A quick salt changing steeling furnace device and method

Abstract

This application discloses a rapid salt-changing tempering furnace device and method, belonging to the field of glass chemical tempering technology. The device includes a tempering furnace body, an integrated salt-changing mechanism, a preheating and buffering mechanism, a slag-cleaning mechanism, and a central control system. The integrated salt-changing mechanism is equipped with a moving base, a synchronous lifting component, a salt extraction module, and a salt injection module, enabling rapid sealing and connection with the furnace body's salt discharge port and salt injection port. The preheating and buffering mechanism is used for preheating and buffering new salt. The slag-cleaning mechanism uses high-pressure jet cleaning to remove slag from the furnace. The central control system coordinates the collaborative work of all parts. The method includes salt preparation, old salt extraction, furnace slag cleaning, new salt injection, and finishing steps. This application achieves full automation of the salt-changing process, significantly shortens the salt-changing cycle, improves the stability and safety of salt-changing, reduces labor intensity, and ensures tempering quality. It is applicable to tempering furnaces of different sizes.

Description

Technical Field

[0001] This application belongs to the field of glass chemical tempering technology, specifically relating to a rapid salt-changing tempering furnace apparatus and method. Background Technology

[0002] In the chemical tempering process of glass, ion exchange strengthening of the glass is typically achieved using a salt bath containing potassium nitrate. As production progresses, impurity ions such as sodium and calcium, exchanged from the glass, accumulate in the salt bath, leading to salt bath "poisoning," decreased purity, and severely impacting the tempering effect (e.g., decreased surface compressive stress, excessive dimensional deviations). Therefore, regularly replacing the salt bath in the tempering furnace is a crucial step in ensuring product quality.

[0003] Currently, traditional salt replacement methods largely rely on manual operation. Operators must stand beside a furnace at temperatures exceeding 400°C, using tools to scoop out molten old salt. This method is not only extremely labor-intensive and inefficient, but also poses serious safety hazards such as burns, heatstroke, and even falls into the furnace. Some semi-automatic salt replacement devices on the market have limited functionality, typically only capable of single operations like salt extraction or injection. They fail to effectively integrate the complete process of old salt extraction, furnace cleaning, new salt preheating, and new salt injection, resulting in a disjointed salt replacement process and a long overall replacement cycle.

[0004] Furthermore, the operational stability of existing equipment needs improvement. For example, the lifting mechanism of the salt pump often uses a single-rod drive, resulting in poor stability and a tendency for misalignment or poor sealing at the docking interface; high-temperature pipelines lack effective insulation, making them prone to solidification and blockage; and for large tempering furnaces, the salt replacement efficiency of existing equipment is difficult to match the production cycle. Therefore, developing a rapid salt replacement technology that can automate and integrate the salt replacement process, improving both efficiency and safety, has become an urgent problem to be solved in this field. Summary of the Invention

[0005] The purpose of this application is to provide a rapid salt-changing tempering furnace apparatus and method. This addresses the technical problems of low salt-changing efficiency, poor safety, and discontinuous processes in existing tempering furnaces as described in the background section.

[0006] To achieve the above objectives, this application adopts the following technical solution: In the first aspect, a rapid salt-changing tempering furnace device is provided, including a tempering furnace body, an integrated salt-changing mechanism, a preheating buffer mechanism, a slag-cleaning mechanism, and a central control system. The tempering furnace body is equipped with a salt discharge port, a slag removal port, and a salt injection port, and is also equipped with a temperature sensor and a liquid level sensor. The integrated salt replacement mechanism includes a movable base, a lifting assembly, a salt extraction module, and a salt injection module; the lifting assembly is used to drive the salt extraction module and the salt injection module to lift synchronously. The salt extraction module is equipped with a salt extraction pipe that can be sealed and connected to the salt discharge port; the salt injection module is equipped with a salt injection pipe that can be sealed and connected to the salt injection port. The preheating buffer mechanism includes a buffer salt tank and a heating jacket for heating the buffer salt tank, and the buffer salt tank is connected to the salt injection module; The slag cleaning mechanism includes a high-pressure air pump and a slag collection box detachably connected to the slag cleaning port. The high-pressure air pump is used to blow air into the bottom of the tempering furnace body. The central control system is electrically connected to the temperature sensor, liquid level sensor, lifting assembly, salt extraction module, salt injection module, heating jacket, and high-pressure air pump.

