A homogenizing circulation device and method for glass insulators

Abstract

The application discloses a kind of homogenizing circulating device and method for glass insulator, device is located outside homogenizing furnace, including inlet circulating device, outlet circulating device and secondary homogenizing conveying device;Inlet circulating device contains inlet truss mechanism and inlet conveying device, outlet circulating device contains outlet truss device and outlet shunt device, secondary homogenizing conveying device is connected with outlet shunt device and inlet conveying device.The method comprises: glass insulator enters furnace and is carried out 260 DEG C to 290 DEG C first homogenization;Outlet truss gripper is taken out and is moved to shunt device;It needs secondary homogenization to be backflowed to inlet again by secondary homogenizing conveying device, and re-enter furnace, and is carried out 260 DEG C to 290 DEG C secondary homogenization, after completion, transfer next process;Without secondary homogenization is directly transferred next process.The application realizes automatic shunting and secondary homogenizing circulation after homogenization, without manual transfer, improve homogenization sufficiency and consistency, reduce self-explosion risk.

Description

Technical Field

[0001] This invention belongs to the field of power equipment technology, specifically a homogeneous circulation device for glass insulators. Background Technology

[0002] As a key component in power transmission and distribution systems, glass insulators provide electrical insulation and mechanical support, and their operational stability directly affects the safe and reliable operation of power grid equipment. During the manufacturing process of tempered glass insulators, due to the combined effects of multiple factors such as raw material formulation, melting process, and molding process, trace amounts of nickel sulfide impurities are often uncontrollably introduced. This impurity is locked in a high-temperature β-phase crystal form during the high-temperature tempering state. However, during long-term operation at room temperature in the power grid, nickel sulfide gradually undergoes a low-temperature phase transformation from β-NiS to α-NiS, accompanied by a volume expansion effect of approximately four percent. This microscopic volume expansion creates a continuous tensile force within the internal stress structure of the glass, gradually weakening its internal structural strength over time, ultimately becoming the main underlying cause of spontaneous breakage of glass insulators during use.

[0003] Given the aforementioned technical problems, the industry currently widely adopts a constant-temperature vulcanization aging process for pretreatment of tempered glass insulators before they leave the factory. The basic principle of this process is to place the insulators in a constant-temperature environment within a set temperature range for continuous heat preservation. This high temperature induces the phase transition process of nickel sulfide impurities in advance, allowing them to complete the transformation from the unstable β phase to the stable α phase before leaving the factory. This exposes and eliminates defective products with a risk of spontaneous explosion in advance within the factory, effectively reducing the spontaneous explosion rate after the products are put into operation on the power grid.

[0004] However, as this process continues to be used in production practice and related application scenarios place more stringent requirements on product reliability, some inherent characteristics of the above-mentioned existing technical solutions at the principle level have gradually revealed many deep-seated limitations in dealing with the challenges of new technologies.

[0005] Firstly, from a process implementation perspective, the process path design of traditional vulcanizing furnace equipment is relatively fixed, and its mechanical structure and control logic only support a single, one-time inlet and outlet conveying process. This means that after the insulator enters the furnace, it can only undergo one vulcanization aging treatment. Within the limited holding time, the phase transformation reaction of nickel sulfide impurities cannot reach a complete state. For insulators with insufficient initial phase transformation, the residual β-phase nickel sulfide inside still has the potential to undergo further phase transformation in the subsequent power grid operating environment, resulting in a certain risk of spontaneous explosion during the service stage, seriously threatening the long-term stable operation of power grid equipment.

[0006] Secondly, from the perspective of production layout and equipment investment, many manufacturing enterprises are limited by the spatial layout and infrastructure conditions of existing production workshops, making it difficult to find suitable space to add vulcanizing furnace equipment to implement the secondary drying and homogenization process on the basis of existing production lines. At the same time, the additional purchase and installation of vulcanizing furnace equipment means a large-scale capital investment and an increase in production costs, which often becomes an important economic factor restricting process improvement in modern manufacturing enterprises that pursue lean production.

[0007] Furthermore, from the perspective of operational safety and product quality, if the traditional manual method is used for the secondary furnace loading operation, operators need to directly contact the glass insulator workpieces that have just undergone the first homogenization process in a high-temperature working environment. This not only exposes them to a high risk of burns from heat radiation, but also makes it difficult to guarantee the accuracy of manual placement, easily leading to positioning problems such as workpiece displacement and positional deviation. During the gripping and handling process, due to the instability of manual operation, it is also very easy for the glass insulators to collide and rub against the clamps, resulting in quality defects such as glass chipping and surface scratches, affecting the product yield and overall quality consistency.

[0008] Finally, from the perspective of production line automation, the existing gantry conveyor equipment only has unidirectional material conveying function. Its mechanical structure and electrical control logic are fixed in unidirectional operation mode from the initial design, and it does not have the ability to perform cyclic operations such as external buffering, reverse material return, and secondary feeding. This structural defect fundamentally restricts the implementation of secondary vulcanization process on existing production lines, making it impossible for single-furnace secondary vulcanization process to form a complete production closed loop.

[0009] In summary, the multiple limitations of the existing equipment structure and process flow have led to the problems of incomplete removal of nickel sulfide phase transformation in glass insulators and a high rate of spontaneous explosion of the products. Summary of the Invention

[0010] The purpose of this invention is to provide a homogeneous circulation device and method for glass insulators, so as to solve the following technical problems raised in the background art: In summary, the multiple limitations of the existing equipment structure and process flow have led to the problems of incomplete removal of nickel sulfide phase transformation in glass insulators and a high rate of spontaneous explosion of the products.

[0011] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: First aspect: A homogenization and circulation device for glass insulators is disposed outside a homogenization furnace. The homogenization and circulation device includes an inlet circulation device, an outlet circulation device, and a secondary homogenization conveying device. The inlet circulation device is located at the inlet side of the homogenization furnace, the outlet circulation device is located at the outlet side of the homogenization furnace, and the secondary homogenization conveying device is located at the rear side of the homogenization furnace. The inlet circulation device includes an inlet truss mechanism and an inlet conveying device. The inlet conveying device is used to transport the glass insulators to be processed. An inlet truss gripper is provided at the bottom of the inlet truss mechanism for transporting the glass insulators into the homogenization furnace for homogenization. The outlet circulation device includes an outlet truss mechanism and an outlet diverting device. An outlet truss gripper is provided at the bottom of the outlet truss mechanism. The two ends of the secondary homogenization conveying device are connected to the outlet diverting device and the inlet conveying device, respectively. The outlet truss gripper is used to transport the homogenized glass insulators to the outlet diverting device. The outlet diverting device is used to send the glass insulators to the next process or to the secondary homogenization conveying device. The secondary homogenization conveying device is used to transport the homogenized glass insulators to the inlet conveying device for secondary homogenization.

[0012] Furthermore, both the entrance truss gripper and the exit truss gripper adopt an arc-shaped structure.

[0013] Furthermore, the curved clamping surfaces of the entrance truss gripper and the exit truss gripper are provided with a layer of high-temperature resistant flexible silicone.

[0014] Furthermore, the thickness of the high-temperature resistant flexible silicone layer is 2mm-4mm.

[0015] Furthermore, the inlet conveying device includes an inlet conveying roller conveyor and a first drive motor. The first drive motor is connected to the conveying roller conveyor and is used to drive the rollers on the first conveying roller conveyor to rotate forward or backward.

[0016] Furthermore, the outlet diversion device includes an outlet conveyor roller conveyor, a first transfer roller conveyor, a second transfer roller conveyor, and a second drive motor; Both the first and second transfer roller conveyors are arc-shaped and connected to the same side of the outlet conveyor roller conveyor; the first transfer roller conveyor is also connected to the secondary conveying device, and the second transfer roller conveyor is also connected to the conveyor line of the next process; the second drive motor is used to drive the rollers on the outlet conveyor roller conveyor to rotate.

[0017] Furthermore, the secondary homogenizing conveying device includes a conveyor belt, a support frame, and a tensioning mechanism; the conveyor belt is a high-temperature resistant silicone conveyor belt, and the tensioning mechanism is used to adjust the tension of the conveyor belt.

[0018] The second aspect: A homogeneous circulation method for glass insulators, using a homogeneous circulation apparatus for glass insulators as described in any one of the first aspects, includes the following steps: S1, the glass insulator enters the homogenizing furnace to complete a constant temperature homogenizing aging treatment of 260℃ to 290℃, which initially induces the phase transformation of nickel sulfide inside the glass from β-NiS to α-NiS. S2, after one homogenization is completed, the outlet truss gripper will automatically remove the insulator and transfer it to the homogenizer outlet diversion device; S3, input the glass insulator into the secondary homogenizing conveyor or the next process; Among them, glass insulators that require secondary homogenization are pre-set by the system and transferred to the secondary homogenization conveying device, while those that do not require secondary homogenization are transferred to the next process. S3.1 During secondary homogenization, the inlet conveyor of the homogenizer furnace reverses to receive the product conveyed by the secondary homogenizer conveyor, and the inlet truss gripper grabs the glass insulator and sends it into the homogenizer furnace. S3.2, the glass insulators undergo a second constant temperature homogenization aging treatment in the furnace, with the temperature controlled between 260℃ and 290℃; S3.3 After the secondary homogenization is completed, the product is removed by the export truss gripper and transferred to the next production process.

