High-energy hole opening method for calcium carbide furnace device

Abstract

The invention belongs to the technical field of calcium carbide furnaces, and discloses a high-energy hole opening method for a calcium carbide furnace device, which comprises the steps of self-checking, parameter setting, positioning and adjusting, high-energy hole opening and ending. After self-checking and verifying the authority, starting multiple systems, completing function detection, and checking hidden dangers of equipment; setting parameters according to furnace eye and working condition information, and presetting laser, cooling and positioning parameters; after positioning adjustment and coarse positioning, the coordinates of the furnace eye are analyzed, and precise alignment and posture locking of the laser assembly are completed; a high-energy eye-opening laser and cooling system scans according to a composite track and is dynamically adjusted until eye opening succeeds; and stopping laser at the ending step, delaying cooling temperature reduction, resetting equipment and filing operation data. According to the high-energy hole opening method for the calcium carbide furnace device, through automation, laser and closed-loop control technologies, traditional manual operation and carbon rod operation are thoroughly replaced, safety risks and material consumption are fundamentally eradicated, remote, accurate and efficient hole opening is achieved, and the operation success rate and continuity are greatly improved.

Description

Technical Field

[0001] This invention relates to the field of calcium carbide furnace technology, specifically to a method for high-energy opening of a calcium carbide furnace device. Background Technology

[0002] The opening of the furnace eye is a crucial link in the continuous production process of a closed calcium carbide furnace, connecting the carbonization reaction inside the furnace with the collection of finished products outside the furnace. Its operational precision, efficiency, and safety directly determine the operational stability, capacity release efficiency, and on-site safety factor of the entire production system. It is the core control point to ensure the continuous, efficient, and safe production of calcium carbide. This link specifically refers to the operation process of precisely opening a stable channel at the iron tapping port (commonly referred to as the furnace eye in the industry) on the lower side wall of the closed calcium carbide furnace, targeting the solidified calcium carbide and slag mixed sealing layer generated by the reaction inside the furnace, through specific technical means such as physical impact, high-temperature burning, or high-energy breakdown.

[0003] However, existing technologies have the following problems: Currently, closed calcium carbide furnaces mainly use manual rod insertion and furnace exit robots for tapping. However, both methods have significant shortcomings and safety hazards. First, the tapping site generally faces high temperatures and harsh environments. If manual rod insertion is used, not only is the labor intensity extremely high, but personnel also have to face high risks such as material collapse and spraying, which can easily cause injuries. Second, the graphite electrode rods used in the operation have defects such as high wear and tear and easy breakage. During the manual replacement of electrode rods, there is also a high risk of personnel injury. Summary of the Invention

[0004] (a) Technical problems to be solved To address the shortcomings of existing technologies, this invention provides a high-energy eye-opening method for a calcium carbide furnace device, which has the advantages of high degree of automation, no need for close human intervention, and low wear of graphite electrode rods. It solves the problems of high labor intensity, high on-site risks, and easy injury to personnel when replacing electrode rods.

[0005] (II) Technical Solution To achieve the above objectives, the present invention provides the following technical solution: a method for high-energy opening of an electric arc furnace device, comprising the following steps: S1. Self-test: After verifying the operation authority through the control cabinet, start the laser emitter and energy regulation system, cooling system, universal robot and infrared positioning system and isometric adjustment system, and complete the self-test; S2. Parameter setting: Preset the laser emission and energy regulation system parameters, cooling control parameters, and positioning reference parameters according to the target furnace eye information and operating parameters; S3. Positioning and Adjustment: The robot base is coarsely positioned by the equidistant adjustment system, and the high-temperature area of ​​the furnace eye is identified by the infrared positioning system and the coordinates of the center point are analyzed. The universal robot drives the laser emission component to complete precise alignment and attitude locking. S4, High-Energy Eye Opening: Start the laser emitter and energy regulation system, and start the cooling system to establish a cooling circuit for the laser emitter and energy regulation system. The laser emitter and energy regulation system output high-energy laser according to the preset mode, scan and melt through the furnace eye along the composite trajectory, and at the same time achieve adaptive adjustment of energy and attitude through multi-system dynamic feedback to complete the eye opening. S5. Final Stage: The laser system is shut down in stages, the cooling system is run for a delay until the equipment cools down, the robot and adjustment system are reset and locked, and the entire operation cycle data is automatically collected and archived.

