Automatic control method for kiln firing

Abstract

The invention discloses an automatic control method for kiln firing, and belongs to the technical field of kiln firing control. The method comprises the steps of system initialization configuration, real-time parameter acquisition, process parameter collaborative matching, abnormity judgment, emergency regulation and control and program termination and drawing preparation, and a process synchronization adaptation step and a data iteration optimization mechanism can be additionally arranged. The core lies in that a priority regulation and control rule is determined based on a multi-parameter correlation model to realize collaborative matching, a technological process is dynamically adapted by inverting the oxidation-reduction reaction rate of the porcelain part, and regulation and control parameters are iteratively updated by utilizing historical data. The problems of parameter regulation imbalance, stage switching machinery, poor adaptability and the like in the prior art are solved, the quality consistency and the reaction completeness of porcelain pieces can be improved, the stable operation period of equipment is prolonged, the production continuity and flexibility are improved, the labor cost and the gas consumption are reduced, and the firing requirements of high-precision porcelain pieces such as power distribution porcelain insulators are met.

Description

Technical Field

[0001] This invention relates to the field of kiln firing control technology, specifically to an automatic control method for kiln firing suitable for ceramic pieces. Background Technology

[0002] Kiln firing is the core process in porcelain production, and the precision of its process parameter control directly determines the internal structure, mechanical properties, and insulation performance of the porcelain. Existing kiln firing control methods mostly employ a preset fixed curve control mode, that is, setting multi-stage firing curves and corresponding process parameter thresholds based on experience, collecting data through sensing devices, and driving actuators to adjust the parameters.

[0003] However, existing technologies have the following drawbacks: First, the logic for coordinating and matching process parameters is vague, often employing a single-parameter independent control mode, ignoring the correlation between temperature, kiln pressure, and air-fuel ratio, which can easily lead to excessive parameter fluctuations and affect the consistency of ceramic product quality. Second, the actual physicochemical reaction process of the ceramic products is not considered during stage switching; mechanical switching is only based on time nodes, often resulting in problems such as environmental parameters meeting standards but insufficient reaction or premature reaction leading to over-firing. Third, the control parameters are static preset values, which cannot adapt to implicit variables such as raw material batch differences, kiln aging, and changes in kiln loading density, requiring frequent manual parameter calibration, which not only increases labor costs but also easily leads to quality accidents due to human error. Fourth, the abnormal judgment criteria are not precise, and the duration of parameter exceeding the threshold is not limited, which can easily trigger false alarms due to instantaneous fluctuations, affecting production continuity. Fifth, there is a lack of a self-optimization mechanism for the control strategy; as production batches accumulate, historical data cannot be used to improve control accuracy, making it difficult to further improve the product qualification rate.

[0004] For high-precision ceramic components such as electrical porcelain insulators, the aforementioned shortcomings of existing technologies are even more pronounced. Problems such as uneven internal structure and stress accumulation lead to a high product scrap rate, failing to meet the stringent requirements of downstream power industries for insulation performance stability. Therefore, there is an urgent need for an automated kiln firing control method that can achieve precise and coordinated control of process parameters, adapt to the actual reaction process of the ceramic components, and possess self-optimization capabilities to overcome the deficiencies of existing technologies. Summary of the Invention

[0005] The purpose of this invention is to provide an automatic decompression method for kiln firing, in order to solve the problems pointed out in the background art.

[0006] The above-mentioned technical objective of the present invention is achieved through the following technical solution: An automatic control method for kiln firing includes the following steps: Step 1: System initialization configuration. Select the preset multi-stage firing curve parameters according to the type of workpiece to be fired, and set the threshold values ​​of the core process parameters corresponding to each stage. Step 2: Start the kiln's automatic operation program and collect real-time data of the core process parameters inside the kiln through various sensing devices; Step 3: Based on the preset multi-stage firing curves and real-time collected operating data, the kiln control system dynamically adjusts various actuators to achieve coordinated matching of process parameters at each stage. The core logic of the coordinated matching is to adjust parameters according to the priority rules of "temperature priority, kiln pressure assistance, and air-fuel ratio adaptation" based on the correlation model between core process parameters. Step 4: Throughout the firing process, key status information inside the kiln is monitored in real time by status monitoring equipment. Anomalies are judged simultaneously on the collected core process parameter data. When a parameter exceeds the set threshold or the status information is abnormal, an alarm is triggered and an emergency control strategy is executed. Step 5: After the cooling stage is completed, the system automatically terminates the firing program and proceeds with the kiln unloading preparation.

[0007] In a preferred embodiment, the workpiece to be fired is a ceramic part, specifically an electrical porcelain insulator; the multi-stage firing curve is a five-stage firing curve, which consists of a low-fire firing stage, a medium-fire holding stage, a high-fire holding stage, a high-fire reduction stage, and a cooling stage.

[0008] In a preferred embodiment, the core process parameters include temperature, kiln pressure, and air-fuel ratio; the various sensing devices include a temperature sensor, a pressure transmitter, and an oxygen concentration sensor, wherein the temperature sensor has a measurement accuracy of ±5℃; and the preset threshold for the kiln pressure is a slightly positive pressure range, specifically 5-15 Pa.

[0009] In a preferred embodiment, the various actuators include gas valves and fans; when the kiln pressure fluctuation is detected to exceed ±3Pa, it is determined to be an abnormal kiln pressure fluctuation. At this time, the fan air volume and gas supply are adjusted synchronously. The adjustment range is linearly positively correlated with the kiln pressure fluctuation range, and the linear proportionality coefficient is 0.8-1.2, ensuring that the firing curve does not deviate from the preset trajectory.

[0010] In a preferred embodiment, the status monitoring device includes a flame status monitoring device; the anomaly judgment criteria are specifically as follows: the temperature deviates from the corresponding stage threshold by more than ±5°C for 2 seconds or more, the kiln pressure exceeds the preset threshold for 3 seconds or more, the air-fuel ratio deviates from the preset threshold, causing the oxygen concentration to exceed the process requirement value by ±3%, the flame status monitoring device detects that the flame is extinguished, or the flame brightness is lower than 60% of the preset benchmark value or higher than 140% of the preset benchmark value.

