Intelligent cooling system for glass furnace

Abstract

This invention relates to the field of glass kiln technology, and in particular to an intelligent cooling system for glass kilns, comprising multiple wall fans, multiple main air ducts, multiple branch air ducts, multiple air nozzles, flow channel fans, valves, and a control module. The control module includes a temperature sensing element array, a data acquisition unit, a spatial thermal state assessment unit, a dynamic decoupling prediction control unit, an encrypted transmission unit, a control execution unit, an air network adaptive reconstruction unit, a corrosion early warning unit, and a monitoring terminal. The data acquisition unit is connected to the temperature sensing element array, the spatial thermal state assessment unit is connected to the data acquisition unit, and the dynamic decoupling prediction control unit is connected to both the spatial thermal state assessment unit and the air network adaptive reconstruction unit. This system solves the technical problems of existing technologies where a single fan simultaneously blows air to cool the kiln, resulting in large main duct diameters, large fan volumes, and reliance on manual experience for precise control of cooling intensity in various parts.

Description

Technical Field

[0001] This invention relates to the field of glass furnace technology, and in particular to an intelligent cooling system for glass furnaces. Background Technology

[0002] Glass furnaces are the most critical core thermal equipment in the glass manufacturing industry, and their technological level directly affects the quality of glass products, energy consumption, and production efficiency. The main function of a glass furnace is to melt the batch materials into a liquid phase at high temperatures, and to complete processes such as clarification, homogenization, and cooling of the molten glass, ultimately providing the required molten glass for the forming process. In actual use, the melting temperature inside a glass furnace can reach nearly 1600℃. Using pressurized air from a blower to cool the furnace's refractory materials can slow down corrosion and extend its service life.

[0003] However, when using a single fan to blow air and cool the kiln simultaneously, there are problems such as the large diameter of the main pipe, the large size of the fan, and the inability to accurately control the cooling intensity of each part due to the reliance on manual experience for air volume adjustment. Summary of the Invention

[0004] The purpose of this invention is to provide an intelligent cooling system for glass kilns, which solves the technical problems of existing technologies that use a single fan to blow air into the kiln for cooling, such as large main pipe diameter, large fan size, and air volume adjustment relying on manual experience, making it impossible to accurately control the cooling intensity of each part.

[0005] To achieve the above objectives, the present invention provides an intelligent cooling system for glass furnaces, including multiple wall fans, multiple main air ducts, multiple branch air ducts, multiple air nozzles, flow channel fans, valves, and a control module. The pool wall fan and the flow tunnel fan are respectively connected to the corresponding main air duct, the branch air duct is connected to the corresponding main air duct, the sealing nozzle is connected to the corresponding branch air duct, and the pressurized air of the flow tunnel fan is used to cool the flow tunnel. The control module includes a temperature sensing element array, a data acquisition unit, a space thermal state assessment unit, a dynamic decoupling prediction control unit, an encrypted transmission unit, a control execution unit, a wind network adaptive reconstruction unit, a corrosion early warning unit, and a monitoring terminal. The data acquisition unit is connected to the temperature sensing element array, the space thermal state assessment unit is connected to the data acquisition unit, the dynamic decoupling prediction control unit is connected to both the space thermal state assessment unit and the wind network adaptive reconstruction unit, the corrosion early warning unit is connected to the space thermal state assessment unit, the control execution unit is connected to the dynamic decoupling prediction control unit through the encrypted transmission unit, and the monitoring terminal is connected to the corrosion early warning unit.

[0006] The encrypted transmission unit uses a hardware encryption chip based on the SM4 national cryptographic algorithm to transmit control commands to the control execution unit via Modbus TCP / IP protocol after SM4 symmetric encryption. The control execution unit has a built-in hardware encryption chip to decrypt the received commands and then execute them.