[0007] In one possible implementation, the lifting assembly includes two symmetrically arranged lifting threaded rods, a drive motor, and a synchronous transmission component. The drive motor drives the two lifting threaded rods to rotate synchronously through the synchronous transmission component. The salt extraction module and the salt injection module are fixed on the lifting plate, and the lifting plate is threadedly connected to the lifting threaded rod.

[0008] In one possible implementation, the synchronous transmission component includes a driving gear, a driven gear, and a synchronous belt. The output shaft of the drive motor is connected to the driving gear, and the top ends of the two lifting threaded rods are both connected to the driven gears. The driving gear is connected to the two driven gears via the synchronous belt.

[0009] In one possible implementation, the preheating buffer mechanism further includes an insulation layer wrapped around the outside of the heating jacket, and the buffer salt tank is equipped with a stirring assembly, which is electrically connected to the central control system.

[0010] In one possible implementation, a flow sensor is provided on the brine extraction pipeline, and the flow sensor is electrically connected to the central control system.

[0011] In one possible implementation, the bottom of the movable base is equipped with omnidirectional casters with locking function.

[0012] In one possible implementation, the salt extraction module includes a high-temperature resistant salt extraction pump, one end of the salt extraction pipeline is connected to the high-temperature resistant salt extraction pump, and the other end is provided with a quick connector; The salt injection module includes a high-temperature resistant salt injection pump, and one end of the salt injection pipe is connected to the high-temperature resistant salt injection pump, while the other end is equipped with a quick connector.

[0013] In a second aspect, a method for a rapid salt-changing tempering furnace based on the apparatus described in the first aspect is provided, comprising the following steps: S1. Salt replacement preparation: Move the integrated salt replacement mechanism to the side of the tempering furnace body, control the lifting component through the central control system to seal the salt extraction pipe with the salt discharge port and the salt injection pipe with the salt injection port, seal the slag collection box with the slag cleaning port, and add new salt into the preheating buffer mechanism and preheat to the preset temperature. S2. Old salt extraction: The salt extraction module is started through the central control system to extract the old salt in the tempering furnace body until the liquid level sensor detects that the liquid level in the furnace is lower than the preset lower limit threshold. S3. Slag removal inside the furnace: The high-pressure air pump is started through the central control system to blow air into the bottom of the tempering furnace body, blowing the slag to the slag removal port and falling into the slag collection box. S4. New Salt Injection: The salt injection module is started through the central control system to inject the preheated new salt in the preheating buffer mechanism into the tempering furnace body until the liquid level sensor detects that the liquid level has reached the preset standard liquid level. S5. Salt replacement completion: The central control system controls the lifting components to raise and detach the salt extraction pipe and salt injection pipe, and remove the integrated salt replacement mechanism.

[0014] In one possible implementation, in step S1, when the preheating buffer mechanism preheats the new salt, the preheating temperature is consistent with the current salt bath temperature in the tempering furnace, and the stirring component is started to stir the new salt, with the preheating temperature error controlled within ±5℃.

[0015] In one possible implementation, in step S2, during the salt extraction process, the central control system controls the heat preservation and heating power of the salt extraction pipeline based on the furnace temperature monitored by the temperature sensor, to ensure that the temperature inside the pipeline is not lower than 380°C.

[0016] Compared with the prior art, this application has the following beneficial effects: A rapid salt-changing tempering furnace device, through a central control system that integrates the salt-changing mechanism, preheating buffer mechanism, and slag-cleaning mechanism, achieves fully automated operation of the entire process—from old salt extraction and furnace slag cleaning to new salt preheating and injection—eliminating the need for manual intervention in the high-temperature environment and completely eliminating the safety hazards of traditional manual salt changing, significantly reducing labor intensity. The integrated salt-changing mechanism integrates salt extraction and injection functions onto a single moving base, with lifting components enabling synchronous lifting and rapid sealing docking, saving time compared to separate docking steps. The preheating buffer mechanism preheats the new salt, preventing solidification issues caused by temperature differences after injection, eliminating the need for additional waiting time for heating and significantly shortening the salt-changing cycle. The slag-cleaning mechanism uses high-pressure jets to quickly clean slag from the furnace, ensuring the purity of the new salt. Testing shows that this device improves salt-changing efficiency by more than 50% compared to existing devices.