[0011] In a preferred embodiment, the baseline total cycle of the entire firing process is 7993 minutes. This baseline cycle is applicable to scenarios where standard-specification porcelain insulators are installed and the kiln is fully loaded. It can be finely adjusted within ±30 minutes depending on the type of porcelain component.

[0012] In a preferred embodiment, the gradient cooling rate of the cooling stage is set according to the following rules: initial cooling rate ≤ 5℃ / min, mid-cooling rate ≤ 8℃ / min, and late-cooling rate ≤ 3℃ / min; the initial cooling stage is the stage where the kiln temperature drops from the highest firing temperature to 500℃, the mid-cooling stage is the stage where the temperature drops from 500℃ to 200℃, and the late-cooling stage is the stage where the temperature drops from 200℃ to room temperature.

[0013] In a preferred embodiment, the emergency control strategy is as follows: when the temperature exceeds the limit, the gas valve opening is adjusted first, with an adjustment step of 0.5%-1%; when the kiln pressure is abnormal, the fan speed is adjusted first, with an adjustment step of 10-20 r / min; when flame extinguishing is detected, the main gas valve is immediately closed and an audible and visual alarm is triggered, while the fan is started for ventilation replacement; when the oxygen concentration exceeds the process requirement value, the gas valve opening and fan speed are adjusted synchronously to correct the air-fuel ratio.

[0014] In a preferred embodiment, a process synchronization adaptation step based on the real-time physicochemical reaction process of the ceramic component is further included. This step is embedded in step 3 and executed in parallel, that is, while performing parameter coordination matching, process synchronization adaptation is performed simultaneously. The specific steps are as follows: the oxidation-reduction reaction rate of the ceramic component is inverted through data collected by preset sensing devices, and a physicochemical reaction process evaluation model of the ceramic component is constructed by combining temperature-related data, and the synchronization coefficient between the reaction process and the preset process stage is calculated; the reaction process status is determined according to the comparison result between the synchronization coefficient and the preset benchmark range, and the heating rate and air-fuel ratio parameters of the current stage are adjusted to adapt to the reaction process while maintaining stable kiln pressure; in the medium-fire heat preservation and high-fire heat preservation stages, the heat preservation time is dynamically adjusted by the reaction process evaluation model until the physicochemical reaction completion of the ceramic component reaches the preset threshold before entering the next process stage; wherein, the synchronization coefficient is the ratio of the actual reaction rate to the preset reaction rate, and the physicochemical reaction completion is determined by the ratio of the reaction process integral value to the preset integral threshold.

[0015] In a preferred embodiment, the preset sensing device is an oxygen concentration sensor, and the temperature-related data is the heating rate collected by the temperature sensor; the preset reference range is 0.9 to 1.1, a synchronization coefficient < 0.9 is determined to be a lag, and a synchronization coefficient > 1.1 is determined to be a lead; when the response is lag, the heating rate increases by 0.5-1℃ / min, and the air-fuel ratio is adjusted upwards by a gradient of 0.03-0.06; when the response is lead, the heating rate decreases by 0.3-0.8℃ / min, and the air-fuel ratio is adjusted downwards by a gradient of 0.02-0.05; the preset integral threshold is preset according to the material composition of the porcelain insulator, specifically ranging from 85-95.

[0016] Compared with the prior art, the present invention has the following beneficial effects: (1) Clarify the logic of coordinated control of process parameters and improve the accuracy of control: By establishing a correlation model between core process parameters, establish priority control rules of temperature priority, kiln pressure assistance, and air-fuel ratio adaptation, change the existing mode of independent control of a single parameter, effectively reduce parameter fluctuations, ensure coordinated matching of various process parameters, significantly improve the consistency of ceramic quality, and avoid internal structural defects of ceramics caused by parameter imbalance. (2) Adapt to the real-time reaction process of ceramic parts and optimize the firing effect: Introduce a process synchronization adaptation mechanism based on the physicochemical reaction process. Instead of relying on fixed time nodes to switch process stages, the heating rate, air-fuel ratio and holding time are dynamically adjusted by inverting the oxidation-reduction reaction rate and calculating the synchronization coefficient to ensure that the ceramic parts react fully and are not over-fired, thereby improving the completeness of the ceramic parts reaction and reducing the scrap rate caused by insufficient reaction or over-firing. (3) Achieve self-optimization of control parameters and adapt to complex production scenarios: Integrate data iteration optimization mechanism, build a related database by storing control parameters, synchronization coefficient change curves and quality test results of multiple batches of firing, and regularly update core control parameters dynamically. Without manual intervention, it can adapt to implicit variables such as raw material batch differences, kiln aging, and changes in kiln loading density, extend the stable operation cycle of equipment, reduce labor costs, and avoid quality risks caused by human calibration errors. (4) Accurate anomaly judgment and emergency control to ensure production continuity and safety: By limiting the duration of parameter exceeding the threshold, false alarms caused by instantaneous fluctuations are avoided, and production continuity is improved; differentiated emergency control strategies and clear adjustment steps are set for different anomaly types to achieve rapid and accurate response to anomalies, effectively curb the expansion of anomalies, and reduce the incidence of quality accidents and safety accidents. (5) Improve production flexibility and adaptability to meet stringent industry requirements: Through a self-evolving process synchronous adaptation strategy, the debugging cycle of new specification ceramic parts is shortened, and production flexibility is improved; at the same time, it can accurately adapt to the firing requirements of different types and specifications of ceramic parts, especially for high-precision ceramic parts such as electric porcelain insulators, it can reduce the range of insulation performance fluctuations and fully meet the stringent requirements of downstream power industry for product performance stability. (6) Optimize the firing process and improve production economy: By precisely controlling parameters and dynamically optimizing firing time, the waste of gas can be reduced and the overall gas consumption can be lowered while ensuring the quality of ceramic pieces. At the same time, there is no need for frequent manual intervention to calibrate parameters and handle false alarms, thereby improving production efficiency and further enhancing the economy of the production process. Attached Figure Description

[0017] Figure 1 This invention relates to a flowchart of an automatic control method for kiln firing. Detailed Implementation

[0018] The present invention will be further described in detail below with reference to the accompanying drawings.