[0019] Furthermore, in step S1, the holding time for one homogenization aging process is 2 to 4 hours.

[0020] Furthermore, in step S3.2, the holding time for the secondary homogenization aging is 1.5 hours to 3 hours.

[0021] Third aspect: A control system for controlling a homogenizing circulation device for glass insulators as described in any of the first aspects, wherein the control system is electrically connected to an inlet circulation device, an outlet circulation device, and a secondary homogenizing conveying device.

[0022] Compared with the prior art, the present invention has the following beneficial effects: The homogenization and circulation device and method for glass insulators provided by this invention realizes the functions of automatic diversion and secondary homogenization and circulation conveying of glass insulators after homogenization by setting an inlet circulation device, an outlet circulation device, and a secondary homogenization and conveying device outside the homogenization furnace. This device and method enable glass insulators that need to be homogenized again to return to the inlet and re-enter the homogenization furnace without manual transfer, thereby improving the sufficiency and consistency of the homogenization process of glass insulators and significantly reducing the risk of spontaneous explosion of the products. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 This is one of the partial structural schematic diagrams of the present invention; Figure 3This is a second partial structural schematic diagram of the present invention; Figure 4 This is a schematic diagram of the method flow of the present invention.

[0024] The markings in the diagram are: 1-homogenizing furnace, 2-inlet conveying device, 3-inlet truss gripper, 4-inlet truss mechanism, 5-secondary homogenizing conveying device, 6-outlet truss device, 7-outlet truss gripper, and 8-outlet diversion device. Detailed Implementation

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0026] Example 1: A homogenizing circulation device for glass insulators is disposed outside a homogenizing furnace 1. The homogenizing circulation device includes an inlet circulation device, an outlet circulation device, and a secondary homogenizing conveying device 5. The inlet circulation device is located on the inlet side of the homogenizing furnace 1, the outlet circulation device is located on the outlet side of the homogenizing furnace 1, and the secondary homogenizing conveying device 5 is located on the rear side of the homogenizing furnace 1. The inlet circulation device includes an inlet truss mechanism 4 and a homogenizing furnace inlet conveying device 2. The inlet conveying device 2 is used to convey the glass insulators to be processed. An inlet truss gripper 3 is provided at the bottom of the inlet truss mechanism 4 for handling the glass insulators. Glass insulators enter homogenizing furnace 1 for homogenization; the outlet circulation device includes an outlet truss device 6 and an outlet diversion device 8; an outlet truss gripper 7 is installed at the bottom of the outlet truss device 6; the two ends of the secondary homogenizing conveying device 5 are connected to the outlet diversion device 8 and the inlet conveying device 2 respectively; the outlet truss gripper 7 is used to transport the homogenized glass insulators to the outlet diversion device 8; the outlet diversion device 8 is used to send the glass insulators to the next process or to the secondary homogenizing conveying device 5; the secondary homogenizing conveying device 5 is used to transport the homogenized glass insulators to the inlet conveying device 2 for secondary homogenization.

[0027] The homogenization circulation device is located outside the homogenizing furnace 1 and is used to complete the conveying, handling, diversion, and secondary circulation of glass insulators outside the homogenizing furnace 1. The inlet circulation device is located on the inlet side of the homogenizing furnace 1 and includes an inlet truss mechanism 4 and a homogenizing furnace inlet conveying device 2. The inlet conveying device 2 is used to convey the glass insulators to be processed. An inlet truss gripper 3 is provided at the bottom of the inlet truss mechanism 4 and is used to transport the glass insulators into the homogenizing furnace 1 for homogenization. The outlet circulation device is located on the outlet side of the homogenizing furnace 1 and includes an outlet truss device 6 and an outlet diversion device 8. An outlet truss gripper 7 is provided at the bottom of the outlet truss device 6 and is used to transport the homogenized glass insulators to the outlet diversion device 8. The outlet diversion device 8 is used to send the glass insulators to the next process or to the secondary homogenization conveying device 5. The secondary homogenization conveying device 5 is located on the rear side of the homogenizing furnace 1 and is connected at both ends to the outlet diversion device 8 and the inlet conveying device 2, respectively. It is used to transport the homogenized glass insulators to the inlet conveying device 2 for secondary homogenization.

[0028] In use, the glass insulators to be processed are first conveyed by the inlet conveying device 2, and then transported into the homogenizing furnace 1 by the inlet truss gripper 3 at the bottom of the inlet truss mechanism 4 for homogenization. After homogenization, the glass insulators are transported from the outlet of the homogenizing furnace 1 to the outlet diversion device 8 by the outlet truss gripper 7 at the bottom of the outlet truss device 6. The outlet diversion device 8 sends the glass insulators to the next process or to the secondary homogenizing conveying device 5 as needed. When secondary homogenization is required, the secondary homogenizing conveying device 5 transports the homogenized glass insulators back to the inlet conveying device 2, and then sends them back into the homogenizing furnace 1 by the inlet truss gripper 3, thus forming a cycle of inlet conveying, homogenization, outlet handling, diversion, secondary conveying and returning to the inlet.

[0029] This device can automatically divert and recycle glass insulators after homogenization outside the homogenizing furnace 1, so that glass insulators that need to be homogenized again can return to the inlet and re-enter the homogenizing furnace 1 without manual transfer, thereby improving the sufficiency and consistency of the homogenization process of glass insulators.

[0030] In a preferred embodiment, both the entrance truss gripper 3 and the exit truss gripper 7 adopt an arc-shaped structure. A high-temperature resistant flexible silicone layer is provided on the arc-shaped clamping surface of both the entrance truss gripper 3 and the exit truss gripper 7. The thickness of the high-temperature resistant flexible silicone layer is 2mm-4mm.

[0031] In this preferred embodiment, both the inlet truss gripper 3 and the outlet truss gripper 7 adopt an arc-shaped structure, which can better fit the shape of the glass insulator, increase the clamping contact area, improve handling stability, and reduce the risk of local stress concentration and glass breakage. The arc-shaped clamping surface is provided with a high-temperature resistant flexible silicone layer, which can protect the surface of the glass insulator in the high-temperature environment of the homogenizing furnace 1 and during the gripping and handling process by means of its high-temperature resistance and flexible cushioning performance, increase friction, prevent slippage, and reduce problems such as scratches and edge chipping caused by hard contact. The silicone layer thickness is set to 2mm-4mm, which can ensure the cushioning protection and fitting effect while avoiding excessive thickness that would cause clamping looseness, positioning deviation or unstable gripping, thus taking into account protection, clamping reliability and service life.

[0032] In a preferred embodiment, the inlet conveying device 2 includes an inlet conveying roller conveyor and a first drive motor. The first drive motor is connected to the conveying roller conveyor and is used to drive the rollers on the first conveying roller conveyor to rotate forward or backward.

[0033] The inlet conveying device 2 includes an inlet conveying roller and a first drive motor. The inlet conveying roller is used to carry and convey the glass insulators to be processed. The first drive motor is connected to the conveying roller and provides power. By driving the roller to rotate forward or backward, the glass insulators can move towards the inlet of the homogenizing furnace 1, which makes it easier for the inlet truss gripper 3 to accurately grab and send them into the homogenizing furnace 1. At the same time, it can be connected to the secondary homogenizing conveying device 5 to receive the secondary homogenizing return parts, thereby improving the conveying flexibility, positioning reliability and automation continuity of the circulating homogenizing process.

[0034] In a preferred embodiment, the outlet diversion device 8 includes an outlet conveyor roller conveyor, a first transfer roller conveyor, a second transfer roller conveyor, and a second drive motor; Both the first and second transfer roller conveyors are arc-shaped and connected to the same side of the outlet conveyor roller conveyor; the first transfer roller conveyor is also connected to the secondary homogenizing conveyor 5, and the second transfer roller conveyor is also connected to the conveyor line of the next process; the second drive motor is used to drive the rollers on the outlet conveyor roller conveyor to rotate.

[0035] In the outlet diversion device 8, the outlet conveyor roller is used to receive the homogenized finished glass insulators transported by the outlet truss gripper 7. The second drive motor drives its rollers to rotate, realizing the stable conveying and temporary storage of glass insulators on the outlet side before diversion. The first transfer roller and the second transfer roller are both arc-shaped structures and connected to the same side of the outlet conveyor roller, which can realize smooth turning and diversion in a limited space. The first transfer roller is connected to the secondary homogenizing conveyor 5 and is used to turn and send the glass insulators that need to be homogenized again into the secondary homogenizing conveyor 5. The second transfer roller is connected to the next process conveyor line and is used to turn and send the glass insulators that do not need to be homogenized into the next process. The arrangement of the two on the same side makes the diversion structure more compact and the path clearer. With the second drive motor driving the outlet conveyor roller, the automation level of outlet diversion, the continuity of conveying and the efficiency of secondary homogenization cycle can be improved.

