A hot top electric smelting furnace bottom thermocouple hole state monitoring system
Patent Information
- Application Number
- CN202611212072.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-08-11
- Publication Date
- 2026-10-13
AI Technical Summary
现有技术仅依靠人工目视方式核查池底热偶孔结构件状态，无法采集温度、冷却调节参数类量化运行数据，无法提前识别构件劣化趋势，不存在自动预警机制，构件异常恶化后易引发玻璃液泄漏安全事故
[0012]本发明提出的一种热顶式电熔炉池底热偶孔的状态监控系统，优点是：依托温度监测单元、冷却控制单元、数据处理单元构建闭环调控链路，可根据池底热偶孔结构件实时温度动态调整冷却强度，自主控制构件温度，减少人工实时调控操作。报警单元可自动输出警示信号，同步留存完整历史数据，能够及时暴露设备异常，避免人工巡检漏检造成的生产损失。
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Figure CN122900265A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of liquid crystal glass substrate processing technology, and in particular to a status monitoring system for thermocouple holes at the bottom of a hot-top electric melting furnace. Background Technology
[0002] The thermocouple hole structure at the bottom of the hot-top electric melting furnace is responsible for temperature measurement and furnace sealing. Operating under the long-term effects of high-temperature molten glass erosion, mechanical scouring, and thermal stress, it is prone to structural deterioration. Current technology relies solely on manual visual inspection of the thermocouple hole structure, which cannot collect quantitative operational data such as temperature and cooling regulation parameters. It cannot identify deterioration trends in advance, and there is no automatic early warning mechanism. Abnormal deterioration of the structure can easily lead to molten glass leakage and safety accidents. Summary of the Invention
[0003] To address the technical problems existing in the background art, the present invention proposes a status monitoring system for the thermocouple holes at the bottom of a hot-top electric melting furnace.
[0004] This invention proposes a status monitoring system for the thermocouple holes at the bottom of a hot-top electric melting furnace, used to monitor the thermocouple hole structure at the bottom of the furnace, including: Temperature monitoring unit is used to acquire temperature information of the thermocouple hole structure at the bottom of the pool; The cooling control unit is used to cool the thermocouple hole structure at the bottom of the pool and can provide feedback on the adjustment parameters of the cooling intensity. The data processing unit is connected to the temperature monitoring unit and the cooling control unit respectively. It is used to receive temperature information and send adjustment commands to the cooling control unit according to the temperature information to change the adjustment parameters. The alarm unit is connected to the data processing unit and is used to receive and record temperature information and adjustment parameters, and to issue a warning signal when the temperature information or adjustment parameters exceed the preset range.
[0005] Preferably, the temperature monitoring unit uses an infrared temperature sensor. The infrared temperature sensor is aligned with the surface to be measured of the thermocouple hole structure at the bottom of the pool in a non-contact manner to continuously collect the real-time temperature information of the surface to be measured, and transmits the collected real-time temperature information to the data processing unit in real time.
[0006] Preferably, the temperature monitoring unit includes multiple infrared temperature sensors, the number of which corresponds one-to-one with the number of thermocouple hole structures at the bottom of the pool, and the multiple infrared temperature sensors monitor the temperature of the multiple thermocouple hole structures at the bottom of the pool respectively.
[0007] Preferably, the cooling control unit has both air cooling and liquid cooling modes. The liquid cooling mode uses circulating pure water as the cooling medium, which is introduced into the thermocouple hole structure at the bottom of the pool to remove heat. The air cooling mode uses clean compressed air to blow onto the thermocouple hole structure at the bottom of the pool to assist in heat dissipation. The adjustment parameters include the wind speed opening parameter for controlling the air cooling intensity and the liquid flow opening parameter for controlling the liquid cooling intensity. The data processing unit changes the cooling intensity by adjusting the wind speed opening parameter and the liquid flow opening parameter respectively.
[0008] Preferably, the data processing unit generates and sends an adjustment command to the cooling control unit to increase the cooling effect intensity when it determines that the temperature exceeds the preset range based on the temperature information fed back by the temperature monitoring unit, so as to drive the cooling control unit to increase its adjustment parameters; the data processing unit also dynamically corrects the adjustment parameters according to the changing trend of the temperature information received in real time, until the temperature falls back to the preset range.