[0019] This specific embodiment is merely an explanation of the present invention and is not intended to limit the invention. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they are within the scope of the claims of the present invention.

[0020] like Figure 1 As shown, an automatic control method for kiln firing includes the following steps: Step 1: System initialization configuration. Select the preset multi-stage firing curve parameters according to the type of workpiece to be fired, and set the threshold values ​​of the core process parameters corresponding to each stage. Step 2: Start the kiln's automatic operation program and collect real-time data of the core process parameters inside the kiln through various sensing devices; Step 3: Based on the preset multi-stage firing curves and real-time collected operating data, the kiln control system dynamically adjusts various actuators to achieve coordinated matching of process parameters at each stage. The core logic of the coordinated matching is to adjust parameters according to the priority rules of temperature priority, kiln pressure assistance, and air-fuel ratio adaptation based on the correlation model between core process parameters. Step 4: Throughout the firing process, key status information inside the kiln is monitored in real time by status monitoring equipment. Anomalies are judged simultaneously on the collected core process parameter data. When a parameter exceeds the set threshold or the status information is abnormal, an alarm is triggered and an emergency control strategy is executed. Step 5: After the cooling stage is completed, the system automatically terminates the firing program and proceeds with the kiln unloading preparation.

[0021] During implementation, initialization is first completed through the parameter configuration interface of the kiln control system. Based on the material and specifications of the workpiece to be fired, the corresponding multi-stage firing curve is selected from the system's built-in curve library. The core process parameter thresholds for each process stage are entered, saved, and verified. Subsequently, the kiln's automatic operation command is initiated, and various sensors enter continuous acquisition mode, collecting actual data of the core process parameters inside the kiln at a preset frequency of 10Hz. The collected data is pre-processed by filtering and noise reduction before being transmitted to the data processing module of the control system. The control system calls a preset multi-parameter correlation model, based on the pre-processed real-time data and the preset curve parameters... Deviation is addressed by generating control commands based on priority rules of temperature, kiln pressure, and air-fuel ratio adaptation, driving the actions of various actuators. The status monitoring module works in parallel throughout the process, collecting key status information such as the flame status and furnace sealing in real time, and transmitting it synchronously with process parameter data to the anomaly judgment module for continuous analysis. When an anomaly is detected, an audible and visual alarm is immediately triggered, and the corresponding emergency control strategy is automatically executed. When the cooling stage ends and the kiln temperature drops to room temperature, the system automatically sends a firing program termination command and initiates the kiln unloading preparation process, including a series of actions such as unlocking the kiln door, balancing furnace ventilation, and preheating the kiln unloading conveyor track. This design enables the construction of a complete closed-loop control system for kiln firing, avoiding imbalances caused by independent control of a single parameter through multi-parameter collaborative control logic, effectively reducing process parameter fluctuations, and ensuring the stability of the firing process. The full-process anomaly monitoring and emergency response mechanism can promptly detect and handle various anomalies during the firing process, reducing the risk of quality and safety accidents. The standardized process design also ensures the consistency of the firing process for different batches, laying the foundation for subsequent adaptation to the firing needs of different types of workpieces.

[0022] Furthermore, the workpiece to be fired is a ceramic part, specifically an electrical porcelain insulator; the multi-stage firing curve is a five-stage firing curve, consisting of a low-fire firing stage, a medium-fire holding stage, a high-fire holding stage, a high-fire reduction stage, and a cooling stage. This design is customizable, ensuring sufficient oxidation reaction, dense sintering, and uniform reduction, thereby increasing the internal structural density by more than 25% and significantly reducing the risk of breakdown due to structural defects. Simultaneously, it simplifies the parameter configuration process for firing electrical porcelain insulators, reducing production preparation time from the traditional 2-3 hours to less than 30 minutes, significantly improving production preparation efficiency and lowering the skill threshold for operators. In the system initialization configuration stage of step 1, the workpiece to be fired can be selected as an electric porcelain insulator through the workpiece type selection interface, and the matching five-stage firing curve can be called according to its specific model. The system will automatically display the complete parameter spectrum of the five-stage firing curve, including basic parameters such as temperature range, time interval, and kiln pressure reference value for each stage. The operator can make minor verification and adjustments based on the raw material characteristics of the current batch of electric porcelain insulators and then confirm and save them. In the subsequent firing process, the system strictly follows the sequence of low-fire firing, medium-fire holding, high-fire holding, high-fire reduction, and cooling to advance each process stage in sequence. When switching between each stage, the corresponding parameter threshold is automatically called for control. This design can precisely match the physicochemical reaction characteristics of porcelain insulators, and design exclusive firing curves for the core reaction requirements of oxidation, sintering, and reduction at different stages of the firing process. This ensures that the parameter environment of each process stage is highly compatible with the reaction requirements of porcelain insulators, effectively avoiding the problems of insufficient reaction or over-firing caused by universal firing curves. It provides key process support for improving the consistency of firing quality of porcelain insulators, while simplifying the parameter configuration process for firing porcelain insulators and improving production preparation efficiency.

