Wireless temperature measuring device suitable for high-temperature area of multi-metal smelting rotary kiln

Abstract

The utility model discloses a wireless temperature measuring device suitable for a high-temperature area of a multi-metal smelting rotary kiln, which comprises a thermocouple, a thermocouple protection sleeve arranged outside the thermocouple, an outer protection shell arranged outside the thermocouple protection sleeve, and a fire-resistant filler layer arranged between the outer protection shell and the thermocouple protection sleeve. The thermocouple protection sleeve is fixedly installed on a rotary kiln outer shell, the outer protection shell is fixedly installed on a rotary kiln lining, the inner side end of the thermocouple protection sleeve is inserted into the inner side of the rotary kiln lining, the wireless temperature transmitter is detachably installed at the outer end of the thermocouple protection sleeve, and the wireless transmitting module is arranged on the wireless temperature transmitter. And the wireless temperature transmitter is matched with the wireless transmitting module and the wireless gateway to transmit the temperature detected by the thermocouple. The wireless temperature measuring device is provided with the corresponding outer protective shell and can effectively isolate or reduce heat radiation.

Description

Technical Field

[0001] This utility model relates to the field of temperature measurement technology, and in particular to a wireless temperature measurement device suitable for the high-temperature area of ​​a rotary kiln in polymetallic smelting. Background Technology

[0002] In polymetallic smelting processes, rotary kilns play a crucial role, with their internal temperature having a decisive impact on smelting efficiency and product quality. Precise temperature control within the kiln directly affects product purity and production efficiency. However, current temperature measurement technology for rotary kilns still faces numerous challenges.

[0003] Traditional wired temperature measurement methods involve vertically inserting a temperature sensor (such as a thermocouple or resistance temperature detector) into the kiln body. A wire is connected to a slip ring fixed to the circumference of the kiln. The slip ring rotates with the kiln and contacts a stationary device fixed to the kiln's support base. The temperature signal is then transmitted to a remote DCS system via a cable. However, this method has significant drawbacks: the slip ring has a complex and precise structure. After prolonged operation, wear between the slip ring and the stationary device accelerates, easily leading to poor contact, which in turn disrupts signal transmission and affects temperature measurement accuracy. In the event of a malfunction, shutdown for maintenance will severely impact production efficiency and increase production costs.

[0004] Non-contact temperature measurement methods, such as using infrared or optical pyrometers to measure the area from the kiln head or tail, also have significant shortcomings. Dust and water mist in the flue gas inside the rotary kiln absorb the radiation energy of the target area, causing the measured value to be lower than the actual value, resulting in inaccurate measurements. Furthermore, the temperature of the target area is affected by various factors such as heat convection, radiation, and conduction, and the influencing factors of dust and water mist in the flue gas inside the rotary kiln vary unpredictably, making it difficult to accurately measure the temperature transfer between the temperature field and the external environment, thus failing to provide reliable data support for production.

[0005] Traditional wireless thermocouples typically use 304 stainless steel for their protective sheaths, resulting in a short average lifespan at 1100℃. Wireless transmitters also experience a higher failure rate in high-heat-radiation environments like rotary kilns. Statistics show that traditional temperature measurement systems experience frequent monthly downtime due to failures, severely impacting production continuity.

[0006] Therefore, it is particularly important to develop a wireless temperature measurement device with a corresponding protective shell and the ability to effectively isolate or reduce heat radiation. Utility Model Content

[0007] To solve the above-mentioned technical problems, this utility model designs a wireless temperature measurement device suitable for the high-temperature area of ​​a rotary kiln for multi-metal smelting.

[0008] The present invention adopts the following technical solution:

[0009] A wireless temperature measurement device suitable for the high-temperature area of ​​a rotary kiln in polymetallic smelting includes a thermocouple, a protective sheath surrounding the thermocouple, and an outer protective shell surrounding the protective sheath. A refractory filler layer is disposed between the outer protective shell and the protective sheath. The protective sheath is fixedly installed on the outer shell of the rotary kiln, and the outer protective shell is fixedly installed on the inner lining of the rotary kiln. The inner end of the protective sheath is inserted into the inner side of the kiln lining. A wireless temperature transmitter is detachably installed on the outer end of the protective sheath, and the wireless temperature transmitter is equipped with a wireless transmission module. The wireless temperature transmitter, in conjunction with the wireless transmission module and a wireless gateway, transmits the temperature detected by the thermocouple.