[0036] In a preferred embodiment, the secondary homogenizing conveying device 5 includes a conveyor belt, a support frame, and a tensioning mechanism. The conveyor belt is a high-temperature resistant silicone conveyor belt, and the tensioning mechanism is used to adjust the tension of the conveyor belt. In this secondary homogenizing conveying device 5, the conveyor belt is used to transport the glass insulators that need to be homogenized again, which are separated from the outlet diverter 8, back to the inlet conveying device 2, realizing a secondary homogenization cycle. The high-temperature resistant silicone conveyor belt can adapt to the residual temperature of the glass insulators after homogenization and has a certain degree of flexibility and anti-slip buffering effect, reducing damage to the glass insulators during the conveying process. The support frame is used to support and fix the conveyor belt and related components to ensure stable conveying path and reliable load bearing. The tensioning mechanism is used to adjust the tension of the conveyor belt to prevent the conveyor belt from loosening, slipping, or running off-center, ensuring continuous, stable, and reliable secondary homogenization return conveying, thereby improving the automation level and operational stability of the entire homogenization cycle device.

[0037] A homogeneous circulation method for glass insulators, using a homogeneous circulation apparatus for glass insulators as described in any one of the first aspects, includes the following steps: S1, the glass insulator enters the homogenizing furnace 1 to complete a constant temperature homogenizing aging treatment of 260℃ to 290℃, which initially induces the phase transformation of nickel sulfide inside the glass from β-NiS to α-NiS.

[0038] In step S1, the purpose of this step is to induce a phase transition from β-NiS to α-NiS in the nickel sulfide inside the glass insulator through isothermal homogenization aging treatment at 260℃ to 290℃, thereby reducing the risk of subsequent spontaneous explosion caused by unstable phases and laying the foundation for subsequent current shunting and possible secondary homogenization.

[0039] S2, after one homogenization is completed, the outlet truss gripper 7 automatically removes the insulator and transfers it to the homogenizer outlet diversion device 8.

[0040] In S2, the function of this step is to achieve automatic discharge and transfer after homogenization. The outlet truss gripper 7 takes the glass insulator out of the homogenizing furnace 1 and transfers it to the outlet diversion device 8, reducing the problems of burns and damage caused by manual contact with high-temperature products, and at the same time providing conditions for diversion connection.

[0041] S3, input the glass insulator into the secondary homogenizing conveyor (5) or the next process; Among them, glass insulators that require secondary homogenization are pre-set by the system and are transferred to the secondary homogenization conveying device 5, while those that do not require secondary homogenization are transferred to the next process. The function of S3 is to transfer glass insulators that require secondary homogenization to the secondary homogenization conveyor 5 for recirculation and rehomogenization, and to directly transfer glass insulators that do not require secondary homogenization to the next process. This can prevent insufficiently homogenized products from flowing into subsequent processes, ensure the consistency and reliability of homogenization quality, and realize automatic diversion of secondary homogenization on demand, reduce manual transfer, and improve production continuity and efficiency.

[0042] S3.1 During the secondary homogenization, the inlet conveyor 2 of the homogenizer furnace reverses to receive the product conveyed by the secondary homogenizer conveyor 5, and the inlet truss gripper 3 grabs the glass insulator and sends it into the homogenizer furnace 1.

[0043] The function of S3.1 is to reverse the inlet conveyor 2 during the secondary homogenization process, so that it connects with the secondary homogenization conveyor 5 and receives the return product. Then, the inlet truss gripper 3 grabs the glass insulator and sends it into the homogenizing furnace 1. This realizes that the secondary homogenized product flows back from the outlet to the inlet and automatically re-enters the furnace, avoiding manual handling and ensuring that the secondary homogenization cycle is continuous, smooth and efficient.

[0044] S3.2, the glass insulators undergo a secondary isothermal homogenization aging treatment in the furnace, with the temperature controlled between 260℃ and 290℃.

[0045] The function of S3.2 is to perform supplementary isothermal homogenization and aging treatment on the secondary homogenized product at 260℃ to 290℃, further promoting the transformation of nickel sulfide inside the glass from β-NiS to α-NiS, so that the product that was not sufficiently homogenized in the first stage can be more fully homogenized, thereby reducing the risk of spontaneous explosion and improving the stability and reliability of glass insulators.

[0046] S3.3 After the secondary homogenization is completed, the product is removed from the export truss grabber 7 and transferred to the next production process.

[0047] The function of S3.3 is to achieve automatic material discharge and process connection after the secondary homogenization is completed. The product is taken out from the homogenizing furnace 1 by the outlet truss gripper 7 and transferred to the next production process, avoiding manual handling of high-temperature products, ensuring that the glass insulators after secondary homogenization can enter the subsequent process in a timely manner, and improving production continuity, automation and transfer efficiency.

[0048] In a preferred embodiment, in step S1, the heat preservation time for one homogenization aging is 2 to 4 hours.

[0049] In S1, the holding time for the first homogenization aging is set to 2 to 4 hours, which provides sufficient time for the transformation of nickel sulfide inside the glass from β-NiS to α-NiS at 260℃ to 290℃, making the first homogenization more complete and reducing the risk of subsequent spontaneous explosion of the glass insulator. If the time is too short, the phase transformation may be insufficient, and if the time is too long, it will reduce production efficiency and increase energy consumption. Therefore, this range takes into account both the homogenization effect and production economy.

[0050] In a preferred embodiment, in step S3.2, the heat preservation time for the secondary homogenization aging is 1.5 hours to 3 hours.

[0051] In S3.2, the holding time for secondary homogenization aging is set to 1.5 hours to 3 hours. Its purpose is to provide supplementary holding time for the secondary homogenized product at 260℃ to 290℃, further promoting the transformation of residual β-NiS to α-NiS, so that the product that was not sufficiently homogenized in the first stage can be more fully homogenized, reducing the risk of spontaneous explosion. This range takes into account both homogenization effect and production efficiency. Too short a time may lead to incomplete phase transformation, while too long a time will increase energy consumption and reduce production capacity.

[0052] A control system for controlling a homogenizing circulation device for glass insulators as described in any of the first aspects, wherein the control system is electrically connected to an inlet circulation device, an outlet circulation device, and a secondary homogenizing conveying device 5.

[0053] This control system is used to uniformly control the glass insulator homogenization and circulation device. Through electrical connection with the inlet circulation device, the outlet circulation device, and the secondary homogenization conveying device 5, it realizes signal interaction and action coordination between the various mechanisms. It can control the forward and reverse rotation of the inlet conveying device 2 and the inlet truss gripper 3 to complete the feeding into the furnace, control the outlet truss gripper 7 to complete the homogenization and take out and transport the product, control the outlet diversion device 8 to send the product to the next process or the secondary homogenization conveying device 5 as needed, and control the secondary homogenization conveying device 5 to return the product that needs to be homogenized to the inlet. This ensures that the homogenization, discharge, diversion and secondary circulation links are automatically connected, improving the automation level, control accuracy, production continuity and homogenization consistency of the device operation.

[0054] To facilitate understanding of the homogenization circulation device and method of the present invention, the homogenization circulation device of the present invention will be further described in detail below, and the various components, connection relationships and working processes of the homogenization circulation device and method for glass insulators will be described in detail.

[0055] Example 2: The homogenization and circulation device for glass insulators provided by this invention is located outside the homogenizing furnace 1 and includes an inlet circulation device, an outlet circulation device, and a secondary homogenizing conveying device 5. The inlet circulation device is located on the inlet side of the homogenizing furnace 1 and is used to convey the glass insulators to be processed to the inlet position of the homogenizing furnace 1 and complete the feeding action. The outlet circulation device is located on the outlet side of the homogenizing furnace 1 and is used to remove the homogenized glass insulators from the outlet position of the homogenizing furnace 1 and perform diversion processing. The secondary homogenizing conveying device 5 is located on the rear side of the homogenizing furnace 1 and is used to realize the external reflux and secondary feeding functions of the homogenized products. The three devices are coordinated and controlled by a control system to form a complete homogenization and circulation process for glass insulators.

[0056] The inlet circulation device includes an inlet truss mechanism 4 and an inlet conveying device 2. The inlet conveying device 2 is installed on the ground foundation on one side of the inlet of the homogenizing furnace 1, and includes an inlet conveying roller conveyor and a first drive motor. The inlet conveying roller conveyor consists of multiple parallel rollers, with both ends of the rollers supported on the frame by bearing seats, forming a continuous bearing surface. The first drive motor is connected to the drive end of the inlet conveying roller conveyor, and the motor output shaft is connected to the rotating shaft of the drive roller via a coupling, used to drive all the rollers on the inlet conveying roller conveyor to rotate synchronously. The first drive motor is controlled by a frequency converter, enabling both forward and reverse rotation. When the first drive motor rotates forward, the rollers on the inlet conveying roller conveyor move the glass insulators towards the inlet of the homogenizing furnace 1, realizing the forward conveying function of the glass insulators to be processed. When the first drive motor rotates in reverse, the inlet conveying roller conveyor can receive return products from the secondary homogenizing conveying device 5, realizing the reverse receiving function. The conveying speed of the inlet conveying roller conveyor is set according to the production cycle requirements, typically adjustable from 0.5 meters to 2 meters per minute.