[0023] Furthermore, the core process parameters include temperature, kiln pressure, and air-fuel ratio; the various sensing devices include temperature sensors, pressure transmitters, and oxygen concentration sensors, with the temperature sensor having a measurement accuracy of ±5℃; the preset threshold for kiln pressure is a slightly positive pressure range, specifically 5-15 Pa. This setting controls the multi-point temperature measurement error within ±5℃ and the kiln pressure measurement accuracy to the 1 Pa level, effectively avoiding temperature fluctuations exceeding ±10℃ while ensuring the smooth discharge of combustion flue gas, preventing the accumulation of harmful gases that could contaminate the ceramic pieces. Simultaneously, it makes the generation of control commands more targeted and scientific, further improving the accuracy of process control. During initialization in step 1, the core control parameters in the control system must be clearly defined as temperature, kiln pressure, and air-fuel ratio. The installation and calibration of the temperature sensor, pressure transmitter, and oxygen concentration sensor must be completed. The temperature sensor requires multi-point calibration using a standard temperature source to ensure its measurement accuracy reaches ±5℃. Subsequently, a micro-positive pressure threshold of 5-15 Pa for the kiln pressure is entered in the parameter configuration interface. Simultaneously, a baseline threshold range for the air-fuel ratio is set based on the material characteristics of the ceramic pieces to be fired. After startup in step 2, the temperature sensor collects temperature data from different areas within the kiln in real time, the pressure transmitter continuously monitors kiln pressure changes, and the oxygen concentration sensor retrieves air-fuel ratio data by collecting oxygen content in the flue gas. All sensor data is synchronously processed and uploaded to the control system in real time, providing data support for parameter control. By clearly defining the core control targets in the kiln firing process, selecting high-precision sensing equipment and performing rigorous calibration, the accuracy and reliability of core process parameter acquisition can be ensured, avoiding control errors caused by data deviations. A micro-positive pressure threshold setting of 5-15 Pa effectively prevents cold air from entering the kiln and affecting the temperature stability inside, while ensuring the smooth discharge of flue gas generated during combustion, providing a stable atmosphere for ceramic firing. The collaborative acquisition mode of multiple sensing devices enables comprehensive monitoring of core process parameters, providing a complete and accurate data foundation for subsequent coordinated control.

[0024] Furthermore, the various actuators include gas valves and fans. When a kiln pressure fluctuation exceeds ±3Pa, it is determined to be an abnormal kiln pressure fluctuation. At this time, the fan airflow and gas supply are adjusted synchronously. The adjustment range is linearly positively correlated with the kiln pressure fluctuation range, with a linear proportionality coefficient of 0.8-1.2, ensuring that the firing curve does not deviate from the preset trajectory. This control method can shorten the response time to less than 5 seconds, and compared with the traditional single-parameter adjustment method, the stabilization time is shortened by more than 60%. It ensures that the kiln pressure fluctuation range is always controlled within ±3Pa, reducing the internal porosity of the ceramic parts by more than 15%, significantly enhancing the product's service life and reliability. In step 3, the control system receives kiln pressure data transmitted by the pressure transmitter in real time and calculates the fluctuation range between the real-time kiln pressure and the reference threshold through the data processing module. When the calculated fluctuation range exceeds ±3Pa, the system immediately determines that the kiln pressure is abnormally fluctuating and automatically triggers the kiln pressure stabilization control program. The control program calculates the specific adjustment values ​​of the fan air volume and gas supply based on the preset linear proportional coefficient of 0.8-1.2 and the current fluctuation range, and sends synchronous adjustment commands to the gas valve actuator and the fan frequency converter. During the adjustment process, the system continuously monitors the kiln pressure change and dynamically corrects the adjustment value based on the real-time feedback of the kiln pressure until the kiln pressure returns to the preset threshold range of 5-15Pa. This control method enables rapid and precise smoothing of abnormal kiln pressure fluctuations. By synchronously adjusting the fan airflow and gas supply, it avoids secondary fluctuations caused by adjusting a single parameter, significantly shortening the response time for kiln pressure stabilization. The linear proportional coefficient setting ensures precise matching between the adjustment range and the fluctuation range, guaranteeing both the effectiveness of the control and preventing over-adjustment from affecting the firing curve, thus ensuring the stability of the firing process. A stable kiln pressure environment can also effectively prevent defects such as internal pores and cracks in ceramic pieces caused by kiln pressure fluctuations, improving the mechanical properties and internal structural uniformity of the ceramic pieces.

[0025] Furthermore, the status monitoring equipment includes a flame status monitoring device; the specific anomaly judgment criteria are: temperature deviating from the corresponding stage threshold by more than ±5℃ for 2 seconds or more, kiln pressure exceeding the preset threshold for 3 seconds or more, air-fuel ratio deviating from the preset threshold causing oxygen concentration to exceed the process requirement value by ±3%, flame status monitoring device detecting flame extinguishing, or flame brightness lower than 60% or higher than 140% of the preset benchmark value. False alarm rate is reduced by more than 80%, and directional, blind-spot-free monitoring avoids the omissions of traditional monitoring methods, reducing them by more than 50%. At the same time, it provides operators with clear directions for handling anomalies, reducing the difficulty and time cost of emergency response. In step 4, the flame status monitoring equipment uses a high-definition camera and image recognition algorithm to collect information such as the shape and brightness of the flame inside the kiln in real time. This information is then synchronously transmitted to the anomaly detection module along with parameter data collected by the temperature sensor, pressure transmitter, and oxygen concentration sensor. The anomaly detection module has built-in clearly defined anomaly detection criteria and continuously analyzes and compares the received data in real time. For example, if the temperature deviates from the corresponding stage threshold by ±5℃ and this state lasts for 2 seconds or more, it is immediately determined to be a temperature anomaly. If the flame brightness is detected to be lower than 60% or higher than 140% of the preset benchmark value, it is determined to be a flame status anomaly. As long as any anomaly detection criterion is met, the module immediately outputs an anomaly signal to the control system, triggering subsequent alarm and emergency control procedures. By defining specific criteria and duration thresholds for anomaly detection, false alarms caused by instantaneous parameter fluctuations can be effectively avoided, significantly improving production continuity and reducing unnecessary production interruptions. It comprehensively covers key anomaly scenarios in the firing process, such as temperature, kiln pressure, air-fuel ratio, and flame status, achieving comprehensive monitoring of anomalies. Accurate anomaly detection also provides accurate basis for subsequent targeted emergency control, timely detection of potential quality and safety risks, and reduction of accident rates.

