Industrial silicon furnace insulation monitoring system

Abstract

The utility model discloses an insulation monitoring system for an industrial silicon furnace, which relates to the technical field of detection, takes a DCS (Distributed Control System) monitoring device as a core hub, is connected with a voltage indication transmitter by virtue of a 4-20MA output line, and implements omnibearing and real-time monitoring on key parts such as a pressure ring, a large protection screen and the like through a high-temperature lead to ensure that no monitoring dead angle exists. The DCS monitoring device displays a picture and has a voice alarm function and a colored tape display function, the insulation state is visually and dynamically presented according to different voltage values, an operator can rapidly perceive abnormity, and the timeliness and accuracy of early warning are greatly improved. Meanwhile, the system carries out scientific grading monitoring on the insulation parts and the insulation relation, A and B types of equipment are clearly divided, differentiated maintenance strategies are adopted for different types, and maintenance resources are reasonably allocated.

Description

Technical Field

[0001] This utility model relates to the field of detection technology, specifically an industrial silicon furnace insulation monitoring system. Background Technology

[0002] In modern industrial production, industrial silicon is an important basic raw material widely used in many fields, such as electronics, chemicals, and metallurgy. The stable operation of the industrial silicon furnace is crucial in the production process, and the insulation performance of the furnace body is one of the key factors affecting its stable operation.

[0003] In the normal production of industrial silicon, the two core systems—water cooling and electrical insulation—require electrical conductivity to perform work on both the equipment electrodes and the material surface inside the furnace. The insulation performance of the furnace shell determines the stability of production. Short circuits and sparking due to poor insulation are not uncommon. Sparking can lead to equipment breakdown or water pipe leaks, requiring emergency furnace shutdowns and posing significant safety hazards.

[0004] However, current industrial silicon furnace insulation monitoring technologies have revealed numerous insurmountable shortcomings. Early monitoring methods were mostly based on simple analog circuit designs, making signal transmission susceptible to interference from harsh operating conditions such as strong electromagnetic fields, high temperatures, and dust. This resulted in severe signal attenuation and distortion, leading to insulation data that was significantly inconsistent with the actual condition of the equipment. In complex industrial environments, the transmission distance of analog signals is limited, making signal interruptions highly likely and resulting in missing monitoring data, posing a significant threat to production safety.

[0005] In the identification and early warning of insulation conditions, previous methods mainly relied on regular manual inspections and simple numerical instrument displays. Manual inspections are not only time-consuming and labor-intensive, but also greatly affected by subjective factors, making it difficult to detect subtle changes in insulation. Simple numerical displays cannot intuitively present the dynamic trends of insulation conditions, making it difficult for operators to promptly detect potential risks and miss the best opportunity for handling.

[0006] Furthermore, the existing maintenance and repair model lacks a scientific classification and management mechanism, and adopts a "one-size-fits-all" maintenance strategy. This approach fails to accurately identify high-risk components and cannot flexibly adjust maintenance plans according to the actual operating conditions of the equipment, resulting in serious waste of maintenance resources and a persistently high equipment failure rate.

[0007] Existing industrial silicon furnace insulation monitoring technology can no longer meet the needs of current industrial silicon production. There is an urgent need for a more advanced, efficient, and accurate insulation monitoring system to improve the operational safety and stability of industrial silicon furnaces, reduce production risks, and increase production efficiency. This is the important background and significance of the research and development of this industrial silicon furnace insulation monitoring system. Utility Model Content

[0008] The purpose of this utility model is to provide an industrial silicon furnace insulation monitoring system, which takes a DCS monitoring device as the core, connects a voltage indicator transmitter through a 4-20MA output line, monitors the insulation status of key components through high-temperature leads, reflects the insulation status with voice alarms and color strip displays of different voltage values, and monitors A and B class equipment in different grades to ensure the safe and stable operation of the industrial silicon furnace.