[0006] Preferably, the self-test in step S1 includes: energy output accuracy detection of the laser emitter and energy regulation system, flow rate and cooling function test of the cooling system, joint movement flexibility verification of the universal robot, furnace eye recognition accuracy verification of the infrared positioning system, and distance adjustment accuracy detection of the equidistant adjustment system. If the self-test fails, an alarm is triggered and the work process is locked.

[0007] Preferably, in step S2, the target furnace eye information includes the furnace eye diameter (300-500mm), location distribution, and adjacent spacing (1.5-2.0m). The operating parameters include the furnace eye blockage thickness and the furnace pressure. The laser energy output parameters are set according to the blockage thickness: light blockage (thickness < 100mm, pressure < 0.03MPa) corresponds to a 5-8kW continuous output mode, and heavy blockage (thickness ≥ 100mm, pressure ≥ 0.05MPa) corresponds to a 12-15kW pulse output mode (pulse frequency 100-500Hz).

[0008] Preferably, in step S3, the coarse positioning involves the equidistant adjustment system adjusting the universal robot base to the initial working area corresponding to the target furnace eye according to the preset furnace eye spacing parameters. The initial working area is a preset area 1.0m ± 0.05m away from the furnace surface. The deviation of the precise alignment does not exceed ± 1mm. The attitude locking is controlled between 89.5° and 90.5° between the central axis of the laser emitter and the furnace surface (furnace eye reference plane). The actual measured value of this angle does not deviate from 90° by more than 0.5°. After completion, the mechanical locking mechanism is triggered to lock.

[0009] Preferably, in step S4, the cooling circuit includes a water-cooled circuit formed by the cooling system, the composite trajectory includes a spiral trajectory with a pitch of 5mm in the initial stage (melting through the core blockage layer) and a radial trajectory with a 15° interval in the advanced stage (expanding the furnace eye range), and the dynamic feedback includes furnace eye position change feedback refreshed by the infrared positioning system every 0.5 seconds and temperature data feedback collected in real time by the cooling system.

[0010] Preferably, the adaptive adjustment in step S4 specifically involves: when the infrared positioning system detects a furnace eye position offset of >5mm, sending a correction signal to the universal robot to adjust the alignment posture of the laser emitting component; when the cooling system detects that the equipment temperature exceeds a preset threshold of 3℃, automatically increasing the water flow rate to further enhance the cooling intensity; if the temperature continues to exceed the preset threshold, triggering an emergency shutdown of the laser system.

[0011] Preferably, the criteria for successfully opening the furnace eye in step S4 are: the laser scanning trajectory covers the preset furnace eye diameter, the infrared detection shows that the temperature in the furnace eye area rises sharply (≥700℃) and the pressure inside the furnace drops to a safe range (<0.02MPa).

[0012] Preferably, in step S5, the stepped shutdown involves gradually reducing the laser energy in a gradient of 15kW→10kW→5kW→0 (each level lasting 5 seconds); the cooling system operates for a delay until the laser emitter cavity temperature is ≤50℃ and the focusing lens temperature is ≤60℃ before shutting down; the full-cycle data includes the furnace eye number, opening time, laser energy consumption, and equipment operating temperature; and the robot and adjustment system are reset to a standby position 5m away from the calcium carbide furnace body and locked.

[0013] Preferably, the control cabinet, cooling system, universal robot, infrared positioning system, equidistant adjustment system, laser emitter, and energy regulation system are electrically or signal-connected to form a closed-loop controlled eye-opening operation system.

