A rock wool electric furnace high-temperature-resistant visual monitoring device and electric furnace

Abstract

This utility model discloses a high-temperature resistant visual monitoring device for rock wool electric furnaces, comprising a camera unit, a protective unit, and an emergency protection unit. The camera unit consists of a high-temperature resistant visible light camera and an infrared thermal imaging camera. The protective unit employs a double-layer water-cooled cavity and a ring-shaped air curtain blowing assembly, using circulating cooling water and compressed air barriers to control the lens temperature below 60℃ and effectively block dust. The emergency protection unit, through a mechanical interlock mechanism, directly drives the cylinder via the mechanical interlock circuit to quickly retract the camera into the safety chamber when water flow, temperature, or air pressure is abnormal, while simultaneously closing the insertion port with a pneumatic butterfly valve. This device solves the problems of camera damage and image blurring in high-temperature (>1000℃) and dusty environments, and has advantages such as fast response and long lifespan, significantly improving the safety and product quality of rock wool production.

Description

Technical Field

[0001] This utility model relates to the technical field of rock wool production equipment, and in particular to a high-temperature resistant visual monitoring device and electric furnace for rock wool electric furnaces. It has high-temperature protection, air curtain isolation and emergency protection functions, and is suitable for monitoring the operating conditions of electric furnaces in high-temperature and dusty environments. Background Technology

[0002] The statements in this section merely refer to the background technology related to this utility model and do not necessarily constitute prior art.

[0003] Rock wool is a loose, short-fiber cotton made from natural rocks such as basalt, diabase, dolomite, iron ore, and bauxite. After processing, it can be made into various products such as boards, pipes, felts, belts, and paper, and can be used for insulation, fireproofing, sound absorption, and earthquake resistance in construction and industrial equipment, pipelines, and kilns. The electric furnace is the core equipment in rock wool production. Compared with cupola furnaces, electric furnaces have the advantages of less pollution and more stable melt quality. During operation, the internal temperature of the rock wool electric furnace can typically reach >1000℃. At this temperature, it is impossible to visually observe the melt inside the furnace in real time during the raw material melting process; the melt can only be released from the furnace when it reaches the ideal state. Therefore, real-time monitoring of the rock wool production process using monitoring devices is crucial for safe production and process control.

[0004] Traditional visual monitoring devices for rock wool electric furnaces typically use high-temperature resistant cameras directly installed at the furnace's observation port. However, these devices suffer from several significant drawbacks in practical applications: 1) Insufficient high-temperature resistance: While existing cameras are nominally high-temperature resistant, the lenses and internal electronic components are constantly exposed to the ultra-high-temperature furnace environment. This makes them susceptible to optical lens deformation and sensor burnout due to heat radiation conduction or hot airflow impact, resulting in extremely short equipment lifespans and high maintenance costs. 2) Severe dust and melt contamination: The melting process of rock wool raw materials in the furnace generates a large amount of dust and splashed melt, which adheres to the camera lens surface, causing image blurring and color distortion in a short period. Long-term accumulation can even clog the lens and heat dissipation holes, leading to monitoring failure and requiring frequent shutdowns for cleaning, thus impacting production efficiency. 3) Lack of emergency protection mechanisms: Traditional devices rely on circulating water cooling or air cooling systems for temperature reduction. If the cooling system malfunctions (such as pipe blockage or pump shutdown), the camera will be quickly exposed to high temperatures and damaged. Existing technology lacks an active protection structure for rapid high-temperature isolation, posing a dual safety hazard of equipment damage and gas leakage within the furnace.

[0005] While some improvement solutions exist (such as adding a heat shield or extending the observation tube), none of them can simultaneously solve the problems of high-temperature protection, lens contamination removal, and emergency protection. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this utility model aims to provide a high-temperature resistant, splash-proof visual monitoring device and electric furnace with active protection functions. Through the structural design of a double-layer water-cooled cavity, a compressed air curtain barrier, and a mechanical emergency retraction mechanism, it solves the problems of camera damage and monitoring failure in high-temperature environments.