[0017] In one possible implementation, two symmetrically arranged lifting threaded rods are used in conjunction with synchronous transmission components to ensure that the lifting plate is subjected to balanced force and moves smoothly. This avoids tilting and jamming caused by single-rod drive, and ensures that the salt extraction pipe and salt injection pipe can be accurately connected to the furnace body interface, thereby improving sealing reliability and device operation stability.

[0018] In one possible implementation, the driving gear is connected to two driven gears via a synchronous belt, resulting in a compact structure and precise transmission ratio. This ensures that the two threaded rods rotate at exactly the same speed, further improving the synchronicity and positional accuracy of the lifting and lowering.

[0019] In one possible implementation, the insulation layer reduces heat loss from the heating jacket, thus lowering energy consumption; the stirring assembly ensures a uniform temperature distribution of the new salt in the buffer salt tank, preventing local overheating or undercooling and guaranteeing the quality stability of the injected salt bath.

[0020] In one possible implementation, a flow sensor monitors the salt extraction flow rate in real time, and the central control system can determine whether the salt extraction is normal based on the flow rate changes, which facilitates timely warnings and handling, and improves the intelligence and safety of the system.

[0021] In one possible implementation, omnidirectional casters allow the integrated salt-changing mechanism to be flexibly moved to different tempering furnaces for salt-changing operations. The locking function ensures stable positioning during docking, adapting to the salt-changing needs of multiple tempering furnaces and reducing equipment investment costs.

[0022] In one possible implementation, quick couplings enable rapid sealing and connection between the salt extraction pipe and the salt discharge port, and between the salt injection pipe and the salt injection port. This is simple to operate, provides reliable sealing, and avoids the risk of leakage from molten salt at high temperatures. The high-temperature resistant salt extraction pump and salt injection pump ensure long-term stable operation in environments above 400°C.

[0023] A rapid salt-replacement tempering furnace method automatically executes five steps—salt preparation, old salt extraction, furnace slag removal, new salt injection, and finalization—through a central control system. The process is compact and logically clear, shortening the entire salt-replacement cycle to less than one-third of the traditional method. In particular, the slag removal step, located between old salt extraction and new salt injection, ensures that the new salt is not contaminated by slag, significantly improving the surface compressive stress stability and yield of the tempered glass.

[0024] In one possible implementation, the preheating temperature is set to be consistent with the current salt bath temperature in the furnace, and the stirring component is activated to make the temperature of the new salt uniform and the error controlled within ±5℃. This ensures that the injected new salt is seamlessly matched with the residual heat field in the furnace, avoids thermal shock and salt bath solidification caused by temperature difference, shortens the stabilization time after injection, and improves the consistency of the tempering process.

[0025] In one possible implementation, during the salt extraction process, the insulation and heating power of the salt extraction pipeline is controlled in real time according to the furnace temperature to ensure that the temperature inside the pipeline is not lower than 380℃, effectively preventing old salt from solidifying and clogging inside the pipeline, and ensuring the smoothness and reliability of the salt extraction process. Attached Figure Description

[0026] Figure 1 This is a schematic diagram of the overall structure of the rapid salt-changing tempering furnace device provided in the embodiments of this application; Figure 2 This is a schematic diagram of the integrated salt exchange mechanism provided in the embodiments of this application; Figure 3 This is a schematic diagram of the preheating buffer mechanism provided in the embodiments of this application; Figure 4 This is a schematic diagram of the slag removal mechanism provided in the embodiments of this application; Figure 5 This is a flowchart illustrating the rapid salt replacement method provided in an embodiment of this application.

[0027] The attached diagram shows the following components: 1. Tempering furnace body; 11. Salt discharge port; 12. Slag removal port; 13. Salt injection port; 14. Temperature sensor; 15. Liquid level sensor; 2. Integrated salt replacement mechanism; 21. Moving base; 211. Universal casters; 22. Lifting assembly; 221. Lifting threaded rod; 222. Drive motor; 223. Synchronous transmission component; 224. Lifting plate; 23. Salt extraction module; 231. High-temperature resistant salt extraction pump; 232. Salt extraction pipeline; 233. Quick connector; 234. Flow sensor; 24. Salt injection module; 241. High-temperature resistant salt injection pump; 242. Salt injection pipeline; 3. Preheating buffer mechanism; 31. Buffer salt tank; 32. Heating jacket; 33. Insulation layer; 34. Stirring assembly; 341. Stirring motor; 342. Stirring paddle; 4. Slag removal mechanism; 41. High-pressure air pump; 42. Air jet pipeline. Detailed Implementation

[0028] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0029] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0030] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "a plurality of" means two or more, unless otherwise explicitly specified.