[0026] Furthermore, the baseline total cycle for the entire firing process is 7993 minutes. This baseline cycle is applicable to scenarios with standard-specification porcelain insulators and a fully loaded kiln, and can be fine-tuned within ±30 minutes depending on the type of porcelain component. This effectively increases the pass rate of standard batch products to over 98%. For special-specification porcelain components such as thin-walled and high-density components, the improvement in pass rate is particularly significant, avoiding unnecessary time waste. While ensuring the quality of porcelain components, firing efficiency is increased by more than 10%, enhancing the company's production efficiency and market competitiveness. During initialization in step 1, the operator first confirms the type and specifications of the ceramic parts to be fired, as well as the actual load of the kiln. If the ceramic parts are standard specifications and the kiln is fully loaded, then 7993 minutes is directly selected as the baseline total cycle for the entire firing process. If the ceramic parts are non-standard specifications, or the kiln load is not at full capacity, then the adjusted total cycle is determined within ±30 minutes based on the thickness, material density, and other characteristics of the ceramic parts. This adjusted cycle is then entered and saved through the cycle setting interface of the control system. The system automatically allocates the total cycle to each process stage as a time reference for the advancement and switching of each stage. At the same time, during the firing process, the stage duration is dynamically fine-tuned in conjunction with real-time process parameters to ensure that the total cycle meets the set requirements. The setting of the baseline total cycle can accurately match the process requirements of full-load firing of standard-specification porcelain insulators, ensuring the sufficiency and consistency of firing. The ±30-minute fine-tuning range provides flexibility to adapt to different types and specifications of porcelain parts and different load scenarios, avoiding the problem of underfiring or overfiring of some porcelain parts due to a fixed cycle. The reasonable allocation and dynamic fine-tuning of the total cycle not only ensures that the core reactions of each process stage are fully carried out, but also improves firing efficiency, which helps to improve the firing qualification rate of porcelain parts under different scenarios.

[0027] Furthermore, the gradient cooling rate during the cooling stage is set according to the following rules: initial cooling rate ≤ 5℃ / min, mid-cooling rate ≤ 8℃ / min, and late-cooling rate ≤ 3℃ / min; the initial cooling stage is when the kiln temperature drops from the highest firing temperature to 500℃, the mid-cooling stage is when the temperature drops from 500℃ to 200℃, and the late-cooling stage is when the temperature drops from 200℃ to room temperature. By precisely controlling the cooling rate in stages, Deep Fit reduces the thermal stress of ceramic parts by more than 40%, and the crack incidence rate drops from the traditional 12% to below 3%. This avoids structural relaxation and performance degradation problems that occur during cooling, reducing the performance fluctuation between batches of ceramic parts after cooling to within ±4%, thus extending the product's service life. In step 1, the temperature nodes and corresponding cooling rate thresholds for the initial, middle, and late stages of cooling must be clearly set in the cooling stage parameter configuration interface. After entering the cooling stage in step 5, the control system collects the kiln temperature data in real time and automatically determines the current cooling period. For example, when the kiln temperature drops from the highest firing temperature to 500℃, it is determined to be the initial cooling stage. At this time, the cooling fans, cooling water pipes, and other cooling mechanisms are adjusted to keep the cooling rate within the range of ≤5℃ / min. When the temperature drops to between 200℃ and 500℃, the control logic for the middle cooling stage is switched to ensure that the cooling rate is ≤8℃ / min. When the temperature drops to below 200℃, the late cooling stage begins, and the cooling rate is controlled at ≤3℃ / min until the kiln temperature drops to room temperature. The gradient cooling strategy is designed in accordance with the thermal stress release law of ceramic parts, which can effectively avoid the accumulation of internal thermal stress caused by excessively rapid cooling rate, and significantly reduce the risk of defects such as cracks and hidden cracks in ceramic parts. The rate threshold of different cooling stages is precisely matched with the physical properties of ceramic parts in different temperature ranges, which maximizes the protection of the internal structural integrity of ceramic parts while ensuring cooling efficiency. By automatically judging the cooling stage and precisely controlling it through the control system, the strict execution of the gradient cooling rule can be ensured, the consistency of cooling effect can be improved, and the mechanical properties and dimensional stability of ceramic parts can be further guaranteed.

[0028] Furthermore, the emergency control strategy specifically includes: when the temperature exceeds the limit, prioritizing the adjustment of the gas valve opening with an adjustment step of 0.5%-1%; when the kiln pressure is abnormal, prioritizing the adjustment of the fan speed with an adjustment step of 10-20 r / min; when flame extinguishing is detected, immediately closing the main gas valve and triggering an audible and visual alarm, while simultaneously starting the fan for ventilation and replacement; when the oxygen concentration exceeds the process requirement value, synchronously adjusting the gas valve opening and fan speed to correct the air-fuel ratio. This increases the success rate of handling various anomalies to over 99%, shortening the time for parameters to return to stability after anomaly handling to less than 10 seconds; the emergency shutdown protection logic when the flame extinguishes can cut off the gas supply within 1 second, minimizing the risk of safety accidents such as gas leaks and explosions, ensuring the safety of personnel and equipment, reducing the scope of anomalies, and improving the enterprise's production management level. In step 4, after the anomaly detection module outputs an anomaly signal, the control system immediately identifies the anomaly type and invokes the corresponding emergency control strategy. If the temperature exceeds the limit, the control system sends an adjustment command to the gas valve actuator, adjusting the valve opening in adjustment steps of 0.5%-1%, while simultaneously monitoring temperature changes in real time and continuously fine-tuning based on temperature feedback until the temperature returns to the threshold range. If the kiln pressure is abnormal, the system prioritizes sending a speed adjustment command to the fan inverter, adjusting the fan speed in steps of 10-20 r / min to achieve rapid stabilization of the kiln pressure. If flame extinguishing is detected, the system immediately triggers the emergency shutdown protection logic, first closing the main gas valve to cut off the gas supply, and simultaneously activating the audible and visual alarm device to alert the operator. Then, the fan is started for ventilation and replacement to expel residual gas in the kiln, preventing gas accumulation and potential safety accidents. If the oxygen concentration exceeds the limit, the system simultaneously calculates the adjustment amount of the gas valve opening and the fan speed, sends a synchronous adjustment command to correct the air-fuel ratio until the oxygen concentration returns to the process requirement range. Customized emergency control strategies designed for different types of anomalies enable precise and targeted handling of anomalies, improving the effectiveness of emergency response; clearly defined adjustment step sizes avoid excessive fluctuations during the adjustment process, ensuring the stability of the control process; emergency shutdown protection logic when the flame is extinguished can minimize the risk of safety accidents; rapid and effective emergency control can also promptly curb the expansion of anomalies, reduce the impact of anomalies on firing quality, reduce scrap rate, and at the same time ensure the safety and continuity of the production process.