[0014] (III) Beneficial Effects Compared with the prior art, the present invention provides a method for high-energy opening of a calcium carbide furnace device, which has the following beneficial effects: This high-energy eye-opening method for calcium carbide furnaces uses automation to replace manual labor, lasers to replace carbon rods, and closed-loop control to replace experience-based operation as its core logic. Through full-process technological optimization, it achieves multiple core benefits. In terms of safety, relying on remote operation of the control cabinet and the safe distance operation mode of robots, it significantly reduces the exposure time of personnel in high-temperature environments and completely eliminates the risks of material collapse and spraying that may be encountered during manual rod handling and carbon rod replacement, minimizing the incidence of operational safety accidents and fundamentally improving the level of operational safety. In terms of cost reduction, the laser energy system completely replaces traditional carbon rods, not only eliminating the cost of carbon rod procurement and replacement, but also intelligently adjusting energy output according to real-time operating conditions to achieve precise energy consumption control. The fully automated operation significantly reduces the intensity of manual operation and the dependence on highly skilled operators, thereby effectively controlling the overall operating cost. In terms of efficiency improvement, with the help of infrared positioning and precise robot alignment technology, combined with a multi-system dynamic feedback adjustment mechanism, the eye-opening time of a single furnace eye is significantly shortened, the eye-opening success rate is greatly improved, rework losses are effectively avoided, and repeated operations and production interruptions caused by positioning deviations or uneven energy are avoided, enhancing the continuity and stability of the process. Attached Figure Description

[0015] Figure 1 This invention provides a schematic flowchart of a high-energy eye-opening method for a calcium carbide furnace device. Figure 2 This invention provides a schematic diagram of the parameter setting process for a high-energy opening method for a calcium carbide furnace device. Figure 3 This invention provides a schematic diagram of the positioning and adjustment process for a high-energy opening method in a calcium carbide furnace device; Figure 4 This invention provides a high-energy opening method for a calcium carbide furnace device, and presents a schematic diagram of the high-energy opening process. Detailed Implementation

[0016] 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.

[0017] Please see Figure 1 , Figure 2 , Figure 3 and Figure 4 This invention provides a technical solution: a method for high-energy opening of a calcium carbide furnace device, comprising the following steps: S1. Self-test: After verifying the operation authority through the control cabinet, start the laser emitter and energy regulation system, cooling system, universal robot and infrared positioning system and isometric adjustment system, and complete the self-test.

[0018] The functional self-test in step S1 includes: energy output accuracy detection of the laser emitter and energy regulation system, flow rate and cooling function test of the cooling system, joint movement flexibility verification of the universal robot, furnace eye recognition accuracy verification of the infrared positioning system, and distance adjustment accuracy detection of the equidistant adjustment system. If the self-test fails, an alarm is triggered and the work process is locked.

[0019] In this step, the laser emitter and energy regulation system, cooling system, universal robot and infrared positioning system, and equidistant adjustment system are started simultaneously, and functional tests are completed to identify potential equipment malfunctions in advance. This ensures that all systems can operate stably and collaboratively during operation, avoiding problems such as increased furnace eye blockage and high-temperature damage caused by mid-operation shutdowns. At the same time, the laser emitter and energy regulation system ensure that the laser energy is output stably according to the preset value, avoiding low opening efficiency or equipment overload due to energy deviation. The cooling system prevents the equipment from burning out due to high temperatures during laser operation. The universal robot's joint mobility allows for flexible adjustment of the laser emitter's position, and the infrared positioning system ensures accurate capture of the furnace eye position, providing reliable coordinates for subsequent positioning adjustments. The equidistant adjustment system ensures that the robot base can move at a preset distance, avoiding collisions or laser focusing failure caused by distance deviations.

[0020] S2. Parameter setting: Preset the laser emission and energy regulation system parameters, cooling control parameters, and positioning reference parameters according to the target furnace eye information and operating parameters.

[0021] In step S2, the target bore information includes bore diameter (300-500mm), location distribution, and adjacent spacing (1.5-2.0m). Operating parameters include bore blockage thickness and internal pressure. Laser energy output parameters are set according to the blockage thickness: light blockage (thickness <100mm, pressure <0.03MPa) corresponds to 5-8kW continuous output mode, and heavy blockage (thickness ≥100mm, pressure ≥0.05MPa) corresponds to 12-15kW pulse output mode (pulse frequency 100-500Hz).