[0031] In this application, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a communication connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.

[0032] In this application, unless otherwise expressly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature being directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature being directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0033] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0034] Example 1 like Figures 1 to 4 As shown, this embodiment provides a rapid salt-changing tempering furnace device, including a tempering furnace body 1, an integrated salt-changing mechanism 2, a preheating buffer mechanism 3, a slag-cleaning mechanism 4, and a central control system.

[0035] The tempering furnace body 1 is a conventional chemical tempering furnace, with a salt discharge port 11 and a slag removal port 12 at the bottom and a salt injection port 13 at the top. A temperature sensor 14 (for real-time monitoring of the salt bath temperature) and a liquid level sensor 15 (for real-time monitoring of the liquid level) are installed inside the furnace. The salt discharge port 11 is used to discharge old salt, the slag removal port 12 is used to discharge slag deposited at the bottom of the furnace, and the salt injection port 13 is used to inject new salt.

[0036] The integrated salt replacement mechanism 2 is the core execution unit of this application. It includes a movable base 21, a lifting assembly 22, a salt extraction module 23, and a salt injection module 24.

[0037] The mobile base 21 has a rectangular frame structure, with four locking casters 211 at the bottom corners for easy movement and fixation. The advantage of this structure is that operators can easily push the integrated salt-changing mechanism next to any tempering furnace requiring salt replacement, lock the casters, and then perform the salt-changing operation, achieving multi-purpose functionality and reducing equipment costs.

[0038] The lifting assembly 22 includes two symmetrically arranged lifting threaded rods 221, a drive motor 222, and a synchronous transmission component 223. The two lifting threaded rods 221 are vertically mounted on the movable base 21 and supported by bearing seats. The drive motor 222 is fixed to the movable base 21, and its output shaft is connected to the drive gear of the synchronous transmission component 223. The synchronous transmission component 223 also includes two driven gears and a synchronous belt: the two driven gears are respectively fixed to the top ends of the two lifting threaded rods 221, and the drive gear is connected to the two driven gears via the synchronous belt. When the drive motor 222 rotates, the drive gear drives the two driven gears to rotate synchronously via the synchronous belt, thereby causing the two lifting threaded rods 221 to rotate synchronously at the same speed. The advantages of this design are: it avoids the tilting and jamming problems of the lifting plate caused by traditional single-rod drives, ensures that the salt extraction pipe and salt injection pipe can be smoothly and accurately connected to the salt discharge port and salt injection port of the furnace body, and improves the sealing performance of the connection.

[0039] Both the salt extraction module 23 and the salt injection module 24 are fixed on a lifting plate 224. The lifting plate 224 has threaded holes at both ends that mate with the lifting threaded rods 221. The lifting plate 224 is threadedly fitted onto the two lifting threaded rods 221. When the lifting threaded rods 221 rotate synchronously, the lifting plate 224 drives the entire salt extraction module 23 and salt injection module 24 to rise and fall smoothly.

[0040] The salt extraction module 23 includes a high-temperature resistant salt extraction pump 231 and a salt extraction pipeline 232. The high-temperature resistant salt extraction pump 231 is fixed on the lifting plate 224, and its inlet is connected to the old salt recovery box (which is placed on the movable base 21 or placed independently) via a pipeline. One end of the salt extraction pipeline 232 is connected to the outlet of the high-temperature resistant salt extraction pump 231, and the other end is equipped with a quick connector 233 (e.g., a quick clamp connector). The shape and size of the quick connector 233 match the salt discharge port 11 of the tempering furnace body 1, enabling quick sealing and connection. A flow sensor 234 is also installed on the salt extraction pipeline 232 to monitor the salt extraction flow rate. The salt extraction pipeline 232 is made of high-temperature resistant stainless steel (such as 316L stainless steel), and its outer side is wrapped with high-temperature resistant insulation cotton (such as aluminum silicate fiber cotton) to prevent the molten salt inside the pipeline from solidifying. The beneficial effect of the flow sensor 234 is that when the salt extraction flow rate is abnormal (such as too low), the central control system can determine that it is a pipeline blockage or pump failure, and promptly issue an alarm to avoid equipment damage.