[0007] It should be noted that the present invention provides a structural solution. As for the individual devices involved, the specific structures for realizing their respective functions already exist in the prior art, as do the protocols, software, or programs involved in their operation. Those skilled in the art are fully aware of this. The present invention does not make any improvements to the individual devices, and therefore does not involve software content. Instead, it relies on the organic integration and consolidation of the components into a whole, that is, it provides a structural solution.

[0008] To achieve the above objectives, in a first aspect, this utility model provides a high-temperature resistant visual monitoring device for rock wool electric furnaces, comprising: a camera unit, a protective unit, and an emergency protection unit;

[0009] The protective unit includes: a double-layer water-cooled cavity and an air curtain blowing assembly. The double-layer water-cooled cavity is coaxially sleeved on the outer surface of the camera unit, and the air curtain blowing assembly is installed at the front end of the camera unit to form a protective air curtain.

[0010] The emergency protection unit includes: a cylinder, a slider, a fixed frame, a pneumatic quick-closing valve and an interlocking trigger assembly. The piston rod of the cylinder is fixedly connected to the slider and is used to drive the slider to move. One end of the fixed frame is fixedly connected to the slider, and the other end is connected to the double-layer water-cooled cavity through a clamp.

[0011] The pneumatic quick-closing valve is installed at the camera unit insertion port on the outside of the electric furnace;

[0012] The interlocking triggering component is hardwired to the cylinder solenoid valve via a relay.

[0013] Furthermore, the camera unit is a high-temperature resistant camera, and the front end of the high-temperature resistant camera lens is covered with a high-temperature resistant protective coating.

[0014] Furthermore, the double-layer water-cooled cavity includes an inner cooling cavity and an outer heat insulation layer arranged sequentially from the inside to the outside.

[0015] Furthermore, the inner cooling cavity is a water-cooled pipeline, and quick connectors are provided at the inlet and outlet of the water-cooled pipeline.

[0016] Furthermore, the air curtain blowing assembly is an annular nozzle assembly, which includes multiple compressed air nozzles arranged around the lens. The nozzle axis forms a certain angle with the center line of the lens, and the gas ejected from the nozzle can form an air curtain barrier covering the field of view of the high-temperature resistant camera lens.

[0017] Furthermore, the annular nozzle assembly is made of high-temperature resistant stainless steel.

[0018] Furthermore, the inlet receives circulating cooling water from the softened water tank circulation pump and discharges it at the outlet; the annular nozzle assembly receives compressed air from the plant area through the air inlet.

[0019] Furthermore, the emergency protection unit also includes: a base and a linear guide rail, wherein the linear guide rail and a cylinder are disposed on the base, the slider is movably connected to the linear guide rail, and the piston rod of the cylinder pushes the slider to move on the linear guide rail.

[0020] Furthermore, the interlocking triggering component includes a water flow sensor, a temperature sensor, and a pressure sensor. The water flow sensor is installed in the water cooling pipeline, the temperature sensor is installed on the outside of the high-temperature resistant camera lens, and the pressure sensor is installed in the compressed air main pipeline.

[0021] Furthermore, the water flow sensor, temperature sensor, and air pressure sensor are all hardwired to the cylinder solenoid valve via relays.

[0022] Furthermore, the pneumatic quick-closing valve is a pneumatic plug-in valve, which is connected to the pneumatic quick-closing valve solenoid valve through an air passage.

[0023] Secondly, this utility model also provides an electric furnace for smelting rock wool, comprising: a furnace body, wherein an insertion port is provided on the side wall of the furnace body, and the insertion port is equipped with the aforementioned high-temperature resistant visual monitoring device for rock wool electric furnace.

[0024] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0025] This utility model's high-temperature resistant visual monitoring device for rock wool electric furnaces employs multiple protection mechanisms, including a double-layer water-cooled cavity, a compressed air curtain barrier, and a mechanical emergency retraction mechanism, enabling it to simultaneously provide high-temperature protection, air curtain isolation, and emergency protection functions. It is suitable for monitoring the operating conditions of electric furnaces in high-temperature and dusty environments, achieving long-term stable monitoring of the furnace's operating conditions and ensuring equipment safety.