[0022] Please see Figure 2In this step, the diameter of the furnace eye, ranging from 300 to 500 mm, determines the final coverage of the laser scanning trajectory. This ensures that the diameter of the furnace eye meets the material discharge requirements after opening, avoiding poor material discharge due to an excessively small diameter or material collapse due to an excessively large diameter. The position distribution and adjacent spacing of 1.5-2.0 m provide a benchmark for the equidistant adjustment system, ensuring that the robot can accurately switch to different furnace eyes for operation and avoiding positional deviations when moving across furnace eyes. At the same time, a slight blockage of <100 mm in the furnace eye corresponds to a 5-8 kW continuous output mode, while a severe blockage of ≥100 mm corresponds to a 12-15 kW pulse output mode, achieving on-demand energy supply and balancing efficiency and energy consumption.

[0023] S3. Positioning and Adjustment: The robot base is coarsely positioned by the equidistant adjustment system. The infrared positioning system is used to identify the high-temperature area of ​​the furnace eye and analyze the coordinates of the center point. The universal robot is then driven to drive the laser emission component to complete precise alignment and attitude locking.

[0024] In step S3, coarse positioning involves the equidistant adjustment system adjusting the universal robot base to the initial working area corresponding to the target furnace eye according to the preset furnace eye spacing parameters. The initial working area is a preset area 1.0m ± 0.05m away from the furnace surface, and the deviation of precise alignment does not exceed ±1mm. Attitude locking is achieved by controlling the angle between the central axis of the laser emitter and the furnace surface (furnace eye reference plane) to be between 89.5° and 90.5°, and the actual measured value of this angle does not deviate from 90° by more than 0.5°. After completion, the mechanical locking mechanism is triggered to lock.

[0025] Please see Figure 3In this step, coarse positioning uses an equidistant adjustment system to move the robot base to the initial working area, quickly narrowing the positioning range and reducing the subsequent precise alignment adjustment travel, thus improving work efficiency and preventing direct collisions between the robot and the furnace body. Infrared positioning and coordinate analysis utilize an infrared positioning system to identify the high-temperature area of ​​the furnace eye and accurately analyze the center point coordinates, solving the problem of the furnace eye being covered by blockages and unable to be located visually. This provides a precise target point for laser action. Precise alignment and attitude locking drive the robot to adjust the laser emission component to the target position and lock its attitude, ensuring that the laser can accurately act on the center point of the furnace eye with optimal energy focusing, while also preventing furnace eye formation caused by attitude deviation during operation. The irregular shape and initial working area distance of 1.0m±0.05m are within the effective range of laser focusing. This ensures that the laser energy density meets the standard and avoids equipment damage caused by the robot being too close to the high-temperature furnace. The precise alignment deviation ≤±1mm ensures that the laser focus point and the center point of the furnace eye are highly coincident, avoiding laser energy dispersion or furnace eye eccentricity due to deviation. The included angle range is between 89.5° and 90.5°, and the actual measured value deviates from 90° by no more than 0.5°. This ensures that the vertical angle minimizes the laser spot and maximizes the energy density, achieving efficient melting and penetration. At the same time, it ensures that the furnace eye cross-section is a regular circle, avoiding uneven furnace eye wall thickness and material collapse risks caused by tilting angles.

[0026] S4, High-Energy Eye Opening: The laser emitter and energy regulation system are activated, and the cooling system is activated to establish a cooling circuit for the laser emitter and energy regulation system. The laser emitter and energy regulation system output high-energy lasers according to a preset mode, scanning and melting through the furnace eye along a composite trajectory. At the same time, the energy and attitude are adaptively adjusted through multi-system dynamic feedback to complete the eye opening.

[0027] In step S4, the cooling circuit includes a water-cooled circuit formed by the cooling system. The composite trajectory includes a spiral trajectory with a pitch of 5mm in the initial stage (melting through the core blockage layer) and a radial trajectory with 15° intervals in the advanced stage (expanding the furnace eye range). The dynamic feedback includes feedback on the furnace eye position change refreshed by the infrared positioning system every 0.5 seconds and feedback on the temperature data collected in real time by the cooling system. In step S4, the adaptive adjustment is as follows: when the infrared positioning system detects a furnace eye position offset of >5mm, it sends a correction signal to the universal robot to adjust the alignment attitude of the laser emitting component; when the cooling system detects that the equipment temperature exceeds the preset threshold of 3℃, it automatically increases the water flow rate to further enhance the cooling intensity. If the temperature continues to exceed the threshold, it triggers an emergency shutdown of the laser system. In step S4, the criteria for successfully opening the furnace eye are: the laser scanning trajectory covers the preset furnace eye diameter, the infrared detection shows a sudden increase in the temperature of the furnace eye area (≥700℃), and the pressure inside the furnace drops to a safe range (<0.02MPa).