[0010] Preferably, the thermocouple protection sleeve includes a flange, a sleeve, and a guide member. The guide member is fixedly welded to the inner side of one end of the sleeve, and a guide cone hole is opened in the center of the guide member. The flange is fixedly installed at the other end of the sleeve.

[0011] Preferably, the flange is provided with mounting holes, and the thermocouple protection sleeve is fixedly installed on the rotary kiln shell by bolts passing through the mounting holes.

[0012] Preferably, a wireless temperature transmitter is detachably mounted on the outer end of the flange via bolts.

[0013] Preferably, a heat insulation gasket is installed between the flange and the rotary kiln shell.

[0014] Preferably, the heat insulation pad is made of multi-layer heat-insulating asbestos.

[0015] Preferably, the refractory filler layer is made of high-alumina cast refractory filler.

[0016] Preferably, the outer protective shell includes a box body with oblique plow blades on both sides of the box body.

[0017] Preferably, the box body is provided with multiple sets of rib hooks on the fire-facing side.

[0018] The beneficial effects of this utility model are: (1) Improved temperature measurement accuracy and stability: The use of wireless transmission technology effectively avoids the signal instability caused by poor slip ring contact, ensuring that temperature data can be transmitted accurately and in real time, providing a solid and reliable basis for temperature control in the production process. In addition, the high-precision design and excellent anti-interference capability of the wireless temperature sensor and wireless gateway significantly reduce the influence of external factors on the temperature measurement results, further enhancing the stability of the temperature measurement system; (2) Reduced equipment maintenance costs: By reducing the use of easily damaged parts such as slip rings, the failure rate and maintenance frequency of the equipment are effectively reduced. The wireless temperature sensor and wireless gateway have a simple structure, are easy to install and replace, greatly reducing maintenance costs and downtime, thereby improving production efficiency. It is worth mentioning that the wireless temperature sensor adopts a long-life battery and low power consumption design, which greatly reduces the frequency and cost of battery replacement. The heat insulation pad effectively reduces heat radiation between the kiln body and the wireless temperature transmitter, extending the service life of the transmitter; while the outer protective shell provides more comprehensive protection for the thermocouple, further extending its service life; (3) Facilitating system expansion and upgrade: The application of wireless communication technology makes system expansion more convenient. Just add a wireless temperature sensor at the temperature measurement location to achieve accurate monitoring of more temperature measurement points. At the same time, the wireless gateway supports multiple communication protocols, which facilitates seamless integration and upgrade with the existing production system, significantly improving the system's compatibility and flexibility. In addition, by configuring two sets of wireless transmission transmitters to achieve mutual redundancy, once a set of equipment fails, it can be quickly switched to the redundant equipment by setting the instrument address, thereby minimizing the impact on production; (4) Realizing remote monitoring and management: With the help of wired or wireless networks, operators can remotely monitor and manage the temperature of the rotary kiln in real time, keep abreast of the kiln's operating status, and greatly improve the efficiency and convenience of production management. Even if the operators are not on site, they can obtain temperature data and alarm information at any time through the DCS system, make quick decisions, and ensure the safe and stable operation of production. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of this utility model;

[0020] Figure 2 This is a schematic diagram of a thermocouple protection sleeve in this utility model;

[0021] Figure 3 yes Figure 2 A left view;

[0022] Figure 4 This is a schematic diagram of the structure of the outer and inner protective boxes in this utility model;

[0023] Figure 5 yes Figure 4 A cross-sectional view along the AA direction;

[0024] Figure 6 yes Figure 4 A cross-sectional view along the BB direction;

[0025] Figure 7 This is a structural schematic diagram of the present invention in use;