[0009] To achieve the above objectives, this utility model provides the following technical solution:

[0010] An industrial silicon furnace insulation monitoring system includes a DCS monitoring device, characterized in that the DCS monitoring device is an automated control system with centralized management and distributed control. In this industrial silicon furnace insulation monitoring system, the DCS monitoring device is responsible for collecting, processing, and analyzing the operating data of the entire system. Through real-time monitoring of each monitoring point, it can promptly detect insulation abnormalities and perform corresponding alarm and control operations. The DCS monitoring device outputs several 4-20mA output lines to a voltage indicating transmitter. The DCS monitoring device transmits signals to the voltage indicating transmitter through these output lines for subsequent signal conversion and processing. The voltage indicating transmitter is a device that converts the measured voltage signal into a standard signal output. In this system, it converts the voltage signal obtained from key components of the industrial silicon furnace into a signal that is easy to transmit and process, enabling the DCS monitoring device to accurately read and analyze it. All voltage indicating transmitters are connected to a grounding terminal. Connecting to the grounding terminal ensures the electrical safety of the equipment, prevents electric shock accidents caused by a live equipment casing, and also helps stabilize the operating state of the equipment and reduce electromagnetic interference. The voltage indicator transmitter has high-temperature leads. Because the ambient temperature during the operation of the industrial silicon furnace is high, ordinary cables cannot function properly. Therefore, high-temperature leads are used to connect the voltage indicator transmitter to key components of the industrial silicon furnace to ensure the stability and reliability of signal transmission. Each high-temperature lead is connected to a key component of the industrial silicon furnace.

[0011] The key components of the industrial silicon furnace specifically include a pressure ring, a large protective screen, a small protective screen, a lower holding cylinder, an upper holding cylinder, a central cover plate, an outer cover plate, an electrode seal, a guide roller, and a fume hood column.

[0012] In industrial silicon furnaces, pressure rings primarily ensure good electrical contact between electrodes and conductive components. Their insulation performance directly affects power transmission efficiency and safe equipment operation. Large protective shields, installed in a large area of ​​the furnace, block high-temperature radiation and splashes, protecting surrounding equipment and personnel. Their insulation performance is crucial for preventing electrical accidents and ensuring normal equipment operation. Small protective shields protect critical local components within the furnace and also require good insulation to prevent leakage. The lower and upper holding cylinders work together to clamp and fix the electrodes; their insulation performance affects the stability and safety of the electrode system. The upper holding cylinder, in addition to fixing the electrodes, also participates in electrode lifting and lowering control; its insulation directly affects normal electrode operation and electrical safety. The central cover plate, located at the center of the furnace top, seals the central area, preventing heat loss and the ejection of gases and materials. Its insulation performance is vital for maintaining a stable furnace atmosphere and safe equipment operation. The outer cover plate works in conjunction with the central cover plate to cover the top or sides of the furnace body, forming a complete sealing and protective structure. Its insulation performance is also a crucial factor in ensuring the normal operation and safety of the equipment. Electrode seals are installed at the penetration points between the electrodes and the furnace body. Their main function is to prevent the leakage of high-temperature, high-pressure gases and dust from the furnace, while simultaneously ensuring the insulation performance of the electrodes and preventing oxidation. Guide rollers provide guidance for the lifting and movement of the electrodes, ensuring they move along a predetermined trajectory. Their insulation performance is crucial for preventing electrical short circuits and other accidents between the electrodes and other components. The fume hood columns primarily support the fume hood, maintaining it at a suitable height and position for effective collection and discharge of flue gas generated within the furnace. Their insulation performance also plays a role in preventing electrical faults and ensuring the normal operation of the equipment.

[0013] The DCS monitoring device corresponding to the voltage indicator transmitter displays appropriate voice alarms and color-coded indicators. Specifically, a green display indicates a voltage ≤70V, signifying good insulation of key components in the industrial silicon furnace and normal equipment operation, requiring no special attention. A yellow display indicates a voltage range of 70-120V, suggesting potential insulation risks requiring close monitoring and timely inspection and maintenance to prevent further deterioration. A red display indicates a voltage ≥120V, indicating severely deteriorated insulation and potential safety hazards such as leakage. The system will issue a voice alarm to remind operators to take immediate action to prevent accidents.

