Device for widening the field of vision of the industrial television of the high-generation plate glass furnace

Abstract

The utility model belongs to glass industry technical field relates to a device that widens high generation plate glass kiln industrial television visual field. Including: refractory brick, inlay in kiln rear wall, the inside of refractory brick is equipped with the horn mouth shape channel that penetrates, the kiln front wall is set up with the kiln rear wall interval parallel, is equipped with the kiln front wall feeding port on the kiln front wall, and is equipped with a plurality of combustion gun nozzle bricks between the kiln rear wall and the kiln front wall, industrial television camera, penetrates round hole section, its camera front end is retracted in the round hole section export, the visual angle of industrial television camera covers the continuous monitoring area of kiln front wall feeding port and combustion gun nozzle brick, industrial television water -cooling plate, is fixed in the kiln rear wall outside, and is connected with industrial television camera. The utility model device not only prolongs the service life of camera, but also realizes the continuous visual monitoring to the kiln internal material mountain shape, liquid level fluctuation and combustion working condition, provides reliable equipment guarantee for kiln process predication, stable production and equipment maintenance.

Description

Technical Field

[0001] This utility model belongs to the field of glass industry technology and relates to a device for broadening the industrial television field of high-generation plate glass furnaces. Background Technology

[0002] With the trend of the flat panel display industry moving towards higher generations and larger sizes, the size and feed rate of substrate glass furnaces are continuously increasing to meet the production demands of large-size panels. The internal temperature of these furnaces is maintained above 1600℃ for extended periods, and the high-alkali molten glass is highly corrosive to refractory materials, resulting in an extremely harsh operating environment. Industrial television monitoring systems, as key equipment for real-time observation of the internal process status of the furnace, require lenses that penetrate the refractory bricks of the furnace's rear wall to capture images, providing visual data for production control. However, with the increasing size of furnaces, traditional industrial television installation structures have the following limitations: (1) Traditional trumpet-shaped viewing angle design is limited by the narrow observation channel and cannot fully cover the key process areas of large kilns, especially the operating status of the burner bricks. Since the shape of the material pile near the burner bricks and the fluctuation of the glass liquid surface directly affect the melting quality, the limited field of vision makes it difficult to detect process abnormalities in a timely manner, increasing the risk of production fluctuations.

[0003] (2) The refractory bricks in the high-temperature zone were originally made of re-sintered mullite. However, under long-term erosion by high-alkali glass melt and thermal shock, the inner wall of the observation channel is prone to deformation or glass phase seepage, resulting in channel blockage, blurred vision, or even complete failure. In addition, the erosion products of the refractory bricks may contaminate the lens, further reducing the reliability of the monitoring system.

[0004] (3) In the existing installation structure, there is a defect in the design of the gap between the lens and the brick. If the gap is too large, the lens will easily protrude from the surface of the brick and be directly exposed to the high temperature airflow or be covered with glass vapor condensate, causing thermal damage or coking of the lens; if the gap is too small, the lens will be squeezed and damaged due to the thermal expansion of the refractory brick. Utility Model Content

[0005] To address the problems in the existing technology, this utility model provides a device for expanding the field of view of industrial television in high-generation plate glass kilns, improving the monitoring coverage of key process areas in large-size kilns, extending the service life of the lens, and providing reliable equipment support for kiln process prediction, stable production, and equipment maintenance.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: This utility model provides a device for broadening the field of view of industrial television in high-generation plate glass furnaces, comprising: Refractory bricks are embedded in the rear wall of a kiln; the refractory bricks have a through funnel-shaped channel inside; the channel includes a round hole section and a funnel-shaped section, and the small-diameter ends of the round hole section and the funnel-shaped section are connected. The front wall of the kiln is arranged parallel to the rear wall of the kiln at intervals; the front wall of the kiln is provided with a feeding port, and multiple burner bricks are provided between the rear wall and the front wall of the kiln; the large-diameter end of the trumpet-shaped section faces the front wall of the kiln. An industrial television lens extends through the circular hole section, with its front end recessed at the outlet of the circular hole section. The field of view of the industrial television lens covers the continuous monitoring area of ​​the feeding port on the front wall of the kiln and the burner brick of the combustion gun. An industrial television water-cooled plate is fixed to the outer side of the rear wall of the kiln and connected to the industrial television lens.

[0007] Preferably, the angle between the axis of the funnel-shaped channel and the horizontal plane is 15°~25°.

[0008] Preferably, the viewing angle of the horn-shaped segment is 60°~120°.

[0009] Preferably, the refractory brick is made of fused α-β alumina, and its chemical composition, by mass percentage, satisfies Al2O3≥96% and SiO2≤4%.

[0010] Preferably, the resistivity of the fused α-β alumina at 1600°C is >900Ω. cm.