[0026] In the diagram: 1. Thermocouple, 2. Thermocouple protective sleeve, 3. High-alumina cast refractory filler, 4. Outer protective shell, 5. Wireless temperature transmitter, 6. Wireless transmitting module, 7. Flange, 8. Sleeve, 9. Guide component, 10. Mounting hole, 11. Box body, 12. Angled plow blade, 13. Flame-facing side wing, 14. Rib hook. Detailed Implementation

[0027] The technical solution of this utility model will be further described in detail below through specific embodiments and with reference to the accompanying drawings:

[0028] Example: Figures 1-7 As shown, a wireless temperature measurement device suitable for the high-temperature area of ​​a rotary kiln in polymetallic smelting includes a thermocouple 1, a thermocouple protective sleeve 2, and an outer protective shell 4. A refractory filler layer is provided between the outer protective shell and the thermocouple protective sleeve. The thermocouple protective sleeve is fixedly installed on the outer shell of the rotary kiln, and the outer protective shell is fixedly installed on the inner lining of the rotary kiln. The inner end of the thermocouple protective sleeve is inserted into the inner side of the rotary kiln lining. A wireless temperature transmitter 5 is detachably installed on the outer end of the thermocouple protective sleeve, and a wireless transmission module 6 is provided on the wireless temperature transmitter. The wireless temperature transmitter, together with the wireless transmission module and the wireless gateway, transmits the temperature detected by the thermocouple.

[0029] The thermocouple protection sleeve includes a flange 7, a sleeve 8, and a guide 9. The guide is fixedly welded to the inner side of one end of the sleeve, and a guide cone hole is opened in the center of the guide. The flange is fixedly installed at the other end of the sleeve.

[0030] The flange is provided with mounting holes 10, and the thermocouple protection sleeve is fixedly installed on the rotary kiln shell by bolts passing through the mounting holes.

[0031] A wireless temperature transmitter is detachably mounted on the outer end of the flange via bolts. A heat insulation gasket is installed between the flange and the rotary kiln shell.

[0032] The refractory filler layer uses high-alumina cast refractory filler 3. The outer protective shell includes a box body 11, with oblique plow blades 12 on both sides of the box body. Multiple sets of reinforcing hooks 14 are provided on the side wing 13 of the box body on the fire-facing side.

[0033] The thermocouples used are high-precision, high-temperature resistant K-type thermocouples, capable of withstanding high-temperature environments exceeding 1000°C inside the rotary kiln. Due to the high temperatures during the heating phase of the rotary kiln, traditional 304 stainless steel protective sleeves have short lifespans and require frequent maintenance and replacement. This device uses GH3039 material, which possesses excellent high-temperature strength and maintains good mechanical properties under high-temperature conditions. Its high-temperature alloy has a maximum temperature resistance of approximately 1150°C, meeting the temperature measurement requirements under rotary kiln operating conditions.

[0034] The wireless temperature transmitter is mechanically connected to the thermocouple via bolts, responsible for collecting and initially processing temperature data. The wireless transmission module transmits the processed data as a wireless signal. The transmitter has a built-in 9VDC lithium battery to power both the transmitter and the transmitting device. The transmitter housing is made of high-temperature and corrosion-resistant metal and is sealed, achieving an IP65 protection rating, effectively preventing damage to the sensor from high temperatures, dust, and corrosive gases within the furnace. In unobstructed environments, the transmission distance can reach 2000 meters; in complex environments, the transmission distance is approximately 500 meters.

[0035] The heat insulation pad is made of multi-layer heat-insulating asbestos material, custom-processed, circular in shape with a diameter of 400mm, and installed on the flange between the kiln body and the thermocouple. It is designed to reduce the heat radiation from the kiln body to the wireless temperature transmitter, thereby extending the service life of the wireless temperature transmitter.

[0036] The wireless gateway is installed in the DCS control room, 200 meters away from the kiln body, and is responsible for receiving temperature signals transmitted by the wireless temperature sensors. This wireless gateway possesses excellent signal processing and forwarding capabilities, supports the LoRa wireless communication protocol, and ensures stable communication with the wireless temperature sensors. Its built-in high-performance microprocessor and communication module can decode, verify, and correct the received signals, and efficiently transmit temperature data to the DCS system via the MODBUS communication protocol.

