A method and system for monitoring bubbling in a glass production line furnace
By introducing multi-parameter monitoring and automated control into the glass production line's melting furnace, the subjectivity of manual observation and the problems of high-temperature radiation have been solved, enabling real-time and accurate monitoring of the bubbling state, reducing defects and losses, and improving the stability and safety of the production line.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-03-03
- Publication Date
- 2026-06-05
AI Technical Summary
Existing methods for monitoring bubble formation in glass production lines rely on manual observation, which is highly subjective and cannot accurately monitor bubble diameter, bubble frequency, gas pressure, and bubbler temperature in real time. This poses a risk of high-temperature radiation, leading to quality defects and furnace shutdown losses.
Employing a multi-parameter monitoring module, data acquisition and processing unit, and automated control components, it acquires and analyzes bubble diameter, bubble frequency, gas pressure, and temperature in real time. Combined with optical signal transceiver components, pressure sensors, and temperature sensors, it dynamically adjusts the preset parameter range to achieve automated and precise monitoring, and eliminates the need for manual intervention through tiered early warning.
It achieves real-time, precise, and automated monitoring of the bubbling state, reducing quality defects and furnace shutdown losses, lowering the risk of artificial high-temperature radiation, and improving control level and production stability.
Smart Images
Figure CN122149566A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of glass melting technology, and in particular to a method and system for monitoring bubbling in a glass production line furnace. Background Technology
[0002] As a core piece of equipment in glass production, the melting furnace relies heavily on bubbling technology as a key auxiliary process. By blowing gas into the high-temperature molten glass through a bubbler at the bottom of the furnace, bubble defects can be reduced and the homogenization of the molten glass can be strengthened. Its working condition directly determines product quality and the stability of the melting furnace. With the glass manufacturing industry moving towards high-end products, the requirements for stability and precision in the bubbling process have significantly increased, but existing monitoring methods and systems have obvious shortcomings.
[0003] Most production lines still rely on manual observation, using industrial televisions or observation glasses. This method is highly subjective and cannot accurately monitor bubble diameter and frequency in real time, easily leading to quality defects or furnace shutdowns and hindering refined control. Furthermore, in the high-temperature environment of the kiln, prolonged manual observation exposes workers to intense heat radiation, posing a risk of burns. Summary of the Invention
[0004] Based on this, it is necessary to address the problems of subjective nature of manual observation, the inability to accurately monitor bubble diameter, bubble frequency, gas pressure, and bubbler temperature in real time, the risk of burns to personnel due to high-temperature heat radiation, and the need to propose a bubble monitoring method and system for glass production line melting furnaces. By setting up multi-parameter monitoring modules, data acquisition and processing units, and automated control components, real-time accurate and automated monitoring of multiple bubble parameters can be achieved, eliminating manual observation, removing personnel safety risks, reducing defects and losses, and improving control levels.
[0005] To achieve the above objectives, the present invention adopts the following technical solution: A method for monitoring bubbling in a glass production line furnace includes: S1: Retrieve a preset parameter range, which includes bubble diameter, bubble frequency, bubbling gas pressure, and bubbler temperature, and dynamically adjust the preset parameter range based on historical normal monitoring data at preset intervals; S2: Obtain bubble diameter and bubble frequency through an optical signal transceiver component installed in the furnace, obtain bubbling gas pressure through a pressure sensor on the gas delivery pipeline, and obtain bubbler temperature through a temperature sensor installed close to the bubbler; S3: Analyze and process the acquired parameters, and compare them with the preset parameter range to determine whether the parameters exceed the limit and whether the bubbling state is abnormal; S4: If the bubbling state is abnormal, a corresponding warning signal will be issued according to the abnormality level; if the bubbling state is normal, real-time monitoring and parameter collection will continue.
[0006] In one embodiment, obtaining the bubble diameter and bubble frequency through the optical signal transceiver component in S2 includes: emitting an optical signal to the molten glass by an optical signal transmitter, receiving the signal after reflection by the bubble, converting the optical signal into a current signal by a signal converter, and calculating the bubble diameter and bubble frequency based on the amplitude and frequency of the current signal.
[0007] In one embodiment, S2 further includes: synchronously acquiring real-time flow parameters of the bubbling gas through a flow sensor on the bubbling gas delivery pipeline.
