduces the risk of glass mass cracking and prevents cracked glass particles from flowing into subsequent processes; compared to continuous high-power heating, staged control can save gas consumption and further reduce production costs.

[0047] Of course, those skilled in the art will recognize that the present invention is not limited to the details of the exemplary embodiments described above, but also includes the same or similar structures that can be implemented in other specific forms without departing from the spirit or essential characteristics of the invention. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0048] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

[0049] The technologies, shapes, and structures not described in detail in this invention are all known technologies.

Claims

1. A material pile elimination device based on active heating, characterized in that, include: The kiln (1) has multiple sets of installation ports (11) and multiple feeding ports (2) alternately spaced along the horizontal direction at the bottom of its front wall. The number of sets of installation ports (11) is one more than the number of feeding ports (2). Multiple gas devices (3) are installed in the installation port (11) one by one to inject heating flames into the kiln (1); The dust collection brick (4), made of high temperature resistant material, is set below the bottom mounting port (11) to receive and collect volatiles or drips from the gas device (3) above and the mounting port (11); The monitoring system is used to collect real-time information on the shape and temperature of the material pile inside the kiln (1); A gas actuator is connected to the gas device (3) and is used to adjust its operating parameters; The control system is connected to the monitoring system and the gas actuator respectively. It is used to generate control commands based on the information collected by the monitoring system and drive the corresponding gas device (3) to perform active heating correction on the material pile.

2. The material pile elimination device based on active heating according to claim 1, characterized in that, The mounting opening (11) is an flared structure with a diameter that gradually increases from the outer wall of the front wall of the kiln (1) towards the inner wall.

3. The material pile elimination device based on active heating according to claim 1, characterized in that, The axial length of the gas device (3) is less than the thickness of the front wall of the kiln (1), and there is a gap between its nozzle end face and the inner wall surface of the front wall of the kiln (1).

4. The material pile elimination device based on active heating according to claim 1, characterized in that, The width of the dust-collecting brick (4) is greater than the maximum diameter of the mounting opening (11) it covers.

5. The material pile elimination device based on active heating according to claim 1, characterized in that, The monitoring system includes an industrial camera for acquiring visual images of the material pile and a temperature sensor for detecting the temperature of the front area of ​​the kiln (1); the industrial camera is configured to acquire panoramic and close-up images of the material pile at a preset frequency through an observation window on the front wall of the kiln (1).

6. The material pile elimination device based on active heating according to claim 1, characterized in that, The control system is configured to perform the following operations: Based on the image and temperature data collected by the monitoring system, a two-dimensional or three-dimensional contour model of the material mountain is established. The contour model is compared with the preset standard material mountain model in real time to identify abnormal areas and abnormal types of the material mountain. Based on the type of anomaly, a control command is generated that includes the identifier of the target gas device (3), the target intake volume, and the duration of action.

7. The material pile elimination device based on active heating according to claim 6, characterized in that, When generating control commands, the control system is further configured to: When an abnormal increase in the volume of the material pile is detected, a first type of instruction is generated to increase the air intake of the corresponding area gas device (3); When a shift in the location of the material pile is detected, a set of second-class instructions is generated to adjust the intake of the gas devices (3) at different locations to form a directional hot airflow to drive the material pile.

8. A method for eliminating material piles based on active heating, applied to the material pile elimination device as described in any one of claims 1-7, comprising the following steps: Real-time acquisition steps: Collect morphological and temperature distribution data of the material pile through the monitoring system; Analysis and judgment steps: Compare the collected real-time data with preset standard parameters to determine whether there is any abnormality in the material mountain and determine the control strategy; Active heating step: Based on the control strategy, the control system sends a command to the gas actuator to precisely adjust the gas intake of the target gas device (3) so as to use the flame generated by it to perform targeted heating correction on the abnormal material mountain area; Resumption of shutdown procedure: Continuously monitor the status of the gas storage facility. After it returns to normal, reduce the gas intake of the target gas device (3) to a preset safety value and then shut it off.

9. The method for eliminating material piles based on active heating according to claim 8, characterized in that, In the active heating step, a phased control strategy is adopted: firstly, the abnormal material is preliminarily heated and softened with a first air intake, and then concentrated melting correction is performed with a second air intake that is higher than the first air intake.

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