[0026] When any sensor exceeds its limit, the mechanical emergency retraction mechanism can quickly retract the camera into the safety chamber. At the same time, the pneumatic butterfly valve quickly closes the insertion port, and the pneumatic plug-in valve is synchronized with the cylinder drive through the interlocking circuit to ensure that the valve plate is completely closed after the camera retracts, preventing high-temperature airflow from entering and preventing damage to the camera during the retraction process. The retraction action does not rely on PLC control, but is directly driven by the mechanical interlocking circuit, with a response time of ≤3 seconds.

[0027] The double-layer water-cooled cavity can reduce the lens surface temperature to below 60°C, preventing the camera lens and electronic components from being easily burned out by high temperatures. The annular air curtain nozzle layout ensures that the blowing airflow evenly covers the lens, avoiding the problem of dust and molten metal splashes in the furnace adhering to the lens surface, which can lead to blurred images or even equipment blockage. This ensures that the entire rock wool production process can be clearly observed, improving the qualification rate of rock wool products. Attached Figure Description

[0028] Figure 1 A schematic diagram of the camera unit and protection unit structure for one or more embodiments;

[0029] Figure 2 A schematic diagram of an emergency protection unit structure for one or more implementations;

[0030] Figure 3 A schematic diagram of an air curtain purging assembly according to one or more embodiments;

[0031] Figure 4 A schematic diagram of a double-layer water-cooled cavity structure for one or more embodiments;

[0032] Figure 5 This is a schematic diagram of the structure of an interlocking trigger component with one or more implementations;

[0033] Figure 6 A schematic diagram of the circuit connection of the interlocking trigger component for one or more embodiments;

[0034] Among them, 1-high temperature resistant camera, 2-double-layer water-cooled cavity, 3.1-outer heat insulation layer, 3.2-inner cooling cavity, 3.3-water-cooled baffle, 3.4-circulating cooling water, 4-ring nozzle assembly, 5-compressed air nozzle, 5.1-air curtain, 6-lens hole, 7-high temperature resistant coating, 8-water inlet, 9-water outlet, 10-air inlet, 11-temperature sensor, 12-water flow sensor, 13-air pressure sensor, 14-pneumatic quick-closing valve, 15-mounting plate, 16-base, 17-cylinder, 18-linear guide rail, 19-slider, 20.1-cylinder solenoid valve, 20.2-pneumatic quick-closing valve solenoid valve, 21-fixed bracket, 22-clamp, 23-filter, 24-bypass valve. Detailed Implementation

[0035] It should be noted that the following detailed descriptions are exemplary and intended to provide further illustration of this application. Unless otherwise specified, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application pertains.

[0036] It should be noted that the terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments according to this application. As used herein, the singular form is intended to include the plural form as well, unless the context clearly indicates otherwise. Furthermore, it should be understood that when the terms "comprising" and / or "including" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or combinations thereof.

[0037] The terminology explanation section includes custom terms, uncommon terms, terms requiring clear explanation, and content related to cited literature. To make the objectives, technical solutions, and advantages of the embodiments of this invention clearer, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention. As mentioned above, in the rock wool production process, monitoring cameras in high-temperature environments are easily damaged by high temperatures or have dust and molten metal splashes adhering to the lens surface, leading to blurred images or even equipment blockage. Therefore, this invention proposes a high-temperature resistant visual monitoring device and electric furnace for rock wool electric furnaces, suitable for monitoring the operating conditions of electric furnaces in high-temperature and dusty environments, ensuring the safety and reliability of rock wool production.