[0009] Preferably, the data processing unit records the temperature information obtained by the temperature monitoring unit and the adjustment parameters fed back by the cooling control unit in real time, and continuously transmits the recorded temperature information and adjustment parameters as historical data to the alarm unit for threshold comparison and trend analysis; the alarm unit receives and stores the historical data to trigger an alarm signal when the temperature information or adjustment parameters exceed the preset range.
[0010] Preferably, the alarm unit includes a temperature threshold range corresponding to the temperature information and an adjustment parameter threshold range corresponding to the adjustment parameter; the alarm unit triggers an alarm signal when it determines that the temperature exceeds the temperature threshold range or the adjustment parameter exceeds the adjustment parameter threshold range; the temperature threshold range and the adjustment parameter threshold range are preset and configurable according to the safety operation requirements of the thermocouple hole structure at the bottom of the pool.
[0011] Preferably, the temperature monitoring unit, cooling control unit, data processing unit, and alarm unit are all connected via high-frequency signal transmission lines.
[0012] This invention proposes a status monitoring system for thermocouple holes at the bottom of a hot-top electric melting furnace. Its advantages include: a closed-loop control system comprised of a temperature monitoring unit, a cooling control unit, and a data processing unit; dynamic adjustment of cooling intensity based on the real-time temperature of the thermocouple hole structure at the bottom of the furnace; autonomous control of component temperature; and reduced manual real-time control operations. The alarm unit automatically outputs warning signals and simultaneously stores complete historical data, enabling timely detection of equipment abnormalities and preventing production losses caused by missed inspections during manual checks. Attached Figure Description
[0013] Figure 1 This is a schematic diagram of a status monitoring system for the thermocouple holes at the bottom of a hot-top electric melting furnace proposed in this invention. Detailed Implementation
[0014] refer to Figure 1 This invention proposes a status monitoring system for thermocouple holes at the bottom of a hot-top electric melting furnace. The system comprises a temperature monitoring unit 1, a cooling control unit 2, a data processing unit 3, and an alarm unit 4. All units communicate and transmit signals via a high-frequency signal transmission line. The system can match the number of temperature monitoring units to the number of thermocouple hole structures at the bottom of the furnace, adapting to the multi-point synchronous monitoring needs of different furnace bodies.
[0015] Temperature monitoring unit 1 continuously acquires temperature information of the thermocouple hole structure 5 at the bottom of the pool. Temperature monitoring unit 1 uses an infrared temperature sensor. The infrared temperature sensor is aligned with the surface to be measured of the thermocouple hole structure 5 at the bottom of the pool in a non-contact manner and continuously collects the real-time temperature information of the surface to be measured. After the collection is completed, the real-time temperature information is synchronously transmitted to data processing unit 3.
[0016] The temperature monitoring unit 1 can be configured with multiple sets of infrared temperature sensors. The number of infrared temperature sensors corresponds one-to-one with the number of thermocouple hole structures 5 at the bottom of the pool. Each set of infrared temperature sensors independently corresponds to a single thermocouple hole structure 5 at the bottom of the pool, completing the synchronous temperature acquisition of multiple components. The temperature data collected by the temperature monitoring unit 1 serves as a quantitative basis for determining the erosion and heat deterioration status of the thermocouple hole structure at the bottom of the pool, providing raw data support for subsequent cooling regulation and threshold alarm.
[0017] The cooling control unit 2 continuously cools the thermocouple hole structure 5 at the bottom of the pool, and simultaneously feeds back the adjustment parameters corresponding to the cooling intensity to the data processing unit 3. The cooling control unit 2 integrates both air-cooling and liquid-cooling modes, which operate synchronously. In liquid-cooling mode, circulating pure water is introduced into the thermocouple hole structure 5 as the cooling medium, relying on the medium circulation to remove the accumulated heat from the component. In air-cooling mode, clean compressed air is output, and the airflow acts on the outside of the thermocouple hole structure to complete auxiliary heat dissipation. The adjustment parameters of the cooling control unit 2 are divided into two categories: the air velocity opening parameter controlling the air-cooling intensity and the liquid flow rate opening parameter controlling the liquid-cooling intensity. After receiving the adjustment command from the data processing unit 3, the unit synchronously adjusts the two types of opening parameters to change the overall cooling intensity. After adjustment, the updated air velocity opening parameters and liquid flow rate opening parameters are sent back to the data processing unit 3 in real time.