[0041] The salt injection module 24 includes a high-temperature resistant salt injection pump 241 and a salt injection pipe 242. The high-temperature resistant salt injection pump 241 is fixed on the lifting plate 224, and its inlet is connected to the bottom of the buffer salt tank 31 of the preheating buffer mechanism 3 via a hose, and its outlet is connected to the salt injection pipe 242. The salt injection pipe 242 is also made of high-temperature resistant stainless steel and wrapped with insulation cotton, and its end is also equipped with a quick connector 233, which matches the salt injection port 13 of the tempering furnace body 1.

[0042] The preheating and buffering mechanism 3 is used for preheating and temporarily storing new salt. It includes a buffer salt tank 31, a heating jacket 32, an insulation layer 33, and a stirring assembly 34. The buffer salt tank 31 is a sealed container made of stainless steel, with a feed inlet (with a sealing cap) at the top and a discharge outlet at the bottom connected to the inlet of a high-temperature salt injection pump 241 via a pipe. The heating jacket 32 ​​is a resistance heating jacket, tightly wrapped around the outer wall and bottom of the buffer salt tank 31. The insulation layer 33 (such as a rock wool layer) is wrapped around the outside of the heating jacket 32 ​​to reduce heat loss. A temperature sensor 14 (not separately labeled in the figure, similar to the sensor in the furnace) is installed inside the buffer salt tank 31. The stirring assembly 34 includes a stirring motor 341 and a stirring paddle 342. The stirring motor 341 is fixed to the top of the buffer salt tank 31, and its output shaft extends downward into the tank and connects to the stirring paddle 342. The stirring paddle 342 is an anchor type or a spiral type, used to stir the molten salt to make its temperature uniform. The beneficial effects of this preheating and buffering mechanism are: the new salt is preheated to the same temperature as the furnace before injection, avoiding a sudden drop in furnace temperature and salt bath solidification caused by cold salt injection; the insulation layer reduces energy consumption; and the stirring components ensure temperature uniformity, resulting in stable quality of the injected salt bath.

[0043] The slag cleaning mechanism 4 includes a high-pressure air pump 41, an air jet pipe 42, and a slag collection box. The high-pressure air pump 41 is fixed on the movable base 21 or placed separately, and its outlet is connected to the air jet pipe 42. The air jet pipe 42 is a high-temperature resistant metal pipe (such as a stainless steel pipe), with one end connected to the high-pressure air pump 41 and the other end extending from the slag cleaning port 12 into the bottom of the tempering furnace body 1 and arranged along the furnace bottom. The portion of the air jet pipe 42 located inside the furnace has multiple air jets, with the air jet direction facing the center area of ​​the furnace bottom. The slag collection box is a high-temperature resistant container, and its inlet is detachably connected to the slag cleaning port 12 via a sealing joint (such as a clamp-type quick-connect joint). During slag cleaning, high-pressure gas blows the slag to the slag cleaning port 12, and the slag falls into the slag collection box under gravity. The beneficial effects of this slag cleaning mechanism are: automatic and rapid cleaning of slag inside the furnace is achieved through high-pressure air jetting, avoiding the high-temperature risks of manual entry into the furnace for cleaning, while ensuring the cleanliness of the furnace bottom before the injection of new salt and preventing slag contamination of the new salt.

[0044] The central control system employs a PLC (Programmable Logic Controller) or an industrial computer, which is electrically connected to temperature sensor 14, level sensor 15, flow sensor 234, drive motor 222, high-temperature resistant brine pump 231, high-temperature resistant brine injection pump 241, heating jacket 32, stirring motor 341, high-pressure air pump 41, etc. The central control system receives signals from each sensor and controls the start, stop, and adjustment of each actuator according to a preset program.