[0038] like Figures 1-2 As shown, in a first aspect, this embodiment provides a high-temperature resistant visual monitoring device for a rock wool electric furnace, including: a camera unit, a protection unit, and an emergency protection unit; the camera unit is a high-temperature resistant camera 1, and the front end of the lens of the high-temperature resistant camera 1 is covered with a high-temperature resistant coating 7; the protection unit includes: a double-layer water-cooled cavity 2 and an air curtain blowing assembly 4, the double-layer water-cooled cavity 2 is coaxially sleeved on the outer surface of the high-temperature resistant camera 1, and the air curtain blowing assembly 4 is installed at the front end of the high-temperature resistant camera 1 to form an air curtain 5.1; the emergency protection unit includes: a cylinder 17, a slider 19, a fixing frame 21, a pneumatic quick-closing valve 14, and an interlock triggering assembly, the piston rod of the cylinder 17 is fixedly connected to the slider 19 to drive the slider 19 to move, one end of the fixing frame 21 is fixedly connected to the slider 19, and the other end is connected to the double-layer water-cooled cavity 2 through a clamp 22; the pneumatic quick-closing valve 14 is installed at the insertion port of the high-temperature resistant camera 1 on the outside of the electric furnace; the interlock triggering assembly is hardwired to the cylinder solenoid valve 20.1 through a relay;

[0039] Optionally, the high-temperature resistant camera 1 includes: at least three high-temperature resistant visible light cameras, evenly distributed in a 120° ring around the upper part of the furnace wall via flanges; and one infrared thermal imaging camera vertically mounted at the center monitoring hole on the furnace top, with its lens axis coinciding with the center line of the furnace chamber; the front ends of the lenses of the high-temperature resistant visible light cameras and the infrared thermal imaging camera are respectively covered with a first high-temperature resistant protective coating and a second high-temperature resistant protective coating.

[0040] Optionally, the first high-temperature resistant protective coating is sapphire high-temperature resistant glass; the second high-temperature resistant protective coating is a ceramic coating that prevents molten metal adhesion.

[0041] like Figure 4 As shown, the double-layer water-cooled cavity 2 includes an inner cooling cavity 3.2 and an outer heat insulation layer 3.1;

[0042] The inner cooling chamber 3.2 is a cooling pipe, through which circulating cooling water 3.4 is introduced; the chamber is provided with several staggered water-cooled baffles 3.3, which are welded and fixed to the inner wall of the chamber to form a meandering water flow channel, ensuring that the circulating cooling water 3.4 can fill the entire inner cooling chamber 3.2.

[0043] The inlet 8 is connected to the softened water tank circulation pump to provide circulating cooling water for the double-layer water-cooled cavity 2, and the outlet 9 is connected to the return water tank.

[0044] Quick connectors are installed at inlet 8 and outlet 9 respectively.

[0045] Understandably, the center of the double-layer water-cooled cavity 2 includes a mounting cavity that can accommodate the high-temperature resistant camera 1, and the high-temperature resistant camera 1 can be coaxially fitted into the mounting cavity of the double-layer water-cooled cavity 2;

[0046] Optionally, the outer insulation layer 3.1 is a thick ceramic fiber insulation layer.

[0047] A temperature sensor 11 is provided on the outer surface of the high-temperature resistant camera 1, and the monitoring threshold is set to 80℃.

[0048] Understandably, the temperature sensor 11 can be fixed to the housing of the high-temperature resistant camera 1 by a clamp to monitor the temperature of the high-temperature resistant camera 1.

[0049] like Figure 3 As shown, the air curtain blowing assembly is a ring nozzle assembly 4 coaxially sleeved on the front end of the high temperature resistant camera 1. The ring nozzle assembly 4 includes multiple compressed air nozzles 5 arranged around the lens and a lens hole 6.

[0050] Optionally, the annular nozzle assembly 4 is made of high-temperature resistant stainless steel;

[0051] Understandably, the air inlet 10 is connected to the annular nozzle assembly 4 through a flexible metal bellows to supply gas to the compressed air nozzle 5. The axis of the compressed air nozzle 5 forms a certain angle with the center line of the lens, and the ejected gas can form an air curtain 5.1 covering a field of view of 60-80°. The main pipeline in the plant provides a compressed air source with a pressure of 0.5±0.1MPa, which is filtered by the filter 23 and then delivered to the nozzle 5. The air pressure sensor 13 is installed on the main compressed air pipeline to detect the air pressure value.

