A digitized kiln

Abstract

The application belongs to the technical field of kiln, and specifically discloses a digital kiln, which comprises a kiln body for carrying raw materials for melting; a sensing assembly connected with the kiln body in a matched mode, comprising an in-furnace pressure sensor, a temperature sensor, a material weight sensor and a gas flow sensor; a control module electrically connected with the sensing assembly and used for receiving detection signals of the sensing assembly; an execution assembly comprising a gas regulating valve arranged on a gas delivery pipeline and a combustion-supporting gas regulating valve arranged on a combustion-supporting pipeline, the execution assembly being electrically connected with the control module; and a data transmission and storage assembly electrically connected with the control module and used for sending detection data and control signals to a cloud or a customer terminal platform. The digital kiln is completely free from dependence on manual experience, realizes digital linkage of raw materials, parameters and gas, solves the problem that traditional furnace parameters cannot be checked, and provides support for production tracing and optimization.

Description

Technical Field

[0001] This application relates to the field of kiln technology, and more particularly to a digital kiln. Background Technology

[0002] Industrial aluminum processing furnaces are industrial thermal equipment specifically designed to heat and melt solid aluminum raw materials (aluminum ingots, aluminum chips, scrap aluminum, etc.) into liquid aluminum. They are a core link in the aluminum processing industry chain, providing basic raw materials for subsequent processes such as casting, forging, and extrusion.

[0003] Traditional furnace charging requires manual weighing before adding materials, which inevitably introduces some errors, resulting in different qualities of molten aluminum between furnaces. Furthermore, different qualities of raw materials require different amounts of gas. Therefore, it is crucial to accurately plan the amount of gas introduced after changes in raw material quality and proportions. In addition, ensuring that the furnace temperature and pressure are in the optimal smelting state for efficient smelting is often judged by experience or observation. While this has some positive significance, it is far from achieving precise control.

[0004] In addition, traditional furnaces are equipped with smoke and dust removal pipelines to meet the environmental protection requirements of the furnaces. Specifically, a main dust removal pipeline is set up in the factory and connected to multiple furnaces through branch pipes. The entire dust removal equipment has a very high power, but when only a few furnaces are started, the dust removal equipment also needs to be started at the same time, which is very costly.

[0005] Therefore, it is necessary to provide a digital kiln that can precisely control production. Utility Model Content

[0006] The purpose of this application is to provide a digital kiln to solve the above-mentioned problems.

[0007] To achieve the above objectives, the technical solution of this application is as follows: A digital kiln, comprising: The kiln body is used to support the melting of raw materials; The sensing components, which are connected in conjunction with the kiln body, include an in-furnace pressure sensor, a temperature sensor, a material weight sensor, and a gas flow sensor. The control module, electrically connected to the sensing component, is used to receive the detection signals from the sensing component. The execution component includes a gas regulating valve installed on the gas transmission pipeline and a combustion-supporting gas regulating valve installed on the combustion-supporting pipeline, and the execution component is electrically connected to the control module; A data transmission and storage component, which is electrically connected to the control module, is used to send detection data and control signals to the cloud or a client terminal platform.

[0008] Preferably, the furnace pressure sensor is disposed on the outer wall of the kiln body, and the detection end is located inside the combustion chamber of the kiln body.

[0009] Preferably, it also includes a hot flue pipe, which is configured to exchange heat with the combustion-supporting pipe to increase the temperature of the combustion-supporting gas.

[0010] Preferably, the temperature sensor includes a combustion-supporting air duct thermocouple, a hot flue thermocouple, and a furnace top thermocouple. The combustion-supporting air duct thermocouple is installed on the combustion-supporting pipe, the hot flue thermocouple is installed on the hot flue pipe, and the furnace top thermocouple is installed on the outer wall of the kiln body, with the detection end located inside the kiln body.

[0011] Preferably, the material weight sensor is located below the kiln body.

[0012] Preferably, the gas regulating valve is an electromagnetic regulating valve, the combustion-supporting gas regulating valve is an electric regulating valve, and the opening signals of the electromagnetic regulating valve and the electric regulating valve are output by the control module.

[0013] Preferably, it also includes a dust collection component, which is disposed above the hydraulic furnace door of the kiln body.

[0014] Preferably, a screw conveyor is provided below the dust collection assembly, the screw conveyor being used to transport and collect the absorbed material.

[0015] The digital kiln disclosed in this application achieves precise control of the raw material melting process through the coordinated work of various components, completely eliminating reliance on manual experience and realizing digital linkage of raw materials, parameters, and gas. This solves the problem of untraceable parameters in traditional kilns and provides support for production traceability and optimization. Attached Figure Description

[0016] Figure 1 This is a front view of the overall structure of this application; Figure 2 This is a left view of the overall structure of this application; Figure 3 This is a block diagram illustrating the control principle of this application.