[0008] In one embodiment, S3 further includes: jointly judging the bubbling gas pressure parameter and the flow parameter: when the pressure parameter is higher than the preset upper limit and the flow parameter is lower than the preset lower limit, it is determined that the bubbler has a blockage fault; when the pressure parameter is lower than the preset lower limit and the flow parameter is higher than the preset lower limit, it is determined that the bubbler has a leakage fault; if a blockage or leakage fault is determined, a corresponding fault warning command is generated.
[0009] In one embodiment, S3 further includes: storing real-time monitoring parameters, historical data, and anomaly records, supporting real-time data updates and historical queries.
[0010] In one embodiment, S4 issues different warning signals according to the level of abnormality, including: when the parameter slightly exceeds the limit and the duration is less than the preset duration, a level one warning is issued, and only an intermittent audible and visual alarm is activated; when the parameter seriously exceeds the limit, the timeout is continuous, or a blockage / leakage fault is determined, a level two warning is issued, the audible and visual alarm is controlled to continue, and the warning information and abnormal data are pushed to the staff terminal through the communication unit.
[0011] In one embodiment, the system includes: a parameter preset module, used to retrieve a preset parameter range including bubble diameter, bubble frequency, gas pressure, and bubbler temperature, and dynamically adjust the preset parameter range at preset time intervals; a data acquisition module, including an optical signal transceiver component, a pressure sensor, and a temperature sensor, used to collect the bubble diameter, bubble frequency, bubbling gas pressure, and bubbler temperature during the bubbling process in the melting furnace, respectively; a judgment module, used to analyze and process the collected parameters, compare them with the preset parameter range, determine whether the parameters exceed the limits, whether the bubbling state is abnormal, and be able to judge the bubbler blockage or leakage fault based on the pressure and flow parameters; and an early warning module, used to issue a first-level or second-level early warning signal according to the abnormality level, and be able to send early warning information to the staff terminal.
[0012] In one embodiment, the data acquisition module further includes a flow sensor, which is installed on the bubbling gas delivery pipeline and works in conjunction with a pressure sensor for fault diagnosis.
[0013] In one embodiment, the optical signal transceiver assembly includes an optical signal transmitter and an optical signal receiver, with the transmitter and receiver positioned opposite each other at the top and bottom of the furnace; the optical signal receiver is connected to a signal converter, which converts the optical signal into a current signal and transmits it to a determination module to calculate the bubble diameter and bubble frequency.
[0014] In one embodiment, the early warning module includes an audible and visual alarm and a communication unit: during a first-level early warning, only an intermittent audible and visual alarm is activated; during a second-level early warning, the audible and visual alarms are continuously activated, and the early warning information and abnormal data are sent to the terminal through the communication unit to achieve remote early warning.
[0015] By acquiring four key parameters of bubbling in real time and comparing them with dynamically adjusted preset ranges, the system achieves precise monitoring of bubbling status and automatic early warning of anomalies, reducing glass bubble defects and furnace shutdown losses, and mitigating the risk of high-temperature radiation to operators. Its closed-loop monitoring and dynamic parameter adjustment design improves monitoring adaptability and accuracy, reduces labor costs, and ensures stable furnace operation. Attached Figure Description
[0016] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.
[0017] in: Figure 1 This is a flowchart of a glass production line melting furnace bubbling monitoring method according to an embodiment of the present invention; Figure 2 This is a schematic diagram of a glass production line furnace bubbling monitoring system according to an embodiment of the present invention. Detailed Implementation
[0018] To facilitate understanding of the present invention, a more detailed description is provided below with reference to the accompanying drawings and specific embodiments. Unless otherwise defined, all technical and scientific terms used in this specification have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used in this specification is for the purpose of describing particular embodiments only and is not intended to limit the invention.
[0019] To address the issues of subjective nature and inability to accurately monitor bubble diameter, bubble frequency, gas pressure, and bubbler temperature in real-time using existing technologies, as well as the risk of burns from high-temperature heat radiation to personnel, a method and system for monitoring bubble formation in glass production line melting furnaces is proposed. By setting up multi-parameter monitoring modules, data acquisition and processing units, and automated control components, real-time accurate and automated monitoring of multiple bubble formation parameters is achieved, eliminating manual observation, removing personnel safety risks, reducing defects and losses, and improving control levels.