[0052] Figure 2 As an emergency protection unit, a linear guide rail 18 and a cylinder 17 are installed on the base 16. A slider 19 is movably connected to the linear guide rail 18, which provides linear motion guidance for the slider 19. The piston rod of the cylinder 17 is rigidly connected to the slider 19, which can drive the slider 19 to move along the linear guide rail 18.

[0053] The emergency protection unit also includes a fixing frame 21, one end of which is fixedly connected to the slider 19 by bolts, and the other end is connected to the double-layer cooling cavity 3 by a clamp 22. The high-temperature resistant camera 1 can be coaxially fitted in the double-layer cooling cavity.

[0054] like Figure 5 As shown, the interlocking triggering component includes: a temperature sensor 11, a water flow sensor 12, and a pressure sensor 13. Each sensor is hardwired to the cylinder solenoid valve 20.1 via a relay. The circuit connection diagram is shown below. Figure 6 As shown;

[0055] Understandably, when the cylinder solenoid valve 20.1 receives the drive signal output by the relay, the motion is transmitted in the following order: the piston rod of the cylinder 17 moves linearly, pushing the slider 19 to slide synchronously on the linear guide rail 18. The slider 19 drives the high-temperature camera 1 to move as a whole through the fixed frame 21, and the displacement direction is parallel to the axis of the guide rail.

[0056] The emergency protection unit also includes a pneumatic plug-in valve 14, which is fixedly installed at the insertion port of the high-temperature resistant camera 1 on the furnace wall of the electric furnace via a mounting plate 15. The sealing surface of the valve plate is a 3mm thick graphite composite layer with a temperature resistance of ≥1300℃. The pneumatic plug-in valve 14 is hardwired to the pneumatic quick-closing valve solenoid valve 20.2 via a relay. When the system receives the signal that the high-temperature resistant camera 1 has exited, the pneumatic quick-closing valve solenoid valve 20.2 drives the pneumatic plug-in valve 14 to close the insertion port.

[0057] Optionally, the pneumatic slide gate valve is the PZ673W-10NR high-temperature resistant pneumatic slide gate valve.

[0058] The working principle of a high-temperature visual monitoring device for rock wool electric furnaces includes:

[0059] The inlet 8 of the double-layer water-cooled cavity 2 receives circulating cooling water 3.4 from the circulating pump of the softened water tank, forming a cooling pipeline in the inner cooling cavity 3.2 and discharging it at the outlet 9; the annular nozzle assembly 4 receives compressed air from the plant area through the air inlet 10, forming an airflow barrier covering the field of view of the lens at the nozzle 5.

[0060] High-temperature resistant camera 1 continuously monitors the state of the rock wool melt inside the furnace;

[0061] Water flow sensor 12 monitors cooling water flow in real time; temperature sensor 11 monitors the internal temperature of the water-cooled cavity in real time; air pressure sensor 13 monitors air curtain pressure in real time. Each sensor is hardwired to cylinder solenoid valve 20.1 via relays.

[0062] When any sensor detects that the current parameter exceeds the preset threshold, the alarm light will sound and light alarm, the relay will output a drive signal to the cylinder solenoid valve 20.1, the piston rod of the cylinder 17 will move linearly, pushing the slider 19 to slide synchronously on the guide rail 18, the slider 19 will drive the high temperature resistant camera 1 to retract outside the furnace through the fixing frame 21, the displacement direction is parallel to the axis of the guide rail, the relay will output a drive signal to the pneumatic quick-closing valve solenoid valve 20.2, and the pneumatic slide valve 14 will close the insertion port;

[0063] The system attempts to restore parameters. The system automatically controls the compressed air bypass valve 24 to open, increasing the amount of compressed air entering. If the parameters of each sensor return to normal (water flow sensor value not less than 3L / min, temperature sensor value not higher than 80℃, and air pressure sensor value not less than 0.3MPa), the relay outputs a drive signal to the cylinder solenoid valve 20.1. The cylinder 17 pushes the high-temperature resistant camera 1 to re-insert into the furnace. The relay outputs a drive signal to the cylinder solenoid valve 20.1, and the pneumatic slide gate valve 14 opens the insertion port, restoring the real-time monitoring function.