[0007] The spatial thermal state assessment unit includes: a spatial location mapper, a neighborhood deviation accumulator, and a blind zone monitor; The spatial location mapper pre-stores the three-dimensional coordinates of each thermocouple on the kiln to associate the received digital temperature value with the corresponding spatial coordinates. The neighborhood deviation accumulator is used to calculate the deviation between the temperature value of each thermocouple and the temperature values ​​of the three thermocouples with the closest spatial distance, and to sum all the deviation values ​​to obtain the temperature field distortion index. The blind zone monitor is used to determine whether the temperature field distortion index exceeds a preset distortion threshold. If it does, it determines that there is a temperature blind zone anomaly in the corresponding area and generates a blind zone alarm signal to be sent to the dynamic decoupling prediction control unit and the corrosion early warning unit.

[0008] The dynamic decoupling prediction control unit includes a target value setter, a multivariable decoupling controller, and a wind turbine output scheduler. The target value setter is used to receive and store the target cooling temperature set for different sections of the kiln; The multivariable decoupling controller is used to execute a multivariable dynamic decoupling algorithm; the multivariable dynamic decoupling algorithm is specifically as follows: Using the deviation between the current measured temperature and the target temperature of each cooling section, as well as the temperature field distortion index, as input variables, and the air volume that each fan should output as output variables, a dynamic correlation matrix describing the thermal interaction between different cooling sections is constructed, and the independent control quantities after eliminating the coupling effects of each region are calculated in real time. The wind turbine output scheduler is used to convert independent control quantities into frequency control signals for the corresponding wind turbines and transmit them to the control execution unit through the encrypted transmission unit.

[0009] The corrosion early warning unit includes: a multidimensional database, a corrosion feature extractor, and a trend early warning device; The multidimensional database is used to record the following data in time series for each sampling period: the target cooling temperature of each cooling section, the actual measured temperature, the output air volume of each fan, and the temperature field distortion index. The corrosion feature extractor is used to extract the temperature field distortion index sequence and the fan output power sequence of each monitoring point over multiple consecutive cooling cycles, and to calculate the long-term slope of the two. The trend early warning device is used to determine that the kiln wall in the corresponding area has undergone significant corrosion and thinning when the long-term change slope exceeds a preset corrosion alarm threshold, and outputs an early warning signal containing the location and severity of corrosion to the external monitoring system.

[0010] The monitoring terminal is an industrial touch screen or a remote monitoring computer. The monitoring terminal displays in real time the temperature cloud map of each cooling section of the kiln, the operating status and output frequency of each fan, the historical change curve of the temperature field distortion index, and the corrosion warning level.

[0011] The intelligent cooling system for the glass kiln also includes a blockchain storage unit, which is connected to the control execution module.

[0012] This invention discloses an intelligent cooling system for a glass kiln. Through a distributed layout of multiple wall-mounted fans and flow-through fans, coupled with the collaborative operation of a dynamic decoupling predictive control unit and a spatial thermal state assessment unit, it solves the technical problems of traditional single-fan cooling systems, such as large main pipe diameters, large fan volumes, reliance on manual experience for airflow adjustment, and inability to precisely control the cooling intensity of different parts. The system utilizes a temperature sensing element array and a spatial thermal state assessment algorithm to automatically identify abnormal thermal states in temperature measurement blind spots, avoiding potential localized overheating. The dynamic decoupling predictive control unit, based on a multivariate decoupling algorithm, can accurately calculate the optimal output airflow for each fan, achieving independent, closed-loop, and precise control of the cooling intensity in different areas of the kiln. Simultaneously, the adaptive reconfiguration unit can automatically open backup pipe valves and dynamically adjust the air network topology to ensure uninterrupted cooling when a fan fails. The corrosion early warning unit, combining temperature field distortion index and historical power data, provides trend warnings for weak areas in refractory materials. Attached Figure Description

[0013] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below.

[0014] Figure 1 This is a schematic diagram of the intelligent cooling system for glass furnaces of the present invention.

[0015] Figure 2 This is a schematic diagram of the intelligent cooling system for glass furnaces of the present invention.