[0020] The following will be combined with the appendix Figure 1 and appendix Figure 2 The present invention provides a detailed description of a method and system for monitoring bubbling in a glass production line melting furnace.
[0021] Please see Figure 1 and Figure 2 , Figure 1 This is a flowchart of a glass production line melting furnace bubbling monitoring method according to an embodiment of the present invention; Figure 2 This is a schematic diagram of a glass production line furnace bubbling monitoring system according to an embodiment of the present invention.
[0022] A method for monitoring bubbling in a glass production line furnace includes: S1: Retrieve a preset parameter range, which includes bubble diameter, bubble frequency, bubbling gas pressure, and bubbler temperature, and dynamically adjust the preset parameter range based on historical normal monitoring data at preset intervals; S2: Obtain bubble diameter and bubble frequency through an optical signal transceiver component installed in the furnace, obtain bubbling gas pressure through a pressure sensor on the gas delivery pipeline, and obtain bubbler temperature through a temperature sensor installed close to the bubbler; S3: Analyze and process the acquired parameters, and compare them with the preset parameter range to determine whether the parameters exceed the limit and whether the bubbling state is abnormal; S4: If the bubbling state is abnormal, a corresponding warning signal will be issued according to the abnormality level; if the bubbling state is normal, real-time monitoring and parameter collection will continue.
[0023] Specifically, S1: Retrieve preset parameter ranges, including a bubble diameter preset range of 0.8-1.2mm, a bubble frequency preset range of 8-12 times / second, a bubble gas pressure preset range of 0.3-0.5MPa, and a bubbler temperature preset range of 300-500℃. Every 12 hours, based on historical normal monitoring data from the past 30 days, dynamically adjust the preset parameter ranges using a linear regression algorithm to ensure the parameters are adapted to the real-time operating conditions of the melting furnace. S2: Install optical signal transceiver components at corresponding positions on both sides of the melting furnace to acquire the bubble diameter and bubble frequency; install a pressure sensor on the main bubble gas delivery pipeline to collect the bubble gas pressure in real time; and install a temperature sensor attached to the outer wall of the top of the bubbler to collect the bubbler temperature. S3: Filter and reduce noise on the acquired bubble diameter, bubble frequency, gas pressure, and bubbler temperature parameters to remove interference data. Then compare each parameter with the preset parameter ranges in S1 to determine whether each parameter exceeds the limit, and comprehensively judge whether the overall bubbling status is abnormal. S4: If the bubbling state is determined to be abnormal, a corresponding warning signal is issued according to the abnormality level; if the state is normal, various parameters are continuously collected and monitored in real time, and steps S2-S4 are executed in a loop.
[0024] By dynamically adjusting the preset parameter range and combining multi-parameter collaborative monitoring and anomaly judgment, the problem of strong subjectivity and inability to monitor accurately in real time by manual observation is solved, realizing automated and refined monitoring of bubbling status, reducing quality defects and furnace shutdown losses, and avoiding the safety risks of manual high-temperature operation.
[0025] In one embodiment, obtaining the bubble diameter and bubble frequency through the optical signal transceiver component in S2 includes: emitting an optical signal to the molten glass by an optical signal transmitter, receiving the signal after reflection by the bubble, converting the optical signal into a current signal by a signal converter, and calculating the bubble diameter and bubble frequency based on the amplitude and frequency of the current signal.
[0026] Specifically, in S2, the optical signal transceiver component includes a laser transmitter and a photoelectric receiver. The laser transmitter is installed at the top of the melting furnace, and the photoelectric receiver is installed at the bottom of the melting furnace. Their axes coincide and are perpendicular to the surface of the molten glass. The laser transmitter emits a continuous laser signal into the molten glass. When the laser signal encounters a bubble in the molten glass, it is reflected. The reflected laser signal is captured by the photoelectric receiver. The photoelectric receiver is connected to a signal converter, which converts the received optical signal into a corresponding current signal. The bubble diameter is calculated based on the amplitude of the current signal (amplitude is positively correlated with bubble diameter), and the bubble frequency is calculated based on the frequency of the current signal. The calculation results are then transmitted to the subsequent analysis stage.
[0027] By combining laser reflection with signal conversion, precise acquisition of bubble diameter and bubble frequency is achieved, with acquisition errors ≤ ±0.05mm and ±0.2 times / second, solving the problem of inaccurate bubble diameter and bubble frequency monitoring in existing monitoring methods and providing reliable data support for bubble state determination.
