Self-adaptive temperature control system of PVB intermediate film cooling water tank

Abstract

The utility model relates to the technical field of temperature control systems, and discloses a PVB intermediate film cooling water tank self-adaptive temperature control system which comprises a cooling main water tank, temperature detection modules and a control module, and the temperature detection modules are arranged in the cooling main water tank, a first cooling auxiliary water tank and a second cooling auxiliary water tank. According to the utility model, cooling water temperature and membrane surface temperature at two sides of a membrane are monitored in real time through the multi-point thermosensitive element arranged in the water tank, and the temperature of the membrane is controlled by combining a self-adaptive intelligent temperature control algorithm, so that the temperature of the membrane is controlled to be constant, and the temperature of the membrane is controlled to be constant. Water temperature on two sides of the water tank is dynamically adjusted, cooling rates on two sides of the membrane are synchronous, and uneven lines or burst caused by overlarge temperature difference are prevented. The system can adapt to PVB membranes with different thicknesses and grain depths, cooling parameters are automatically adjusted, and the production stability and the product percent of pass are remarkably improved.

Description

TECHNICAL FIELD

[0001] The utility model relates to temperature control system technical field, concretely is a kind of PVB interlayer cooling water tank self-adapting temperature control system. BACKGROUND

[0002] PVB interlayer is widely used in the field such as automobile laminated glass, building safety glass, its production process includes extrusion forming, cooling and shaping and winding and other key steps.Cooling water tank plays a vital role in this process, its function is to quickly cool the film from high-temperature molten state, ensure that film surface line is clear, thickness is uniform, and keep good mechanical properties and optical properties.

[0003] Although there are various cooling water tank designs on the market, traditional cooling water tank generally has the following shortcomings: 1.water temperature is fixed, response lag, the water temperature of traditional cooling water tank is usually preset as fixed value, cannot be flexibly adjusted according to the change of film thickness and line depth.In production process, film thickness and line design can change frequently, fixed water temperature can lead to uneven film cooling, affect surface quality;

[0004] 2.the water temperature difference of both sides is large, and the film is not evenly cooled, in cooling water tank, water flow path is limited, it is easy to cause the water temperature difference of both sides of water tank to be too large, the cooling rate of both sides of film is inconsistent, and quality defects such as line depth difference or pattern burst asymmetry occur;

[0005] 3.lack of intelligent temperature control and feedback mechanism, most existing water tank only relies on single temperature control device, lacks detection equipment for real-time temperature of film surface, so that the system cannot accurately adjust water temperature.Environmental temperature change in production process, equipment aging and process parameter adjustment and other factors can affect the cooling effect of film, but traditional system is difficult to respond and correct in time. INVENTION CONTENTS

[0006] The utility model aims at providing a kind of PVB interlayer cooling water tank self-adapting temperature control system to solve the problems raised in the above background.

[0007] To achieve the above object, the utility model provides the following technical scheme: a PVB interlayer cooling water tank self -adaptation temperature control system, include: cooling main water tank, temperature detection module and control module, the cooling main water tank both sides are equipped with first cooling auxiliary water tank and second cooling auxiliary water tank, the cooling main water tank, first cooling auxiliary water tank and second cooling auxiliary water tank inside are equipped with temperature detection module, control module and temperature detection module electric connection, first cooling auxiliary water tank and second cooling auxiliary water tank outside are equipped with heat exchange control module, heat exchange control module includes heat exchanger and water pump, control module electric connection has alarm protection module, the cooling main water tank both sides inner wall bottom is equipped with lower water guide shell, lower water guide shell top both sides are equipped with connecting shell, connecting shell top is equipped with upper water guide shell, lower water guide shell is located PVB interlayer below, upper water guide shell is located PVB interlayer above, lower water guide shell between is equipped with water outlet pipe, upper water guide shell between is also provided with water outlet pipe.

[0008] Further, the alarm protection module includes an audible and visual alarm and a fault diagnosis, and the fault diagnosis is used for displaying fault information.

[0009] Further, the temperature detection module includes a plurality of thermosensitive elements, and the inner walls of the cooling main water tank, the first cooling auxiliary water tank and the second cooling auxiliary water tank are provided with the plurality of thermosensitive elements.