[0057] The inlet truss mechanism 4 is located above the inlet of the homogenizer 1, and includes the inlet truss body and the inlet truss gripper 3 located at the bottom of the inlet truss body. The inlet truss body is a frame steel structure, with its upper end fixedly installed on the roof structure of the workshop or on an independent support column to ensure structural stability during operation. A lifting mechanism is provided vertically along the inlet truss body. The lifting mechanism consists of an electric cylinder or a hydraulic cylinder, with the cylinder body fixed to the upper frame of the inlet truss body. The telescopic rod extends downward and is fixedly connected to the upper connecting plate of the inlet truss gripper 3. Driven by the control system, the telescopic rod of the lifting mechanism extends or retracts, causing the inlet truss gripper 3 to move up and down vertically. A horizontal moving mechanism is provided horizontally along the inlet truss body. The horizontal moving mechanism consists of a linear guide rail and a servo motor. The linear guide rail is fixedly installed on the top frame of the inlet truss body, and the slider is installed on the guide rail and can slide back and forth along the guide rail. A servo motor drives a slider to move on a guide rail via a rack and pinion mechanism, causing the entire inlet truss gripper 3 to reciprocate horizontally between the inlet of the homogenizer 1 and the inlet conveyor 2. The lifting and lowering motion of the inlet truss gripper 3 and its horizontal movement work together to form a two-dimensional motion trajectory, enabling precise gripping of glass insulators on the inlet conveyor rollers and accurate placement into the inlet of the homogenizer 1.

[0058] The entrance truss gripper 3 adopts an arc-shaped clamping structure, with its main body made of high-strength aluminum alloy, featuring light weight and high strength. The arc-shaped clamping surface of the entrance truss gripper 3 is formed into an arc shape that adapts to the outer contour of the glass insulator, and the radius of the arc is customized according to the outer diameter of the glass insulator to be processed. The typical outer diameter of the glass insulator is 280mm to 450mm, and the corresponding arc radius of the gripper is set to 140mm to 225mm. The arc-shaped clamping structure can increase the contact area with the outer circular surface of the glass insulator during the gripping process, so that the clamping force is evenly distributed along the arc surface, avoiding the local stress concentration phenomenon caused by point contact. Under the traditional point contact clamping method, the glass insulator is subjected to excessive pressure locally, which can easily lead to edge chipping or breakage. The arc-shaped clamping structure of this invention disperses the concentrated load into a surface load, significantly reducing the risk of damage to the glass insulator due to uneven force during the gripping process.

[0059] A high-temperature resistant flexible silicone layer is applied to the arc-shaped clamping surface of the entrance truss gripper 3. This silicone layer is fixed to the clamping surface through a hot vulcanization bonding process. The high-temperature resistant flexible silicone layer is made of high-temperature resistant silicone material, which maintains stable physical properties at temperatures above 200℃, without softening or decomposing. The thickness of the silicone layer is set between 2mm and 4mm, with the specific thickness selected based on the weight and surface finish requirements of the glass insulator. A thinner silicone layer of 2mm provides moderate flexibility and anti-slip effect while maintaining high clamping and positioning accuracy. A thicker silicone layer of 4mm provides a softer cushioning effect, suitable for glass insulator products with higher surface quality requirements. The high-temperature resistant flexible silicone layer forms a flexible buffer layer between the entrance truss gripper 3 and the glass insulator. Utilizing the high-temperature resistance and flexible deformation capability of the silicone material, it protects the surface of the glass insulator from scratches or impact damage during the high-temperature environment of the homogenizing furnace 1 and during gripping and handling. Meanwhile, the presence of the silicone layer increases the coefficient of friction between the gripper and the glass insulator, reaching over 0.8, effectively preventing slippage or detachment during handling. The silicone layer thickness is set to 2mm to 4mm, ensuring sufficient cushioning and surface adhesion while avoiding problems such as increased clamping gaps, decreased positioning accuracy, or unstable gripping caused by an excessively thick silicone layer.

[0060] The outlet circulation device is located on one side of the outlet of the homogenizing furnace 1, and includes an outlet truss device 6 and an outlet diversion device 8. The structure of the outlet truss device 6 is basically the same as that of the inlet truss mechanism 4, including the outlet truss body and the outlet truss gripper 7 located at the bottom of the outlet truss body. The outlet truss body also adopts a frame steel structure, with the upper end fixedly installed on the workshop's support structure. The outlet truss body is equipped with a lifting mechanism in the vertical direction, which consists of an electric cylinder or a hydraulic cylinder, driving the outlet truss gripper 7 to move up and down in the vertical direction. The outlet truss body is equipped with a horizontal moving mechanism in the horizontal direction, which consists of a linear guide rail and a servo motor, driving the outlet truss gripper 7 to move horizontally back and forth between the outlet of the homogenizing furnace 1 and the outlet diversion device 8. The lifting and horizontal movement of the outlet truss gripper 7 forms a two-dimensional motion trajectory, realizing the precise gripping of the glass insulators inside the homogenizing furnace 1 and accurate placement into the outlet diversion device 8.

[0061] The export truss gripper 7 adopts the same arc-shaped clamping structure as the inlet truss gripper 3, and its main body is made of high-strength aluminum alloy. The arc-shaped clamping surface of the export truss gripper 7 is also formed into an arc shape that matches the outer contour of the glass insulator, with the radius of the arc customized according to the outer diameter of the glass insulator to be processed. A high-temperature resistant flexible silicone layer is also applied to the arc-shaped clamping surface of the export truss gripper 7, with a thickness of 2mm to 4mm. The combined application of the arc-shaped clamping structure and the high-temperature resistant flexible silicone layer effectively protects the surface of the glass insulator when the export truss gripper 7 grips the glass insulator from the high-temperature environment of the homogenizing furnace 1. Since the temperature of the glass insulator remains high after homogenization, direct contact between ordinary metal clamping structures and the high-temperature glass can easily cause thermal stress damage. The high-temperature resistant flexible silicone layer of this invention has excellent thermal insulation performance and flexibility, forming an effective thermal buffer and mechanical protection between the gripper and the glass insulator, reducing the potential damage risk caused by material softening or thermal stress due to high temperatures.

[0062] The outlet diversion device 8 is located on the ground below the outlet of the homogenizing furnace 1, and includes an outlet conveyor roller, a first transfer roller, a second transfer roller, and a second drive motor. The outlet conveyor roller consists of multiple parallel rollers, with both ends of the rollers supported on the frame by bearing seats, forming a bearing surface for receiving the homogenized finished glass insulators transported by the outlet truss gripper 7. The second drive motor is connected to the drive end of the outlet conveyor roller, and the motor output shaft is connected to the rotating shaft of the drive roller via a coupling, used to drive all the rollers on the outlet conveyor roller to rotate synchronously. The second drive motor is also controlled by a frequency converter, enabling both forward and reverse rotation, used to adjust the movement direction and conveying speed of the glass insulators on the outlet conveyor roller.

[0063] Both the first and second transfer roller conveyors are formed into an arc shape, and they are connected to the same end of the exit conveyor roller conveyor. The arc-shaped transfer roller conveyor consists of multiple sets of small-diameter rollers arranged along an arc-shaped trajectory, forming an arc-shaped conveying surface that allows the glass insulators to be smoothly turned. The output end of the first transfer roller conveyor is connected to the input end of the secondary homogenizing conveyor 5, used to turn and convey glass insulators requiring further homogenization to the secondary homogenizing conveyor 5. The output end of the second transfer roller conveyor is connected to the conveyor line of the next process, used to turn and convey glass insulators that do not require secondary homogenization to the next production process. The first and second transfer roller conveyors adopt the same arc-shaped structure design, with the arc curvature radius designed according to the size of the glass insulators and the turning requirements, typically set to 500mm to 800mm. This allows for smooth turning and diversion of glass insulators within a limited space, avoiding slippage or collision damage caused by excessive turning angles or short turning paths.

[0064] The outlet diversion device 8 detects the arrival signal of the glass insulator using position sensors installed on the outlet conveyor rollers. These position sensors, either photoelectric or proximity sensors, are installed at key points on the outlet conveyor rollers. When a glass insulator passes the detection area of ​​the position sensor, the sensor generates a trigger signal and sends it to the control system. The control system determines the homogenization status of the glass insulator based on the detected arrival signal and sends a steering command to the second drive motor, controlling the glass insulator to enter either the first or second transfer roller. When secondary homogenization is required, the second drive motor controls the outlet conveyor roller to transport the glass insulator to the first transfer roller, which then turns the glass insulator and transports it to the secondary homogenization conveyor 5. When secondary homogenization is not required, the second drive motor controls the outlet conveyor roller to transport the glass insulator to the second transfer roller, which then turns the glass insulator and transports it to the next process. The diversion determination can be based on pre-set production batch information, product quality inspection results, or instruction signals from the production management system.

[0065] The secondary homogenizing conveyor 5 is located in the space behind the homogenizing furnace 1, with its two ends connected to the outlet diversion device 8 and the inlet conveyor 2, respectively. The secondary homogenizing conveyor 5 includes a conveyor belt, a support frame, and a tensioning mechanism. The conveyor belt is made of high-temperature resistant silicone rubber and is configured as a closed loop to form a continuous conveying path. The high-temperature resistant silicone conveyor belt is made of high-temperature resistant silicone rubber material, capable of withstanding the residual temperature of the glass insulators after homogenization. When the glass insulators exit the furnace after homogenization, their surface temperature is still high, reaching 150℃ to 200℃. Ordinary conveyor belt materials cannot withstand such high temperatures and will experience deformation, softening, or adhesion. The high-temperature resistant silicone conveyor belt can maintain stable physical properties at temperatures above 250℃, meeting the conveying requirements of high-temperature products. Simultaneously, the high-temperature resistant silicone conveyor belt has a certain degree of flexible cushioning performance and an anti-slip textured structure, which can effectively support and protect the glass insulators during conveying, reducing damage to the glass insulators caused by conveying vibration or impact. The anti-slip texture structure consists of diamond or herringbone patterns processed on the surface of the conveyor belt, which can increase the friction between the belt and the glass insulator and prevent the product from slipping during transportation.