[0028] In one embodiment, S2 further includes: synchronously acquiring real-time flow parameters of the bubbling gas through a flow sensor on the bubbling gas delivery pipeline.
[0029] Specifically, in S2, a flow sensor is installed on a branch line of the bubbling gas delivery pipeline, close to the pressure sensor. The flow sensor works synchronously with the pressure sensor to collect real-time flow parameters of the bubbling gas. The collection frequency is the same as that of the pressure sensor (once every 0.5 seconds). The collected flow parameters, along with pressure parameters, bubble diameter, bubble frequency, and bubbler temperature parameters, are transmitted to the analysis and processing stage to achieve multi-dimensional parameter collaborative collection.
[0030] By supplementing the collection of flow parameters and enriching the dimensions of monitoring parameters, flow data support is provided for subsequent bubbling device fault diagnosis, avoiding the problem that faults cannot be accurately identified by relying on a single parameter, and further improving the comprehensiveness and reliability of bubbling device monitoring.
[0031] In one embodiment, S3 further includes: jointly judging the bubbling gas pressure parameter and the flow parameter: when the pressure parameter is higher than the preset upper limit and the flow parameter is lower than the preset lower limit, it is determined that the bubbler has a blockage fault; when the pressure parameter is lower than the preset lower limit and the flow parameter is higher than the preset lower limit, it is determined that the bubbler has a leakage fault; if a blockage or leakage fault is determined, a corresponding fault warning command is generated.
[0032] Specifically, after analyzing and processing the various parameters, in addition to comparing each parameter with the preset range, the bubbling gas pressure parameter and flow rate parameter are also jointly judged: the preset gas flow rate range is 10-15m³ / h. 3 / h, when the pressure parameter collected by the pressure sensor is >0.5MPa (preset upper limit) and the flow parameter collected by the flow sensor is <10m³ / h. 3 When the pressure parameter is less than 0.3 MPa (preset lower limit) and the flow rate is greater than 15 m³ / h, the bubbler is immediately identified as clogged; when the pressure parameter is less than 0.3 MPa (preset lower limit) and the flow rate is greater than 15 m³ / h, the bubbler is immediately identified as clogged. 3 When the time reaches / h (preset upper limit), a leak is detected in the bubbler; if a blockage or leak is detected, a corresponding fault warning command is immediately generated and transmitted to the warning module.
[0033] By combining pressure and flow parameters, the system can accurately identify bubbling blockage and leakage faults with a response time of ≤1 second. This avoids misjudgment based on a single parameter, allows for timely detection of core bubbling faults, reduces losses such as furnace shutdown and scrapped glass products caused by the escalation of the fault, and improves the operational stability of the furnace.
[0034] In one embodiment, S3 further includes: storing real-time monitoring parameters, historical data, and anomaly records, supporting real-time data updates and historical queries.
[0035] Specifically, in S3, while analyzing and processing parameters, real-time monitored data such as bubble diameter, bubble frequency, gas pressure, bubbler temperature (including supplementary flow parameters), parameter comparison results, and anomaly judgment results are stored in the embedded storage module. The storage module supports real-time data updates, updating real-time data once every 0.5 seconds, while retaining nearly 180 days of historical monitoring data and all anomaly records. Staff can use the operating terminal to query historical data by time range, parameter type, and anomaly type, which facilitates tracing the changing patterns of the bubbling state and troubleshooting the causes of faults.
[0036] Through the storage and retrieval mechanism, the real-time change trajectory and abnormal event information of key parameters such as bubble diameter, bubble frequency, gas pressure, bubbler temperature and flow rate during the bubbling process of the melting furnace can be completely preserved. This enables comprehensive storage and convenient retrieval of monitoring data, providing data support for the optimization of the melting furnace bubbling process, fault tracing, and operational review. It also facilitates staff to summarize experience and further improve the level of refined control of the bubbling process, while meeting the data traceability protection requirements of the patent.
[0037] In one embodiment, S4 issues different warning signals according to the level of abnormality, including: when the parameter slightly exceeds the limit and the duration is less than the preset duration, a level one warning is issued, and only an intermittent audible and visual alarm is activated; when the parameter seriously exceeds the limit, the timeout is continuous, or a blockage / leakage fault is determined, a level two warning is issued, the audible and visual alarm is controlled to continue, and the warning information and abnormal data are pushed to the staff terminal through the communication unit.