[0017] In the picture: 1. Kiln body; 10. Kiln top thermocouple; 11. Kiln internal pressure sensor; 2. Combustion aid pipe; 20. Combustion aid air duct thermocouple; 3. Hot flue pipe; 30. Hot flue thermocouple; 4. Hydraulic furnace door; 5. Dust collection assembly; 50. Dust collection hood; 51. Dust collection pipe; 52. Filter bag; 53. Screw conveyor; 54. Exhaust fan; 55. Exhaust duct; 56. Dust collection area; 57. Exhaust duct area; 6. Weighing sensor; 7. Burner. Detailed Implementation

[0018] The present application will now be described in further detail with reference to the accompanying drawings. The drawings are simplified schematic diagrams, illustrating only the basic structure of the present application, and therefore only show the components relevant to the present application.

[0019] like Figure 1-3 As shown, a digital kiln includes: The kiln body 1 is used to support solid aluminum raw materials and realize their melting process.

[0020] The sensing components, which are connected to the kiln body 1, include an in-furnace pressure sensor 11, a temperature sensor, a material weight sensor, and a gas flow sensor; the gas flow sensor is connected in series with the gas pipeline; each sensor is securely connected to the kiln body 1 and the pipeline through a standardized interface, so as to collect various key parameters inside the kiln in real time.

[0021] The control module, electrically connected to the sensing component, is used to receive the detection signals from the sensing component and to analyze and process them according to preset algorithms and logic.

[0022] The control module can be an industrial-grade PLC, which can be installed in a control box on one side of the kiln body 1 and electrically connected to each sensor through shielded wires.

[0023] The execution components include a gas regulating valve installed on the gas transmission pipeline and a combustion-supporting gas regulating valve installed on the combustion-supporting pipeline 2. The execution components are electrically connected to the control module. Specifically, the gas valve and the combustion-supporting gas valve are respectively installed on the corresponding pipelines and are both connected to the PLC output terminal.

[0024] The data transmission and storage component is electrically connected to the control module and is used to send detection data and control signals to the cloud or client terminal platform, facilitating remote monitoring and management by users.

[0025] The data transmission and storage components are integrated into the control box, including a communication module and a local storage unit, enabling real-time data upload to the cloud and local storage.

[0026] This digital kiln achieves precise control over the raw material melting process through the coordinated operation of the aforementioned components, completely eliminating reliance on manual experience and realizing digital linkage of raw materials, parameters, and gas. This solves the problem of untraceable parameters in traditional kilns and provides support for production traceability and optimization.

[0027] In some further embodiments, the furnace pressure sensor 11 is disposed on the outer wall of the kiln body 1, and the detection end is located in the combustion chamber inside the kiln body 1.

[0028] The furnace pressure sensor 11 is installed through a pre-set threaded hole on the top of the furnace wall, with its position directly facing the core area of ​​the combustion chamber to avoid local pressure interference.

[0029] The detection end of the furnace pressure sensor 11 extends into the furnace by an appropriate length, contacting the core area while avoiding splashing molten aluminum. Compared to traditional side mounting, top mounting avoids high-temperature radiation from the molten pool, extending the sensor's lifespan; the precise depth of the detection end reduces detection fluctuations caused by airflow disturbances, providing reliable data for combustion gas regulation.

[0030] In some further embodiments, a hot flue pipe 3 is also included, which is configured to exchange heat with the combustion-supporting pipe 2 to increase the temperature of the combustion-supporting gas.

[0031] The hot flue pipe 3 and the combustion-supporting pipe 2 can adopt a shell-and-tube heat exchange structure or other common heat exchange structures.

[0032] One end of the hot flue connects to the furnace exhaust port, and the other end connects to the main exhaust system of the plant. Temperature detection points are installed at both the inlet and outlet ends. This structure fully recovers the waste heat of the high-temperature flue gas, increases the temperature of the combustion-supporting gas, and reduces gas consumption. At the same time, the preheated combustion-supporting gas can improve combustion efficiency, reduce pollutant emissions, and solve the problem of waste heat from flue gas in traditional furnaces.

[0033] The combustion-supporting pipe 2 is connected to the burner 7 and is used to introduce oxygen (air). In some further embodiments, the temperature sensor includes a combustion air duct thermocouple 20, a hot flue thermocouple 30, and a furnace top thermocouple 10. The combustion air duct thermocouple 20 is installed on the combustion air duct 2, the hot flue thermocouple 30 is installed on the hot flue pipe 3, and the furnace top thermocouple 10 is installed on the outer wall of the kiln body 1, with the detection end located inside the kiln body 1.