[0016] In the diagram: 1-Pool wall fan, 2-Main duct, 3-Branch duct, 4-Air nozzle, 5-Flow tunnel fan, 6-Valve, 7-Control module, 8-Temperature sensing element array, 9-Data acquisition unit, 10-Spatial thermal state assessment unit, 11-Dynamic decoupling prediction control unit, 12-Encrypted transmission unit, 13-Control execution unit, 14-Air network adaptive reconstruction unit, 15-Corrosion early warning unit, 16-Monitoring terminal, 17-Spatial location mapper, 18-Neighborhood deviation accumulator, 19-Blind zone monitor, 20-Target value setter, 21-Multivariable decoupling controller, 22-Fan output scheduler, 23-Multidimensional database, 24-Corrosion feature extractor, 25-Trend early warning device, 26-Blockchain storage unit, 27-Login module, 28-Access control module; Detailed Implementation

[0017] The embodiments of the present invention are described in detail below. Examples of the embodiments are shown in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, but should not be construed as limiting the present invention.

[0018] Please refer to Figure 1 and Figure 2 , Figure 1 This is a schematic diagram of the intelligent cooling system for glass furnaces of the present invention. Figure 2 This is a schematic diagram of the intelligent cooling system for a glass furnace according to the present invention. An embodiment of the present invention provides an intelligent cooling system for a glass furnace, including multiple wall fans 1, multiple main air ducts 2, multiple branch air ducts 3, multiple air nozzles 4, a flow channel fan 5, valves 6, and a control module 7; the control module 7 includes a temperature sensing element array 8, a data acquisition unit 9, a spatial thermal state assessment unit 10, a dynamic decoupling prediction control unit 11, an encrypted transmission unit 12, a control execution unit 13, an air network adaptive reconstruction unit 14, a corrosion early warning unit 15, and a monitoring terminal 16; the spatial thermal state assessment unit 10 includes a spatial location mapper 17, a neighborhood deviation accumulator 18, and a blind zone monitor 19; the dynamic... The state decoupling prediction control unit 11 includes a target value setter 20, a multivariable decoupling controller 21, and a fan output scheduler 22; the corrosion early warning unit 15 includes a multidimensional database 23, a corrosion feature extractor 24, and a trend early warning device 25; the intelligent cooling system for glass kilns also includes a blockchain storage unit 26, a login module 27, and an access control module 28. The aforementioned solution solves the technical problems in the prior art where, when a single fan is used to simultaneously blow air into the kiln for cooling, the main pipe diameter is large, the fan size is large, and the air volume adjustment relies on manual experience, making it impossible to accurately control the cooling intensity of each part.

[0019] In this specific embodiment, the data acquisition unit 9 is connected to the temperature sensing element array 8, the space thermal state assessment unit 10, and the dynamic decoupling prediction control unit 11, respectively, and is used to collect the temperature signals of each temperature measuring point in real time and convert them into digital temperature values. The spatial thermal state assessment unit 10 is connected to the data acquisition unit 9 and the corrosion early warning unit 15. It is used to receive the digital temperature value and calculate the overall temperature field distortion index of the kiln based on the cumulative temperature deviation of each thermocouple and the three thermocouples closest to its spatial location, so as to identify the abnormal thermal state of the temperature measurement blind zone. The dynamic decoupling prediction control unit 11 is connected to the data acquisition unit 9, the spatial thermal state assessment unit 10 and the wind network adaptive reconstruction unit 14 respectively. It is used to calculate the optimal output air volume control signal of each fan 1 based on the preset cooling target temperature, the digital temperature value and the temperature field distortion index, through the built-in multivariate dynamic decoupling algorithm. The wind network adaptive reconfiguration unit 14 is connected to the dynamic decoupling prediction control unit 11, each wind turbine 1, and the actuator of each normally closed manual valve, respectively. It is used to monitor the operating status of each wind turbine 1, and when a fault is detected in a certain wind turbine 1, it controls the normally closed manual valve on the corresponding series pipeline to open according to the preset "wind turbine-valve-duct" topology relationship, and sends the reconfigured wind network topology information to the dynamic decoupling prediction control unit 11. The corrosion early warning unit 15 is connected to the space thermal state assessment unit 10 and is used to receive and record the temperature field distortion index of each cooling cycle. Combined with the historical output power data of each fan 1, a multi-dimensional time series database is established, and the corrosion weak areas of the kiln refractory material are given early warning through trend analysis algorithm.