[0038] Specifically, in S4, the preset abnormality level judgment criteria are as follows: when the parameter slightly exceeds the limit (within 10% of the preset range) and the duration is <5 seconds, it is judged as a level one warning. At this time, only the audible and visual intermittent alarm is activated (the alarm frequency is 1 time / second, and each alarm lasts for 0.5 seconds), which does not affect the normal operation of the production line and reminds the staff to pay attention to changes in the working conditions. When the parameter seriously exceeds the limit (exceeds the preset range by 10% or more), the duration of the slight exceedance is ≥5 seconds, or it is determined that there is a bubbler blockage / leakage fault, it is judged as a level two warning. At this time, the audible and visual alarm is controlled to continuously alarm, and the warning information and corresponding abnormal data (such as the over-limit parameter value and fault type) are pushed to the staff's mobile terminal and the workshop monitoring terminal through the 4G communication unit to achieve real-time reminders.
[0039] By implementing tiered early warning systems, differentiated alerts can be provided for different levels of anomalies. This prevents minor anomalies from triggering excessive alarms and impacting production, and avoids serious anomalies from going unnoticed and causing the malfunctions to escalate. At the same time, remote push notifications ensure that staff can promptly grasp the situation, improving the efficiency of fault handling and reducing losses.
[0040] A glass production line melting furnace bubbling monitoring system includes: a parameter preset module, used to retrieve a preset parameter range including bubble diameter, bubble frequency, gas pressure, and bubbler temperature, and dynamically adjust the preset parameter range at preset time intervals; a data acquisition module, including an optical signal transceiver component, a pressure sensor, and a temperature sensor, used to collect the bubble diameter, bubble frequency, bubbling gas pressure, and bubbler temperature during the melting furnace bubbling process, respectively; a judgment module, used to analyze and process the collected parameters, compare them with the preset parameter range, determine whether the parameters exceed the limits, whether the bubbling state is abnormal, and be able to judge the bubbler blockage or leakage fault based on the pressure and flow parameters; and an early warning module, used to issue a first-level or second-level early warning signal according to the abnormality level, and be able to send early warning information to the operator's terminal.
[0041] Specifically, the system includes a parameter preset module, a data acquisition module, a judgment module, and an early warning module. These modules are electrically connected and work collaboratively. The parameter preset module uses a microcontroller with a built-in preset parameter database, storing initial preset ranges for bubble diameter, bubble frequency, gas pressure, and bubbler temperature. It retrieves historical normal monitoring data every preset time interval (12 hours) and dynamically adjusts the preset parameter ranges using a built-in algorithm. The data acquisition module includes an optical signal transceiver, a pressure sensor, and a temperature sensor. The optical signal transceiver is used to collect bubble diameter and bubble frequency data; the pressure sensor is installed on the gas delivery pipeline to collect bubbler gas pressure; and the temperature sensor is positioned close to the bubbler to collect bubbler temperature data. The judgment module uses a PLC controller to receive parameters transmitted from the data acquisition module. After filtering and noise reduction, the parameters are compared with the preset parameter ranges to determine if the parameters exceed limits or if the bubbler status is abnormal. It can also combine pressure and flow parameters to jointly determine faults. The early warning module is connected to the judgment module and issues a level one or level two early warning signal based on the abnormality level output by the judgment module. It can also send early warning information to the operator's terminal.
[0042] With its simple structure and strong adaptability, the system, which integrates microcontroller, multi-sensor collaborative data acquisition, PLC, hierarchical early warning and terminal linkage, can be directly integrated into the existing glass production line melting furnace to achieve automated and comprehensive monitoring of the bubbling state. This solves the problems of missing monitoring systems and inaccurate monitoring in the existing system, improves product quality and melting furnace operation stability, and reduces labor costs and safety risks.
[0043] In one embodiment, the data acquisition module further includes a flow sensor, which is installed on the bubbling gas delivery pipeline and works in conjunction with a pressure sensor for fault diagnosis.
