A kiln regenerator grid anti-blockage and unblocking control system

Abstract

This invention provides a kiln regenerator grid anti-clogging and unblocking control system, belonging to the field of kiln technology. It solves the technical problems of high labor intensity and low efficiency in existing manual unblocking methods, as well as inaccurate positioning and difficulty in evaluating the unblocking effect of simple mechanical unblocking. It includes a detection and positioning subsystem, an execution unblocking subsystem, a verification and evaluation subsystem, a control and decision-making subsystem, and a safety and assurance subsystem. This invention achieves accurate identification, positioning, and component analysis of blockages through multi-sensor fusion and adaptive algorithms, constructing an intelligent closed loop from perception and diagnosis to decision-making, improving unblocking accuracy and efficiency. Relying on a moving mechanism and modular execution unit, it realizes fully automated operation of the positioning-melting-purging-verification process, forming an efficient and reliable unblocking closed loop. It integrates active cooling, multiple safety protections, and real-time status monitoring mechanisms to ensure stable system operation, supports fault early warning and predictive maintenance, and effectively manages operational risks.

Description

Technical Field

[0001] This invention belongs to the field of kiln technology and relates to an anti-blockage and unblocking control system, particularly an anti-blockage and unblocking control system for the grid body of a kiln regenerator. Background Technology

[0002] The regenerator chamber of a kiln is a key heat exchange device in high-temperature kiln systems in industries such as glass and metallurgy. Its internal grid serves as the heat storage medium, playing a crucial role in recycling waste heat from flue gas and preheating combustion air. During long-term operation, impurities in the fuel and ash in the flue gas form molten sulfates and silicates under high temperatures. These substances cool and solidify within the pores of the grid, leading to a decrease in the grid's porosity. This not only significantly reduces the kiln's thermal efficiency and increases energy consumption but also can cause product defects due to blockages detaching and entering the molten glass.

[0003] Currently, manual dredging and simple mechanical dredging are the main methods used. Manual dredging is labor-intensive, has a harsh working environment, and is inefficient. While simple mechanical dredging avoids direct personnel entry, it suffers from problems such as inaccurate positioning, poor temperature control, and difficulty in evaluating the dredging effect. Furthermore, it cannot target the specific components of the blockage. Summary of the Invention

[0004] The purpose of this invention is to address the aforementioned problems in existing technologies by proposing a kiln regenerator grid anti-blockage and unblocking control system. The technical problem to be solved by this invention is the intelligent operation of the entire process of accurate detection, intelligent decision-making, automatic unblocking, and effect verification of regenerator grid blockage.

[0005] The objective of this invention can be achieved through the following technical solutions: A kiln regenerator grid anti-blocking and unblocking control system includes a detection and positioning subsystem, an execution unblocking subsystem, a verification and evaluation subsystem, a control and decision-making subsystem, and a safety and assurance subsystem. The detection and positioning subsystem includes an infrared thermal imaging detection module and a multi-sensor fusion positioning module; the execution unblocking subsystem includes a moving guide rail module, a segmented combustion and melting module, and a high-pressure purging module; the verification and evaluation subsystem includes a result judgment module; the control and decision-making subsystem includes a central control module, a data fusion and decision-making module, and a process control module; and the safety and assurance subsystem includes a thermal management module, an emergency safety module, and a status monitoring module. The infrared thermal imaging detection module uses non-contact infrared thermal imaging technology to collect global temperature field data of the lattice and identify areas of abnormal temperature. The multi-sensor fusion positioning module integrates data from multiple sensor sources to accurately calculate the three-dimensional spatial coordinates and attributes of the blockage. The moving guide rail module carries and drives the end effector, moving it precisely and stably to the target blockage location according to control commands. The segmented combustion and melting module precisely controls the high-temperature flame according to the type of blockage, heating and melting the blockage in segments according to a preset strategy to soften or liquefy it. After the melting process, the high-pressure purging module uses high-pressure airflow to remove the softened blockage from the lattice holes and collects the generated dust. The result judgment module compares the detected porosity with a preset standard, determines whether it meets the standard, and generates instructions to continue or terminate the operation accordingly. The central control module, serving as the system's hardware control core and human-machine interface, is responsible for underlying logic operations, command issuance, and equipment status monitoring. The data fusion and decision-making module processes front-end sensing data, performs blockage location and path planning, and manages and optimizes unblocking process parameters. The process control module ensures that the system strictly follows the preset technical route sequence and manages the cyclical unblocking process in cases of non-compliance. The thermal management module ensures the long-term stable operation of core components in the high-temperature environment of the kiln through active cooling measures and passive refractory material protection, avoiding thermal damage. The emergency safety module designs multiple active protection mechanisms for gas and high-temperature hazards, which are automatically triggered in abnormal situations to ensure equipment and personnel safety. The status monitoring module performs periodic self-checks and real-time diagnostics on the health status of key system components, enabling fault warnings and predictive maintenance.

[0006] The working principle of this invention is as follows: After the system is started, the infrared thermal imaging detection module in the detection and positioning subsystem first performs a non-contact panoramic real-time scan of the grid surface, collects global temperature field data, and identifies areas with abnormal temperatures. Subsequently, the multi-sensor fusion positioning module integrates data from multiple sensors to accurately calculate the three-dimensional spatial coordinates and characteristic attributes of the blockage. The unblocking subsystem then responds, and the moving guide module drives the end effector to move precisely to the target position based on the obtained coordinate information. The segmented combustion and melting module calls the corresponding process parameters according to the type of blockage and implements segmented heating and melting through a precisely controlled high-temperature flame. The high-pressure purging module then uses high-pressure airflow to remove the molten material and collect the generated dust. After unblocking is completed, the verification and evaluation subsystem starts working, and the results are evaluated. The judgment module compares the detection data with preset standards and generates corresponding instructions. The entire process is coordinated by the control and decision-making subsystem. The central control module of this subsystem is responsible for hardware control and human-machine interaction. The data fusion and decision-making module processes the perceived data and optimizes process parameters. The process control module ensures that each link is executed in the order of "detection-location-execution-verification" and manages the cyclic dredging process when the standards are not met. The entire process is supported by the safety and protection subsystem. The thermal management module ensures the stable operation of the equipment in high-temperature environments through active cooling and passive protection. The emergency safety module implements multiple protections against gas and high-temperature hazards. The status monitoring module performs real-time diagnosis and early warning of the system's health status, ultimately forming a complete intelligent dredging solution.

[0007] The infrared thermal imaging detection module includes an infrared thermal imager unit, a thermal image data transmission unit, a temperature cloud map generation unit, a porosity detection unit, and an abnormal area identification unit. The infrared thermal imager unit uses an uncooled focal plane detector with a temperature measurement range of 100-650℃, an accuracy of ±1℃, and a frame rate of ≥30fps. It is deployed on the top of the heat storage chamber for periodic panoramic scanning. The thermal image data transmission unit achieves low-latency and interference-resistant data transmission through armored fiber optic cable or gigabit industrial Ethernet. The temperature cloud map generation unit processes and renders the one-dimensional temperature data array into a pseudo-color two-dimensional / three-dimensional temperature field distribution cloud map. The abnormal area identification unit automatically delineates the blocked area based on a preset temperature threshold and image processing algorithm. The porosity detection unit combines the data scanned by the uncooled focal plane detector with the pseudo-color two-dimensional / three-dimensional temperature field distribution cloud map to analyze the change in the uniformity of the temperature field distribution before and after unblocking to quantitatively calculate the real-time porosity.