[0010] Further, the heat exchanger is a plate heat exchanger, the first cooling auxiliary water tank and the second cooling auxiliary water tank are connected with two plate heat exchangers through two water pumps and pipelines, the first cooling auxiliary water tank, the second cooling auxiliary water tank and the heat exchanger connection pipeline are provided with electromagnetic valves, and the electromagnetic valves are electrically connected with the control module.

[0011] Further, the control module includes a PLC controller and an intelligent temperature control algorithm, and the intelligent temperature control algorithm includes a fuzzy control algorithm, a PID control algorithm and a historical database model.

[0012] Further, according to the cooling operation direction of the PVB interlayer, the PVB interlayer sequentially passes through the first cooling auxiliary water tank, the cooling main water tank and the second cooling auxiliary water tank during cooling, the first cooling auxiliary water tank is a precooling zone, the cooling main water tank is an equalizing cooling zone, and the second cooling auxiliary water tank is a deep cooling zone, and the water temperature in the first cooling auxiliary water tank, the cooling main water tank and the second cooling auxiliary water tank gradually decreases.

[0013] Further, the upper water guide shell top surface is provided with a rack, the connecting shell is in sliding connection with the inner wall of the cooling main water tank, sliding grooves for connecting shell sliding are arranged on both sides of the inner wall of the cooling main water tank, and a gear is rotationally arranged on one side of the inner wall of the cooling main water tank and matched with the rack.

[0014] Compared with the prior art, the utility model has the advantages that:

[0015] The temperature detection module, the cooling main water tank and the control module are arranged, when the PVB interlayer film cooling water tank self-adapting temperature control system is used, the cooling area is designed in sections, the whole cooling water tank is divided into pre-cooling area, uniform cooling area and deep cooling area according to the direction of the film running, the water temperature is gradually reduced, the film thermal deformation and internal stress residual are reduced, and the surface quality of the PVB film is ensured.

[0016] The multiple thermal elements arranged in the water tank can accurately measure the temperature. Each sensor is equipped with an independent data acquisition module to ensure real-time acquisition and transmission of multiple point data and keep the water temperature difference of the water tank within the set range.

[0017] The system has an intelligent control algorithm, including a fuzzy control algorithm, a PID control algorithm and a historical database model. According to the real-time monitored temperature data, the system automatically adjusts the temperature of the water tank and the flow rate of the water pump to optimize the film cooling process.

[0018] The multiple point thermal elements arranged in the water tank can real-time monitor the cooling water temperature on both sides of the film and the surface temperature of the film. Combined with the self-adapting intelligent temperature control algorithm, the water temperature on both sides of the water tank is dynamically adjusted to ensure that the cooling rates of both sides of the film are synchronized and prevent the phenomenon of uneven lines or bursting caused by excessive temperature difference. The system can adapt to PVB films of different thicknesses and line depths, automatically adjust the cooling parameters, significantly improve the production stability and product qualification rate, and has wide application prospect and industrial value.

[0019] The parts not involved in the device are the same as or can be realized by the prior art. BRIEF DESCRIPTION OF DRAWINGS

[0020] Figure 1 It is an electronic element connection control system schematic diagram of the PVB interlayer film cooling water tank self-adapting temperature control system.

[0021] Figure 2 It is a cooling main water tank connection structure perspective view of the PVB interlayer film cooling water tank self-adapting temperature control system.

[0022] Figure 3 It is a cooling main water tank connection structure main sectional view of the PVB interlayer film cooling water tank self-adapting temperature control system.

[0023] Figure 4 The figure is a schematic view of the heat exchanger structure in the prior art.

[0024] In the figure: 1, cooling main water tank; 101, lower water guide shell; 102, water outlet pipe; 103, connecting shell; 104, chute; 105, upper water guide shell; 106, rack; 107, gear; 2, first cooling auxiliary water tank; 3, second cooling auxiliary water tank; 4, temperature detection module; 5, control module; 6, heat exchange control module; 7, alarm protection module. DETAILED DESCRIPTION

[0025] The technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments.