[0028] Please see Figure 4In this step, the two systems start simultaneously: the laser system and the cooling system. This ensures that the high temperatures generated by the laser operation are dissipated in real time, preventing overheating damage to the equipment. A cooling loop is established to provide continuous cooling protection for the laser emitter and energy regulation system. The laser trajectory scanning, along a composite trajectory, melts through the furnace eye. Through the synergistic effect of different trajectories, it simultaneously removes the core blockage layer and expands the furnace eye area, improving opening efficiency and forming quality. Dynamic feedback and adaptive adjustment respond in real time to positional deviations and temperature changes during the operation. This dynamic adjustment ensures that the laser always operates precisely and the equipment always remains within a safe temperature range, providing core protection for handling complex working conditions. The cooling system utilizes the high specific heat capacity of water to efficiently remove the heat generated by the laser system, serving as a core heat dissipation method under high-temperature operations. Simultaneously, the initial spiral trajectory has a pitch of 5mm, a small pitch... The spiral mechanism concentrates laser energy in the center of the furnace eye, rapidly melting through the dense core blockage layer and laying the foundation for subsequent furnace eye expansion. The advanced radial trajectory, with 15° intervals, allows for outward scanning from the center point, uniformly expanding the furnace eye area. The 15° interval balances scanning efficiency and coverage integrity. The infrared positioning system refreshes every 0.5 seconds, capturing real-time changes in the furnace eye's position and providing timely data support for attitude correction. Correction is initiated when the deviation exceeds a threshold to prevent cumulative deviation from causing the laser to deviate from the furnace eye, ensuring accurate opening. When the temperature exceeds a preset threshold by 3°C, cooling intensity is increased, such as by increasing water flow rate, to intervene in the equipment's heating trend in advance and prevent the shutdown threshold from affecting operations. When the laser trajectory covers a preset diameter, the temperature rises by ≥700°C, and the pressure is <0.02MPa, the combination of these three factors enables accurate judgment of successful opening.

[0029] S5. Final Stage: The laser system is shut down in stages, the cooling system is run for a delay until the equipment cools down, the robot and adjustment system are reset and locked, and the entire operation cycle data is automatically collected and archived.

[0030] In step S5, the step-by-step shutdown involves gradually reducing the laser energy in a gradient of 15kW→10kW→5kW→0 (each step is maintained for 5 seconds); the cooling system runs for a delay until the laser emitter cavity temperature is ≤50℃ and the focusing lens temperature is ≤60℃ before shutting down; the full cycle data includes the furnace eye number, opening time, laser energy consumption and equipment operating temperature, and the robot and adjustment system are reset to the standby position 5m away from the calcium carbide furnace body and locked.

[0031] In this step, the stepped shutdown of the laser system avoids the current surge caused by sudden laser energy shutdown, extending the lifespan of the laser emitter and energy regulation system. After the laser is shut down, the equipment remains at a high temperature. The delayed cooling system can reduce the temperature to a safe range, preventing residual heat from damaging equipment components. The robot and adjustment system are moved to the standby position and locked to prevent the equipment from being impacted by external forces when not in operation. At the same time, it prepares the position for the next operation. Data is collected and archived, recording the data of the entire operation cycle, providing a basis for subsequent equipment maintenance, process improvement, and problem tracing. The laser stepped shutdown gradient is: 15kW→10kW→5kW→0, each level maintained for 5 seconds, which allows the equipment current and energy output to transition smoothly, avoiding the impact load caused by instantaneous fluctuations. The cooling delay shutdown threshold is cavity ≤50℃ and lens ≤60℃. This temperature is the upper limit for safe operation of equipment components, ensuring that the equipment is in a state without damage risk after shutdown. The standby position is 5m away from the furnace body, away from the high-temperature furnace body and the working area, avoiding the equipment from being affected by residual heat and dust, while reserving sufficient working space.