[0011] Preferably, the inner diameter of the circular hole section is clearance-fitted with the outer diameter of the industrial television lens.

[0012] Preferably, the length L1 of the circular hole segment and the length L2 of the industrial television lens satisfy the following condition: 0 < L1 - L2 ≤ 5 mm.

[0013] Preferably, the inner wall of the circular hole section is provided with a ceramic fiber buffer layer.

[0014] Preferably, a high-temperature resistant sealing gasket layer is provided between the industrial TV water-cooled plate and the rear wall of the kiln.

[0015] Preferably, it also includes an image analysis module; the image analysis module is electrically connected to the industrial television lens.

[0016] Compared with the prior art, the present invention has the following beneficial effects: This invention enables comprehensive monitoring of key process areas within a high-generation plate glass furnace. The funnel-shaped channel within the refractory bricks, through an optimized combination of circular and funnel-shaped sections, provides precise installation and positioning for the industrial television lens and creates an ideal observation optical path. The funnel-shaped design, extending towards the furnace's front wall, significantly widens the monitoring field of view, allowing a single image to simultaneously cover the material distribution at the feeding port and the operating status of multiple combustion lances. The lens tip being recessed within the circular section outlet effectively prevents the adhesion of high-temperature condensates, forming a dual protection mechanism in conjunction with the external water-cooling plate. This invention not only extends the lens's lifespan but also enables continuous visual monitoring of the furnace's internal material pile morphology, liquid level fluctuations, and combustion conditions, providing reliable equipment support for furnace process prediction, stable production, and equipment maintenance. Attached Figure Description

[0017] To more clearly illustrate the technical solutions of the embodiments of this utility model, the accompanying drawings used in the embodiments will be briefly introduced below. It should be understood that the following drawings only show some embodiments of this utility model and should not be regarded as a limitation on the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 The front view of the device for expanding the industrial television field of view of high-generation plate glass furnaces according to this utility model; Figure 2 A top view of the device for expanding the industrial television field of view of high-generation plate glass furnaces according to this utility model; Figure 3 This is a schematic diagram of the TV brick of this utility model.

[0019] Among them: 1. Refractory bricks; 2. Kiln rear wall; 3. Burner bricks; 4. Kiln front wall; 5. Kiln front wall feeding port; 6. Kiln liquid level line; 7. Horn mouth section field of view; 8. Industrial TV lens; 9. Industrial TV water cooling plate. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. The components of the embodiments of this utility model described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0021] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0022] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.

[0023] In the description of the embodiments of this utility model, it should be noted that if terms such as "upper," "lower," "horizontal," or "inner" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the utility model product is in use, they are only for the convenience of describing the utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation on the utility model. Furthermore, terms such as "first" and "second" are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0024] Furthermore, the use of the term "horizontal" does not imply that the component must be absolutely horizontal, but rather that it can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal than "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0025] In the description of the embodiments of this utility model, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," "connect," and "link" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0026] The present invention will now be described in further detail with reference to the accompanying drawings: The primary objective of this invention is to provide a device for broadening the field of view in industrial television broadcasts of high-generation plate glass furnaces, characterized in that, as Figures 1-3 As shown, it includes: Refractory brick 1 is embedded in the rear wall 2 of the kiln; the interior of refractory brick 1 has a through funnel-shaped channel; the channel includes a round hole section and a funnel-shaped section, and the small-diameter ends of the round hole section and the funnel-shaped section are connected. The front wall 4 of the kiln is set parallel to the rear wall 2 of the kiln at intervals; the front wall 4 of the kiln is provided with a feeding port 5, and multiple burner bricks 3 are provided between the rear wall 2 and the front wall 4 of the kiln; the large-diameter end of the trumpet section faces the front wall 4 of the kiln. Industrial television lens 8 penetrates the circular hole section, with its front end recessed at the outlet of the circular hole section. The field of view of industrial television lens 8 covers the continuous monitoring area of ​​the feeding port 5 on the front wall of the kiln and the burner brick 3. The industrial television water-cooled plate 9 is fixed to the outside of the rear wall 2 of the kiln and connected to the industrial television lens 8.

[0027] This utility model provides a device for expanding the field of view of an industrial television camera in a high-generation plate glass kiln. Through multi-component collaborative design, it achieves comprehensive monitoring of the internal process status of the kiln and long-term stable operation of the equipment. The refractory brick 1 serves as the core supporting structure. Its trumpet-shaped channel design (a combination of round hole sections and trumpet sections) maximizes the field of view of the industrial television lens 8, fully covering the material distribution at the feeding port 5 on the front wall of the kiln and the working status of the burner brick 3. This forms a continuous monitoring network for key process parameters such as material pile stability and flame symmetry, overcoming the limitations and lag of traditional manual observation. Simultaneously, the recessed installation prevents the lens from being directly exposed to high-temperature areas, significantly reducing the risk of glass condensate adhesion. The industrial television water-cooled plate 9 maintains stable lens temperature through an active heat dissipation mechanism, extending equipment life and preventing image distortion caused by high temperatures. Its thermal insulation performance, combined with that of the refractory brick 1, provides dual protection, ensuring that the monitoring system can still output clear and continuous real-time images in environments above 1600℃, providing intuitive data for process adjustments and equipment maintenance.