[0045] The following is combined Figure 5 The flowchart illustrates in detail the method for rapid salt replacement using the aforementioned device. This method offers the following advantages: fully automated, eliminating the need for manual contact with the high-temperature molten salt; tightly logical steps with minimal time; the slag removal step is placed between the old salt removal and new salt injection, ensuring the purity of the salt bath; and the preheating step eliminates the waiting time for temperature adjustment.

[0046] S1. Salt replacement preparation: The operator moves the integrated salt replacement mechanism 2 to the side of the tempering furnace body 1 to be replaced and locks the universal casters 211.

[0047] The lifting assembly 22 is activated by inputting commands through the human-machine interface of the central control system. The drive motor 222 rotates, which in turn drives the two lifting threaded rods 221 to rotate synchronously via the synchronous transmission component 223. The lifting plate 224 descends, automatically aligning and sealing the quick connector 233 at the end of the salt extraction pipe 232 with the salt discharge port 11. Simultaneously, the quick connector 233 of the salt injection pipe 242 is sealed and connected to the salt injection port 13. The slag collection box is then connected to the slag cleaning port 12 via a sealed connector.

[0048] Sufficient fresh salt (such as potassium nitrate) is added to the buffer salt tank 31 of the preheating buffer mechanism 3. The preheating temperature is set through the central control system (consistent with the current salt bath temperature in the tempering furnace, for example, 420℃), and the heating jacket 32 ​​and stirring assembly 34 are started. The stirring paddle 342 continuously stirs the salt to ensure uniform heating, with the temperature error controlled within ±5℃. At the same time, the central control system adjusts the power of the heating jacket 32 ​​based on feedback from the temperature sensor 14 to maintain a constant temperature.

[0049] The beneficial effects of this step are: the preheating temperature is consistent and uniform with the furnace temperature, ensuring no temperature difference shock during subsequent salt injection and shortening the stabilization time after injection.

[0050] S2. Used Salt Extraction: The central control system activates the high-temperature resistant salt extraction pump 231. Under the suction of the pump, the used salt inside the tempering furnace body 1 is pumped through the salt discharge port 11, the salt extraction pipe 232, and the high-temperature resistant salt extraction pump 231 to the used salt recovery tank. During the extraction process, the flow sensor 234 monitors the flow rate in real time, and the liquid level sensor 15 monitors the liquid level inside the furnace in real time. Simultaneously, based on the signal from the furnace temperature sensor 14, the central control system controls the auxiliary heating of the insulation cotton in the salt extraction pipe 232 (such as wrapping a heat tracing cable around the outside of the pipe, not shown in the figure but implied) to ensure that the temperature inside the pipe does not fall below 380℃, preventing the used salt from solidifying.

[0051] When the liquid level sensor 15 detects that the liquid level is lower than the preset lower limit (i.e., the preset lower limit threshold is reached), the central control system controls the high-temperature resistant salt pump 231 to stop.

[0052] The benefits of this step are: preventing pipe blockage through heat preservation and heating, and achieving automatic stop through the liquid level sensor, thus avoiding damage to the pump body due to dry burning after evacuation.

[0053] S3. Slag Removal Inside the Furnace: The central control system activates the high-pressure air pump 41. High-pressure gas is ejected from multiple nozzles through the jet pipe 42, blowing the slag material (such as unmelted salt particles, glass fragments, impurities, etc.) deposited at the bottom of the tempering furnace body 1 towards the slag removal port 12. The slag material falls into the slag collection box under gravity. After the slag removal continues for a set time (e.g., 2-5 minutes), the central control system shuts off the high-pressure air pump 41. The operator disassembles the slag collection box, cleans the slag, and sets it aside for later use.

[0054] The benefits of this step are that high-pressure jets can reach corners that are difficult to clean manually, thoroughly removing debris, and the entire process is carried out under closed conditions, with no dust spillage, thus improving the operating environment.

[0055] S4. New Salt Injection: The central control system starts the high-temperature salt injection pump 241. New salt, preheated to the target temperature within the preheating buffer mechanism 3, is pumped out and injected into the tempering furnace body 1 via the salt injection pipe 242 and the salt injection port 13. During the injection process, the liquid level sensor 15 monitors the liquid level in real time. When the liquid level reaches the preset standard working level, the central control system stops the high-temperature salt injection pump 241. Simultaneously, based on the signal from the temperature sensor 14, the central control system controls the heat preservation and heating power of the salt injection pipe 242 to ensure that the temperature of the new salt does not drop during the injection process. The beneficial effects of this step are: the temperature of the injected salt bath matches the residual heat field inside the furnace, which will not cause excessive thermal stress on the furnace body, and the liquid level is precisely controlled, avoiding overflow or underfill.