[0026] Embodiment one: please refer to Figures 1-4 The present application provides a technical solution: a PVB interlayer cooling water tank self-adaptive temperature control system, comprising: a cooling main water tank 1, a temperature detection module 4 and a control module 5, the cooling main water tank 1 is provided with a first cooling auxiliary water tank 2 and a second cooling auxiliary water tank 3 on both sides respectively, the cooling water tank adopts an integral frame structure, the external material is a corrosion-resistant stainless steel composite plate, and the inner wall is plated with a wear-resistant and stain-resistant coating. The water tank as a whole has a waterproof sealing structure, ensuring that the water circulation is leakproof.

[0027] The cooling main water tank 1, the first cooling auxiliary water tank 2 and the second cooling auxiliary water tank 3 are provided with a temperature detection module 4 inside, the control module 5 is electrically connected with the temperature detection module 4, the first cooling auxiliary water tank 2 and the second cooling auxiliary water tank 3 are both provided with a heat exchange control module 6 outside, the heat exchange control module 6 comprises a heat exchanger and a water pump, and the control module 5 is electrically connected with an alarm protection module 7;

[0028] The lower water guide shell 101 is slidably arranged at the bottom of the inner wall of the cooling main water tank 1, the connecting shell 103 is fixed at the top of the two sides of the lower water guide shell 101, the upper water guide shell 105 is fixed at the top end of the connecting shell 103, the lower water guide shell 101 is located below the PVB middle film, the upper water guide shell 105 is located above the PVB middle film, the water outlet pipe 102 is fixed between the lower water guide shells 101, and the water outlet pipe 102 is also fixed between the upper water guide shells 105. The rack 106 is fixed to the top surface of the upper water guide shell 105, the connecting shell 103 is in sliding connection with the inner wall of the cooling main water tank 1, the sliding groove 104 for sliding of the connecting shell 103 is arranged on the two sides of the inner wall of the cooling main water tank 1, the gear 107 is rotatably arranged on one side of the inner wall of the cooling main water tank 1, and the gear 107 is matched with the rack 106. The servo motor is fixed to the outer wall of the cooling main water tank 1, the output shaft of the servo motor is fixedly connected with the middle part of the gear 107, the gear 107 is driven to rotate in reverse by the servo motor, the rack 106 is controlled to reciprocate, so that the lower water guide shell 101, the upper water guide shell 105, the water outlet pipe 102 and the connecting shell 103 are driven to move left and right, the cooled water is sprayed into the cooling main water tank 1 again through the water outlet of the heat exchanger connected with the lower water guide shell 101 and the upper water guide shell 105 and the water outlet pipe, and the left and right movement of the water outlet pipe 102 and the arrangement of the heat exchanger on the upper and lower sides of the PVB can ensure the uniformity of the water temperature in the cooling main water tank 1. Similarly, the first cooling auxiliary water tank 2 and the second cooling auxiliary water tank 3 can also be provided with the same structure to ensure the uniformity of the water temperature.

[0029] The alarm protection module 7 comprises an audible and visual alarm and a fault diagnosis for displaying fault information. The audible and visual alarm is provided, for example, to automatically send an alarm signal in the following fault conditions: the water temperature difference between the left and right water tanks exceeds ±0.5℃; the water pump abnormally stops or the flow is insufficient; the temperature sensor fails; the system controller data is abnormal.

[0030] Fault diagnosis: an intelligent diagnosis system is provided to display fault information in real time and prompt the operator to take corresponding measures. The system supports connection with the central control system MES / ERP of the production line, remote alarm and monitoring, and ensures safe and stable operation of the production line.

[0031] The temperature detection module 4 comprises a plurality of thermosensitive elements installed at key positions of the inner wall of the water tank, the membrane inlet, the outlet and the membrane running channel, forming a three-dimensional temperature detection network. The inner walls of the cooling main water tank 1, the first cooling auxiliary water tank 2 and the second cooling auxiliary water tank 3 are provided with a plurality of thermosensitive elements, which are either NTC thermistors or PT100 platinum resistors. The NTC thermistors or PT100 platinum resistors have high sensitivity and fast response performance, and the temperature measurement accuracy reaches ±0.1℃. Each sensor is equipped with an independent data acquisition module to ensure real-time data acquisition and transmission of multiple points. The temperature detection module 4 judges whether the temperature difference between the left and right water tanks exceeds the set threshold according to the temperature data feedback of the two sides of the membrane, and triggers the intelligent temperature control algorithm to adjust the cooling water temperature