[0028] The angle between the axis of the funnel-shaped channel and the horizontal plane is 15°~25°, providing the industrial television lens 8 with a more optimized observation angle. This tilted structure allows the lens to naturally align with the key process area between the feeding port 5 on the front wall of the kiln and the burner brick 3, avoiding monitoring blind spots that may be caused by a horizontal perspective and preventing direct impact of high-temperature airflow on the lens from a vertical perspective. The tilted channel structure facilitates the natural sliding of condensate, reducing obstruction of the field of view. In addition, the field of view 7 of the funnel section is 60°~120°. This field of view range allows the industrial television lens to simultaneously and clearly capture key process parameters such as material distribution at the feeding port, combustion status of the burner, and dynamics of the molten glass surface, completely eliminating the blind spots present in traditional monitoring methods. This not only ensures continuous observation of the entire process from the front wall 4 to the rear wall 2 of the kiln, but also allows operators to more intuitively grasp the changing trends of the material pile morphology, providing a complete visual basis for precise control of the kiln's operating conditions.

[0029] As shown in Table 1, different flare sizes correspond to specific viewing angle ranges. On the one hand, they completely cover the main shape inside the kiln and the working area of ​​the combustion gun during normal operation, achieving blind-spot-free intelligent monitoring. On the other hand, by optimizing the viewing angle, they avoid the problem of condensate adhesion caused by lens extension and prevent the lens from being in a high-temperature environment for a long time, thus significantly extending the service life of the industrial television lens 8.

[0030] Table 1. Field of view angle range corresponding to different flare end sizes

[0031] Refractory brick 1 is made of fused α-β alumina. By mass percentage, its chemical composition meets the requirements of Al2O3≥96%, SiO2≤4%, and its resistivity at 1600℃>900Ω. This material effectively resists corrosion from high-temperature molten glass and acidic / alkaline atmospheres in extreme furnace environments, ensuring the long-term reliability of industrial television installation structures. Its unique high-resistivity characteristics prevent current interference that may occur in high-temperature environments, ensuring the stability of monitoring signals. Simultaneously, its dense structure effectively blocks direct heat radiation damage to the lens.

[0032] The inner diameter of the circular aperture section is fitted with the outer diameter of the industrial television lens 8 to ensure the radial stability of the lens under high-temperature conditions, preventing displacement caused by vibration or airflow impact. It also provides a reasonable clearance for thermal expansion, avoiding mechanical stress caused by material expansion differences under high-temperature conditions. Furthermore, given that the length of the industrial television lens 8 ranges from 245 to 255 mm and the length of the industrial television water-cooled plate 9 ranges from 330 to 350 mm, the length L1 of the circular aperture section and the length L2 of the industrial television lens 8 should satisfy: 0 < L1 - L2 ≤ 5 mm. The design of the lens tip being recessed within 5 mm of the circular aperture section outlet ensures optimal field of view while keeping the lens tip in a relatively low-temperature region. This effectively reduces the risk of high-temperature molten material adhering to the lens surface and prevents the lens from excessively extending into the kiln and being directly exposed to high-temperature radiation, creating ideal working conditions for the long-term stable operation of the industrial television system.

[0033] The inner wall of the circular hole section is equipped with a ceramic fiber buffer layer. This buffer layer not only effectively absorbs the thermal expansion difference between the lens and the refractory brick 1, avoiding structural stress damage caused by temperature fluctuations, but its porous structure also forms a thermal insulation barrier, significantly reducing the impact of high temperature on the lens's thermal radiation. Meanwhile, a high-temperature resistant sealing gasket is provided between the industrial television water-cooled plate 9 and the kiln rear wall 2. This high-temperature resistant sealing gasket is preferably made of electrofused α-β alumina, providing the water-cooling system with multiple protections including thermal isolation, electrical insulation, and mechanical protection.

[0034] This utility model device also includes an image analysis module, which is electrically connected to the industrial television lens 8. The image analysis module is configured to perform the following: based on the image sequence captured by the industrial television lens 8, identify the real-time fluctuation amplitude of the kiln liquid level line 6 using an edge detection algorithm. The flame pattern of the burner brick 3 was determined to deviate from the preset combustion parameters by analyzing the flame color spectrum; the outline of the material pile was extracted using image segmentation technology, and the standard deviation of the material pile height distribution was calculated. .