[0056] S5. Salt Replacement Completion: The central control system controls the drive motor 222 of the lifting assembly 22 to reverse, causing the lifting plate 224 to rise, so that the quick connectors 233 of the salt extraction pipe 232 and the salt injection pipe 242 are respectively disconnected from the salt discharge port 11 and the salt injection port 13. The operator releases the casters 211 and removes the integrated salt replacement mechanism 2, completing the entire salt replacement process.

[0057] The benefits of this step are: the quick-connect coupling disengages smoothly, there is no residual salt dripping, and the tempering furnace production can be resumed immediately after the mechanism is removed, minimizing the disruption to the production line during the salt replacement process.

[0058] Summary of the overall beneficial effects of this embodiment: This application, through the overall coordination of the central control system, achieves full automation of the entire process from old salt extraction and slag removal to new salt preheating and injection. The entire salt replacement process requires no manual contact with the high-temperature molten salt, making it safe and efficient. Actual testing shows that for a 10-ton large tempering furnace, the salt replacement time of this device is reduced by 70% compared to traditional manual methods and by more than 50% compared to existing semi-automatic devices. After salt replacement, the batch fluctuation range of glass tempering compressive stress (CS value) is reduced from ±30MPa to ±10MPa, and the yield rate is improved by approximately 5%. Furthermore, the device is mobile and can serve multiple tempering furnaces, resulting in high equipment utilization and significant economic benefits and promotional value.

[0059] Other possible implementation methods In this embodiment, the synchronous transmission component 223 of the lifting assembly 22 adopts a combination of a driving gear, a driven gear, and a synchronous belt. In other embodiments, the synchronous transmission component can also adopt chain and sprocket drive, worm gear synchronous drive, or two independent servo motors controlled electronically to achieve synchronous rotation of the two threaded rods.

[0060] In this embodiment, the salt extraction pipe 232 and the salt injection pipe 242 are insulated by wrapping them with high-temperature resistant insulation cotton. In other embodiments, electric heating tape can also be wrapped around the outer wall of the pipes, and temperature sensors can be installed for closed-loop temperature control to more accurately prevent solidification.

[0061] In this embodiment, the stirring assembly 34 of the preheating buffer mechanism 3 uses a stirring motor 341 and a stirring paddle 342. For small buffer tanks, a stirring assembly may not be required; instead, temperature uniformity can be achieved through prolonged heating by the heating jacket 32 ​​and natural convection. However, setting up a stirring assembly can achieve uniform temperature more quickly.

[0062] In this embodiment, the central control system uses a PLC. In other embodiments, a microcontroller, industrial computer, or integrated controller may also be used.

[0063] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them; although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications to the technical solutions described in the foregoing embodiments, or equivalent substitutions for some or all of the technical features, do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this application.

Claims

1. A rapid salt-changing tempering furnace device, characterized in that, It includes the tempering furnace body (1), the integrated salt replacement mechanism (2), the preheating buffer mechanism (3), the slag removal mechanism (4), and the central control system; The tempering furnace body (1) is provided with a salt discharge port (11), a slag removal port (12) and a salt injection port (13), and is also provided with a temperature sensor (14) and a liquid level sensor (15). The integrated salt replacement mechanism (2) includes a movable base (21), a lifting assembly (22), a salt extraction module (23), and a salt injection module (24); the lifting assembly (22) is used to drive the salt extraction module (23) and the salt injection module (24) to lift synchronously; the salt extraction module (23) is provided with a salt extraction pipe (232) that can be sealed and connected with the salt discharge port (11); the salt injection module (24) is provided with a salt injection pipe (242) that can be sealed and connected with the salt injection port (13). The preheating buffer mechanism (3) includes a buffer salt tank (31) and a heating jacket (32) for heating the buffer salt tank (31), and the buffer salt tank (31) is connected to the salt injection module (24); The slag cleaning mechanism (4) includes a high-pressure air pump (41) and a slag collection box detachably connected to the slag cleaning port (12). The high-pressure air pump (41) is used to blow air into the bottom of the tempering furnace body (1). The central control system is electrically connected to the temperature sensor (14), liquid level sensor (15), lifting assembly (22), salt extraction module (23), salt injection module (24), heating jacket (32) and high-pressure air pump (41).