[0008] With the above structure, after system startup, the infrared thermal imager unit deployed on the top of the heat storage chamber works first. The uncooled focal plane detector performs periodic panoramic scans of the lattice surface, acquiring the raw one-dimensional temperature data array. Subsequently, the thermal image data transmission unit uploads this massive amount of data in real time via armored fiber optic cable or gigabit industrial Ethernet in a low-latency, high-interference-resistant manner. After the data arrives at the processing system, the temperature cloud map generation unit immediately processes and renders it, generating an intuitive pseudo-color two-dimensional / three-dimensional temperature field distribution cloud map, realizing the visualization of the global temperature situation. On this basis, the anomaly area identification unit identifies the anomaly area based on the preset temperature... Thresholds and advanced image processing algorithms automatically analyze and delineate suspicious blockage areas with abnormal temperatures from cloud maps. Simultaneously, the porosity detection unit operates in sync, comprehensively utilizing the raw data scanned by the detector and the generated multi-dimensional temperature field cloud map. Through precise algorithms, it quantitatively analyzes the dynamic changes in the uniformity of the temperature field distribution of the grid before and after the unblocking operation, and then calculates the real-time porosity value. This porosity result directly serves the verification and evaluation subsystem, serving as the core basis for judging whether the unblocking effect meets the standards. The coordinates of the identified blockage area are then sent to the control and decision-making subsystem to provide accurate target positioning for subsequent precise unblocking execution.

[0009] The moving guide rail module includes a moving track assembly and a winch assembly. The moving track assembly includes a longitudinal support track, which is fixedly installed on the top of the heat storage chamber. Two symmetrically arranged travel carriages (carriage 1) are provided on the longitudinal support track, and a transverse track is provided between the two travel carriages (carriage 1). A travel carriage (carriage 2) is provided on the transverse track. The winch assembly includes a winch, which is fixedly installed at the lower end of the travel carriage (carriage 2). The winch is provided with a guide sleeve and a steel rope. The steel rope passes through the inner side of the guide sleeve and is provided with a lifting pulley.

[0010] Using the above structure, two symmetrical travel carriages can move longitudinally along the longitudinal support track, and travel carriage two can move laterally along the transverse track, together forming a two-dimensional moving platform that can be precisely positioned in the horizontal plane. Subsequently, the winch assembly is activated, and the winch winds up and unwinds the steel rope, which is suspended by the lifting pulley at its end and drives the actuator below to perform vertical lifting and lowering movements. The guide sleeve is made of high-temperature resistant alloy material and is used to guide the steel rope and other pipelines, while preventing the steel rope from swaying. Through the coordinated work of travel carriage one, travel carriage two and the winch, this module finally achieves precise positioning and stable movement of the end effector in the three-dimensional space of the heat storage chamber, ensuring that it can reach any target blockage coordinate provided by the detection and positioning subsystem.

[0011] The multi-sensor fusion positioning module includes a high-definition vision unit, a laser ranging unit, a component analysis unit, and a blockage positioning algorithm unit. The high-definition vision unit is equipped with a wide-angle, image-stabilized industrial camera with an anti-fog coating to assist in identifying surface textures and structural damage. The laser ranging unit uses a phase-type laser ranging sensor with a ranging range of 0.1-10m and an accuracy of ±1mm, used for spatial positioning and collision avoidance. The component analysis unit uses a LIBS analyzer, based on laser-induced breakdown spectroscopy technology, to identify sulfate and glass phase components. The blockage positioning algorithm unit integrates temperature, visual, distance, and component data, and outputs accurate three-dimensional coordinates through a machine learning model. The industrial camera, phase-type laser ranging sensor, and LIBS analyzer are all located at the lower end of the travel vehicle.

[0012] Using the above structure, the multi-sensor fusion positioning module starts working after the infrared thermal imaging detection module initially identifies the temperature anomaly area. The industrial camera, phase-type laser rangefinder, and LIBS analyzer move in tandem with the travel vehicle to the area above the anomaly. First, the high-definition vision unit uses an industrial camera equipped with wide-angle image stabilization to perform optical imaging of the target area, capturing the surface texture and structural damage details of the blockage. Simultaneously, the laser rangefinder uses a phase-type rangefinder to accurately measure the relative distance between the sensor and the target point, achieving spatial positioning and providing collision protection for the actuator movement. The composition analysis unit uses laser-induced breakdown spectroscopy to perform micro-area composition analysis on the blockage, quickly identifying whether it is a sulfate or glass phase substance. Finally, all the collected temperature, visual, distance, and composition data are uniformly transmitted to the blockage positioning algorithm unit. This unit uses a machine learning-based data fusion algorithm to comprehensively calculate the multi-source information, outputting the precise three-dimensional coordinates and boundary range of the blockage area in the kiln world coordinate system, providing complete spatial positioning basis for subsequent unblocking operations.

[0013] The segmented combustion and melting module includes a counterweight heat insulation block and a combustion gun assembly. The shape and specifications of the counterweight heat insulation block match the internal shape and specifications of the lattice body. The counterweight heat insulation block is a platform-like structure, wider at the top and narrower at the bottom, and is made of high-temperature resistant ceramic material. A lifting ring is located at the middle of the upper end of the counterweight heat insulation block, below the lifting pulley. A high-temperature resistant tube is located at the lower end of the counterweight heat insulation block, and a heat insulation cover is located at the lower end of the high-temperature resistant tube. The heat insulation cover has a conical structure, wider at the bottom and narrower at the top, and a mounting block is located at the lower end of the heat insulation cover. A position sensor is installed on the counterweight heat insulation block. The combustion gun assembly includes several rectangularly distributed, angle-adjustable components. The combustion nozzle and gas cluster coil are designed with a silicon carbide ceramic nozzle head and a double-layered nozzle body. The combustion nozzles are detachably mounted below the mounting block. The gas cluster coil is mounted on the second travel carriage. The shaft of the gas cluster coil is connected to the shaft of the winch. One end of the gas cluster coil is connected to an external gas transmission pipeline. The other end of the gas cluster coil passes through a guide sleeve, a counterweight heat insulation block, a high-temperature resistant pipe, and a heat insulation cover, and is connected to several combustion nozzles. Each gas pipeline of the gas cluster coil is equipped with a proportional valve and a mass flow meter.

[0014] Using the above structure, the counterweight heat insulation block, with its top-large and bottom-small platform structure, matches the internal shape of the grid, allowing it to quickly enter the grid. The counterweight heat insulation block is connected to the lifting pulley via a lifting ring and descends precisely under the drive of the moving guide rail module. Its built-in position sensor provides real-time feedback on positioning information. The combustion gun assembly is fixed to the high-temperature resistant pipe below the counterweight heat insulation block via an installation block. The combustion gun angle can be adjusted, allowing it to tilt at a certain angle for easy melting. Gas is supplied from an external gas pipeline to the gas bundle coil fitting. One end of the gas bundle coil fitting is synchronously wound and unwound with the winch shaft, while the other end passes sequentially through the guide sleeve, counterweight heat insulation block, high-temperature resistant pipe, and heat insulation cover, before being supplied to each combustion gun according to a preset flow rate via high-precision proportional valves and mass flow meters in each branch. During operation, based on the blockage location data and component analysis results, corresponding process parameters are called, and segmented heating and melting are implemented by adjusting the gas flow rate and the gun angle, achieving precise high-temperature treatment of blockages in different locations and of different types.

[0015] The high-pressure purging module consists of a high-pressure blower, an air conveying coil, a purging head, and a dust collection assembly. The dust collection assembly includes a high-temperature resistant hose, a cyclone separator, and a bag filter. The high-pressure blower is mounted on a transverse track, and the air conveying coil is mounted on a travel carriage. The shaft of the air conveying coil is connected to the shaft of a winch. One end of the air conveying coil is connected to the outlet of the high-pressure blower, and the other end passes through a guide sleeve and a counterweight insulation block, and is connected to the counterweight insulation block. Several purge heads are connected below the hot block, and the position of the purge heads matches the position of the combustion spray gun. Each air duct at the other end of the air duct bundle coil is equipped with a control valve and a flow meter. The cyclone separator and the bag filter are both located outside the heat storage room. The air inlet of the cyclone separator is connected to one end of the high-temperature resistant hose, and the other end of the high-temperature resistant hose is connected to the air outlet of the heat storage room. The air outlet of the cyclone separator is connected to the bag filter. The air outlet of the bag filter is connected to the air inlet of the high-pressure blower through a multi-way valve.