[0035] When process parameters are detected to exceed the safety threshold ( >First preset threshold, abnormal flame pattern and When the level reaches the second preset threshold, the system automatically triggers a graded alarm mechanism, enabling operators to take precise control measures for different working conditions such as liquid level fluctuations, abnormal combustion, or uneven material distribution.

[0036] The installation method of this utility model device includes the following steps: A funnel-shaped channel is machined into the refractory brick 1. A CNC machine tool is used to ensure that the diameter of the circular hole section and the outer diameter of the industrial television lens 8 form a clearance fit of 0.5~1mm. This design ensures the positioning accuracy of the lens and provides a safety margin for high-temperature expansion. The inner wall of the circular hole section needs to be sprayed with a ceramic fiber buffer layer to absorb thermal stress and reduce the damage of heat radiation to the lens. The pre-treated refractory brick 1 is embedded into the pre-set hole in the rear wall 2 of the kiln. High-temperature mortar (temperature resistance ≥1600℃) is used to fill the gap between the brick and the furnace wall to ensure airtightness. When the industrial television lens 8 passes through the circular hole section of the refractory brick 1, it is necessary to ensure that the front end of the lens is recessed within 5mm of the outlet. This design can effectively prevent high-temperature condensates (such as glass vapor deposition) in the kiln from adhering to the lens. The focus is adjusted by real-time image until the continuous monitoring area of ​​the feeding port 5 on the front wall of the kiln and the burner brick 3 of the lance is clearly displayed simultaneously. Then, the industrial TV water-cooled plate 9 is fastened to the mounting base on the outside of the kiln rear wall 2 through the flange structure, and connected to the industrial TV lens 8. At the same time, the industrial TV water-cooled plate 9 is also connected to the cooling water pipe.

[0037] The above are merely preferred embodiments of this utility model and are not intended to limit the scope of this utility model. Various modifications and variations can be made to this utility model by those skilled in the art. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A device for broadening the field of view of industrial television in high-generation plate glass furnaces, characterized in that, include: Refractory brick (1) is embedded in the rear wall (2) of the kiln; the refractory brick (1) has a through funnel-shaped channel inside; the channel includes a round hole section and a funnel-shaped section, and the small diameter end of the round hole section and the funnel-shaped section are connected. The front wall (4) of the kiln is arranged parallel to the rear wall (2) of the kiln at intervals; the front wall (4) of the kiln is provided with a feeding port (5), and multiple burner bricks (3) are provided between the rear wall (2) of the kiln and the front wall (4); the large-diameter end of the trumpet section faces the front wall (4) of the kiln. An industrial television lens (8) penetrates the circular hole section, with its front end recessed at the outlet of the circular hole section. The field of view of the industrial television lens (8) covers the continuous monitoring area of ​​the feeding port (5) on the front wall of the kiln and the burner brick (3). The industrial television water-cooled plate (9) is fixed to the outside of the rear wall (2) of the kiln and connected to the industrial television lens (8).

2. The device for broadening the field of view of industrial television in high-generation plate glass furnaces according to claim 1, characterized in that, The angle between the axis of the funnel-shaped channel and the horizontal plane is 15°~25°.

3. The device for broadening the field of view of industrial television in high-generation plate glass furnaces according to claim 1, characterized in that, The field of view (7) of the horn-shaped section is 60°~120°.

4. The device for broadening the field of view of industrial television in high-generation plate glass furnaces according to claim 1, characterized in that, The refractory brick (1) is made of fused α-β alumina, and its chemical composition, by mass percentage, satisfies Al2O3≥96% and SiO2≤4%.

5. The device for broadening the field of view of industrial television in high-generation plate glass furnaces according to claim 4, characterized in that, The resistivity of the fused α-β alumina at 1600℃ is >900Ω. cm.

6. The device for broadening the field of view of industrial television in high-generation plate glass furnaces according to claim 1, characterized in that, The inner diameter of the circular hole section is clearance-fitted with the outer diameter of the industrial television lens (8).

7. The device for broadening the field of view of industrial television in high-generation plate glass furnaces according to claim 1, characterized in that, The length L1 of the circular hole segment and the length L2 of the industrial television lens (8) satisfy: 0 < L1 - L2 ≤ 5 mm.

8. The device for broadening the field of view of industrial television in high-generation plate glass furnaces according to claim 1, characterized in that, The inner wall of the circular hole section is provided with a ceramic fiber buffer layer.

9. The device for broadening the field of view of industrial television in high-generation plate glass furnaces according to claim 1, characterized in that, A high-temperature resistant sealing gasket is provided between the industrial TV water-cooled plate (9) and the kiln rear wall (2).

10. The device for broadening the field of view of industrial television in high-generation plate glass furnaces according to claim 1, characterized in that, It also includes an image analysis module; the image analysis module and the industrial television lens (8) are electrically connected.

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