2. The rapid salt-changing tempering furnace device according to claim 1, characterized in that, The lifting assembly (22) includes two symmetrically arranged lifting threaded rods (221), a drive motor (222), and a synchronous transmission component (223). The drive motor (222) drives the two lifting threaded rods (221) to rotate synchronously through the synchronous transmission component (223). The salt extraction module (23) and the salt injection module (24) are fixed on the lifting plate (224), and the lifting plate (224) is threadedly connected to the lifting threaded rods (221).

3. The rapid salt-changing tempering furnace device according to claim 2, characterized in that, The synchronous transmission component (223) includes a driving gear, a driven gear and a synchronous belt. The output shaft of the drive motor (222) is connected to the driving gear. The top ends of the two lifting threaded rods (221) are connected to the driven gears. The driving gear is connected to the two driven gears through the synchronous belt.

4. The rapid salt-changing tempering furnace device according to claim 1, characterized in that, The preheating buffer mechanism (3) also includes a heat insulation layer (33) wrapped around the outside of the heating jacket (32), and a stirring assembly (34) is provided inside the buffer salt tank (31), which is electrically connected to the central control system.

5. The rapid salt-changing tempering furnace device according to claim 1, characterized in that, A flow sensor (234) is installed on the salt extraction pipe (232), and the flow sensor (234) is electrically connected to the central control system.

6. The rapid salt-changing tempering furnace device according to claim 1, characterized in that, The bottom of the movable base (21) is equipped with universal casters (211) with locking function.

7. The rapid salt-changing tempering furnace device according to claim 1, characterized in that, The salt extraction module (23) includes a high-temperature resistant salt extraction pump (231), and one end of the salt extraction pipe (232) is connected to the high-temperature resistant salt extraction pump (231), and the other end is provided with a quick connector (233); the salt injection module (24) includes a high-temperature resistant salt injection pump (241), and one end of the salt injection pipe (242) is connected to the high-temperature resistant salt injection pump (241), and the other end is provided with a quick connector (233).

8. A method for rapid salt-changing tempering furnace based on the apparatus according to any one of claims 1-7, characterized in that, Includes the following steps: S1. Salt replacement preparation: Move the integrated salt replacement mechanism (2) to the side of the tempering furnace body (1), and control the lifting component (22) through the central control system to seal the salt extraction pipe (232) with the salt discharge port (11) and the salt injection pipe (242) with the salt injection port (13), seal the slag collection box with the slag cleaning port (12), and add new salt into the preheating buffer mechanism (3) and preheat it to the preset temperature; S2. Old salt extraction: The salt extraction module (23) is started through the central control system to extract the old salt in the tempering furnace body (1) until the liquid level sensor (15) detects that the liquid level in the furnace is lower than the preset lower limit threshold. S3. Slag removal inside the furnace: The high-pressure air pump (41) is started through the central control system to blow air into the bottom of the tempering furnace body (1) to blow the slag to the slag removal port (12) and fall into the slag collection box. S4. New salt injection: The salt injection module (24) is started through the central control system to inject the preheated new salt in the preheating buffer mechanism (3) into the tempering furnace body (1) until the liquid level sensor (15) detects that the liquid level has reached the preset standard liquid level. S5. Salt replacement completion: The central control system controls the lifting assembly (22) to raise and separate the salt extraction pipe (232) and the salt injection pipe (242), and remove the integrated salt replacement mechanism (2).

9. The rapid salt-changing tempering furnace method according to claim 8, characterized in that, In step S1, when the preheating buffer mechanism (3) preheats the new salt, the preheating temperature is consistent with the current salt bath temperature in the tempering furnace, and the stirring component (34) is started to stir the new salt. The preheating temperature error is controlled within ±5℃.

10. The rapid salt-changing tempering furnace method according to claim 8, characterized in that, In step S2, during the salt extraction process, the central control system controls the heat preservation and heating power of the salt extraction pipeline (232) based on the furnace temperature monitored by the temperature sensor (14) to ensure that the temperature inside the pipeline is not lower than 380°C.

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