[0032] The control cabinet, cooling system, universal robot, infrared positioning system, equidistant adjustment system, laser emitter, and energy regulation system are electrically or signal connected to form a closed-loop control eye-opening operation system. In this step, a closed-loop control system of command issuance, status feedback, and adjustment execution is constructed. The control cabinet sends operation commands to each system, each system provides real-time feedback on its operating status, and the control cabinet adjusts the commands based on the feedback data to ensure fully automated and precise operation, completing the eye-opening operation without human intervention.

[0033] Example: Taking the opening operation of a 40500kVA closed calcium carbide furnace in a chemical enterprise as an example, the specific process is as follows: S1, Self-test Operators, located 10 meters from the furnace in the control room, input their fingerprints and verify their operating permissions via the control cabinet. After confirmation, they click the start button, simultaneously activating the laser emitter and energy regulation system, cooling system, universal robot and infrared positioning system, and equidistant adjustment system for a full-function self-test. Laser system: Outputs 0.5kW test laser; the energy detector shows that the actual output deviates from the set value by ≤±2%, indicating that the energy output accuracy is qualified. Cooling system: Start the main cooling pump. The flow meter shows a water flow rate of 18L / min (rated range 15-25L / min). Within 30 seconds, the simulated heat source temperature will drop from 80℃ to 45℃. The cooling function and flow rate test are qualified. Universal robot: executes joint movement commands throughout the entire stroke, joint movement is smooth without jamming, encoder feedback repeatability error ≤ ±0.08mm, and joint flexibility is qualified; Infrared positioning system: Captures images of the furnace eye area, automatically identifies high-temperature areas (temperature 620℃) and fits the center point coordinates, with a deviation from the preset furnace eye coordinates ≤ ±3mm, indicating qualified recognition accuracy; Equidistant adjustment system: The robot base moves 1.8m along the guide rail, and the laser rangefinder shows that the actual moving distance is 1.8m ± 0.02m, which is within acceptable limits.

[0034] If all system self-test items show as qualified, the control cabinet interface will jump to the parameter setting page. If any item fails, an audible and visual alarm will be triggered immediately, the work process will be locked, and the fault must be investigated and the self-test will be repeated.

[0035] S2, Parameter Setting Input the target furnace eye information into the control cabinet interface, such as furnace eye number, diameter 400mm, and distance between adjacent furnace eyes 1.8m; input the operating parameters, blockage thickness 120mm, furnace pressure 0.06MPa, the system automatically judges it as severe blockage, laser energy parameters: the system automatically matches 14kW pulse output mode, pulse frequency set to 300Hz, cooling control parameters: set the target temperature of the cooling system cavity ≤55℃, lens ≤65℃, the over-temperature threshold is set to automatically increase the water flow rate when the temperature exceeds the target temperature by 3℃, positioning reference parameter settings: set the initial working area distance to 1.0m±0.05m, the accurate alignment deviation threshold ≤±1mm, attitude locking angle 89.5°-90.5°. After the operator verifies that the parameters are correct, click save, the system generates a furnace eye-specific opening plan and jumps to the positioning adjustment stage.

[0036] S3, Positioning and Adjustment Coarse positioning execution: The equidistant adjustment system receives the initial positioning command for the furnace eye and drives the robot base to move along the guide rail to an area 1.0m ± 0.03m away from the furnace surface. After the movement is completed, the base automatically locks to prevent displacement. The infrared positioning system is activated and extracts the high-temperature edge of the blockage layer through the temperature gradient algorithm, and resolves the three-dimensional coordinates of the furnace eye center point (X: 2850mm, Y: 1620mm, Z: 3100mm). The coordinates are transmitted to the robot control system in real time. The universal robot receives the coordinate data and drives the laser emitting component to move. First, the X / Y axes are adjusted to align the laser focus point with the center point, and then the Z-axis attitude is adjusted. The dual-axis tilt sensor shows that the angle between the laser axis and the furnace surface is 90.2°, which triggers the mechanical locking mechanism to rigidly fix the component attitude. The infrared positioning system verifies again and shows that the deviation between the focus point and the center point is 0.6mm and the angle is 90.1°, which is considered as qualified positioning. The system is ready to enter the high-energy opening stage.