[0066] The support frame is positioned beneath the conveyor belt to support and secure the conveyor belt and related components. Constructed from welded steel sections, the support frame forms a stable load-bearing structure. Multiple roller supports are mounted on the support frame to support the driven and driving rollers of the conveyor belt. The driving rollers are driven by a motor via a reducer, causing the conveyor belt to rotate in a circular motion. The design of the support frame ensures the stability of the conveyor path and the reliability of its load-bearing capacity, capable of withstanding the static and dynamic loads generated by the glass insulators placed on the conveyor belt.

[0067] The tensioning mechanism, mounted on the support frame, is used to adjust the tension of the conveyor belt and prevent it from becoming loose, slipping, or running off-track during operation. The tensioning mechanism includes a tension adjusting screw and a tensioning slide. The tension adjusting screw is vertically mounted on the side plate of the support frame, with its lower end fixed to the support frame via a bearing seat. The screw has a standard thread machined into it. The tensioning slide is fitted onto the threaded section of the tension adjusting screw. A linear bearing is installed between the slide and the support frame, allowing the slide to move vertically up and down but not rotate. When the tension adjusting screw is rotated, the slide moves vertically up and down, changing the position of the tensioned side of the conveyor belt and thus adjusting the overall tension. Proper tension setting ensures sufficient friction between the conveyor belt and the drive roller, guaranteeing reliable transmission of the conveyor drive and preventing premature aging or breakage of the conveyor belt due to over-tension. Tension can be detected in real-time by installing a tension sensor under the conveyor belt, or by manually observing the wrap angle of the conveyor belt on the drive roller for empirical judgment.

[0068] The input end of the secondary homogenizing conveyor 5 is connected to the output end of the first transfer roller conveyor, and the output end of the secondary homogenizing conveyor 5 is connected to the input end of the inlet conveyor 2. Driven by a motor, the high-temperature resistant silicone conveyor belt performs a circular cyclic motion, moving the glass insulators received from the first transfer roller conveyor along the conveying path to the position where they connect with the inlet conveyor 2. When the glass insulators reach the output end of the secondary homogenizing conveyor 5, they are perfectly aligned with the input port of the inlet conveyor 2, allowing for a smooth transition to the inlet conveyor 2, where they await secondary loading by the inlet truss gripper 3. The conveying speed of the secondary homogenizing conveyor 5 and the receiving speed of the inlet conveyor 2 are matched and coordinated through a control system to ensure a smooth transition of the glass insulators and avoid conveying gaps or accumulation caused by speed mismatch.

[0069] This invention also includes a control system electrically connected to the inlet circulation device, the outlet circulation device, and the secondary homogenizing conveying device 5. The control system coordinates and controls all components of the glass insulator homogenizing circulation device, enabling signal interaction and action coordination between the mechanisms to ensure automatic and continuous operation of the homogenizing circulation process. The control system adopts a distributed control architecture, with each actuator equipped with an independent driver and controller, communicating with the main controller via an industrial bus. This distributed architecture reduces the complexity of the control system and improves its reliability and response speed.

[0070] The control system includes a main controller, input modules, output modules, and a communication module. The main controller, using a programmable logic controller (PLC) or industrial control computer, is responsible for processing input signals, running preset control programs, and sending control commands to each output module. The main controller uses a Siemens S7-1500 series PLC or equivalent, featuring high-speed processing capabilities and rich communication interfaces to meet the needs of real-time control and multi-device coordination. The input modules receive signals from various sensors and detection devices, including position sensor signals, temperature sensor signals, and position detection signals. These modules combine digital and analog input modules to receive and process various types of sensor signals. The output modules send control signals to each drive device, including control signals for the first drive motor, the second drive motor, the lifting mechanism, and the horizontal movement mechanism. These modules combine digital and analog output modules to control the operation of each drive motor via a frequency converter or servo driver. The communication module facilitates data exchange between the control system and the upper-level production management system, receiving production task instructions and providing feedback on production status information. The communication module supports industrial Ethernet protocols such as Profinet, Ethernet / IP, and Modbus, enabling seamless integration with factory MES systems.

[0071] The control system is electrically connected to the inlet conveyor 2. The control system controls the rotation direction of the rollers on the inlet conveyor track by sending forward or reverse control commands to the first drive motor. When glass insulators to be processed need to be conveyed towards the inlet of the homogenizing furnace 1, the control system sends a forward control command, causing the first drive motor to rotate forward and drive the rollers to convey the product towards the inlet. When return products need to be received from the secondary homogenizing conveyor 5, the control system sends a reverse control command, causing the first drive motor to rotate in reverse and drive the rollers to receive the product towards the input end of the inlet conveyor 2. The control commands of the control system include functions such as start, stop, speed setting, and direction switching, and are transmitted through the analog input port or digital communication port of the frequency converter.

[0072] The control system is electrically connected to the entrance truss mechanism 4. The control system sends control commands to the lifting and horizontal movement mechanisms of the entrance truss mechanism 4, controlling the entrance truss gripper 3 to complete a series of complex actions. The control program of the control system pre-sets the working cycle of the entrance truss gripper 3, including the following sequence of actions: First, the control system sends a descent command to the lifting mechanism, and the entrance truss gripper 3 descends to the specified gripping height above the entrance conveyor rollers; second, the control system sends a clamping command to the gripper, and the arc-shaped clamping structure clamps the glass insulator, with a high-temperature resistant flexible silicone layer adhering to and covering the surface of the glass insulator; third, the control system sends an ascending command to the lifting mechanism, and the entrance truss gripper 3 grips the glass insulator and ascends to the specified height; fourth, the control system sends a moving command to the horizontal movement mechanism, and the entrance truss gripper 3 moves horizontally to above the inlet of the homogenizing furnace 1; fifth, the control system sends a descent command to the lifting mechanism, and the entrance truss gripper 3 descends into the homogenizing furnace 1 to the specified position; finally, the control system sends a release command to the gripper, and the glass insulator is placed in the homogenization treatment area inside the homogenizing furnace 1. The above sequence of actions is automatically executed by the control system according to the preset timing and parameters, realizing the automatic feeding of glass insulators into the furnace.

[0073] The control system is electrically connected to the outlet truss device 6. The control system sends control commands to the lifting and horizontal movement mechanisms of the outlet truss device 6 to control the outlet truss gripper 7 to complete the automatic material discharge action. The control program pre-sets the working cycle of the outlet truss gripper 7, including the following sequence of actions: First, the control system sends a descent command to the lifting mechanism, and the outlet truss gripper 7 descends to a designated position inside the homogenizing furnace 1; second, the control system sends a clamping command to the gripper, and the arc-shaped clamping structure clamps the glass insulator; third, the control system sends an ascending command to the lifting mechanism, and the outlet truss gripper 7 grabs the glass insulator and rises to a designated height; fourth, the control system sends a moving command to the horizontal movement mechanism, and the outlet truss gripper 7 moves horizontally above the outlet diverter 8; fifth, the control system sends a descent command to the lifting mechanism, and the outlet truss gripper 7 descends to a designated position on the outlet conveyor roller; finally, the control system sends a release command to the gripper, and the glass insulator is placed on the outlet conveyor roller. The timing of the above sequence of actions is coordinated with the timing of the inlet truss mechanism 4 to ensure the continuous flow of products within the homogenizing furnace 1.

[0074] The control system is electrically connected to the outlet diversion device 8. The control system receives detection signals from the position sensors on the outlet diversion device 8 to determine the position status of the glass insulator and the diversion requirement. After the position sensor detects that the glass insulator has reached the designated diversion position, it sends a position signal to the control system. The control system sends corresponding steering control commands to the second drive motor according to the preset diversion logic or the diversion command sent by the upper-level system. When secondary homogenization is required, the second drive motor controls the outlet conveyor rollers to transport the glass insulator towards the first transfer roller direction; when secondary homogenization is not required, the second drive motor controls the outlet conveyor rollers to transport the glass insulator towards the second transfer roller direction.

[0075] The control system is electrically connected to the secondary homogenizing conveyor 5. The control system controls the start, stop, and speed of the high-temperature silicone conveyor belt by sending operating control commands to the drive motor of the secondary homogenizing conveyor 5. When glass insulators requiring secondary homogenization need to be transported from the outlet diverter 8 back to the inlet conveyor 2, the control system sends a start command to the drive motor, which drives the conveyor belt to transport the glass insulators from the input end to the output end. When there are no products to be transported on the conveyor belt, the control system can send a stop command to stop the conveyor belt or keep it running at a low speed to reduce energy consumption. The operating speed of the conveyor belt is set according to the cycle time requirements of the secondary homogenization process to ensure it matches the receiving speed of the inlet conveyor 2.

[0076] The present invention also provides a homogenization circulation method for glass insulators, the method using the homogenization circulation apparatus described in any of the above embodiments, and comprising the following steps.