[0016] Using the above structure, the high-pressure blower generates high-pressure airflow, which is transported via the air delivery bundle coil. The rotating shaft of the air delivery bundle coil is connected to the rotating shaft of the winch, thus achieving synchronous winding and unwinding. One end is connected to the outlet of the high-pressure blower, and the other end passes through the guide sleeve and the counterweight heat insulation block in sequence, and is connected to multiple purging heads arranged below the counterweight heat insulation block. Each air delivery pipe is equipped with a control valve and a flow meter for precisely controlling the airflow output of each purging head. During the purging process, the purging head outputs high-pressure airflow, which carries the molten air through the high-pressure airflow. The blockages are cleared from the grid holes. At the same time, the cyclone separator draws the generated dust-laden hot air from the heat storage chamber outlet through a high-temperature resistant hose, and then sends it to the bag filter. The bag filter collects the dust and discharges the hot air. The hot air is then sent to the inlet of the high-pressure blower through a multi-way valve to achieve efficient separation and collection of dust, complete the unblocking operation, ensure that the emissions meet the standards, and recycle the hot air. During the melting process, the airflow of each blow head is controlled by the control valve and flow meter, and combustion air is provided to the combustion gun.

[0017] The result judgment module includes a compliance judgment unit and an instruction generation unit. The compliance judgment unit compares the real-time detected permeability with the user-preset qualification standard based on logical judgment. The instruction generation unit generates control instructions for ending the operation or repeating the dredging based on the comparison results.

[0018] Using the above structure, after the dredging operation is completed, the module starts the verification process. Its compliance judgment unit automatically compares the aperture ratio data collected and calculated in real time by the infrared thermal imaging detection module with the user's preset qualified standard threshold based on preset logic. Subsequently, the instruction generation unit immediately generates the corresponding control instruction based on the comparison result. If the aperture ratio meets the standard, an "operation end" instruction is generated. If it does not meet the standard, an "repeat dredging" instruction is generated. This instruction is sent to the control and decision subsystem, thereby driving the system to execute subsequent cyclic operations or process termination operations.

[0019] The central control module includes a central control unit, an industrial computer, and an HMI unit. The central control unit uses a Siemens S7-1500 redundant system as the logic control core, which is responsible for processing all input / output signals and executing sequential control and motion control. The industrial computer and HMI unit run configuration software and provide a graphical human-machine interface for status monitoring, parameter setting, and alarm management.

[0020] Adopting the above structure, the central control module serves as the hardware control core and human-machine interface hub of the entire system. Employing a hierarchical architecture, its central control unit is built upon a redundant Siemens S7-1500 system. As the lower-level control core, it processes all sensor input signals and actuator output commands in real time, precisely executing various low-level control tasks. Simultaneously, the industrial computer and HMI unit act as the upper-level monitoring platform, running professional configuration software. Through an intuitive graphical interface, they provide operators with full system status monitoring, process flow animation display, real-time / historical data curve analysis, parameter configuration, and hierarchical alarm management functions. The two units achieve data synchronization and command interaction through a high-speed industrial network, jointly constructing a control hub integrating real-time control and visual monitoring. This ensures the coordinated operation of all subsystems and rapid response to abnormal conditions, thereby guaranteeing the stable and efficient execution of the entire dredging process.

[0021] The data fusion and decision-making module includes a path planning unit, a process parameter library unit, and an adaptive learning unit. The path planning unit automatically plans the optimal movement path based on the path planning algorithm and the coordinates of the blockage point. The process parameter library unit stores and manages the unblocking process parameters for different blockage types and severity based on a database server. The adaptive learning unit continuously optimizes the process parameters and improves system efficiency through machine learning based on intelligent learning algorithms and historical operation data.

[0022] With the above structure, after the module starts, the path planning unit first uses the precise coordinates of the blockage point provided by the multi-sensor fusion positioning module and the path planning algorithm to automatically calculate the optimal movement path of the moving guide module that is collision-free and highly efficient. The process parameter library unit then calls the set of unblocking process parameters that match the current type and severity of the blockage from the built-in database server. During this process, the adaptive learning unit runs continuously. Based on the intelligent learning algorithm, it dynamically optimizes and updates the process parameter library by analyzing the continuously accumulated historical operation data. Through the coordinated operation of the above units, the entire module finally outputs a comprehensive decision-making scheme covering the movement path and process parameters, which is then scheduled and executed by the central control module, thereby realizing the intelligentization of unblocking operations and continuous improvement of efficiency.

[0023] The process control module includes a sequence control unit and a loop control unit. The sequence control unit ensures that the system strictly follows the technical route of "detection-location-execution-verification". The loop control unit is responsible for controlling the number of times and the process of repeated clearing when dealing with substandard situations through loop control, and automatically triggers a "manual intervention alarm" when the maximum number of loops is reached to avoid ineffective operations.

[0024] Using the above structure, the process control module constructs control logic based on a state machine model. Through the sequence control unit, it strictly defines and manages each state transition in the core workflow of "infrared detection → blockage location → combustion gun location → segmented combustion → high-pressure purging → orifice rate detection," ensuring that each subsystem is put into operation in an orderly manner at precise time points, thereby guaranteeing the complete execution of the technical route. When the verification result fails to meet the standard, the cycle control unit is immediately activated, automatically controlling the actuator to repeatedly clear the blockage along the preset path and counting the number of cycles in real time. If the maximum set number of cycles is reached and the standard is still not met, the "manual intervention alarm" is automatically triggered, and the current operation process is paused, thereby ensuring the quality of clearing while effectively avoiding ineffective system operation.

[0025] The thermal management module includes an industrial chiller and two water supply coils. The water supply coils are both mounted on the second travel carriage. The shafts of the water supply coils are connected to the shafts of the winches. One end of each water supply coil is connected to the inlet and outlet of the industrial chiller. One end of each water supply coil passes through a guide sleeve, a counterweight heat insulation block, and a high-temperature resistant pipe in sequence and is connected to the double-layer gun body of several combustion nozzles. The industrial chiller, the two water supply coils, and the double-layer gun bodies of several combustion nozzles form a circulating water cooling circuit.

[0026] With the above structure, an industrial chiller provides circulating cooling medium. Two water-carrying coils are installed on the second travel carriage, and their shafts are driven by the winch shaft to achieve synchronous winding and unwinding. One end of each coil is connected to the inlet and outlet of the industrial chiller, and the other end passes through a guide sleeve, a counterweight heat insulation block, and a high-temperature resistant pipe, respectively, and is connected to the internal channels of the double-layer gun body of several combustion spray guns to form a closed cooling circuit. This achieves continuous active cooling of the combustion spray guns in high-temperature operating environments, ensuring their long-term stable operation.

[0027] The emergency safety module includes a backfire prevention unit, an inert gas protection unit, and an emergency retreat unit. The backfire prevention unit is equipped with a flame arrester and a flame detector, both of which are installed inside the combustion nozzle to prevent the gas flame from burning back into the combustion nozzle's gas pipeline. The inert gas protection unit is an external nitrogen delivery pipeline connected to one end of the gas bundle coil fitting via a multi-way valve. In an emergency, the multi-way valve automatically switches, causing the gas bundle coil fitting to deliver nitrogen, which then purges the gas bundle coil fitting's pipeline. In the event of a system failure or emergency stop, the emergency retreat unit drives the moving guide rail module and the segmented combustion melting module to a safe standby position.

[0028] The above structure ensures the safe operation of the system through a triple protection mechanism. The backfire prevention unit is equipped with a flame arrestor and flame detector at the combustion nozzle to monitor the combustion status in real time and block the flame backfire path. The inert gas protection unit is connected to a multi-way valve through an external nitrogen delivery pipeline. When an abnormality is detected, it automatically switches the gas path and replaces the original gas in the gas bundle coil with nitrogen to achieve inertization and purging of the pipeline system. When the system triggers a fault or emergency stop signal, the emergency retreat unit immediately drives the moving guide rail module and the segmented combustion and melting module to withdraw to the preset safe standby position. This forms a comprehensive safety protection system from the combustion process and gas system to the actuators.

[0029] The status monitoring module includes a system self-test unit and a real-time diagnosis and alarm unit. The system self-test unit is responsible for automatically detecting the health status of each sensor, actuator and subsystem before the system starts. The real-time diagnosis and alarm unit is responsible for continuously monitoring key parameters, diagnosing faults and triggering graded alarms during system operation.