[0044] Specifically, the data acquisition module also includes a flow sensor, which is an electromagnetic flow sensor with an accuracy class of 0.5. It is installed on a branch pipe of the bubbling gas delivery pipeline, adjacent to the pressure sensor (with a spacing of ≤5cm). The flow sensor and the pressure sensor collect data synchronously and transmit the collected real-time flow parameters of the bubbling gas to the judgment module. Together with the pressure parameters, the judgment module judges whether the bubbler is blocked or leaking, ensuring the accuracy of the fault judgment.
[0045] By using flow sensors, the functionality of the data acquisition module is improved, providing key flow data for fault diagnosis. This avoids misjudgment or missed diagnosis of faults due to a lack of flow parameters, further enhancing the system's fault identification capability and ensuring that bubbler faults can be detected in a timely and accurate manner.
[0046] In one embodiment, the optical signal transceiver assembly includes an optical signal transmitter and an optical signal receiver, with the transmitter and receiver positioned opposite each other at the top and bottom of the furnace; the optical signal receiver is connected to a signal converter, which converts the optical signal into a current signal and transmits it to a determination module to calculate the bubble diameter and bubble frequency.
[0047] Specifically, the optical signal transceiver assembly includes an optical signal transmitter and an optical signal receiver. The optical signal transmitter is a semiconductor laser transmitter with a wavelength of 650nm and a power of 5mW. It is installed in a pre-reserved mounting hole at the top of the melting furnace and emits optical signals vertically toward the surface of the molten glass. The optical signal receiver is a photodiode receiver, which is installed at the bottom of the melting furnace, coinciding with the axis of the optical signal transmitter. It is used to receive the optical signals reflected by the bubbles. The optical signal receiver is connected to a signal converter via a signal line. The signal converter is an A / D converter that converts the received analog optical signal into a digital current signal and transmits it to the determination module. The determination module calculates the bubble diameter and bubble frequency based on the amplitude and frequency of the current signal.
[0048] By using optical signal transmitters and receivers, the accuracy and stability of bubble diameter and frequency acquisition are ensured, adapting to the high temperature and complex working environment of the melting furnace, avoiding data distortion caused by optical signal interference, and providing reliable protection for accurate system monitoring.
[0049] In one embodiment, the early warning module includes an audible and visual alarm and a communication unit: during a first-level early warning, only an intermittent audible and visual alarm is activated; during a second-level early warning, the audible and visual alarms are continuously activated, and the early warning information and abnormal data are sent to the terminal through the communication unit to achieve remote early warning.
[0050] Specifically, the early warning module includes an audible and visual alarm and a communication unit. The audible and visual alarm is installed in the workshop monitoring room and uses a combination of red LED lights and a buzzer. During a level one warning, the LED lights flash intermittently and the buzzer sounds intermittently (1 time / second). During a level two warning, the LED lights remain constantly lit and the buzzer sounds continuously with adjustable volume. The communication unit uses a 4G / 5G dual-mode communication module to establish a wireless connection with the staff's mobile terminals and the workshop monitoring host. During a level two warning, the communication unit receives the warning information and abnormal data transmitted by the judgment module and quickly pushes it to the corresponding terminal. It also supports terminal feedback of handling instructions to achieve closed-loop management of warning and handling.
[0051] By implementing tiered early warning and remote push functions, staff can promptly grasp abnormal situations. Closed-loop management improves the efficiency of fault handling, further reduces production losses caused by abnormal situations, and enhances the system's practicality and operability.
[0052] This invention provides a method and system for monitoring bubbling in glass production line melting furnaces, addressing the shortcomings of existing monitoring methods, such as reliance on manual labor, strong subjectivity, and insufficient accuracy. It replaces manual observation, eliminates high-temperature safety hazards, reduces labor intensity, and improves the objectivity and reliability of monitoring. It achieves automated and accurate acquisition of multiple parameters, providing support for anomaly detection. Parameters can be dynamically adjusted to adapt to different glass production needs, accurately identifying bubbling anomalies and equipment malfunctions, providing tiered early warnings and traceable information, thus aiding in process optimization. Some embodiments support coordinated handling, improving production efficiency. The system is highly adaptable, heat-resistant, long-lasting, and has low maintenance costs. The above embodiments are only used to illustrate the technical solutions of this invention and are not intended to limit it. Under the framework of this invention, the technical features of the above embodiments or different embodiments can be combined, the steps can be implemented in any order, and many other variations of different aspects of this invention exist as described above. For simplicity, these variations are not provided in detail. Although the invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. These modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this invention.