[0032] The heat exchanger is a plate heat exchanger. The first cooling auxiliary water tank 2 and the second cooling auxiliary water tank 3 are connected to two plate heat exchangers through two water pumps and pipelines. The first cooling auxiliary water tank 2, the second cooling auxiliary water tank 3 and the heat exchanger connecting pipeline are provided with electromagnetic valves, which are electrically connected with the control module 5. The two water tanks are independently controlled to adapt to different temperature requirements. A double-circuit heat exchange system is adopted to connect the left and right water tanks. The water pumps of the left and right water tanks are independent of each other and are frequency-controlled pumps, which automatically adjust the water flow rate and pressure according to the temperature change in the water tank.

[0033] Automatic water replacement and filtration: The system is equipped with an automatic water replacement function. The water quality sensor monitors the water quality in real time and automatically drains and replenishes water when detecting abnormal water quality, ensuring the cooling effect and equipment cleanliness.

[0034] Energy-saving design: The system automatically enters a low-power energy-saving mode in a non-production state to avoid energy waste

[0035] The control module 5 comprises a PLC controller and an intelligent temperature control algorithm, which includes a fuzzy control algorithm, a PID control algorithm and a historical database model. The built-in production process database records the optimal water tank temperature distribution parameters under different membrane thicknesses, groove depths and production speeds, forming an intelligent decision-making model. The system can automatically analyze historical temperature data and real-time production parameters, predict future water temperature trends, and adjust the power output of the heat exchanger and the flow rate of the water pump in advance to ensure the continuity and stability of production.

[0036] According to the cooling direction of the PVB interlayer, the PVB interlayer successively passes through the first cooling auxiliary water tank 2, the cooling main water tank 1 and the second cooling auxiliary water tank 3 during cooling. The first cooling auxiliary water tank 2 is a pre-cooling zone, the cooling main water tank 1 is a uniform cooling zone, and the second cooling auxiliary water tank 3 is a deep cooling zone. The water temperature in the first cooling auxiliary water tank 2, the cooling main water tank 1 and the second cooling auxiliary water tank 3 gradually decreases.

[0037] When the self-adaptive temperature control system of the PVB interlayer cooling water tank is used, the cooling area is designed in sections, so that the entire cooling water tank is divided into a pre-cooling zone, an equalizing cooling zone and a deep cooling zone according to the direction of the film running, the water temperature is gradually reduced, the thermal deformation and internal stress residual of the film are reduced, and the surface quality of the PVB film is ensured.

[0038] The multiple thermosensitive elements arranged inside the water tank have the effect of accurate temperature measurement. Each sensor is equipped with an independent data acquisition module to ensure real-time collection and transmission of multi-point data, and to ensure that the water temperature difference of the water tank is kept within the set range.

[0039] Through the intelligent control algorithm built in the system, including fuzzy control algorithm, PID control algorithm and historical database model, the system automatically adjusts the temperature of the water tank and the flow rate of the water pump according to the real-time monitored temperature data, and optimizes the film cooling process.

[0040] Example 2: In this example, based on example 1, a PVB film cooling control system with a thickness of 0.76 mm is provided

[0041] 1. Start-up preparation

[0042] 1.1 Equipment inspection and start-up

[0043] Check whether the appearance of the cooling water tank is damaged, and confirm that the water level in the water tank reaches the mark.

[0044] Check the connection and power supply of the water pump (4a), heat exchanger (4b) and temperature detection module (2).

[0045] Start the PLC controller (3) for system initialization and self-checking.

[0046] 1.2 Parameter setting

[0047] Set the target film thickness to 0.76 mm and the production line speed to 10 m / min.

[0048] Set the initial water temperature of the left and right water tanks to 18℃ and 16℃ respectively, and set the water pump flow rate to 120 L / min.

[0049] Start the temperature detection module to enable real-time monitoring and data acquisition functions.

[0050] 2. Cooling process monitoring and adjustment

[0051] 2.1 Real-time temperature monitoring

[0052] When the film enters the cooling water tank, the thermosensitive elements (2a) in the temperature detection module continuously collect temperature data at the upper and lower, left and right key positions of the film passing path.