[0030] With the above structure, the status monitoring module first activates the system self-test unit upon system power-on, automatically performing a comprehensive health status check on all sensor communication links, actuator mechanisms, valve switching status, water cooling system, and air circuit sealing, generating a detailed self-test report within a specified period. Once the system enters the operational phase, the real-time diagnostic and alarm unit is activated. It continuously collects and analyzes motor current, bearing temperature, and vibration data, comparing them in real-time with preset normal value ranges. Using a rule-based expert system, it performs fault diagnosis, immediately triggering a graded alarm mechanism based on severity upon detecting any anomalies. Simultaneously, it records complete operational data to provide a basis for predictive maintenance decisions. Through this combination of periodic and continuous monitoring, the module effectively achieves comprehensive monitoring of the system's health status and fault early warning, significantly improving system reliability and maintenance efficiency.

[0031] Compared with existing technologies, the anti-blocking and unblocking control system for the regenerator chamber of this kiln has the following advantages: 1. By collaborating with the infrared thermal imaging detection module and the multi-sensor fusion positioning module, accurate identification, component analysis, and three-dimensional coordinate positioning of blockages are achieved. Combined with the path planning and adaptive learning algorithms of the data fusion and decision-making module, as well as the centralized scheduling of the central control module, a complete closed loop from state perception and intelligent diagnosis to optimized decision-making is formed, improving the accuracy and efficiency of unblocking.

[0032] 2. Through the coordination of travel carriage one, travel carriage two and the winch, the end effector is precisely positioned in three-dimensional space; the segmented combustion melting module uses counterweight heat insulation blocks, adjustable-angle combustion guns and high-precision gas control to achieve customized melting of different blockages; the high-pressure purging module completes cleaning and environmentally friendly emissions through position-matched purging heads and dust collection components. The entire process is strictly controlled by the process control module according to the sequence of "infrared detection → blockage location → segmented combustion → high-pressure purging → porosity detection", and the result judgment module verifies the effect and cyclically controls based on the real-time porosity, forming an efficient and reliable closed loop operation.

[0033] 3. The circulating water cooling circuit, consisting of an industrial chiller and a water supply coil, provides continuous active cooling for the combustion nozzle; the emergency safety module effectively addresses hazards such as gas and high temperature through backfire prevention devices, inert gas protection, and emergency retreat units; and the status monitoring module enables early warning and predictive maintenance of key system components through periodic self-testing and real-time diagnostics. Attached Figure Description

[0034] Figure 1 This is the system architecture diagram of the present invention.

[0035] Figure 2 This is a system workflow diagram of the present invention.

[0036] Figure 3 This is a schematic diagram of the working principle of the detection and positioning subsystem in this invention.

[0037] Figure 4 This is a schematic diagram of the working principle of the verification and evaluation subsystem in this invention.

[0038] Figure 5 This is the architecture and data interaction diagram of the control and decision-making subsystem in this invention.

[0039] Figure 6 This is the overall diagram of subsystem association and data flow in this invention.

[0040] Figure 7 This is a schematic diagram of the structure of some components in this invention.

[0041] Figure 8 This is a schematic diagram of the moving guide rail module in this invention.

[0042] Figure 9 This is a schematic diagram of the segmented combustion and melting module in this invention.

[0043] In the diagram, 1. Moving track assembly; 2. Guide sleeve; 3. Winch assembly; 4. Counterweight heat insulation block; 5. Combustion gun assembly; 6. Longitudinal support track; 7. Traveling carriage one; 8. Traveling carriage two; 9. Winch; 10. Transverse track; 11. Steel rope; 12. Lifting pulley; 13. Lifting ring; 14. High-temperature resistant pipe; 15. Mounting block; 16. Combustion spray gun; 17. Heat insulation cover. Detailed Implementation

[0044] The following are specific embodiments of the present invention, which are described in conjunction with the accompanying drawings to further illustrate the technical solutions of the present invention. However, the present invention is not limited to these embodiments.

[0045] like Figure 1-9 As shown, the anti-blocking and unblocking control system for the regenerator chamber of this kiln includes a detection and positioning subsystem, an execution unblocking subsystem, a verification and evaluation subsystem, a control and decision-making subsystem, and a safety and assurance subsystem. The detection and positioning subsystem includes an infrared thermal imaging detection module and a multi-sensor fusion positioning module; the execution unblocking subsystem includes a moving guide rail module, a segmented combustion and melting module, and a high-pressure purging module; the verification and evaluation subsystem includes a result judgment module; the control and decision-making subsystem includes a central control module, a data fusion and decision-making module, and a process control module; and the safety and assurance subsystem includes a thermal management module, an emergency safety module, and a status monitoring module. The infrared thermal imaging detection module uses non-contact infrared thermal imaging technology to collect global temperature field data of the grid and identify areas of abnormal temperature. The multi-sensor fusion positioning module integrates data from multiple sensor sources to accurately calculate the three-dimensional spatial coordinates and attributes of the blockage. The moving guide rail module carries and drives the end effector, moving it precisely and stably to the target blockage location according to control commands. The segmented combustion and melting module precisely controls the high-temperature flame according to the type of blockage, heating and melting the blockage in segments according to a preset strategy to soften or liquefy it. After the melting process, the high-pressure purging module uses high-pressure airflow to remove the softened blockage from the grid holes and collects the generated dust. The result judgment module compares the detected porosity with a preset standard, determines whether it meets the standard, and generates instructions to continue or terminate the operation accordingly. The control module, serving as the system's hardware control core and human-machine interface, is responsible for underlying logic operations, command issuance, and equipment status monitoring. The data fusion and decision-making module processes front-end perceived data, performs blockage location and path planning, and manages and optimizes unblocking process parameters. The process control module ensures that the system strictly follows the preset technical route sequence and manages the cyclic unblocking process in cases of non-compliance. The thermal management module ensures that core execution components operate stably in the high-temperature environment of the kiln through active cooling measures and passive refractory material protection, avoiding thermal damage. The emergency safety module designs multiple active protection mechanisms for hazardous sources such as gas and high temperatures, which are automatically triggered in abnormal situations to ensure equipment and personnel safety. The status monitoring module performs periodic self-checks and real-time diagnostics on the health status of key system components, enabling fault warnings and predictive maintenance.

[0046] After system startup, the infrared thermal imaging module in the detection and positioning subsystem first performs a non-contact panoramic real-time scan of the grid surface, collecting global temperature field data and identifying areas of temperature anomalies. Subsequently, the multi-sensor fusion positioning module integrates data from multiple sensors to accurately calculate the three-dimensional spatial coordinates and characteristic attributes of the blockage. The unblocking subsystem then responds, and the moving guide module drives the end effector to precisely move to the target position based on the obtained coordinate information. The segmented combustion and melting module calls the corresponding process parameters according to the type of blockage, implementing segmented heating and melting through precisely controlled high-temperature flames. The high-pressure purging module then uses high-pressure airflow to remove the molten material and collect the generated dust. After unblocking, the verification and evaluation subsystem starts operating, and the result judgment module... The detection data is compared with preset standards and corresponding instructions are generated. The entire process is coordinated by the control and decision-making subsystem. The central control module of this subsystem is responsible for hardware control and human-machine interaction. The data fusion and decision-making module processes the perceived data and optimizes process parameters. The process control module ensures that each link is executed in the order of "detection-location-execution-verification" and manages the cyclic dredging process when the standards are not met. The entire process is supported by the safety and protection subsystem. The thermal management module ensures the stable operation of the equipment in high-temperature environments through active cooling and passive protection. The emergency safety module implements multiple protections against dangerous sources such as gas and high temperature. The status monitoring module performs real-time diagnosis and early warning of the system's health status, ultimately forming a complete intelligent dredging solution.