[0037] S4, High-Energy Eye Opening The operator clicks the start button, and the laser emitter and energy regulation system output laser light in 14kW pulse mode. Simultaneously, the cooling system is activated, establishing a water-cooling circuit. Following the initial spiral phase, starting from the center point of the furnace eye, the laser travels along a spiral trajectory with a pitch of 5mm, gradually expanding from a diameter of 100mm to 200mm, advancing 5mm for every 360° rotation, continuously melting through the 120mm thick core blockage layer. Infrared thermography shows the center point temperature rising from 620℃ to 950℃. After completing the spiral trajectory, the system automatically switches to a radial trajectory with 15° intervals, scanning from the center point outwards to a diameter of 400mm. Each beam uses a pulse output with a 6ms irradiation followed by a 4ms pause (10ms period, 100Hz frequency), clearing the outer loose blockage. During the operation, the infrared positioning system refreshed the coordinates every 0.5 seconds, showing no shift in the furnace eye position. After 2.8 minutes of operation, the cooling system temperature sensor showed that the laser cavity temperature rose to 58℃ (3℃ above the target temperature). The system automatically increased the water flow rate, and after 15 seconds, the cavity temperature dropped to 54℃. Throughout the entire process, there was no positional shift exceeding 5mm, and the robot did not need to correct its posture. After 4 minutes of operation, the system simultaneously met three judgment criteria: 1. The laser scanning trajectory covered a diameter of 400mm; 2. The infrared detection showed that the furnace eye area temperature suddenly rose to 1020℃ (400℃ higher than the initial value ≥ 700℃); 3. The furnace pressure dropped to 0.015MPa (< 0.02MPa). The control cabinet interface popped up a message indicating successful furnace eye opening, and the system automatically entered the finishing stage.

[0038] S5, Final Stage The system reduces laser energy in a gradient of 14kW→10kW→5kW→0, maintaining each level for 5 seconds. After 15 seconds, the laser is completely shut off to avoid current surges. The cooling system continues to operate, and temperature sensors monitor the cavity temperature down to 48℃ and the lens temperature down to 55℃ (both below the threshold) after 1.5 minutes. The system then automatically shuts down the cooling system. The universal robot moves the laser assembly to a standby position 5m away from the furnace body. The equidistant adjustment system drives the base back to its initial parking area, and all moving parts are locked to prevent displacement during non-operational states. The system automatically collects and archives operational data, including furnace eye number, eye opening time (4 minutes), laser energy consumption (0.93kWh), and maximum cavity temperature (58℃). The data is stored in the enterprise system and can be retrieved and reviewed at any time.

[0039] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. 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, and no reference numerals in the claims should be construed as limiting the scope of the claims.

[0040] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A method for high-energy eye opening in a calcium carbide furnace device, characterized in that, Includes the following steps: S1. Self-test: After verifying the operation authority through the control cabinet, start the laser emitter and energy regulation system, cooling system, universal robot and infrared positioning system and isometric adjustment system, and complete the self-test; S2. Parameter setting: Preset the laser emission and energy regulation system parameters, cooling control parameters, and positioning reference parameters according to the target furnace eye information and operating parameters; S3. Positioning and Adjustment: The robot base is coarsely positioned by the equidistant adjustment system, and the high-temperature area of ​​the furnace eye is identified by the infrared positioning system and the coordinates of the center point are analyzed. The universal robot is driven to drive the laser emission component to complete precise alignment and attitude locking. S4, High-Energy Eye Opening: Start the laser emitter and energy regulation system, and start the cooling system to establish a cooling circuit for the laser emitter and energy regulation system. The laser emitter and energy regulation system output high-energy laser according to the preset mode, scan and melt through the furnace eye along the composite trajectory, and at the same time achieve adaptive adjustment of energy and attitude through multi-system dynamic feedback to complete the eye opening. S5. Final Stage: The laser system is shut down in stages, the cooling system is run for a delay until the equipment cools down, the robot and adjustment system are reset and locked, and the entire operation cycle data is automatically collected and archived.