[0020] The pool wall fan 1 and the flow tunnel fan 5 are respectively connected to the corresponding main air duct 2, the branch air duct 3 is connected to the corresponding main air duct 2, the sealing nozzle 4 is connected to the corresponding branch air duct 3, and the pressurized air of the flow tunnel fan 5 is used to cool the flow tunnel. The data acquisition unit 9 is connected to the temperature measuring element array 8, the space thermal state assessment unit 10 is connected to the data acquisition unit 9, the dynamic decoupling prediction control unit 11 is connected to both the space thermal state assessment unit 10 and the wind network adaptive reconstruction unit 14, the corrosion early warning unit 15 is connected to the space thermal state assessment unit 10, the control execution unit 13 is connected to the dynamic decoupling prediction control unit 11 through the encrypted transmission unit 12, and the monitoring terminal 16 is connected to the corrosion early warning unit 15. By employing a distributed layout of multiple pool wall fans 1 and flow tunnel fans 5, in conjunction with the collaborative work of the dynamic decoupling prediction control unit 11 and the spatial thermal state assessment unit 10, the system solves the technical problems of traditional single-fan cooling, such as large main pipe diameter, large fan volume, reliance on manual experience for airflow adjustment, and inability to accurately control the cooling intensity of various parts. The system utilizes the temperature sensing element array 8 and the spatial thermal state assessment algorithm to automatically identify abnormal thermal states in temperature measurement blind spots, avoiding potential local overheating hazards. The dynamic decoupling prediction control unit 11, based on a multivariate decoupling algorithm, can accurately calculate the optimal output airflow of each fan 1, achieving independent, closed-loop, and precise control of the cooling intensity of each area of ​​the kiln. Simultaneously, the air network adaptive reconstruction unit 14 can automatically open the backup pipe valve 6 when a fan 1 fails, dynamically adjusting the air network topology to ensure uninterrupted cooling. The corrosion early warning unit 15, combining the temperature field distortion index and historical power data, provides trend warnings for weak areas of the refractory material.

[0021] Secondly, the encrypted transmission unit 12 uses a hardware encryption chip based on the SM4 national cryptographic algorithm to transmit the control command to the control execution unit 13 after SM4 symmetric encryption via the Modbus TCP / IP protocol. The control execution unit 13 has the same built-in hardware encryption chip to decrypt the received command and then execute it.

[0022] Meanwhile, the spatial position mapper 17 pre-stores the three-dimensional coordinates of each thermocouple on the kiln to associate the received digital temperature value with the corresponding spatial coordinates; The neighborhood deviation accumulator 18 is used to calculate the deviation between the temperature value of each thermocouple and the temperature values ​​of the three thermocouples with the closest spatial distance, and to sum all the deviation values ​​to obtain the temperature field distortion index. The blind zone monitor 19 is used to determine whether the temperature field distortion index exceeds a preset distortion threshold. If it does, it determines that there is a temperature blind zone anomaly in the corresponding area and generates a blind zone alarm signal to be sent to the dynamic decoupling prediction control unit 11 and the corrosion early warning unit 15.

[0023] Furthermore, the target value setter 20 is used to receive and store the target cooling temperatures set for different sections of the kiln; The multivariable decoupling controller 21 is used to execute a multivariable dynamic decoupling algorithm; the multivariable dynamic decoupling algorithm is specifically as follows: Using the deviation between the current measured temperature and the target temperature of each cooling section, as well as the temperature field distortion index, as input variables, and the air volume that each fan 1 should output as output variables, a dynamic correlation matrix describing the thermal interaction between different cooling sections is constructed, and the independent control quantity after eliminating the coupling effect of each region is calculated in real time. The wind turbine output scheduler 22 is used to convert independent control quantities into frequency control signals corresponding to the wind turbine 1, and transmit them to the control execution unit 13 through the encrypted transmission unit 12.