[0047] The infrared thermal imaging detection module includes an infrared thermal imager unit, a thermal image data transmission unit, a temperature cloud map generation unit, a porosity detection unit, and an abnormal area identification unit. The infrared thermal imager unit uses an uncooled focal plane detector with a temperature measurement range of 100-650℃, an accuracy of ±1℃, and a frame rate of ≥30fps. It is deployed on the top of the heat storage chamber for periodic panoramic scanning. The thermal image data transmission unit achieves low-latency and interference-resistant data transmission through armored fiber optic cable or gigabit industrial Ethernet. The temperature cloud map generation unit processes and renders the one-dimensional temperature data array into a pseudo-color two-dimensional / three-dimensional temperature field distribution cloud map. The abnormal area identification unit automatically delineates the blocked area based on a preset temperature threshold and image processing algorithm. The porosity detection unit combines the data scanned by the uncooled focal plane detector with the pseudo-color two-dimensional / three-dimensional temperature field distribution cloud map to analyze the change in the uniformity of the temperature field distribution before and after unblocking to quantitatively calculate the real-time porosity.

[0048] After the system starts up, the infrared thermal imager unit deployed on the top of the heat storage chamber works first. The uncooled focal plane detector performs periodic panoramic scans of the lattice surface, acquiring the raw one-dimensional temperature data array. Subsequently, the thermal image data transmission unit uploads this massive amount of data in real time via armored fiber optic cable or gigabit industrial Ethernet in a low-latency, high-interference-resistant manner. After the data arrives at the processing system, the temperature cloud map generation unit immediately processes and renders it, generating an intuitive pseudo-color two-dimensional / three-dimensional temperature field distribution cloud map, realizing the visualization of the global temperature situation. On this basis, the anomaly area identification unit identifies abnormal areas based on preset temperature thresholds and pre-defined parameters. Advanced image processing algorithms automatically analyze and delineate suspicious blockage areas with abnormal temperatures from cloud maps. Simultaneously, the porosity detection unit operates in parallel, comprehensively utilizing the raw data scanned by the detector and the generated multi-dimensional temperature field cloud map. Through precise algorithms, it quantitatively analyzes the dynamic changes in the uniformity of the temperature field distribution of the grid before and after the unblocking operation, and then calculates the real-time porosity value. This porosity result directly serves the verification and evaluation subsystem, serving as the core basis for judging whether the unblocking effect meets the standards. The coordinates of the identified blockage area are then sent to the control and decision-making subsystem to provide accurate target positioning for subsequent precise unblocking execution.

[0049] The mobile guide rail module includes a mobile rail assembly 1 and a winch assembly 3. The mobile rail assembly 1 includes a longitudinal support rail 6, which is fixedly installed on the top of the heat storage chamber. Two symmetrically arranged travel carriages 7 are provided on the longitudinal support rail 6. A transverse rail 10 is provided between the two travel carriages 7. A second travel carriage 8 is provided on the transverse rail 10. The winch assembly 3 includes a winch 9, which is fixedly installed at the lower end of the second travel carriage 8. A guide sleeve 2 and a steel rope 11 are provided on the winch 9. The steel rope 11 passes through the inner side of the guide sleeve 2 and is provided with a lifting pulley 12.

[0050] Two symmetrical travel carriages 7 can move longitudinally along the longitudinal support track 6, and travel carriage 8 can move laterally along the transverse track 10, together forming a two-dimensional moving platform that can be precisely positioned in the horizontal plane. Subsequently, the winch assembly 3 is activated, and the winch 9 winds up and unwinds the steel rope 11, which is suspended by the lifting pulley 12 at its end and drives the actuator below to perform vertical lifting and lowering movements. The guide sleeve 2 is made of high-temperature resistant alloy material. The guide sleeve 2 is used to guide the steel rope 11 and other pipelines, while preventing the steel rope 11 from swaying. Through the coordinated work of travel carriages 7, travel carriage 8 and winch 9, this module finally realizes the precise positioning and stable movement of the end effector in the three-dimensional space of the heat storage chamber, ensuring that it can reach any target blockage coordinate provided by the detection and positioning subsystem.

[0051] The multi-sensor fusion positioning module includes a high-definition vision unit, a laser ranging unit, a component analysis unit, and a blockage positioning algorithm unit. The high-definition vision unit is equipped with a wide-angle, image-stabilized industrial camera with an anti-fog coating to assist in identifying surface textures and structural damage. The laser ranging unit uses a phase-type laser ranging sensor with a ranging range of 0.1-10m and an accuracy of ±1mm, used for spatial positioning and collision avoidance. The component analysis unit uses a LIBS analyzer based on laser-induced breakdown spectroscopy (LIBS) technology to identify sulfate and glass phase components. The blockage positioning algorithm unit integrates temperature, visual, distance, and component data, and outputs accurate three-dimensional coordinates through a machine learning model. The industrial camera, phase-type laser ranging sensor, and LIBS analyzer are all located at the lower end of the travel carriage 28.

[0052] The multi-sensor fusion positioning module starts working after the infrared thermal imaging detection module initially identifies the temperature anomaly area. The industrial camera, phase-type laser rangefinder, and LIBS analyzer move in tandem with the travel vehicle 28 to the area above the anomaly. First, the high-definition vision unit uses an industrial camera equipped with wide-angle image stabilization to perform optical imaging of the target area, capturing detailed features of the surface texture and structural damage of the blockage. At the same time, the laser rangefinder uses a phase-type rangefinder to accurately measure the relative distance between the sensor and the target point, achieving spatial positioning and providing collision protection for the actuator movement. The composition analysis unit uses laser-induced breakdown spectroscopy to perform micro-area composition analysis on the blockage, quickly identifying whether it is a sulfate or glass phase substance. Finally, all the collected temperature, visual, distance, and composition data are uniformly transmitted to the blockage positioning algorithm unit. This unit uses a machine learning-based data fusion algorithm to comprehensively calculate the multi-source information and output the precise three-dimensional coordinates and boundary range of the blockage area in the kiln world coordinate system, providing a complete spatial positioning basis for subsequent unblocking operations.

[0053] The segmented combustion and melting module includes a counterweight heat insulation block 4 and a combustion gun assembly 5. The shape and specifications of the counterweight heat insulation block 4 match the internal shape and specifications of the lattice body. The counterweight heat insulation block 4 is a platform-shaped body that is larger at the top and smaller at the bottom. The counterweight heat insulation block 4 is made of high-temperature resistant ceramic material. A lifting ring 13 is provided at the middle of the upper end of the counterweight heat insulation block 4, and the lifting ring 13 is located below the lifting pulley 12. A high-temperature resistant tube 14 is provided at the lower end of the counterweight heat insulation block 4, and a heat insulation cover 17 is provided at the lower end of the high-temperature resistant tube 14. The heat insulation cover 17 has a conical structure that is smaller at the top and larger at the bottom. A mounting block 15 is provided at the lower end of the heat insulation cover 17. A position sensor is provided on the counterweight heat insulation block 4. The combustion gun assembly 5 includes several rectangularly distributed angle-adjustable... The combustion nozzle 16 and the gas bundle coil are connected in sections. The nozzle head of the combustion nozzle 16 is made of silicon carbide ceramic material. The nozzle body of the combustion nozzle 16 has a double-layer structure. The combustion nozzles 16 are detachably installed below the mounting block 15. The gas bundle coil is installed on the travel carriage 8. The shaft of the gas bundle coil is connected to the shaft of the winch 9. One end of the gas bundle coil is connected to the external gas transmission pipeline. The other end of the gas bundle coil passes through the guide sleeve 2, the counterweight heat insulation block 4, the high temperature resistant pipe 14 and the heat insulation cover 17 in sequence, and is connected to several combustion nozzles 16 respectively. Each gas pipeline of the gas bundle coil is equipped with a proportional valve and a mass flow meter.