[0029] Furthermore, it also includes a process synchronization and adaptation step based on the real-time physicochemical reaction process of the ceramic parts; this step is embedded in step 3 and executed in parallel, that is, while performing parameter coordination matching, process synchronization and adaptation are performed simultaneously; the specific steps are as follows: the oxidation-reduction reaction rate of the ceramic parts is inverted through data collected by preset sensing devices, and a physicochemical reaction process evaluation model of the ceramic parts is constructed by combining temperature-related data, and the synchronization coefficient between the reaction process and the preset process stage is calculated; the reaction process status is determined according to the comparison result between the synchronization coefficient and the preset benchmark range, and the heating rate and air-fuel ratio parameters of the current stage are adjusted to adapt to the reaction process while maintaining stable kiln pressure; in the medium-fire heat preservation and high-fire heat preservation stages, the heat preservation time is dynamically adjusted by the reaction process evaluation model until the physicochemical reaction completion of the ceramic parts reaches the preset threshold, and then the next process stage is entered; where the synchronization coefficient is the ratio of the actual reaction rate to the preset reaction rate, and the physicochemical reaction completion is determined by the ratio of the reaction process integral value to the preset integral threshold. This design incorporates implicit variables, increasing the physicochemical reaction completion rate of ceramic parts to over 95%, and improving their mechanical strength and insulation properties by over 20%. This effectively avoids performance shortcomings caused by incomplete reactions, providing a crucial guarantee for improving the overall quality of ceramic parts. It is particularly suitable for the production of high-precision ceramic parts with stringent performance requirements, enhancing the product's market competitiveness. In step 3, while initiating parameter coordination and matching control, the system simultaneously activates the process synchronization adaptation submodule. This submodule collects relevant data through preset sensing devices, combines it with temperature change data collected by temperature sensors, and inversely calculates the oxidation-reduction reaction rate of the ceramic parts. It calls the preset ceramic parts physicochemical reaction process evaluation model, inputs reaction rate and temperature-related data, and calculates the synchronization coefficient between the reaction process and the current preset process stage. The synchronization coefficient is compared with the preset benchmark range to determine whether the reaction process is lagging, normal, or ahead of schedule. Under the premise of maintaining stable kiln pressure, the heating rate and air-fuel ratio parameters of the current stage are adjusted according to the determination result. During the medium-temperature and high-temperature heat preservation stages, the submodule continuously calculates the physicochemical reaction completeness of the ceramic parts. When the reaction completeness reaches the preset threshold, it sends a stage switching signal to the main control system, and the main system then executes the start-up operation of the next process stage. If the threshold is not reached, the heat preservation time is extended. This design breaks away from the traditional mechanical model of switching process stages based on fixed time nodes, achieving dynamic adaptation of process parameters to the actual physicochemical reaction process of the ceramic. This fundamentally solves the problems of insufficient reaction or over-firing caused by factors such as batch differences in raw materials and different kiln loading densities. By dynamically adjusting the heating rate, air-fuel ratio, and holding time, it ensures that the physicochemical reaction of the ceramic is sufficient and uniform in each process stage, significantly improving the completeness of the reaction and the uniformity of the internal structure. The dynamic adjustment of the holding time in the medium and high firing stages further ensures the full progress of the core reaction, providing a key guarantee for improving the overall quality of the ceramic.

[0030] Furthermore, the preset sensing device is an oxygen concentration sensor, and the temperature-related data is the heating rate collected by the temperature sensor; the preset reference range is 0.9 to 1.1, a synchronization coefficient < 0.9 is determined to be a lag, and a synchronization coefficient > 1.1 is determined to be a lead; when the reaction is lag, the heating rate increases by 0.5-1℃ / min, and the air-fuel ratio is adjusted upwards by a gradient of 0.03-0.06; when the reaction is lead, the heating rate decreases by 0.3-0.8℃ / min, and the air-fuel ratio is adjusted downwards by a gradient of 0.02-0.05; the preset integration threshold is preset according to the material composition of the porcelain insulator, specifically ranging from 85-95. The specific parameters and judgment criteria set make the process synchronization adaptation strategy highly operable and precise, avoiding fuzzy adjustments during the adaptation process and ensuring consistent adaptation effects in different scenarios. Its measurement accuracy reaches ±0.1%, keeping the reaction rate calculation error within 5%. Extensive experimental verification has shown that while ensuring adaptation effectiveness, the parameter adjustment process is smooth, increasing the insulation breakdown voltage of porcelain insulators by more than 15%, better meeting the stringent requirements of the downstream power industry. In the process synchronization and adaptation submodule of step 3, an oxygen concentration sensor is selected as the core data acquisition device to collect real-time oxygen concentration data in the kiln, while simultaneously extracting heating rate data collected by a temperature sensor. The oxygen concentration data is then substituted into a preset reaction rate inversion model to calculate the redox reaction rate of the ceramic parts. Combining the heating rate data with the physicochemical reaction process evaluation model, a synchronization coefficient is calculated. This synchronization coefficient is compared with a preset benchmark range of 0.9 to 1.1. If the synchronization coefficient is <0.9, it is determined to be a reaction lag. In this case, maintaining stable kiln pressure is crucial. Under the premise of increasing the heating rate by 0.5-1℃ / min, the air-fuel ratio is increased by 0.03-0.06. If the synchronization coefficient is greater than 1.1, it is determined that the reaction is ahead of schedule. The heating rate is decreased by 0.3-0.8℃ / min, and the air-fuel ratio is decreased by 0.02-0.05. According to the material composition of the porcelain insulator, the corresponding preset integral threshold in the range of 85-95 is retrieved from the system parameter library as the standard for judging the completeness of the physicochemical reaction. When the integral value of the reaction completeness reaches the threshold, the stage switching is triggered. The setting of these specific parameters and judgment criteria improves the operability and accuracy of the process synchronization and adaptation strategy; the selection of oxygen concentration sensors can accurately reflect the progress of the oxidation-reduction reaction of ceramic parts, providing reliable data support for the inversion of reaction rate; the setting of adjustment range and gradient under different reaction states ensures the stability and effectiveness of adaptation adjustment, avoiding process fluctuations caused by excessive adjustment range; the setting of preset integration threshold accurately matches the material characteristics of electric porcelain insulators, ensuring the sufficiency of their physicochemical reaction, and further improving the firing quality and performance consistency of electric porcelain insulators.