[0018] Data processing unit 3 establishes signal connections with temperature monitoring unit 1 and cooling control unit 2, serving as the central hub for data reception, logical operations, and command issuance in the entire system. Data processing unit 3 continuously receives real-time temperature information uploaded by temperature monitoring unit 1 and determines the temperature values. When the determined temperature value exceeds a preset range, the unit generates an adjustment command and sends it to cooling control unit 2. The command increases the cooling intensity, driving cooling control unit 2 to adjust the fan speed and liquid flow rate parameters. Data processing unit 3 synchronously tracks the continuous trend of real-time temperature changes, dynamically corrects the adjustment command sent to cooling control unit 2 based on temperature rises and falls, and continuously adjusts the adjustment parameters until the temperature information fed back by temperature monitoring unit 1 falls back within the preset range. Data processing unit 3 continuously stores and records two types of data: all temperature information output by temperature monitoring unit 1 and all adjustment parameters fed back by cooling control unit 2. After recording, the unit continuously transmits all stored data as historical data to alarm unit 4 for threshold comparison and operating condition trend analysis.
[0019] Alarm unit 4 establishes a signal connection with data processing unit 3, continuously receiving temperature information, adjustment parameters, and historical data transmitted by data processing unit 3. Alarm unit 4 has two built-in independent threshold ranges: a temperature threshold range matching the temperature information and an adjustment parameter threshold range matching the adjustment parameters. Both threshold ranges are pre-configured according to the safety operation standards of the thermocouple hole structure at the bottom of the pool, supporting readjustment as needed. Alarm unit 4 performs real-time comparison calculations between data and thresholds. When any of the following situations occur, the unit outputs a warning signal: the temperature information exceeds the temperature threshold range, or the adjustment parameter exceeds the adjustment parameter threshold range. Alarm unit 4 receives and completely stores all historical data sent by data processing unit 3. The stored data is used for long-term tracking of temperature changes and cooling parameter trends of the thermocouple hole structure at the bottom of the pool, assisting on-site personnel in analyzing the causes of component deterioration and troubleshooting equipment abnormalities.
[0020] Complete system linkage workflow: The infrared temperature sensor of temperature monitoring unit 1 continuously collects the surface temperature of each thermocouple hole structure 5 at the bottom of the pool and transmits the temperature information to data processing unit 3. Data processing unit 3 reads the temperature information and determines whether the temperature exceeds the preset range. If it does, it sends an adjustment command to cooling control unit 2 to increase the cooling intensity. After receiving the command, cooling control unit 2 synchronously adjusts the fan speed opening parameter and liquid flow opening parameter to improve the air cooling and liquid cooling heat dissipation capacity, and at the same time sends the updated adjustment parameters back to data processing unit 3. Data processing unit 3 continuously tracks the temperature change trend and dynamically corrects the adjustment command until the component temperature returns to the safe range. Data processing unit 3 records the temperature information and adjustment parameters throughout the process and synchronously transmits the real-time data and historical stored data to alarm unit 4. Alarm unit 4 compares the received data with the preset threshold range. When any indicator of temperature or adjustment parameter exceeds the limit, it outputs a warning signal. On-site personnel conduct on-site verification and fault handling based on the warning signal. Alarm unit 4 retains all historical data for future operational review and degradation trend analysis.
[0021] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.