Claims
1. A method for monitoring bubbling in a glass production line melting furnace, characterized in that, include: S1: Retrieve a preset parameter range, the preset parameters including bubble diameter, bubble frequency, bubbling gas pressure and bubbler temperature, and dynamically adjust the preset parameter range according to historical normal monitoring data at preset intervals; S2: The bubble diameter and bubble frequency are obtained through the optical signal transceiver component set in the melting furnace, the bubbling gas pressure is obtained through the pressure sensor on the gas delivery pipeline, and the bubbler temperature is obtained through the temperature sensor set close to the bubbler. S3: Analyze and process the acquired parameters, and compare them with the preset parameter range to determine whether the parameters exceed the limit and whether the bubbling state is abnormal; S4: If the bubbling state is abnormal, a corresponding warning signal will be issued according to the abnormality level; if the bubbling state is normal, real-time monitoring and parameter collection will continue.
2. The method according to claim 1, characterized in that, In S2, obtaining the bubble diameter and bubble frequency through the optical signal transceiver component includes: emitting an optical signal from the optical signal transmitter to the molten glass, receiving the signal after reflection by the bubble, converting the optical signal into a current signal through a signal converter, and calculating the bubble diameter and bubble frequency based on the amplitude and frequency of the current signal.
3. The method according to claim 1, characterized in that, S2 also includes: synchronously collecting real-time flow parameters of bubbling gas through a flow sensor on the bubbling gas delivery pipeline.
4. The method according to claim 3, characterized in that, S3 also includes: jointly judging the bubbling gas pressure parameter and flow parameter: when the pressure parameter is higher than the preset upper limit and the flow parameter is lower than the preset lower limit, it is determined that the bubbler has a blockage fault; when the pressure parameter is lower than the preset lower limit and the flow parameter is higher than the preset lower limit, it is determined that the bubbler has a leakage fault; if a blockage or leakage fault is determined, a corresponding fault warning command is generated.
5. The method according to claim 1, characterized in that, S3 also includes: storing real-time monitoring parameters, historical data and anomaly records, supporting real-time data updates and historical queries.
6. The method according to claim 1, characterized in that, S4 issues different warning signals based on the level of abnormality, including: when the parameter slightly exceeds the limit and the duration is less than the preset time, a level 1 warning is issued, and only an intermittent audible and visual alarm is activated; when the parameter seriously exceeds the limit, the timeout is continuous, or a blockage / leakage fault is determined, a level 2 warning is issued, which controls the continuous audible and visual alarm and pushes the warning information and abnormal data to the staff terminal through the communication unit.
7. A glass production line melting furnace bubbling monitoring system, characterized in that, include: The parameter preset module is used to retrieve a preset parameter range including bubble diameter, bubble frequency, gas pressure and bubbler temperature, and dynamically adjust the preset parameter range at preset time intervals. The data acquisition module includes an optical signal transceiver component, a pressure sensor, and a temperature sensor, which are used to collect the bubble diameter, bubble frequency, bubbling gas pressure, and bubbler temperature during the bubbling process in the melting furnace, respectively. The judgment module is used to analyze and process the collected parameters, compare them with the preset parameter range, determine whether the parameters exceed the limit, whether the bubbling state is abnormal, and can judge the bubbler blockage or leakage fault based on the pressure and flow parameters. The early warning module is used to issue level one or level two early warning signals based on the level of abnormality, and can also send early warning information to staff terminals.
8. The system according to claim 7, characterized in that, The data acquisition module also includes a flow sensor, which is installed on the bubbling gas delivery pipeline and works in conjunction with the pressure sensor for fault diagnosis.
9. The system according to claim 7, characterized in that, The optical signal transceiver assembly includes an optical signal transmitter and an optical signal receiver, with the transmitter and receiver positioned opposite each other at the top and bottom of the furnace. The optical signal receiver is connected to a signal converter, which converts the optical signal into a current signal and transmits it to the determination module to calculate the bubble diameter and bubble frequency.
10. The system according to claim 7, characterized in that, The early warning module includes an audible and visual alarm and a communication unit: for a first-level early warning, only an intermittent audible and visual alarm is activated; for a second-level early warning, the audible and visual alarms are continuous, and the early warning information and abnormal data are sent to the terminal through the communication unit to achieve remote early warning.