2. The method for high-energy opening of a calcium carbide furnace device according to claim 1, characterized in that: The functional self-test in step S1 includes: energy output accuracy detection of the laser emitter and energy regulation system, flow rate and cooling function test of the cooling system, joint movement flexibility verification of the universal robot, furnace eye recognition accuracy verification of the infrared positioning system, and distance adjustment accuracy detection of the equidistant adjustment system. If the self-test fails, an alarm is triggered and the work process is locked.

3. The method for high-energy opening of a calcium carbide furnace device according to claim 1, characterized in that: In step S2, the target bore information includes bore diameter (300-500mm), location distribution, and adjacent spacing (1.5-2.0m). The operating parameters include bore blockage thickness and internal pressure. The laser energy output parameters are adapted to the blockage thickness: light blockage (thickness < 100mm, pressure < 0.03MPa) corresponds to a 5-8kW continuous output mode, and heavy blockage (thickness ≥ 100mm, pressure ≥ 0.05MPa) corresponds to a 12-15kW pulse output mode (pulse frequency 100-500Hz).

4. The method for high-energy opening of a calcium carbide furnace device according to claim 1, characterized in that: In step S3, the coarse positioning refers to the equidistant adjustment system adjusting the universal robot base to the initial working area corresponding to the target furnace eye according to the preset furnace eye spacing parameters. The initial working area is a preset area 1.0m ± 0.05m away from the furnace surface. The deviation of the precise alignment does not exceed ± 1mm. The attitude locking refers to controlling the angle formed by the central axis of the laser emitter and the furnace surface (furnace eye reference plane) between 89.5° and 90.5°, and the actual measured value of this angle does not deviate from 90° by more than 0.5°. After completion, the mechanical locking mechanism is triggered to lock.

5. The method for high-energy opening of a calcium carbide furnace device according to claim 1, characterized in that: In step S4, the cooling circuit includes a water-cooled circuit formed by the cooling system. The composite trajectory includes a spiral trajectory with a pitch of 5mm in the initial stage (melting through the core blockage layer) and a radial trajectory with a 15° interval in the advanced stage (expanding the furnace eye range). The dynamic feedback includes furnace eye position change feedback refreshed by the infrared positioning system every 0.5 seconds and temperature data feedback collected in real time by the cooling system.

6. The method for high-energy opening of a calcium carbide furnace device according to claim 1, characterized in that: The adaptive adjustment mentioned in step S4 is as follows: when the infrared positioning system detects that the position of the furnace eye is offset by more than 5mm, it sends a correction signal to the universal robot to adjust the alignment posture of the laser emitting component; when the cooling system detects that the equipment temperature exceeds the preset threshold of 3℃, it automatically increases the water flow rate to further enhance the cooling intensity; if the temperature continues to exceed the threshold, it triggers an emergency shutdown of the laser system.

7. The method for high-energy opening of a calcium carbide furnace device according to claim 1, characterized in that: The criteria for successfully opening the furnace eye in step S4 are: the laser scanning trajectory covers the preset furnace eye diameter, the infrared detection shows that the temperature in the furnace eye area rises sharply (≥700℃) and the pressure inside the furnace drops to a safe range (<0.02MPa).

8. The method for high-energy opening of a calcium carbide furnace device according to claim 1, characterized in that: In step S5, the stepped shutdown involves gradually reducing the laser energy in a gradient of 15kW→10kW→5kW→0 (each level lasting 5 seconds); the cooling system runs for a delay until the laser emitter cavity temperature is ≤50℃ and the focusing lens temperature is ≤60℃ before shutting down; the full-cycle data includes the furnace eye number, opening time, laser energy consumption, and equipment operating temperature; the robot and adjustment system are reset to the standby position 5m away from the calcium carbide furnace body and locked.

9. The method for high-energy opening of a calcium carbide furnace device according to claim 1, characterized in that: The control cabinet, cooling system, universal robot, infrared positioning system, equidistant adjustment system, laser emitter, and energy regulation system are electrically or signal-connected to form a closed-loop control eye-opening operation system.

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