[0031] In this embodiment, the process synchronization adaptation step also integrates a data iteration optimization mechanism to achieve dynamic optimization of control parameters. The basic data sources for the data iteration optimization mechanism are the oxygen concentration sensor data and preset benchmark ranges, etc. Specifically, the system automatically stores the control parameters of the entire firing process of each batch of ceramic parts, the synchronization coefficient change curve, and the corresponding batch product quality test results, and constructs a database related to control parameters, reaction process, and product quality. After firing 5 batches of the same type of ceramic parts, a weighted iterative algorithm is used based on the database to dynamically update the preset benchmark range, heating rate adjustment range, air-fuel ratio adjustment gradient, and preset integral threshold. The core logic of the weighted iterative algorithm is: updated parameter value = initial parameter value × quality test result weight × quality coefficient + reaction process stability weight × stability coefficient + firing efficiency weight × efficiency coefficient, wherein the update weight is set according to the following weights: 60% for quality test results, 30% for reaction process stability, and 10% for firing efficiency. The iteration convergence condition is that the difference between the updated parameters of two consecutive batches is less than 0.01. The updated parameters are used as the initial control parameters for subsequent batches of firing, realizing the self-evolution optimization of the process synchronization adaptation strategy. This data iteration and optimization mechanism, after 5-10 iterations, improves parameter adaptation accuracy by over 30%, reduces manual parameter calibration costs by over 90%, and stabilizes the product qualification rate at over 98%. It reduces the traditional 15-20 batches to 5-8 batches, significantly improving the company's production flexibility and market responsiveness. The system automatically stores data, recording in real-time the change curves of control parameters, the dynamic changes of synchronization coefficients, and the quality inspection results of the corresponding batches of products throughout the entire firing process of each batch of ceramic pieces. This includes test data on insulation performance, mechanical properties, and internal structural uniformity. This data is then categorized and stored in a database linking control parameters, reaction process, and product quality. After firing five batches of the same type of ceramic pieces, the system automatically triggers a data iteration and optimization program. It extracts all historical data for that type of ceramic piece from the database and uses a weighted iterative algorithm. This algorithm assigns 60% to quality inspection results, 30% to reaction process stability, and 10% to firing efficiency. The updated parameter values ​​for the preset baseline range, heating rate adjustment range, air-fuel ratio adjustment gradient, and preset integral threshold are calculated. The system checks if the difference between the updated parameters of two consecutive batches is less than 0.01. If so, iteration stops, and the updated parameters are used as the initial control parameters for subsequent firings of that type of ceramic piece. If not, iterative calculation continues until convergence is achieved. This data iterative optimization mechanism enables the self-evolution of control parameters, allowing the process synchronization adaptation strategy to continuously absorb the experience of historical production data and constantly improve its adaptability to different production scenarios and raw material characteristics. It can automatically adapt to implicit variables such as batch differences in raw materials, kiln aging, and changes in kiln loading density without manual intervention in parameter calibration, significantly reducing labor costs and avoiding quality risks caused by human calibration errors. The product quality-centric weight setting ensures that the optimized parameters prioritize product quality while also considering reaction process stability and firing efficiency. The setting of iterative convergence conditions guarantees the stability of parameter optimization, avoiding frequent parameter fluctuations, further improving the consistency of the production process and the stability of product quality, and shortening the debugging cycle for new types of ceramic parts.

[0032] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or terminal device that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or terminal device. Unless otherwise specified, an element defined by the phrase "comprising..." or "including..." does not exclude the presence of additional elements in the process, method, article, or terminal device that includes said element. Additionally, in this document, "greater than," "less than," "exceeding," etc., are understood to exclude the stated number; "above," "below," "within," etc., are understood to include the stated number.

[0033] The above description of the embodiments is provided to facilitate understanding and use of the present invention by those skilled in the art. It is obvious to those skilled in the art that various modifications can be easily made to the embodiments, and the general principles described herein can be applied to other embodiments without creative effort. Therefore, the present invention is not limited to the above embodiments. Improvements and modifications made by those skilled in the art based on the disclosure of the present invention without departing from the scope of the present invention should be within the protection scope of the present invention.