[0077] In step S1, the glass insulator enters the homogenizing furnace 1 to undergo a constant-temperature homogenization aging treatment at 260℃ to 290℃, initially inducing a phase transformation from β-NiS to α-NiS in the nickel sulfide inside the glass. In step S1, the glass insulator to be processed is first conveyed by the inlet conveyor 2. The first drive motor of the inlet conveyor 2 drives the rollers on the inlet conveyor roller conveyor to rotate, conveying the glass insulator towards the inlet of the homogenizing furnace 1. When the glass insulator reaches the designated gripping position on the inlet conveyor roller conveyor, this position is detected by a position sensor, and the sensor signal is sent to the control system. After receiving the positioning signal, the control system starts the operation cycle of the inlet truss mechanism 4. Under the control of the control system, the inlet truss gripper 3 performs a series of actions, including descending, gripping, rising, moving horizontally above the inlet of the homogenizing furnace 1, descending into the furnace, and placing, transporting the glass insulator to the homogenization treatment area within the homogenizing furnace 1. The homogenizing furnace 1 performs a constant-temperature homogenization aging treatment at 260℃ to 290℃ on the glass insulator inside the furnace. Under these temperature conditions, the nickel sulfide impurities inside the glass insulator undergo a preliminary phase transformation from the unstable β phase to the stable α phase, reducing the risk of subsequent spontaneous explosion due to β phase residue. The temperature uniformity within the homogenizing furnace 1 is controlled within ±5℃ to ensure that each glass insulator undergoes homogenization treatment under the same temperature conditions. The holding time for each homogenization aging process is set to 2 to 4 hours to ensure that the nickel sulfide phase transformation reaction can proceed fully.

[0078] In step S2, after the homogenization process is completed, the outlet truss gripper 7 automatically removes the insulator and transfers it to the outlet diversion device 8 of the homogenizing furnace. In step S2, after the homogenization process is completed and the set holding time is reached, the furnace door of the homogenizing furnace 1 opens, and the control system sends a discharge command to the outlet truss device 6. Under the control of the control system, the outlet truss gripper 7 at the bottom of the outlet truss device 6 performs a series of actions: descending to a designated position inside the furnace, gripping the glass insulator, rising, moving horizontally above the outlet diversion device 8, descending to a designated position on the outlet conveyor roller, and releasing and placing it. This automatically removes the homogenized glass insulator from the homogenizing furnace 1 and transfers it to the outlet conveyor roller of the outlet diversion device 8. This step achieves automatic discharge and transfer of the homogenized product, reducing the safety risks and quality defects such as burns and damage caused by direct human contact with high-temperature products.

[0079] Step S3 involves feeding the glass insulators into the secondary homogenizing conveyor 5 or the next process. Whether secondary homogenization is required is preset by the system and determined based on actual needs. When secondary homogenization is required, the second drive motor controls the outlet conveyor rollers to transport the glass insulators to the first transfer rollers, which then turn the glass insulators and transport them to the secondary homogenizing conveyor 5. When secondary homogenization is not required, the second drive motor controls the outlet conveyor rollers to transport the glass insulators to the second transfer rollers, which then turn the glass insulators and transport them to the next production process. This step achieves automatic diversion of the primary homogenized products, preventing insufficiently homogenized products from flowing into subsequent processes, ensuring the consistency and reliability of homogenization quality, and simultaneously enabling automatic diversion for on-demand secondary homogenization, reducing manual handling, and improving production continuity and efficiency.

[0080] When secondary homogenization is required, the following steps are included after step S3.

[0081] In step S3.1, during secondary homogenization, the inlet conveyor 2 of the homogenizing furnace reverses to receive the product conveyed by the secondary homogenizing conveyor 5, and the inlet truss gripper 3 grabs the glass insulators and feeds them into the homogenizing furnace 1. In step S3.1, the high-temperature resistant silicone conveyor belt of the secondary homogenizing conveyor 5 performs a circular cyclic motion under the action of the drive motor, conveying the glass insulators received from the first transfer roller to the position where it docks with the inlet conveyor 2. At this time, the control logic of the control system causes the first drive motor of the inlet conveyor 2 to rotate in the reverse direction, and the inlet conveyor roller receives the glass insulators transitioning from the secondary homogenizing conveyor 5 in the reverse direction. When the glass insulator reaches the designated gripping position on the inlet conveyor roller, the inlet truss gripper 3 performs the same gripping and feeding action as in step S1 under the control of the control system, and feeds the glass insulator back into the homogenizing furnace 1 for secondary homogenization. This step realizes the automatic re-entry of the secondary homogenized product from the outlet back to the inlet into the furnace, eliminating the need for manual handling and ensuring the continuity, smoothness, and efficiency of the secondary homogenization cycle.

[0082] In step S3.2, the glass insulator undergoes a secondary isothermal homogenization aging treatment in the furnace, with the temperature controlled between 260℃ and 290℃. In step S3.2, the homogenization furnace 1 performs a supplementary isothermal homogenization aging treatment at 260℃ to 290℃ on the glass insulators entering the furnace for the second time. Under this temperature condition, the nickel sulfide impurities remaining after the first homogenization treatment continue to undergo a transformation from the β phase to the α phase, resulting in a more complete and thorough phase transformation process compared to the first homogenization treatment. The secondary homogenization treatment further processes the product that was not sufficiently homogenized in the first treatment, significantly reducing the risk of spontaneous explosion of the glass insulator due to incomplete nickel sulfide phase transformation, and improving the structural stability and long-term operational reliability of the glass insulator. The holding time for the secondary homogenization aging is set to 1.5 hours to 3 hours, based on a comprehensive consideration of the target characteristics of the secondary homogenization treatment. Unlike the primary homogenization treatment, the secondary homogenization treatment targets products that still require supplementary treatment after the primary homogenization. The proportion of residual β-phase nickel sulfide in these products is relatively low, and the time required for the phase transformation is correspondingly shortened. Setting the holding time for the secondary homogenization aging to 1.5 to 3 hours can ensure that the residual phase change is fully carried out while taking into account the overall production efficiency and energy economy.

[0083] In step S3.3, after the secondary homogenization is completed, the outlet truss gripper 7 removes the product and transfers it to the next production process. In step S3.3, after the secondary homogenization is completed and the set holding time is reached, the furnace door of the homogenizing furnace 1 opens, and the outlet truss gripper 7, under the control of the control system, performs the same discharge action as in step S2, removing the glass insulator after secondary homogenization from the homogenizing furnace 1 and transferring it to the outlet conveyor roller of the outlet diversion device 8. At this time, since the product has completed the secondary homogenization, it no longer needs to undergo a third homogenization. Therefore, the control system directly controls the second drive motor to transport the glass insulator to the second transfer roller, which then turns the glass insulator and transports it to the next production process. This step realizes automatic discharge and process connection of the product after secondary homogenization, ensuring that the glass insulator after secondary homogenization can enter the subsequent production process in a timely manner, improving production continuity, automation, and product transfer efficiency.

[0084] The operating cycles of the inlet and outlet circulation devices are coordinated and matched. These cycles are managed and coordinated by a control system. When the inlet truss gripper 3 feeds the glass insulator into the homogenizing furnace 1 and closes the furnace door, the control system starts timing. Once homogenization is complete and the set holding time has been reached, the control system sends a discharge command to the outlet truss device 6 and simultaneously sends a next loading command to the inlet truss mechanism 4, achieving continuous operation of inlet loading and outlet discharge. In some embodiments, the inlet and outlet circulation devices can also adopt an alternating operation mode, meaning that the inlet truss mechanism 4 only begins its next loading operation after the outlet truss device 6 completes one discharge action. Through reasonable coordination of the operating cycles, the production capacity of the homogenizing furnace 1 can be fully utilized, improving overall production efficiency.

[0085] The conveying speed of the secondary homogenizing conveyor 5 is matched with the conveying speed of the inlet conveyor 2. The drive motor of the secondary homogenizing conveyor 5 operates under the control of the control system, and its conveying speed is adjusted according to the receiving capacity of the inlet conveyor 2. When the secondary homogenizing conveyor 5 conveys the glass insulators to the position where they dock with the inlet conveyor 2, the inlet conveyor 2 is precisely in a waiting-to-receive state. The glass insulators can smoothly transition from the secondary homogenizing conveyor 5 to the inlet conveyor 2, avoiding conveying gaps or accumulation caused by speed mismatch. Through speed matching control, the continuity and stability of the secondary homogenizing return process are ensured.

[0086] The homogenization circulation device also includes safety protection devices, which are installed around the inlet circulation device, the outlet circulation device, and the secondary homogenization conveying device 5. These safety protection devices include safety light curtains, safety door locks, and protective covers. The safety light curtain is installed within the travel range of the truss mechanism. When personnel or other objects are detected entering the danger zone, the safety light curtain sends a stop signal to the control system, which immediately stops the movement of the truss mechanism to prevent collision injuries. The safety door lock is installed at the furnace door of the homogenizing furnace 1. The control system only allows the homogenization process to start when the furnace door is completely closed and locked, preventing safety accidents caused by misoperation. The protective cover is installed on the outside of the moving parts of the conveying device to prevent personnel from accidentally contacting moving rollers, chains, gears, or other components, causing mechanical injury. The installation of these safety protection devices ensures the safe and reliable operation of the homogenization circulation device.