[0037] The thermocouple protection sleeve is installed and fixed inside the rotary kiln. It is made of 310S material with a DN50 specification and is designed to protect the thermocouple and facilitate quick maintenance and replacement of the thermocouple during the production process.

[0038] The outer protective shell is installed inside the rotary kiln and is manufactured using a non-standard, custom-made method. High-alumina cast refractory filler is used for casting at the thermocouple protective sheath to protect the thermocouple from damage caused by high-temperature calcined sand.

[0039] This invention relates to a wireless temperature sensor that collects real-time temperature data from a rotary kiln using thermocouples, converts the temperature signals into digital signals, and performs efficient data processing and encoding. The encoded data is then transmitted wirelessly via a wireless transmission module. Upon receiving signals from multiple wireless temperature sensors, the wireless gateway analyzes and summarizes the signals, and transmits the temperature data to the DCS system via a wired or wireless network. The DCS system displays, stores, and analyzes the received temperature data in real time, and automatically adjusts the burner settings based on temperature changes, achieving precise and stable temperature control within the rotary kiln. Throughout this process, the low-power design of the wireless temperature sensor ensures stable operation for extended periods under battery power, while the powerful processing and forwarding capabilities of the wireless gateway guarantee fast and accurate transmission of temperature data.

[0040] The embodiments described above are merely preferred solutions of this utility model and are not intended to limit this utility model in any way. Other variations and modifications are possible without departing from the technical solutions described in the claims.

Claims

1. A wireless temperature measuring device suitable for the high-temperature zone of a rotary kiln in polymetallic smelting, comprising a thermocouple, characterized in that, The thermocouple is provided with a thermocouple protective sleeve, and an outer protective shell is provided outside the thermocouple protective sleeve. A refractory filler layer is provided between the outer protective shell and the thermocouple protective sleeve. The thermocouple protective sleeve is fixedly installed on the outer shell of the rotary kiln, and the outer protective shell is fixedly installed on the inner lining of the rotary kiln. The inner end of the thermocouple protective sleeve is inserted into the inner side of the rotary kiln lining. A wireless temperature transmitter is detachably installed on the outer end of the thermocouple protective sleeve, and a wireless transmission module is provided on the wireless temperature transmitter.

2. The wireless temperature measuring device for the high-temperature zone of a rotary kiln in polymetallic smelting according to claim 1, characterized in that, The thermocouple protection sleeve includes a flange, a sleeve, and a guide member. The guide member is fixedly welded to the inner side of one end of the sleeve, and a guide cone hole is opened in the center of the guide member. The flange is fixedly installed at the other end of the sleeve.

3. The wireless temperature measuring device for the high-temperature zone of a rotary kiln in polymetallic smelting according to claim 2, characterized in that, The flange is provided with mounting holes, and the thermocouple protection sleeve is fixedly installed on the rotary kiln shell by bolts passing through the mounting holes.

4. A wireless temperature measuring device suitable for the high-temperature zone of a rotary kiln in polymetallic smelting according to claim 2, characterized in that, A wireless temperature transmitter is detachably installed on the outer end of the flange via bolts.

5. A wireless temperature measuring device suitable for the high-temperature zone of a rotary kiln in polymetallic smelting according to claim 2, characterized in that, A heat insulation gasket is installed between the flange and the rotary kiln shell.

6. A wireless temperature measuring device suitable for the high-temperature zone of a rotary kiln in polymetallic smelting according to claim 5, characterized in that, The heat insulation pad is made of multi-layer heat-insulating asbestos.

7. A wireless temperature measuring device suitable for the high-temperature zone of a rotary kiln in polymetallic smelting according to claim 1, characterized in that, The refractory filler layer is made of high-alumina cast refractory filler.

8. A wireless temperature measuring device suitable for the high-temperature zone of a rotary kiln in polymetallic smelting according to claim 1, characterized in that, The outer protective shell includes a box body, with oblique plow blades on both sides of the box body.

9. A wireless temperature measuring device suitable for the high-temperature zone of a rotary kiln in polymetallic smelting according to claim 8, characterized in that, The box body is equipped with multiple sets of rib hooks on the fire-facing side.

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