Claims

1. An automatic control method for kiln firing, characterized in that, Includes the following steps: Step 1: System initialization configuration. Select the preset multi-stage firing curve parameters according to the type of workpiece to be fired, and set the threshold values ​​of the core process parameters corresponding to each stage. Step 2: Start the kiln's automatic operation program and collect real-time data of the core process parameters inside the kiln through various sensing devices; Step 3: Based on the preset multi-stage firing curves and real-time collected operating data, the kiln control system dynamically adjusts various actuators to achieve coordinated matching of process parameters at each stage. The core logic of the collaborative matching is to adjust the parameters according to the priority rules of "temperature priority, kiln pressure assistance, and air-fuel ratio adaptation" based on the correlation model between core process parameters. Step 4: Throughout the firing process, key status information inside the kiln is monitored in real time by status monitoring equipment. Anomalies are judged simultaneously on the collected core process parameter data. When a parameter exceeds the set threshold or the status information is abnormal, an alarm is triggered and an emergency control strategy is executed. Step 5: After the cooling stage is completed, the system automatically terminates the firing program and executes the kiln unloading preparation.

2. The automatic control method for kiln firing according to claim 1, characterized in that, The workpiece to be fired is a ceramic part, specifically an electrical porcelain insulator; the multi-stage firing curve is a five-stage firing curve, which consists of a low-fire firing stage, a medium-fire holding stage, a high-fire holding stage, a high-fire reduction stage, and a cooling stage.

3. The automatic control method for kiln firing according to claim 1, characterized in that, The core process parameters include temperature, kiln pressure, and air-fuel ratio; the various sensing devices include temperature sensors, pressure transmitters, and oxygen concentration sensors, wherein the temperature sensor has a measurement accuracy of ±5℃; the preset threshold for kiln pressure is a slightly positive pressure range, specifically 5-15Pa.

4. The automatic control method for kiln firing according to claim 1, characterized in that, The various actuators include gas valves and fans; when the kiln pressure fluctuation exceeds ±3Pa, it is determined to be an abnormal kiln pressure fluctuation. At this time, the fan air volume and gas supply are adjusted synchronously. The adjustment range is linearly positively correlated with the kiln pressure fluctuation range, and the linear proportionality coefficient is 0.8-1.2 to ensure that the firing curve does not deviate from the preset trajectory.

5. The automatic control method for kiln firing according to claim 1, characterized in that, The status monitoring equipment includes a flame status monitoring equipment; the specific abnormal judgment criteria are as follows: the temperature deviates from the corresponding stage threshold by more than ±5°C for 2 seconds or more, the kiln pressure exceeds the preset threshold for 3 seconds or more, the air-fuel ratio deviates from the preset threshold, causing the oxygen concentration to exceed the process requirement value by ±3%, the flame status monitoring equipment detects that the flame is extinguished, or the flame brightness is lower than 60% of the preset benchmark value or higher than 140% of the preset benchmark value.

6. The automatic control method for kiln firing according to claim 1, characterized in that, The baseline total cycle for the entire firing process is 7993 minutes. This baseline cycle is applicable to scenarios where standard-specification porcelain insulators are installed and the kiln is fully loaded. It can be finely adjusted within ±30 minutes depending on the type of porcelain component.

7. The automatic control method for kiln firing according to claim 1, characterized in that, The gradient cooling rate during the cooling stage is set according to the following rules: initial cooling rate ≤ 5℃ / min, mid-cooling rate ≤ 8℃ / min, and late-cooling rate ≤ 3℃ / min; the initial cooling stage is the stage where the kiln temperature drops from the highest firing temperature to 500℃, the mid-cooling stage is the stage where the temperature drops from 500℃ to 200℃, and the late-cooling stage is the stage where the temperature drops from 200℃ to room temperature.

8. The automatic control method for kiln firing according to claim 1, characterized in that, The specific emergency control strategy is as follows: when the temperature exceeds the limit, the gas valve opening is adjusted first, with an adjustment step of 0.5%-1%; when the kiln pressure is abnormal, the fan speed is adjusted first, with an adjustment step of 10-20 r / min; when flame extinguishing is detected, the main gas valve is immediately closed and an audible and visual alarm is triggered, while the fan is started for ventilation and replacement; when the oxygen concentration exceeds the process requirement value, the gas valve opening and fan speed are adjusted synchronously to correct the air-fuel ratio.

9. The automatic control method for kiln firing according to claim 1, characterized in that, It also includes a process synchronization and adaptation step based on the real-time physicochemical reaction process of the ceramic parts; this step is embedded in step 3 and executed in parallel, that is, while performing parameter coordination matching, process synchronization and adaptation are performed simultaneously; the specific steps are as follows: the oxidation-reduction reaction rate of the ceramic parts is inverted through the data collected by the preset sensing equipment, and a physicochemical reaction process evaluation model of the ceramic parts is constructed by combining temperature-related data, and the synchronization coefficient between the reaction process and the preset process stage is calculated; the reaction process status is determined according to the comparison result between the synchronization coefficient and the preset benchmark range, and the heating rate and air-fuel ratio parameters of the current stage are adjusted to adapt to the reaction process while maintaining the kiln pressure stability; in the medium-fire heat preservation and high-fire heat preservation stages, the heat preservation time is dynamically adjusted by the reaction process evaluation model until the physicochemical reaction completion of the ceramic parts reaches the preset threshold, and then the next process stage is entered; where the synchronization coefficient is the ratio of the actual reaction rate to the preset reaction rate, and the physicochemical reaction completion is determined by the ratio of the reaction process integral value to the preset integral threshold.

10. The automatic control method for kiln firing according to claim 9, characterized in that, The preset sensing device is an oxygen concentration sensor, and the temperature-related data is the heating rate collected by the temperature sensor; the preset reference range is 0.9 to 1.1, a synchronization coefficient < 0.9 is considered a lag, and a synchronization coefficient > 1.1 is considered a lead; when the response is lag, the heating rate increases by 0.5-1℃ / min, and the air-fuel ratio is adjusted upwards by a gradient of 0.03-0.06; when the response is lead, the heating rate decreases by 0.3-0.8℃ / min, and the air-fuel ratio is adjusted downwards by a gradient of 0.02-0.05; the preset integration threshold is preset according to the material composition of the porcelain insulator, specifically ranging from 85-95.

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