[0054] The counterweight heat insulation block 4, with its top-large, bottom-small platform structure, matches the internal shape of the lattice, allowing it to quickly enter the lattice. The counterweight heat insulation block 4 is connected to the lifting pulley 12 via the lifting ring 13 and descends precisely under the drive of the moving guide rail module. Its built-in position sensor provides real-time feedback on positioning information. The combustion gun assembly 5 is fixed to the high-temperature resistant pipe 14 below the counterweight heat insulation block 4 via the mounting block 15. The combustion nozzle 16 can be angled, allowing it to tilt at a certain angle for easier melting. The fuel gas is supplied by an external fuel gas delivery pipe. The gas is transported to the gas cluster coil, one end of which is synchronously wound and unwound with the shaft drive of the winch 9. The other end passes through the guide sleeve 2, the counterweight heat insulation block 4, the high-temperature resistant pipe 14, and the heat insulation cover 17 in sequence, and then supplies each combustion nozzle 16 with a preset flow rate through the high-precision proportional valves and mass flow meters of each branch. During operation, according to the blockage location data and component analysis results, the corresponding process parameters are called, and the gas flow rate and nozzle angle are adjusted to implement segmented heating and melting, so as to achieve precise high-temperature treatment of blockages of different locations and types.

[0055] The high-pressure purging module consists of a high-pressure blower, an air conveying coil, a purging head, and a dust collection assembly. The dust collection assembly includes a high-temperature resistant hose, a cyclone separator, and a bag filter. The high-pressure blower is mounted on the transverse track 10, and the air conveying coil is mounted on the travel carriage 8. The shaft of the air conveying coil is connected to the shaft of the winch 9. One end of the air conveying coil is connected to the outlet of the high-pressure blower, and the other end passes through the guide sleeve 2 and the counterweight heat insulation block 4, and is connected to the counterweight heat insulation block 4. Several purge heads are connected below the heat insulation block 4. The position of the purge heads matches the position of the combustion spray gun 16. Each air duct at the other end of the air duct bundle coil is equipped with a control valve and a flow meter. The cyclone separator and the bag filter are both located outside the heat storage room. The air inlet of the cyclone separator is connected to one end of the high-temperature resistant hose, and the other end of the high-temperature resistant hose is connected to the air outlet of the heat storage room. The air outlet of the cyclone separator is connected to the bag filter. The air outlet of the bag filter is connected to the air inlet of the high-pressure blower through a multi-way valve.

[0056] A high-pressure blower generates high-pressure airflow, which is transported via an air delivery bundle coil. The shaft of the air delivery bundle coil is connected to the shaft of the winch 9 for synchronous winding and unwinding. One end is connected to the outlet of the high-pressure blower, and the other end passes through the guide sleeve 2 and the counterweight heat insulation block 4, and is connected to multiple purging heads arranged below the counterweight heat insulation block 4. Each air delivery duct is equipped with a control valve and a flow meter to precisely regulate the airflow output of each purging head. During the purging process, the purging head outputs high-pressure airflow, which purifies the molten blockage. The obstruction is removed from the lattice holes. At the same time, the cyclone separator draws the generated dust-laden hot air from the heat storage chamber outlet through a high-temperature resistant hose, and then delivers it to the bag filter. The bag filter collects the dust and discharges the hot air. The hot air is delivered to the air inlet of the high-pressure blower through a multi-way valve to achieve efficient separation and collection of dust, complete the unblocking operation and ensure that the emissions meet the standards, and recycle the hot air. During the melting process, the airflow of each blow head is controlled by the control valve and flow meter, and combustion air is provided to the combustion gun 16.

[0057] The result judgment module includes a compliance judgment unit and an instruction generation unit. The compliance judgment unit compares the real-time detected porosity with the user-preset qualification standard based on logical judgment. The instruction generation unit generates control instructions for ending the operation or repeating the dredging based on the comparison results.

[0058] After the unblocking operation is completed, the module initiates the verification process. Its compliance judgment unit automatically compares the aperture ratio data collected and calculated in real time by the infrared thermal imaging detection module with the user's preset qualified standard threshold based on preset logic. Subsequently, the instruction generation unit immediately generates the corresponding control instruction based on the comparison result. If the aperture ratio meets the standard, an "operation end" instruction is generated; if it does not meet the standard, an "repeat unblocking" instruction is generated. This instruction is then sent to the control and decision subsystem, thereby driving the system to execute subsequent cyclic operations or process termination operations.

[0059] The central control module includes a central control unit, an industrial computer, and an HMI unit. The central control unit uses a Siemens S7-1500 redundant system as the logic control core, which is responsible for processing all input / output (I / O) signals and executing sequential control and motion control. The industrial computer and HMI unit run configuration software and provide a graphical human-machine interface for status monitoring, parameter setting, and alarm management.

[0060] The central control module, serving as the hardware control core and human-machine interface hub of the entire system, adopts a hierarchical architecture. Its central control unit is built on a Siemens S7-1500 redundant system, acting as the lower-level control core to process all sensor input signals and actuator output commands in real time, accurately executing various low-level control tasks. Meanwhile, the industrial computer and HMI unit serve as the upper-level monitoring platform, running professional configuration software. Through an intuitive graphical interface, they provide operators with interactive functions such as full system status monitoring, process flow animation display, real-time / historical data curve analysis, parameter configuration, and hierarchical alarm management. The two units achieve data synchronization and command interaction through a high-speed industrial network, jointly constructing a control hub that integrates real-time control and visual monitoring. This ensures the coordinated operation of all subsystems and rapid response to abnormal conditions, thereby guaranteeing the stable and efficient execution of the entire dredging process.

[0061] The data fusion and decision-making module includes a path planning unit, a process parameter library unit, and an adaptive learning unit. The path planning unit automatically plans the optimal movement path based on the path planning algorithm and the coordinates of the blockage point. The process parameter library unit is based on a database server to store and manage the unblocking process parameters for different blockage types and severity. The adaptive learning unit is based on intelligent learning algorithms and historical operation data to continuously optimize process parameters and improve system efficiency through machine learning.

[0062] After the module starts, the path planning unit first uses the precise coordinates of the blockage point provided by the multi-sensor fusion positioning module and the path planning algorithm to automatically calculate the optimal movement path of the moving guide module that is collision-free and highly efficient. The process parameter library unit then calls the set of unblocking process parameters that match the current type and severity of the blockage from the built-in database server. During this process, the adaptive learning unit runs continuously. Based on the intelligent learning algorithm, it dynamically optimizes and updates the process parameter library by analyzing the continuously accumulated historical operation data. Through the coordinated operation of the above units, the entire module finally outputs a comprehensive decision plan covering the movement path and process parameters, which is then scheduled and executed by the central control module, thereby realizing the intelligentization of unblocking operations and continuous improvement of efficiency.

[0063] The process control module includes a sequence control unit and a loop control unit. The sequence control unit ensures that the system strictly follows the technical route of "detection-location-execution-verification". The loop control unit is responsible for controlling the number of times and the process of repeated clearing when dealing with substandard situations through loop control, and automatically triggers a "manual intervention alarm" when the maximum number of loops is reached to avoid ineffective operations.

[0064] The process control module constructs control logic based on a state machine model. Through the sequence control unit, it strictly defines and manages each state transition in the core workflow of "infrared detection → blockage location → combustion gun location → segmented combustion → high-pressure purging → orifice rate detection," ensuring that each subsystem is put into operation in an orderly manner at precise time points, thereby guaranteeing the complete execution of the technical route. When the verification result fails to meet the standard, the cycle control unit is activated, automatically controlling the actuator to repeatedly clear the blockage along the preset path and counting the number of cycles in real time. If the maximum set number of cycles is reached and the standard is still not met, the "manual intervention alarm" is automatically triggered, and the current operation process is paused, thereby ensuring the quality of clearing while effectively avoiding ineffective system operation.

[0065] The thermal management module includes an industrial chiller and two water supply coils. The water supply coils are both mounted on the travel carriage 8. The shafts of the water supply coils are connected to the shaft of the winch 9. One end of each water supply coil is connected to the inlet and outlet of the industrial chiller. One end of each water supply coil passes through the guide sleeve 2, the counterweight heat insulation block 4, and the high-temperature resistant pipe 14 in sequence and is connected to the double-layer gun body of several combustion spray guns 16. The industrial chiller, the two water supply coils, and the double-layer gun bodies of several combustion spray guns 16 form a circulating water cooling circuit.