[0087] The homogenizing circulation unit also includes a condition monitoring device, which monitors the operating status of each component. This device includes temperature sensors, vibration sensors, and current sensors. Temperature sensors are located inside the homogenizing furnace 1 to monitor the furnace temperature in real time, ensuring it remains within the set range. Vibration sensors are located at key support points of the truss mechanism and conveying device to monitor the equipment's vibration status. Abnormal vibration is detected and an alarm is sent to the control system, facilitating timely detection of potential equipment failures. Current sensors are located in the power supply circuits of each drive motor to monitor the motor's operating current. Abnormal current is detected to determine if overload or stall faults exist. The condition monitoring device uploads all monitored parameters to the control system in real time. The control system analyzes and processes the data to achieve comprehensive monitoring of the homogenizing circulation unit's operating status and provide early warning of potential faults.

[0088] The homogenizing and circulating device of this invention adopts a modular design, allowing for flexible assembly and disassembly of its components. The inlet circulating device, outlet circulating device, and secondary homogenizing conveying device 5 are relatively independent modular units, each with its own complete mechanical structure and electrical control system. Modules are connected via standardized interfaces, including mechanical and electrical interfaces. Mechanical interfaces use flange connections or quick-clamp connections for easy assembly and disassembly. Electrical interfaces use a unified plug-and-socket connection method, employing standardized signal and power cables. When adjustments to the production line layout or replacement / repair is required, the modules can be easily disassembled and reassembled, improving the equipment's adaptability and maintenance convenience. Simultaneously, the modular design facilitates capacity expansion according to production needs, such as increasing the number of inlet and outlet circulating devices to meet higher production efficiency requirements.

[0089] The technical effects of the present invention will be described in detail below through specific embodiments and comparative examples.

[0090] Example 3: This embodiment uses the homogenization circulation device provided by the present invention to homogenize the glass insulator. The glass insulator is model XXX-01, with a skirt diameter of 380mm, a creepage distance of 1460mm, and a rated mechanical load of 120kN. The homogenization treatment temperature is set to 275℃, and the temperature uniformity is controlled within ±5℃. The first homogenization holding time is set to 3 hours, and the second homogenization holding time is set to 2 hours. The processing flow is as follows: Glass insulators to be processed are conveyed to the gripping position by the inlet conveyor 2. The inlet truss gripper 3 grips the insulators and sends them into the homogenizing furnace 1. The homogenizing furnace 1 is heated to 275℃ and held for 3 hours to complete the first homogenization process. The outlet truss gripper 7 removes the product and transfers it to the outlet diversion device 8. Based on the product batch information, it is determined whether secondary homogenization is required. Products requiring secondary homogenization are returned to the inlet conveyor 2 via the secondary homogenizing conveyor 5, and the inlet truss gripper 3 grips them again and sends them into the homogenizing furnace 1 for secondary homogenization. After holding the secondary homogenization for 2 hours, the product is discharged and enters the next production process. A total of 1000 glass insulators were processed, with a product appearance inspection pass rate of 99.8%, showing no chipping or breakage. A follow-up survey was conducted one year after the products were put into actual operation on the power grid, and the spontaneous breakage rate was 0.05%, far lower than the spontaneous breakage rate of products that did not undergo secondary homogenization.

[0091] Comparative Example 1: The glass insulators were homogenized using a traditional homogenization process without a secondary homogenization conveying device 5. The homogenization temperature was set at 275℃, and the initial homogenization holding time was 3 hours. The process was as follows: the glass insulators to be processed were manually transported to the inlet of the homogenization furnace 1, where the inlet truss gripper 3 picked them up and fed them into the furnace. The furnace 1 was heated to 275℃ and held for 3 hours to complete the homogenization process. The outlet truss gripper 7 removed the products and transferred them to the outlet diversion device 8. The products then directly entered the next production process without secondary homogenization. A total of 1000 glass insulators of the same model as in Example 3 were processed. The product appearance inspection pass rate was 98.5%, and 0.3% of the products suffered minor bump damage due to improper handling during manual transport. A follow-up survey was conducted after one year of actual operation in the power grid, and the spontaneous breakage rate was 0.32%.

[0092] Example 4: This embodiment uses the homogenization circulation device provided by the present invention to homogenize another specification of glass insulator. The glass insulator model is XXX-02, the shed diameter is 420mm, the creepage distance is 1650mm, and the rated mechanical load is 160kN. The homogenization treatment temperature is set at 280℃, and the temperature uniformity is controlled within ±5℃. The first homogenization heat preservation time is set at 3.5 hours, and the second homogenization heat preservation time is set at 2.5 hours. The processing flow is the same as in Embodiment 3. A total of 800 glass insulators were processed, and the product appearance inspection pass rate was 99.9%, with no damage. A follow-up survey was conducted after one year of actual operation in the power grid, and the spontaneous explosion rate was 0.04%.

[0093] Comparative Example 2: The glass insulators underwent homogenization treatment using traditional methods, with a single homogenization and heat preservation time of 3.5 hours, without a secondary homogenization function. 800 pieces of the same model XXX-02 glass insulators were processed, with a product appearance inspection pass rate of 97.8%. Due to manual handling and insufficient primary homogenization, 0.5% of the products showed a slight risk of spontaneous explosion. A follow-up survey was conducted after one year of actual operation in the power grid, and the spontaneous explosion rate was 0.41%.

[0094] Data Comparison Table

[0095]

[0096] A comparison of the data from the above embodiments and comparative examples clearly shows that using the homogenization circulation device and method provided by this invention for homogenization treatment of glass insulators can significantly improve the product appearance qualification rate and reduce the product spontaneous breakage rate. The spontaneous breakage rates of the products in Embodiments 3 and 4 are 0.05% and 0.04%, respectively, significantly lower than 0.32% in Comparative Example 1 and 0.41% in Comparative Example 2, with a reduction of more than 80%. This technical effect is mainly due to the fact that the present invention, through secondary homogenization treatment, makes the nickel sulfide phase transformation inside the glass more complete and thorough, eliminating the inherent causes of spontaneous breakage of glass insulators.

[0097] Meanwhile, because this invention achieves automated loading and unloading and automatic diversion functions, the product appearance qualification rate is also significantly improved. The product appearance qualification rates of Examples 3 and 4 are 99.8% and 99.9%, respectively, which are higher than 98.5% of Comparative Example 1 and 97.8% of Comparative Example 2. This technical effect is mainly due to the use of an arc-shaped clamping structure and a high-temperature resistant flexible silicone layer in this invention, which avoids local stress concentration and surface damage caused by traditional clamping methods; at the same time, automated transfer reduces the uncertainty caused by manual operation.

[0098] Example 5: Based on the homogenization and circulation device described in Examples 1 and 2, this embodiment adds an online monitoring and adaptive control structure for the phase change process, providing an adaptive homogenization and circulation device and method based on online monitoring of nickel sulfide phase change. This is used to solve the problems of glass insulators with insufficient phase change after one homogenization being difficult to identify objectively and accurately, as well as insufficient homogenization or energy waste caused by fixed heat preservation time.

[0099] In this embodiment, the composition, connection relationship and working mode of the homogenizer 1, inlet conveying device 2, inlet truss gripper 3, inlet truss mechanism 4, secondary homogenizing conveying device 5, outlet truss device 6, outlet truss gripper 7 and outlet diversion device 8 are the same as in embodiment 2, and will not be repeated here.

[0100] The additional device components in this embodiment include an acoustic emission pickup unit, a signal acquisition and feature extraction module, and a phase transition determination and decision unit. The acoustic emission pickup unit is installed at least at one location in the conveying path of the homogenizing furnace 1, including the inner wall of the furnace chamber, the inner side of the furnace door, the furnace bearing station, the outlet diversion device 8, and the secondary homogenizing conveying device 5, and is used to pick up the transient elastic wave signal released by the glass insulator due to the nickel sulfide phase transition during the homogenization process. The acoustic emission pickup unit includes a high-temperature resistant waveguide and an acoustic emission sensor. One end of the high-temperature resistant waveguide extends into the homogenizing furnace 1 and is close to the area to be monitored, while the other end extends to the outside of the homogenizing furnace 1 and is connected to the acoustic emission sensor, thus protecting the acoustic emission sensor from the high-temperature environment of the homogenizing furnace 1. The acoustic emission sensor is connected to the signal acquisition and feature extraction module through a preamplifier. The signal acquisition and feature extraction module is used to filter, amplify, and perform analog-to-digital conversion on the acoustic emission signal, and to extract characteristic quantities such as acoustic emission event rate, ring count, cumulative energy, and amplitude distribution. The phase change determination and decision unit is electrically connected to the signal acquisition and feature extraction module. It is used to determine the degree of progress of the nickel sulfide phase change inside the glass insulator based on the characteristic quantities, generate a homogenization completion determination result, and send it to the control system. The control system controls the inlet circulation device, the outlet circulation device, and the secondary homogenization conveying device 5 to perform corresponding actions based on the determination result.

[0101] The principle behind this structural assessment lies in the fact that the phase transition of nickel sulfide inside the glass insulator from β-NiS to α-NiS is accompanied by approximately 4% volume expansion. During this phase transition, localized micro-strains and micro-cracks are generated within the glass matrix, releasing transient elastic waves, i.e., acoustic emission signals. The more active the phase transition, the higher the acoustic emission event rate and the stronger the accumulated energy; as the phase transition nears completion, the acoustic emission signal decays. Therefore, the activity level of the acoustic emission signal directly reflects the extent of the nickel sulfide phase transition and can serve as an objective measure of the adequacy of homogenization treatment. This helps overcome the subjectivity and lag inherent in judging homogenization solely based on batch estimations or manual experience.