[0064] On the other hand, this embodiment also provides a rock wool electric melting furnace, including: a furnace body, an insertion port on the side wall of the furnace body, and the above-mentioned high temperature resistant visual monitoring device for rock wool electric furnace installed at the insertion port.

[0065] The above description is merely a preferred embodiment of this application and is not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A high-temperature resistant visual monitoring device for rock wool electric furnaces, characterized in that, include: Camera unit, protective unit, and emergency protection unit; The protective unit includes: a double-layer water-cooled cavity and an air curtain blowing assembly. The double-layer water-cooled cavity is coaxially sleeved on the outer surface of the camera unit, and the air curtain blowing assembly is installed at the front end of the camera unit to form a protective air curtain. The emergency protection unit includes: a cylinder, a slider, a fixed frame, a pneumatic quick-closing valve and an interlocking trigger assembly. The piston rod of the cylinder is fixedly connected to the slider and is used to drive the slider to move. One end of the fixed frame is fixedly connected to the slider, and the other end is connected to the double-layer water-cooled cavity through a clamp. The pneumatic quick-closing valve is installed at the camera unit insertion port on the outside of the electric furnace; The interlocking triggering component is hardwired to the cylinder solenoid valve via a relay.

2. The high-temperature visual monitoring device for rock wool electric furnace according to claim 1, characterized in that, The camera unit is a high-temperature resistant camera, and the front end of the high-temperature resistant camera lens is covered with a high-temperature resistant protective coating.

3. The high-temperature visual monitoring device for rock wool electric furnace according to claim 1, characterized in that, The double-layer water-cooled cavity includes an inner cooling cavity and an outer heat insulation layer arranged sequentially from the inside to the outside.

4. The high-temperature visual monitoring device for rock wool electric furnace according to claim 3, characterized in that, The inner cooling chamber is a water-cooled pipeline, with quick connectors installed at the inlet and outlet of the water-cooled pipeline.

5. The high-temperature visual monitoring device for rock wool electric furnace according to claim 4, characterized in that, The air curtain blowing assembly is an annular nozzle assembly, which includes multiple compressed air nozzles arranged around the lens. The nozzle axis forms a certain angle with the center line of the lens, and the ejected gas forms an air curtain barrier covering the field of view of the high-temperature resistant camera lens.

6. The high-temperature visual monitoring device for rock wool electric furnace according to claim 5, characterized in that, The inlet receives circulating cooling water from the softened water tank circulation pump and discharges it at the outlet; the annular nozzle assembly receives compressed air from the plant area through the air inlet.

7. The high-temperature visual monitoring device for rock wool electric furnace according to claim 1, characterized in that, The emergency protection unit further includes: a base and a linear guide rail. The linear guide rail and a cylinder are mounted on the base. The slider is movably connected to the linear guide rail. The piston rod of the cylinder pushes the slider to move on the linear guide rail.

8. The high-temperature visual monitoring device for rock wool electric furnace according to claim 2, characterized in that, The interlocking triggering component includes a water flow sensor, a temperature sensor, and a pressure sensor. The water flow sensor is installed on the water cooling pipeline, the temperature sensor is installed on the outside of the high-temperature resistant camera, and the pressure sensor is installed on the compressed air main pipeline.

9. The high-temperature visual monitoring device for rock wool electric furnace according to claim 1, characterized in that, The pneumatic quick-closing valve is a pneumatic plug-in valve, which is connected to the pneumatic quick-closing valve solenoid valve through an air pipeline.

10. An electric furnace for melting rock wool, characterized in that, include: The furnace body has an insertion port on its side wall, and the high-temperature visual monitoring device for rock wool electric furnace as described in any one of claims 1-9 is installed at the insertion port.

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