[0066] The industrial chiller provides circulating cooling medium. Two water-carrying coils are installed on the travel carriage 8, and their shafts are driven by the shaft of the winch 9 to achieve synchronous winding and unwinding. One end of each coil is connected to the inlet and outlet of the industrial chiller, and the other end passes through the guide sleeve 2, the counterweight heat insulation block 4, and the high-temperature resistant pipe 14 in sequence, and is connected to the double-layer internal channel of several combustion spray guns 16 to form a closed cooling circuit, thereby achieving continuous active cooling of the combustion spray guns in high-temperature operating environments and ensuring their long-term stable operation.

[0067] The emergency safety module includes a backfire prevention unit, an inert gas protection unit, and an emergency retreat unit. The backfire prevention unit is equipped with a flame arrester and a flame detector, both of which are installed inside the combustion torch 16 to prevent the gas flame from backfireing into the gas pipeline of the combustion torch 16. The inert gas protection unit is an external nitrogen delivery pipeline, which is connected to one end of the gas bundle coil fitting via a multi-way valve. In an emergency, the multi-way valve automatically switches to supply nitrogen to the gas bundle coil fitting, and the supplied nitrogen purges the pipeline of the gas bundle coil fitting. In the event of a system failure or emergency stop, the emergency retreat unit drives the moving guide rail module and the segmented combustion melting module to a safe standby position.

[0068] The system operates safely through a triple protection mechanism. The backfire prevention unit is equipped with a flame arrestor and flame detector at the combustion nozzle 16 to monitor the combustion status in real time and block the flame backfire path. The inert gas protection unit is connected to a multi-way valve through an external nitrogen delivery pipeline. When an abnormality is detected, the gas path is automatically switched to replace the original gas in the gas bundle coil with nitrogen to achieve inertization and purging of the pipeline system. When the system triggers a fault or emergency stop signal, the emergency retreat unit immediately drives the moving guide rail module and the segmented combustion and melting module to withdraw to the preset safe standby position. This forms a comprehensive safety protection system from the combustion process and gas path system to the actuator.

[0069] The status monitoring module includes a system self-test unit and a real-time diagnosis and alarm unit. The system self-test unit is responsible for automatically detecting the health status of each sensor, actuator and subsystem before the system starts. The real-time diagnosis and alarm unit is responsible for continuously monitoring key parameters, diagnosing faults and triggering graded alarms during system operation.

[0070] Upon system power-on, the status monitoring module first activates the system self-test unit, automatically performing a comprehensive health status check on all sensor communication links, actuator mechanisms, valve switching status, water cooling system, and air circuit sealing, generating a detailed self-test report within a specified period. Once the system enters the operational phase, the real-time diagnostic and alarm unit is activated. It continuously collects and analyzes key operating parameters such as motor current, bearing temperature, and vibration data, comparing them in real-time with preset normal value ranges. Using a rule-based expert system, it performs fault diagnosis, immediately triggering a graded alarm mechanism based on severity upon detecting any anomalies. Simultaneously, it records complete operational data to provide a basis for predictive maintenance decisions. Through this combination of periodic and continuous monitoring, the module effectively achieves comprehensive monitoring of the system's health status and provides early warning of faults, significantly improving system reliability and maintenance efficiency.

[0071] In summary, by working together with the infrared thermal imaging detection module and the multi-sensor fusion positioning module, accurate identification, component analysis, and three-dimensional coordinate positioning of blockages can be achieved. Combined with the path planning and adaptive learning algorithms of the data fusion and decision-making module, and the centralized scheduling of the central control module, a complete closed loop from state perception and intelligent diagnosis to optimized decision-making is formed, improving the accuracy and efficiency of unblocking. Through the coordination of travel carriage 7, travel carriage 8 and winch 9, the end effector is precisely positioned in three-dimensional space; the segmented combustion melting module uses counterweight heat insulation block 4, adjustable angle combustion gun 16 and high-precision gas control to achieve customized melting of different blockages; the high-pressure purging module completes cleaning and environmentally friendly emissions through position-matched purging head and dust collection components. The entire process is strictly controlled by the process control module according to the sequence of "infrared detection → blockage location → segmented combustion → high-pressure purging → porosity detection", and the result judgment module verifies the effect and cyclically controls based on the real-time porosity, forming an efficient and reliable closed loop operation. The combustion nozzle 16 is continuously and actively cooled by a circulating water cooling circuit consisting of an industrial chiller and a water supply coil; the emergency safety module effectively responds to dangerous sources such as gas and high temperature through a backfire prevention device, inert gas protection and emergency retreat unit; and the status monitoring module realizes fault warning and predictive maintenance of key system components through periodic self-testing and real-time diagnosis.

[0072] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

Claims

1. A kiln regenerator chamber grid anti-blocking and unblocking control system, comprising a detection and positioning subsystem, an execution and unblocking subsystem, a verification and evaluation subsystem, a control and decision-making subsystem, and a safety and security subsystem, characterized in that, The detection and positioning subsystem includes an infrared thermal imaging detection module and a multi-sensor fusion positioning module; the execution and unblocking subsystem includes a moving guide rail module, a segmented combustion and melting module, and a high-pressure purging module; the verification and evaluation subsystem includes a result judgment module; the control and decision-making subsystem includes a central control module, a data fusion and decision-making module, and a process control module; and the safety and security subsystem includes a thermal management module, an emergency safety module, and a status monitoring module. The infrared thermal imaging detection module uses non-contact infrared thermal imaging technology to collect global temperature field data of the grid and identify areas with abnormal temperatures. The multi-sensor fusion positioning module integrates data from multiple sensor sources to accurately calculate the three-dimensional spatial coordinates and attributes of the blockage. The moving guide rail module carries and drives the end effector, moving it precisely and stably to the target blockage location according to control commands. The segmented combustion and melting module precisely controls the high-temperature flame according to the type of blockage, heating and melting the blockage in segments according to a preset strategy. After the melting process, the high-pressure purging module uses high-pressure airflow to remove the softened blockage from the grid holes and collects the generated dust. The result judgment module compares the detected porosity with a preset standard, determines whether it meets the standard, and generates instructions to continue or terminate the operation. The central control module, as the hardware control core and human-machine interface of the system, is responsible for underlying logic operations, command issuance, and equipment status monitoring. The data fusion and decision-making module processes front-end sensing data, performs blockage location and path planning, and manages and optimizes dredging process parameters; the process control module ensures that the system strictly follows the preset technical route sequence and manages the cyclic dredging process in case of non-compliance; the thermal management module ensures that the core execution components work stably for a long time in the high-temperature environment of the kiln through active cooling measures and passive refractory material protection, avoiding thermal damage. The emergency safety module is designed with multiple active protection mechanisms for gas and high-temperature hazards, which are automatically triggered in abnormal situations to ensure the safety of equipment and personnel; the status monitoring module performs periodic self-checks and real-time diagnoses on the health status of key system components, enabling fault warnings and predictive maintenance.

2. The kiln regenerator grid anti-blockage and unblocking control system according to claim 1, characterized in that, The infrared thermal imaging detection module includes an infrared thermal imager unit, a thermal image data transmission unit, a temperature cloud map generation unit, a porosity detection unit, and an abnormal area identification unit. The infrared thermal imager unit uses an uncooled focal plane detector with a temperature measurement range of 100-650℃, an accuracy of ±1℃, and a frame rate of ≥30fps. It is deployed on the top of the heat storage chamber to perform periodic panoramic scanning. The thermal imaging data transmission unit achieves low-latency, interference-resistant data transmission via armored fiber optic cable or gigabit industrial Ethernet; the temperature cloud map generation unit processes and renders the one-dimensional temperature data array into a pseudo-color two-dimensional / three-dimensional temperature field distribution cloud map; the abnormal area identification unit automatically delineates the blocked area based on a preset temperature threshold and image processing algorithm; and the porosity detection unit uses data scanned by an uncooled focal plane detector combined with the pseudo-color two-dimensional / three-dimensional temperature field distribution cloud map to analyze the change in the uniformity of the temperature field distribution before and after unblocking to quantitatively calculate the real-time porosity. The moving guide rail module includes a moving rail assembly (1) and a winch assembly (3). The moving rail assembly (1) includes a longitudinal support rail (6), which is fixedly installed on the top of the heat storage chamber. Two symmetrically arranged travel carriages (7) are provided on the longitudinal support rail (6). A transverse rail (10) is provided between the two travel carriages (7). A travel carriage (8) is provided on the transverse rail (10). The winch assembly (3) includes a winch (9), which is fixedly installed at the lower end of the travel carriage (8). A guide sleeve (2) and a steel rope (11) are provided on the winch (9). The steel rope (11) passes through the inner side of the guide sleeve (2). A lifting pulley (12) is provided on the steel rope (11).