[0014] The system performs tiered monitoring of the insulating components of industrial silicon furnaces and the insulation relationships between them. Tiered monitoring is intended to manage insulating components and insulation relationships of different importance in a more targeted manner, improving the efficiency and accuracy of the monitoring system and enabling timely detection and handling of potential insulation problems.

[0015] The tiered monitoring specifically separates Class A and Class B equipment. For Class A equipment, after an early warning is issued, planned maintenance is urgently arranged. Class A equipment typically consists of critical components vital to the safe operation and normal production of industrial silicon furnaces. Problems with the insulation performance of these components could lead to serious accidents, therefore, immediate maintenance is necessary after an early warning to eliminate safety hazards. For Class B equipment, operation is observed after an early warning. Class B equipment has a relatively smaller direct impact on production; after an early warning, observation can be conducted first, and a decision on whether maintenance is necessary can be made based on the actual situation. This allows for the rational allocation of maintenance resources while ensuring equipment safety, thereby reducing production costs.

[0016] The Class A equipment specifically includes: insulation between the copper tile and the pressure ring. The copper tile is a crucial connecting component between the electrode and the conductive system. Its insulation performance with the pressure ring directly affects the transmission of electrical energy and the safe operation of the equipment. Insulation problems can lead to serious consequences such as current leakage and equipment damage. Insulation between the copper tile hanger and the large protective screen. The copper tile hanger supports the copper tile. Poor insulation between it and the large protective screen can lead to electrical short circuits and other faults, affecting the normal operation of the equipment. Insulation between the bottom ring and the pressure ring and the small protective screen. The bottom ring provides support and sealing at the bottom of the furnace. Its insulation performance with the pressure ring and the small protective screen is crucial for maintaining electrical safety and equipment stability within the furnace. Insulation between the large protective screen and the lower holding cylinder. The insulation between the large protective screen and the lower holding cylinder is related to the protection of the equipment and the normal operation of the electrode system. Poor insulation can cause electrical accidents. Insulation between the upper and lower holding cylinders. The upper and lower holding cylinders work together to fix and raise / lower the electrode. Their insulation performance directly affects the stability and safety of the electrode system. The insulation between the upper handle and the lower brake plays a crucial role in the control and fixation of the electrode. Good insulation between them is fundamental to ensuring the normal operation of the equipment. The insulation between the upper handle and the lifting cylinder is also essential. The lifting cylinder drives the raising and lowering of the electrode; poor insulation between the upper handle and the lifting cylinder can lead to interference between the hydraulic and electrical systems, affecting the normal operation of the equipment. The insulation between the upper brake and the carbon electrode is crucial for fixing the carbon electrode, and its insulation performance is related to the safe operation of the electrode and the stability of the electrical system. The insulation between the lifting cylinder and the steel platform is vital for preventing electrical short circuits and ensuring the safe operation of the equipment. Poor insulation between the upper brake and the platform can lead to safety accidents such as electric shock to operators and also affect the normal operation of the equipment. Finally, the insulation between the upper brake and the electrode directly affects the fixation of the electrode and electrical safety; decreased insulation performance can cause various safety problems.

[0017] The Class B equipment specifically includes insulation between the central cover plates. The insulation performance between the central cover plates mainly affects the sealing of the furnace top and electrical safety, and has a relatively small direct impact on production. Insulation between the central cover plate and the outer cover plates, and insulation between the central cover plate and the outer cover plates, relates to the overall sealing and protection of the furnace top, affecting the operating environment of the equipment to some extent, but its importance is slightly lower than that of Class A equipment. Insulation between the central cover plate and the electrode seal; poor insulation between the central cover plate and the electrode seal may lead to problems such as gas leakage inside the furnace, but its impact on the safe operation of the equipment is relatively small. Insulation between the electrode seal and the guide rollers; the insulation performance between the electrode seal and the guide rollers mainly affects the operating environment of the electrodes and the stability of the guiding system, and has a relatively small direct impact on production. Insulation between the fume hood columns and the second-layer steel platform. The insulation between the fume hood columns and the second-layer steel platform is mainly to prevent electrical accidents, and has a relatively small impact on the normal operation of the equipment.