[0024] Furthermore, the multidimensional database 23 is used to record the following data in time series for each sampling period: the target cooling temperature of each cooling section, the actual measured temperature, the output air volume of each fan 1, and the temperature field distortion index; The corrosion feature extractor 24 is used to extract the temperature field distortion index sequence and the output power sequence of the fan 1 over multiple consecutive cooling cycles for each monitoring point, and to calculate the long-term slope of the two. The trend warning device 25 is used to determine that significant corrosion and thinning of the kiln wall in the corresponding area has occurred when the long-term change slope exceeds a preset corrosion alarm threshold, and outputs a warning signal containing the location and severity of corrosion to the external monitoring system. The monitoring terminal 16 is an industrial touch screen or a remote monitoring computer, which displays in real time the temperature cloud map of each cooling section of the kiln, the operating status and output frequency of each fan 1, the historical change curve of the temperature field distortion index, and the corrosion warning level.

[0025] The blockchain storage unit 26 is connected to the control execution module 13. The blockchain storage unit 26 is used to store the entire control process for subsequent optimization.

[0026] The login module 27 is connected to the monitoring terminal 16, and the access control module 28 is connected to the login module 27. The login module 27 requires operators to authenticate their identity before accessing the monitoring terminal 16, effectively preventing unauthorized personnel from misoperating or tampering with cooling parameters. The access control module 28 adopts role-based access control (RBAC) combined with dynamic tokens or biometric recognition, which can finely allocate functional permissions according to the login user's identity level (such as operator, engineer, administrator).

[0027] Furthermore, the multivariable dynamic decoupling predictive control algorithm also includes an adaptive adjustment step: in each control cycle, the difference between the current temperature field distortion index and the historical average distortion index is calculated. If the current distortion index is higher than the historical average, the prediction time domain length of the predictive control is automatically extended to enhance the feedforward compensation capability; if the current distortion index is lower than the historical average, the prediction time domain length is automatically shortened to improve the system response speed.

[0028] The corrosion early warning unit 15 has three levels of warning signals: when the long-term slope exceeds the corrosion alarm threshold but does not exceed twice the threshold, a level one warning is output, indicating slight corrosion; when the slope exceeds twice the threshold but does not exceed three times the threshold, a level two warning is output, indicating moderate corrosion; when the slope exceeds three times the threshold, a level three warning is output, indicating severe corrosion. Each level of warning signal includes the corrosion location coordinates, the corrosion severity index, and suggested treatment measures.

[0029] Working Principle: By distributing multiple pool wall fans 1 and flow tunnel fans 5, and coordinating the dynamic decoupling prediction control unit 11 and the spatial thermal state assessment unit 10, the system solves the technical problems of traditional single-fan cooling, such as large main pipe diameter, large fan volume, reliance on manual experience for airflow adjustment, and inability to accurately control the cooling intensity of each part. The system utilizes the temperature sensing element array 8 and the spatial thermal state assessment algorithm to automatically identify abnormal thermal states in temperature measurement blind spots, avoiding potential local overheating hazards. The dynamic decoupling prediction control unit 11, based on a multivariate decoupling algorithm, can accurately calculate the optimal output airflow of each fan 1, achieving independent, closed-loop, and precise control of the cooling intensity of each area of ​​the kiln. Simultaneously, the air network adaptive reconstruction unit 14 can automatically open the backup pipe valve 6 when a fan 1 fails, dynamically adjusting the air network topology to ensure uninterrupted cooling. The corrosion early warning unit 15, combining the temperature field distortion index and historical power data, provides trend warnings for weak areas of the refractory material.

[0030] The above-disclosed embodiments are merely one or more preferred embodiments of this application and should not be construed as limiting the scope of this application. Those skilled in the art can understand that all or part of the processes for implementing the above embodiments and equivalent changes made in accordance with the claims of this application still fall within the scope of this application.