[0102] When using the homogenization circulation device of this embodiment, during a homogenization aging process, the acoustic emission pickup unit picks up the acoustic emission signal of the glass insulator in the homogenization furnace 1 in real time. The signal acquisition and feature extraction module acquires and extracts features from the acoustic emission signal. The phase change determination and decision unit evaluates the degree of phase change online based on features such as acoustic emission event rate and cumulative energy, and feeds the evaluation results back to the control system.

[0103] When the homogenization aging reaches the set holding time, the phase transformation determination and decision unit judges whether the phase transformation has converged. If the acoustic emission event rate has decreased to below the first set threshold and remains below the first set duration, it is determined that the phase transformation of the glass insulators in this area has been basically completed, and secondary homogenization is not required; if the acoustic emission event rate is still higher than the first set threshold, it is determined that the phase transformation has not been completed, and secondary homogenization is required. The control system controls the outlet diversion device 8 to complete the diversion according to the judgment result. Glass insulators that require secondary homogenization are sent to the secondary homogenization conveyor 5 via the first transfer roller conveyor, while glass insulators that do not require secondary homogenization are sent to the next process via the second transfer roller conveyor.

[0104] During the secondary homogenization, the acoustic emission pickup unit continues to monitor the glass insulators in the furnace online. When the acoustic emission event rate drops below the first set threshold and remains below it for a first set duration, it is determined that the phase transition is basically complete, and the control system ends the secondary homogenization and heat preservation prematurely, shortening the actual heat preservation time. If the acoustic emission event rate still has not converged when the secondary homogenization and heat preservation reaches the second set duration, it is determined that the glass insulator has abnormal nickel sulfide content or abnormal phase transition. The control system marks it as a defective product and sends it to the defective product buffer position via the third transfer roller after the secondary homogenization is completed. The outlet diversion device 8 adds a third transfer roller and a defective product buffer position to the original first and second transfer rollers. The third transfer roller is connected to the defective product buffer position to receive glass insulators that are still determined to be defective after the secondary homogenization, preventing potentially defective products from flowing into the next process.

[0105] The first set threshold, the first set duration, and the second set duration can be set according to the specifications of the glass insulator and the homogenization process requirements. For example, the first set threshold can be set to an acoustic emission event rate of no more than once per minute, the first set duration can be set to 10 to 30 minutes, and the second set duration can be set to 3 hours.

[0106] Furthermore, multiple acoustic emission pickup units are arranged in the homogenizing furnace 1 according to the carrying position or the furnace section. The signal acquisition and feature extraction module acquires and extracts the acoustic emission signals of each acoustic emission pickup unit. The phase transition determination and decision unit performs phase transition convergence determination for each section. Based on this, the control system performs zoned current transfer on the glass insulators of each section to compensate for insufficient local homogenization caused by the uneven temperature field in the furnace and improve the consistency of homogenization processing.

[0107] Furthermore, during the process of conveying the glass insulator from the outlet diversion device 8 to the secondary homogenizing conveying device 5 or the next process, the acoustic emission pickup unit set on the conveying path supplements the monitoring of the residual phase change signal of the glass insulator, as a supplementary basis for diversion determination, and further improves the accuracy of diversion determination.

[0108] Furthermore, the phase change determination and decision-making unit binds and records the temperature history, actual heat preservation time, acoustic emission characteristic data, and shunting determination results of each homogenization process with the glass insulator or furnace batch, and uploads them to the production management system through the control system to form a traceable quality data chain, providing data support for subsequent quality analysis and process parameter optimization.

[0109] This embodiment improves the determination of homogenization sufficiency by monitoring the nickel sulfide phase transformation process online, transforming it from batch estimation and manual experience to direct measurement of the phase transformation process. This enhances the objectivity and accuracy of the secondary homogenization and diversion determination, preventing incompletely transformed products from flowing into the next process. Adaptive holding time control shortens the average holding time while ensuring complete phase transformation, reducing energy consumption and increasing production capacity. Automatic rejection of products that still fail secondary homogenization prevents potentially hazardous products from entering the power grid, further reducing the risk of spontaneous explosion.

[0110] In the description of this invention, it should be understood that the terms "coaxial," "bottom," "one end," "top," "middle," "other end," "upper," "side," "top," "inner," "front," "center," "both ends," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention 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. Therefore, they should not be construed as limitations on this invention.

[0111] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "setting," "connection," "fixing," "screw connection," 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 or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components or the interaction between two components. Unless otherwise explicitly limited, those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0112] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A homogenizing circulation device for glass insulators, disposed outside a homogenizing furnace (1), characterized in that, The homogenization and circulation device includes an inlet circulation device, an outlet circulation device, and a secondary homogenization and conveying device (5); An inlet circulation device is set on the inlet side of the homogenizer (1), an outlet circulation device is set on the outlet side of the homogenizer (1), and a secondary homogenizing conveying device (5) is set on the rear side of the homogenizer (1). The inlet circulation device includes an inlet truss mechanism (4) and a homogenizer inlet conveying device (2); The inlet conveying device (2) is used to convey the glass insulators to be processed. The inlet truss mechanism (4) is equipped with an inlet truss gripper (3) at the bottom. The inlet truss gripper (3) is used to transport the glass insulators into the homogenizing furnace (1) for homogenization. The outlet circulation device includes an outlet truss device (6) and an outlet diversion device (8); an outlet truss grabber (7) is provided at the bottom of the outlet truss device (6). The two ends of the secondary homogenizing conveying device (5) are connected to the outlet diversion device (8) and the inlet conveying device (2) respectively; The outlet truss gripper (7) is used to transport the homogenized glass insulators to the outlet diversion device (8); the outlet diversion device (8) is used to send the glass insulators to the next process or to the secondary homogenization conveying device (5); the secondary homogenization conveying device (5) is used to convey the homogenized glass insulators to the inlet conveying device (2) for secondary homogenization.

2. The homogenization circulation device for glass insulators according to claim 1, characterized in that: Both the entrance truss gripper (3) and the exit truss gripper (7) adopt an arc-shaped structure.

3. The homogenization circulation device for glass insulators according to claim 1, characterized in that: The arc-shaped clamping surfaces of the entrance truss gripper (3) and the exit truss gripper (7) are provided with a layer of high-temperature resistant flexible silicone.

4. A homogenization circulation device for glass insulators according to claim 3, characterized in that: The thickness of the high-temperature resistant flexible silicone layer is 2mm-4mm.

5. A homogenization circulation device for glass insulators according to claim 1, characterized in that: The inlet conveying device (2) includes an inlet conveying roller and a first drive motor. The first drive motor is connected to the conveying roller and is used to drive the rollers on the first conveying roller to rotate forward or backward.

6. A homogenization circulation device for glass insulators according to claim 1, characterized in that: The outlet diversion device (8) includes an outlet conveyor roller, a first transfer roller, a second transfer roller and a second drive motor; Both the first and second transfer roller conveyors are arc-shaped and connected to the same side of the outlet conveyor roller conveyor. The first transfer roller conveyor is also connected to the secondary homogenizing conveyor (5), and the second transfer roller conveyor is also connected to the conveyor line of the next process. The second drive motor is used to drive the rollers on the outlet conveyor roller conveyor to rotate.

7. A homogenization circulation device for glass insulators according to claim 1, characterized in that: The secondary homogenizing conveyor (5) includes a conveyor belt, a support frame and a tensioning mechanism; the conveyor belt is a high-temperature resistant silicone conveyor belt and the tensioning mechanism is used to adjust the tension of the conveyor belt.

8. A homogenization circulation method for glass insulators, using a homogenization circulation apparatus for glass insulators as described in any one of claims 1-7, characterized in that, Includes the following steps: S1, the glass insulator enters the homogenizing furnace (1) to complete a constant temperature homogenizing aging treatment of 260℃ to 290℃, which initially induces the phase transformation of nickel sulfide inside the glass from β-NiS to α-NiS; S2, after one homogenization is completed, the outlet truss gripper (7) automatically removes the insulator and transfers it to the homogenizer outlet diversion device (8). S3, input the glass insulator into the secondary homogenizing conveyor (5) or the next process; Among them, glass insulators that require secondary homogenization are pre-set by the system and are transferred to the secondary homogenization conveying device (5), while those that do not require secondary homogenization are transferred to the next process. S3.1 During the secondary homogenization, the inlet conveying device (2) of the homogenizer furnace reverses to receive the product conveyed by the secondary homogenizing conveying device (5), and the inlet truss gripper (3) grabs the glass insulator and sends it into the homogenizer furnace (1). S3.2, the glass insulators undergo a second constant temperature homogenization aging treatment in the furnace, with the temperature controlled between 260℃ and 290℃; S3.3 After the secondary homogenization is completed, the product is taken out by the export truss gripper (7) and transferred to the next production process.

9. A homogeneous circulation method for glass insulators according to claim 8, characterized in that: In step S1, the holding time for one homogenization aging process is 2 to 4 hours.

10. A homogeneous circulation method for glass insulators according to claim 8, characterized in that: In step S3.2, the holding time for the secondary homogenization aging is 1.5 hours to 3 hours.

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