Claims
1. A status monitoring system for thermocouple holes at the bottom of a hot-top electric melting furnace, used to monitor the thermocouple hole structure (5) at the bottom of the furnace, characterized in that, include: Temperature monitoring unit (1) is used to obtain temperature information of thermocouple hole structure (5) at the bottom of the pool; Cooling control unit (2) is used to cool the thermocouple hole structure (5) at the bottom of the pool and can provide feedback on the adjustment parameters of its cooling effect intensity; The data processing unit (3) is connected to the temperature monitoring unit (1) and the cooling control unit (2) respectively. It is used to receive temperature information and send adjustment commands to the cooling control unit (2) according to the temperature information to change the adjustment parameters. The alarm unit (4) is connected to the data processing unit (3) by signal. It is used to receive and record temperature information and adjustment parameters, and to issue a warning signal when the temperature information or adjustment parameters exceed the preset range.
2. The status monitoring system for the thermocouple holes at the bottom of a hot-top electric melting furnace according to claim 1, characterized in that: The temperature monitoring unit (1) uses an infrared temperature sensor. The infrared temperature sensor is aligned with the surface to be measured of the thermocouple hole structure (5) at the bottom of the pool in a non-contact manner. It is used to continuously collect the real-time temperature information of the surface to be measured and transmit the collected real-time temperature information to the data processing unit (3) in real time.
3. The status monitoring system for the thermocouple holes at the bottom of a hot-top electric melting furnace according to claim 2, characterized in that: The temperature monitoring unit (1) includes multiple infrared temperature sensors. The number of infrared temperature sensors corresponds one-to-one with the number of thermocouple hole structures (5) at the bottom of the pool. The multiple infrared temperature sensors monitor the temperature of the multiple thermocouple hole structures (5) at the bottom of the pool respectively.
4. The status monitoring system for the thermocouple holes at the bottom of a hot-top electric melting furnace according to claim 1, characterized in that: The cooling control unit (2) has both air cooling and liquid cooling modes. The liquid cooling mode uses circulating pure water as the cooling medium and passes it into the thermocouple hole structure (5) at the bottom of the pool to remove heat. The air cooling mode uses clean compressed air to blow onto the thermocouple hole structure (5) at the bottom of the pool to assist in heat dissipation. The adjustment parameters include the wind speed opening parameter for controlling the air cooling intensity and the liquid flow opening parameter for controlling the liquid cooling intensity. The data processing unit (3) changes the cooling intensity by adjusting the wind speed opening parameter and the liquid flow opening parameter respectively.
5. The status monitoring system for the thermocouple holes at the bottom of a hot-top electric melting furnace according to claim 1, characterized in that: The data processing unit (3) generates and sends an adjustment command to the cooling control unit (2) to increase the cooling effect intensity when the temperature exceeds the preset range based on the temperature information fed back by the temperature monitoring unit (1), so as to drive the cooling control unit (2) to increase its adjustment parameters; the data processing unit (3) also dynamically corrects the adjustment parameters based on the changing trend of the temperature information received in real time, until the temperature falls back to the preset range.
6. The status monitoring system for the thermocouple holes at the bottom of a hot-top electric melting furnace according to claim 5, characterized in that: The data processing unit (3) records the temperature information obtained by the temperature monitoring unit (1) and the adjustment parameters fed back by the cooling control unit (2) in real time, and continuously transmits the recorded temperature information and adjustment parameters as historical data to the alarm unit (4) for threshold comparison and trend analysis; the alarm unit (4) receives and stores the historical data, which is used to trigger a warning signal when the temperature information or adjustment parameters exceed the preset range.
7. The status monitoring system for the thermocouple holes at the bottom of a hot-top electric melting furnace according to claim 6, characterized in that: The alarm unit (4) includes a temperature threshold range corresponding to the temperature information and an adjustment parameter threshold range corresponding to the adjustment parameter; the alarm unit (4) triggers an alarm signal when it determines that the temperature exceeds the temperature threshold range or the adjustment parameter exceeds the adjustment parameter threshold range; the temperature threshold range and the adjustment parameter threshold range are preset and configurable according to the safety operation requirements of the bottom thermocouple hole structure (5).
8. The status monitoring system for the thermocouple holes at the bottom of a hot-top electric melting furnace according to claim 1, characterized in that: The temperature monitoring unit (1), cooling control unit (2), data processing unit (3) and alarm unit (4) are all connected by a high-frequency signal transmission line.