Claims

1. An intelligent cooling system for a glass furnace, characterized in that, It includes multiple pool wall fans, multiple main air ducts, multiple branch air ducts, multiple air nozzles, flow tunnel fans, valves, and control modules; The pool wall fan and the flow tunnel fan are respectively connected to the corresponding main air duct, the branch air duct is connected to the corresponding main air duct, the sealing nozzle is connected to the corresponding branch air duct, and the pressurized air of the flow tunnel fan is used to cool the flow tunnel. The control module includes a temperature sensing element array, a data acquisition unit, a space thermal state assessment unit, a dynamic decoupling prediction control unit, an encrypted transmission unit, a control execution unit, a wind network adaptive reconstruction unit, a corrosion early warning unit, and a monitoring terminal. The data acquisition unit is connected to the temperature sensing element array, the space thermal state assessment unit is connected to the data acquisition unit, the dynamic decoupling prediction control unit is connected to both the space thermal state assessment unit and the wind network adaptive reconstruction unit, the corrosion early warning unit is connected to the space thermal state assessment unit, the control execution unit is connected to the dynamic decoupling prediction control unit through the encrypted transmission unit, and the monitoring terminal is connected to the corrosion early warning unit.

2. The intelligent cooling system for glass furnaces as described in claim 1, characterized in that, The encrypted transmission unit uses a hardware encryption chip based on the SM4 national cryptographic algorithm. The control commands are symmetrically encrypted with SM4 and then transmitted to the control execution unit via the Modbus TCP / IP protocol. The control execution unit has the same built-in hardware encryption chip to decrypt the received commands and then execute them.

3. The intelligent cooling system for glass furnaces as described in claim 2, characterized in that, The spatial thermal state assessment unit includes: a spatial location mapper, a neighborhood deviation accumulator, and a blind zone monitor; The spatial location mapper pre-stores the three-dimensional coordinates of each thermocouple on the kiln to associate the received digital temperature value with the corresponding spatial coordinates. The neighborhood deviation accumulator is used to calculate the deviation between the temperature value of each thermocouple and the temperature values ​​of the three thermocouples with the closest spatial distance, and to sum all the deviation values ​​to obtain the temperature field distortion index. The blind zone monitor is used to determine whether the temperature field distortion index exceeds a preset distortion threshold. If it does, it determines that there is a temperature blind zone anomaly in the corresponding area and generates a blind zone alarm signal to be sent to the dynamic decoupling prediction control unit and the corrosion early warning unit.

4. The intelligent cooling system for glass furnaces as described in claim 3, characterized in that, The dynamic decoupling prediction control unit includes a target value setter, a multivariable decoupling controller, and a wind turbine output scheduler. The target value setter is used to receive and store the target cooling temperature set for different sections of the kiln; The multivariable decoupling controller is used to execute a multivariable dynamic decoupling algorithm; the multivariable dynamic decoupling algorithm is specifically as follows: Using the deviation between the current measured temperature and the target temperature of each cooling section, as well as the temperature field distortion index, as input variables, and the air volume that each fan should output as output variables, a dynamic correlation matrix describing the thermal interaction between different cooling sections is constructed, and the independent control quantities after eliminating the coupling effects of each region are calculated in real time. The wind turbine output scheduler is used to convert independent control quantities into frequency control signals for the corresponding wind turbines and transmit them to the control execution unit through the encrypted transmission unit.

5. The intelligent cooling system for glass furnaces as described in claim 4, characterized in that, The corrosion early warning unit includes: a multidimensional database, a corrosion feature extractor, and a trend early warning device; The multidimensional database is used to record the following data in time series for each sampling period: the target cooling temperature of each cooling section, the actual measured temperature, the output air volume of each fan, and the temperature field distortion index. The corrosion feature extractor is used to extract the temperature field distortion index sequence and the fan output power sequence of each monitoring point over multiple consecutive cooling cycles, and to calculate the long-term slope of the two. The trend early warning device is used to determine that the kiln wall in the corresponding area has undergone significant corrosion and thinning when the long-term change slope exceeds a preset corrosion alarm threshold, and outputs an early warning signal containing the location and severity of corrosion to the external monitoring system.

6. The intelligent cooling system for glass furnaces as described in claim 5, characterized in that, The monitoring terminal is an industrial touch screen or a remote monitoring computer. The monitoring terminal displays in real time the temperature cloud map of each cooling section of the kiln, the operating status and output frequency of each fan, the historical change curve of the temperature field distortion index, and the corrosion warning level.

7. The intelligent cooling system for glass furnaces as described in claim 6, characterized in that, The intelligent cooling system for the glass kiln also includes a blockchain storage unit, which is connected to the control execution module.

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