3. The kiln regenerator grating anti-blockage and unblocking control system according to claim 2, characterized in that, The multi-sensor fusion positioning module includes a high-definition vision unit, a laser ranging unit, a component analysis unit, and a blockage positioning algorithm unit. The high-definition vision unit is equipped with a wide-angle, image-stabilized industrial camera with an anti-fog coating to assist in identifying surface textures and structural damage. The laser ranging unit uses a phase-type laser ranging sensor with a ranging range of 0.1–10m and an accuracy of ±1mm, used for spatial positioning and collision avoidance. The component analysis unit uses a LIBS analyzer, based on laser-induced breakdown spectroscopy technology, to identify sulfate and glass phase components. The blockage positioning algorithm unit integrates temperature, visual, distance, and component data, and outputs accurate three-dimensional coordinates through a machine learning model. The industrial camera, phase-type laser ranging sensor, and LIBS analyzer are all located at the lower end of the travel vehicle two (8). The segmented combustion and melting module includes a counterweight heat insulation block (4) and a combustion gun assembly (5). The shape and specifications of the counterweight heat insulation block (4) match the internal shape and specifications of the lattice body. The counterweight heat insulation block (4) is a platform-shaped structure with a larger upper part and a smaller lower part. The counterweight heat insulation block (4) is made of high-temperature resistant ceramic material. A lifting ring (13) is provided at the middle position of the upper end of the counterweight heat insulation block (4). The lifting ring (13) is located below the lifting pulley (12). A high-temperature resistant tube (14) is provided at the lower end of the counterweight heat insulation block (4). A heat insulation cover (17) is provided at the lower end of the high-temperature resistant tube (14). The heat insulation cover (17) has a conical structure with a smaller upper part and a larger lower part. An installation block (15) is provided at the lower end of the heat insulation cover (17). A position sensor is provided on the counterweight heat insulation block (4). The combustion gun assembly (5) includes a gas cluster. The gas coil and several rectangularly distributed, angle-adjustable combustion nozzles (16) are provided. The nozzle head of the combustion nozzle (16) is made of silicon carbide ceramic material. The nozzle body of the combustion nozzle (16) is a double-layer structure. The combustion nozzles (16) are detachably installed below the mounting block (15). The gas coil is installed on the travel carriage two (8). The rotating shaft of the gas coil is connected to the rotating shaft of the winch (9). One end of the gas coil is connected to the external gas transmission pipeline. The other end of the gas coil passes through the guide sleeve (2), the counterweight heat insulation block (4), the high temperature resistant pipe (14) and the heat insulation cover (17) in sequence and is connected to several combustion nozzles (16) respectively. Each gas pipeline of the gas coil is equipped with a proportional valve and a mass flow meter.

4. The kiln regenerator grid anti-blockage and unblocking control system according to claim 3, characterized in that, The high-pressure purging module consists of a high-pressure blower, an air conveying coil, a purging head, and a dust collection assembly. The dust collection assembly includes a high-temperature resistant hose, a cyclone separator, and a bag filter. The high-pressure blower is mounted on a transverse track (10), and the air conveying coil is mounted on a travel carriage (8). The shaft of the air conveying coil is connected to the shaft of a winch (9). One end of the air conveying coil is connected to the outlet of the high-pressure blower, and the other end of the air conveying coil passes through a guide sleeve (2) and a counterweight heat insulation block (4) and is connected to the dust collection head. Several purge heads are connected below the counterweight insulation block (4). The position of the purge head matches the position of the combustion spray gun (16). Each air duct at the other end of the air duct bundle coil is equipped with a control valve and a flow meter. The cyclone separator and the bag filter are both located outside the heat storage room. The air inlet of the cyclone separator is connected to one end of the high-temperature resistant hose. The other end of the high-temperature resistant hose is connected to the air outlet of the heat storage room. The air outlet of the cyclone separator is connected to the bag filter. The air outlet of the bag filter is connected to the air inlet of the high-pressure blower through a multi-way valve. The result judgment module includes a compliance judgment unit and an instruction generation unit. The compliance judgment unit compares the real-time detected permeability with the user-preset qualification standard based on logical judgment. The instruction generation unit generates control instructions for ending the operation or repeating the dredging based on the comparison results.

5. The kiln regenerator grid anti-blockage and unblocking control system according to claim 4, characterized in that, The central control module includes a central control unit, an industrial computer, and an HMI unit. The central control unit uses a Siemens S7-1500 redundant system as the logic control core, which is responsible for processing all input / output signals and executing sequential control and motion control. The industrial computer and HMI unit run configuration software and provide a graphical human-machine interface for status monitoring, parameter setting, and alarm management.

6. The kiln regenerator grid anti-blockage and unblocking control system according to claim 5, characterized in that, The data fusion and decision-making module includes a path planning unit, a process parameter library unit, and an adaptive learning unit. The path planning unit automatically plans the optimal movement path based on the path planning algorithm and the coordinates of the blockage point. The process parameter library unit is based on a database server and stores and manages unblocking process parameters for different types and severity of blockages. The adaptive learning unit continuously optimizes process parameters and improves system efficiency through machine learning, based on intelligent learning algorithms and historical operation data.

7. The kiln regenerator grid anti-blockage and unblocking control system according to claim 6, characterized in that, The process control module includes a sequence control unit and a loop control unit. The sequence control unit ensures that the system strictly follows the technical route of "detection-location-execution-verification" in sequence. The loop control unit is responsible for controlling the number of times and the process of repeated clearing when dealing with substandard situations through loop control, and automatically triggers "manual intervention alarm" when the maximum number of loops is reached to avoid ineffective operations.

8. The kiln regenerator grid anti-blockage and unblocking control system according to claim 7, characterized in that, The thermal management module includes an industrial chiller and two water supply coils. The water supply coils are all mounted on the travel carriage 2 (8). The shafts of the water supply coils are connected to the shafts of the winch (9). One end of each water supply coil is connected to the inlet and outlet of the industrial chiller. The other end of each water supply coil passes through the guide sleeve (2), the counterweight heat insulation block (4), and the high-temperature resistant pipe (14) in sequence and is connected to the double-layer gun body of several combustion spray guns (16). The industrial chiller, the two water supply coils, and the double-layer gun body of several combustion spray guns (16) form a circulating water cooling circuit.

9. A kiln regenerator grid anti-blockage and unblocking control system according to claim 8, characterized in that, The emergency safety module includes a backfire prevention device unit, an inert gas protection unit, and an emergency retreat unit. The backfire prevention device unit is equipped with a flame arrester and a flame detector. Both the flame arrester and the flame detector are installed inside the combustion nozzle (16) to prevent the gas flame from backfired into the gas pipeline of the combustion nozzle (16). The inert gas protection unit is a nitrogen delivery pipeline installed on the outside. The nitrogen delivery pipeline is connected to one end of the gas bundle coil fitting through a multi-way valve. In an emergency, the multi-way valve automatically switches to make the gas bundle coil fitting switch to deliver nitrogen. The delivered nitrogen purges the pipeline of the gas bundle coil fitting. In the event of a system failure or emergency stop, the emergency retreat unit drives the moving guide rail module and the segmented combustion and melting module to a safe standby position.

10. A kiln regenerator grid anti-blockage and unblocking control system according to claim 9, characterized in that, The status monitoring module includes a system self-test unit and a real-time diagnosis and alarm unit. The system self-test unit is responsible for automatically detecting the health status of each sensor, actuator and subsystem before the system starts. The real-time diagnosis and alarm unit is responsible for continuously monitoring key parameters, diagnosing faults and triggering graded alarms during system operation.

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