[0053] 2.2 Intelligent temperature control algorithm analysis

[0054] The PLC controller (3) receives the temperature data, starts the PID regulation algorithm, and dynamically adjusts the water temperature of the left and right water tanks according to the membrane outlet temperature.

[0055] If the membrane outlet temperature is higher than the target value (20℃), the system instructs the heat exchange control module to increase the cooling power of the heat exchanger and increase the flow rate of the water pump.

[0056] If the membrane temperature difference exceeds ±0.5℃, the system automatically reduces the temperature of one side of the water tank to ensure uniform cooling of the membrane surface.

[0057] 2.3 Data recording and analysis

[0058] The system stores the real-time collected temperature data into the process database, and generates a cooling data analysis report every 10 minutes during production.

[0059] 3. Abnormal processing and alarm

[0060] 3.1 Water temperature abnormal alarm

[0061] If the water temperature difference between the left and right water tanks exceeds ±1℃, the alarm protection module (5) immediately sends an audible and visual alarm signal.

[0062] The system automatically records the alarm log and displays the fault location and abnormal reason.

[0063] 3.2 Water flow shortage alarm

[0064] If the water pump flow rate is lower than the set value or the heat exchanger power output is insufficient, the system automatically stops and performs remote alarm and information push.

[0065] Example Three: In this example, based on Example One, a thick film production cooling process with a groove depth of 0.02mm is provided

[0066] 1. System initialization and preparation

[0067] 1.1 Membrane parameter setting

[0068] The PVB membrane thickness is set to 1.14mm, the surface groove depth is set to 0.02mm, and the production speed is set to 8m / min.

[0069] 1.2 Process preset

[0070] According to the historical data of the process database, the initial values of the left and right water tank water temperatures are set to 17℃ and 15℃ respectively, and the flow rate is set to 140L / min.

[0071] 2. Cooling process control and regulation

[0072] 2.1 Subsection cooling strategy

[0073] Pre-cooling zone: The membrane enters the water tank and is initially cooled. The water temperatures in the left and right water tanks are 17°C and 16°C, respectively.

[0074] Uniform cooling zone: The membrane enters the middle section, and the water temperature is dynamically adjusted to 16°C and 15°C. The guide plate maintains stable water flow and reduces temperature difference.

[0075] Deep cooling zone: The membrane approaches the outlet, and the water temperature is adjusted to 14.5°C and 14°C to achieve final cooling and pattern setting.

[0076] 2.2 Dynamic temperature control adjustment

[0077] According to the real-time data feedback from the temperature detection module, the intelligent temperature control algorithm samples the membrane surface temperature every second and automatically adjusts the water tank temperature difference.

[0078] The system automatically detects the consistency of the pattern depth when the membrane passes through the water tank outlet. If the pattern error is greater than ±0.02mm, the left water tank temperature is immediately lowered, and the water pump flow rate is increased.

[0079] 3. Abnormalities and response mechanisms

[0080] 3.1 Pattern depth monitoring abnormalities

[0081] If the pattern depth detection shows that the patterns on both sides are not symmetrical, the system automatically alarms and prompts the operator to check the water tank left and right water tank water temperature settings.

[0082] 3.2 Automatic adjustment and alarm record

[0083] The automatic alarm record system displays abnormal adjustment time and processing data.

[0084] After fault recovery, the equipment continues to run, and production data is saved to the cloud management system.

[0085] Example 3: Rapid cooling of ultra-thin membrane (0.38mm thickness)

[0086] 1. Start-up and parameter configuration

[0087] 1.1 System check

[0088] Check if the water tank is full of cooling water to ensure that the heat exchanger is running normally, and set the water pump flow rate to 200L / min.

[0089] 1.2 Parameter setting

[0090] Set the membrane thickness to 0.38mm, the production speed to 15m / min, and the initial water temperatures in the left and right water tanks to 12°C and 10°C, respectively.

[0091] 2. Dynamic cooling process monitoring and control

[0092] 2.1 Real-time temperature monitoring and feedback

[0093] During the ultra-thin film cooling process, the film samples 5 times per second at all temperature detection points on the path, ensuring real-time temperature detection.