[0018] Compared with the prior art, the beneficial effects of this utility model are:

[0019] The DCS monitoring device and voltage indicator transmitter are connected by a 4-20mA output line, which accurately and stably converts the electrical signal into a voltage signal that is easy to monitor, ensuring the reliability of data transmission. Many existing technologies may have problems with insufficient accuracy and poor stability in the signal conversion and transmission links.

[0020] The DCS monitoring device's voice alarm and color-coded display visually present the insulation status based on different voltage values, allowing operators to detect abnormalities immediately. Compared to existing technologies that rely solely on manual inspections or simple numerical displays, this significantly improves the timeliness and accuracy of early warnings.

[0021] The system monitors insulating components and their relationships in different categories, classifying equipment into A and B categories and adopting different response strategies. This makes maintenance and repair more targeted and scientific. Compared with the general maintenance methods of existing technologies, it can effectively reduce maintenance costs and improve the operating efficiency and safety of industrial silicon furnaces.

[0022] When insulation abnormalities occur, the fault point can be quickly located through accurate monitoring data. Compared with existing technologies that require a lot of time for troubleshooting, this greatly shortens the fault handling time and reduces production stoppages caused by faults.

[0023] It can be seamlessly integrated with other existing automated control systems of industrial silicon furnaces, and can be quickly upgraded without large-scale modification of the entire production system. Compared with the complex modification process of some existing technologies, it has higher operability and economy. Attached Figure Description

[0024] Figure 1 This is a connection diagram of an industrial silicon furnace insulation monitoring system according to this utility model.

[0025] In the diagram: 1. DCS monitoring device, 2. Voltage indicator transmitter, 3. Pressure ring, 4. Large protection screen, 5. Small protection screen, 6. Lower handle cylinder, 7. Upper handle cylinder, 8. Center cover plate, 9. Outer cover plate, 10. Electrode seal, 11. Guide roller, 12. Fume hood column. Detailed Implementation

[0026] The technical solutions of the present invention will now be described in detail with reference to the accompanying drawings of the embodiments.

[0027] like Figure 1 As shown, an industrial silicon furnace insulation monitoring system includes a DCS monitoring device 1, characterized in that the DCS monitoring device 1 has several 4-20mA output lines connected to a voltage indicator transmitter 2, the voltage indicator transmitter 2 is connected to a grounding terminal, and the voltage indicator transmitter 2 has high-temperature leads, each of which is connected to a key component of the industrial silicon furnace.

[0028] The key components of the industrial silicon furnace specifically include a pressure ring 3, a large protective screen 4, a small protective screen 5, a lower holding cylinder 6, an upper holding cylinder 7, a central cover plate 8, an outer cover plate 9, an electrode seal 10, a guide roller 11, and a fume hood column 12.

[0029] The DCS monitoring device 1 corresponding to the voltage indicator transmitter 2 is set with corresponding voice alarms and color band displays. Specifically, a green display is set for voltage ≤70V, a yellow display is set for voltage 70-120V, and a red display is set for voltage ≥120V.

[0030] The system performs tiered monitoring of the insulating components of industrial silicon furnaces and the insulation relationships between them.

[0031] The tiered monitoring specifically separates Class A equipment into Class B equipment; after a warning is issued for Class A equipment, emergency planned maintenance is arranged, while after a warning is issued for Class B equipment, its operation is observed.

[0032] The Class A equipment specifically includes insulation between the copper tile and the pressure ring, insulation between the copper tile hanger and the large protective screen, insulation between the bottom ring and the pressure ring and the small protective screen, insulation between the large protective screen and the lower handle cylinder, insulation between the upper and lower handle cylinders, insulation between the upper handle cylinder and the lower brake, insulation between the upper handle cylinder and the lifting cylinder, insulation between the upper brake and the carbon electrode, insulation between the lifting cylinder and the steel platform, insulation between the upper brake and the platform, and insulation between the upper brake and the electrode.

[0033] The Class B equipment specifically includes insulation between the central cover plates, insulation between the central cover plate and the outer cover plates, insulation between the central cover plate and the electrode seal, insulation between the electrode seal and the guide roller, and insulation between the fume hood column and the second-layer steel platform.

[0034] The specific implementation method of the industrial silicon furnace insulation monitoring system is as follows: After completing the hardware setup, connect several 4-20mA output lines of the DCS monitoring device 1 to the voltage indicator transmitter 2 via professional wiring, ensuring a stable connection and avoiding strong interference sources. Then, connect the voltage indicator transmitter 2 to the grounding terminal to ensure reliable grounding. Next, use high-temperature resistant and wear-resistant high-temperature leads to connect to components such as the pressure ring 3 and the large protection screen 4. During the wiring process, pay attention to protecting the high-temperature leads to prevent damage in the harsh environment of the industrial silicon furnace, such as high temperature and dust. In the background program of the DCS monitoring device 1, set up the display screen corresponding to the voltage indicator transmitter 2, and develop programs for voice alarm and color strip display functions, programming according to the rule of green for voltage ≤70V, yellow for 70-120V, and red for ≥120V. At the same time, in the system database, establish a graded monitoring data model of insulating components and insulation relationships, clarify the specific scope of Class A and Class B equipment, and write corresponding execution programs for early warning and handling strategies for different types of equipment. After the system is put into operation, professional technicians will regularly inspect and maintain the hardware equipment and update the software program in a timely manner to ensure the stable operation of the system and provide reliable protection for the insulation monitoring of industrial silicon furnaces.

Claims

1. An industrial silicon furnace insulation monitoring system comprising a DCS monitoring device (1), characterized in that, The DCS monitoring device (1) is connected with several 4-20MA output lines to connect with the voltage indicating transmitter (2), the voltage indicating transmitter (2) is connected with the ground end, the voltage indicating transmitter (2) is connected with high temperature lead, each high temperature lead is connected with the key components of the industrial silicon furnace; the key components of the industrial silicon furnace specifically include the pressure ring (3), the large protection screen (4), the small protection screen (5), the lower holding cylinder (6), the upper holding cylinder (7), the center cover plate (8), the peripheral cover plate (9), the electrode seal (10), the guide roller (11), the smoke hood stand column (12); the voltage indicating transmitter (2) is connected with the corresponding DCS monitoring device (1) display screen, and the corresponding voice alarm and color band display are set, specifically, the voltage ≤70V is green display, the voltage 70-120V is yellow display, and the voltage ≥120V is red display.

2. The industrial silicon furnace insulation monitoring system according to claim 1, wherein The system monitors the insulation relationship between the insulation parts of the industrial silicon furnace and the insulation parts.

3. An industrial silicon furnace insulation monitoring system according to claim 2, characterised in that, The grading monitoring is specifically separating the A-type equipment and the B-type equipment; the A-type equipment is arranged for emergency planned maintenance after early warning, and the B-type equipment is observed after early warning.

4. The industrial silicon furnace insulation monitoring system according to claim 3, wherein The A-type equipment specifically includes the insulation of the copper tile and the pressure ring, the insulation of the copper tile hanging and the large protection screen, the insulation of the bottom ring and the pressure ring and the small protection screen, the insulation between the large protection screen and the lower holding cylinder, the insulation between the upper and lower holding cylinders, the insulation between the upper holding cylinder and the lower brake, the insulation between the upper holding cylinder and the lifting oil cylinder, the insulation between the upper brake and the carbon electrode, the insulation between the lifting oil cylinder and the steel platform, the insulation between the upper brake and the platform, and the insulation between the upper brake and the electrode.

5. The industrial silicon furnace insulation monitoring system according to claim 3, wherein The B-type equipment specifically includes the insulation between the center cover plates, the insulation between the center cover plate and the peripheral cover plate, the insulation between the center cover plate and the electrode seal, the insulation between the electrode seal and the guide roller, and the insulation between the smoke hood stand column and the second layer steel platform.

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