[0094] 2.2 Intelligent adjustment and optimization

[0095] When the ultra-thin film passes at high speed, the intelligent temperature control algorithm preferentially increases the water pump flow rate and the heat exchanger power to ensure that the cooling rate matches the production speed.

[0096] If the film outlet temperature is higher than 14℃, the system automatically reduces the left and right water tank temperature to 10℃ and 9℃.

[0097] 3. Abnormal handling and automatic recording

[0098] 3.1 Film deformation alarm

[0099] If the cooling rate on both sides of the film is uneven, the system will automatically reduce the water pump speed to reduce water flow impact and optimize the water flow path for the film to pass through.

[0100] 3.2 Automatic data storage and report generation

[0101] Cooling process data is uploaded to the central management system every 5 minutes, and detailed production process monitoring reports are generated.

[0102] Based on the embodiments in the utility model, all other embodiments obtained by those of ordinary skill in the art without creative labor belong to the scope of protection of the utility model.

Claims

1. A PVB interlayer cooling water tank adaptive temperature control system, comprising: Cooling main water tank (1), temperature detection module (4) and control module (5), characterized by: the cooling main water tank (1) two sides are respectively equipped with first cooling auxiliary water tank (2) and second cooling auxiliary water tank (3), the cooling main water tank (1), first cooling auxiliary water tank (2) and second cooling auxiliary water tank (3) inside are equipped with temperature detection module (4), the control module (5) is electrically connected with temperature detection module (4), the first cooling auxiliary water tank (2) and second cooling auxiliary water tank (3) outside are equipped with heat exchange control module (6), the heat exchange control module (6) includes heat exchanger and water pump, the control module (5) is electrically connected with alarm protection module (7); The lower water guide shell (101) is located below the PVB interlayer, and the upper water guide shell (105) is located above the PVB interlayer.

2. The self-adapting temperature control system of a PVB interlayer cooling water tank according to claim 1, characterized in that: The alarm protection module (7) includes an audible and visual alarm and a fault diagnosis, and the fault diagnosis is used to display fault information.

3. The self-adapting temperature control system of a PVB interlayer cooling water tank according to claim 1, characterized in that: The temperature detection module (4) includes a plurality of thermosensitive elements, and the inner walls of the cooling main water tank (1), the first cooling auxiliary water tank (2) and the second cooling auxiliary water tank (3) are provided with the plurality of thermosensitive elements.

4. The self-adapting temperature control system of a PVB interlayer cooling water tank according to claim 1, characterized in that: The heat exchanger is a plate heat exchanger, the first cooling auxiliary water tank (2) and the second cooling auxiliary water tank (3) are connected with two plate heat exchangers through two water pumps and pipelines, and electromagnetic valves are arranged on the pipelines connecting the first cooling auxiliary water tank (2), the second cooling auxiliary water tank (3) and the heat exchanger.

5. The self-adapting temperature control system of a PVB interlayer cooling water tank according to claim 1, characterized in that: The control module (5) includes a PLC controller and an intelligent temperature control algorithm, and the intelligent temperature control algorithm includes a fuzzy control algorithm, a PID control algorithm and a historical database model.

6. The self-adapting temperature control system of a PVB interlayer cooling water tank according to claim 1, characterized in that: According to the cooling operation direction of the PVB interlayer, the PVB interlayer sequentially passes through the first cooling auxiliary water tank (2), the cooling main water tank (1) and the second cooling auxiliary water tank (3) during cooling, the first cooling auxiliary water tank (2) is a precooling zone, the cooling main water tank (1) is an equalizing cooling zone, and the second cooling auxiliary water tank (3) is a deep cooling zone, and the water temperature in the first cooling auxiliary water tank (2), the cooling main water tank (1) and the second cooling auxiliary water tank (3) gradually decreases.

7. The self-adapting temperature control system of a PVB interlayer cooling water tank according to claim 1, characterized in that: The upper water guide shell (105) top surface is provided with a rack (106), the connecting shell (103) and the cooling main water tank (1) inner wall are in sliding connection, the cooling main water tank (1) inner wall both sides are provided with a sliding groove (104) for connecting shell (103) sliding, the cooling main water tank (1) inner wall one side is provided with a gear (107), the gear (107) and the rack (106) are matched.

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