[0034] All temperature sensors are high-temperature resistant thermocouples, equipped with removable ceramic protective tubes for easy maintenance. The combustion air duct thermocouple 20 is fixed to the combustion air duct 2 to detect the temperature of the combustion gas after heat exchange; the hot flue gas thermocouple 30 is installed on the hot flue gas duct 3 to monitor the flue gas temperature before heat exchange; the furnace top thermocouple 10 is fixed through a hole in the furnace top, with its sensing end extending into the center of the combustion chamber to reflect the true furnace temperature. All thermocouple cables are run through high-temperature resistant flexible tubing to the control box to prevent high-temperature aging.

[0035] Multi-point detection enables full-link monitoring of "gas-flue gas-furnace". The control module can comprehensively judge the operating conditions based on multiple sets of data and accurately adjust the gas supply, avoiding the temperature fluctuation problem caused by traditional single detection.

[0036] In some further embodiments, the material weight sensor is located below the kiln body 1.

[0037] The material weight sensor uses multiple sets of weighing sensors 6, which are evenly installed between the furnace body support feet and the foundation, so that the force is evenly distributed.

[0038] Compared to traditional single-feeding bin detection, the sensor below the furnace directly measures the actual mass inside the furnace, avoiding feeding residue and spillage errors. This provides reliable data for the control module to accurately calculate gas demand, solving the problem of gas waste or insufficient smelting caused by large errors in traditional manual weighing.

[0039] In some further embodiments, the gas regulating valve is an electromagnetic regulating valve, the combustion-supporting gas regulating valve is an electric regulating valve, and the opening signals of the electromagnetic regulating valve and the electric regulating valve are output by the control module.

[0040] Gas regulating valves can be direct-acting electromagnetic regulating valves, while auxiliary gas regulating valves can be electric regulating valves, specifically electric gate valves. These are connected in series with the corresponding pipeline via flanges, and the flange connections are sealed to prevent leakage.

[0041] Electromagnetic and electric regulating valves receive current signals from the control module to adjust their opening degree. Their built-in feedback module transmits the actual opening degree back to the control module, forming a closed-loop regulation system. Compared to traditional manual or pneumatic valves, electromagnetic and electric regulating valves offer faster response and higher precision, quickly responding to control commands to ensure stable furnace temperature and avoid aluminum melt quality problems caused by the lag in traditional regulation methods.

[0042] In some further embodiments, a dust collection assembly 5 is also included, which is disposed above the hydraulic furnace door 4 of the kiln body 1.

[0043] The dust collection assembly 5 can be a bag filter and also includes a dust collection hood 50. The dust collection hood 50 is provided with a dust collection pipe 51. One end of the dust collection pipe 51 is located in the dust collection hood 50, and the other end is connected to the dust collection area 56. The dust collection area 56 is provided with multiple filter bags 52. The filter bags 52 are fitted on the filter bag 52 frame. An air duct 57 is provided above the filter bags 52. The air duct 57 is connected to the fan 54 through an air duct 55.

[0044] By equipping the kiln body 1 with a separate dust collection component 5, the dust removal cost can be greatly reduced. Compared with the unified dust removal method in traditional equipment, the separate dust collection component 5 makes the use of the kiln body 1 more flexible.

[0045] In some further embodiments, a screw conveyor 53 is provided below the dust collection assembly 5 for conveying and collecting the absorbed material.

[0046] The screw conveyor 53 has an opening at the top of its conveying pipe, which is located below the filter bag 52 in the dust collection area 56. When it is necessary to remove the filtered material attached to the outside of the filter bag 52, the material can be blown down by backflushing so that it falls into the conveying pipe and is conveyed and collected for unified recycling.

[0047] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this application.

Claims

1. A digital kiln, characterized in that, include: The kiln body (1) is used to support the melting of raw materials; The sensing components are connected in conjunction with the kiln body (1) and include an in-furnace pressure sensor (11), a temperature sensor, a material weight sensor and a gas flow sensor. The control module, electrically connected to the sensing component, is used to receive the detection signals from the sensing component. The execution component includes a gas regulating valve installed on the gas transmission pipeline and a combustion-supporting gas regulating valve installed on the combustion-supporting pipeline (2), and the execution component is electrically connected to the control module; A data transmission and storage component, which is electrically connected to the control module, is used to send detection data and control signals to the cloud or a client terminal platform.

2. The digital kiln according to claim 1, characterized in that, The furnace pressure sensor (11) is installed on the outer wall of the kiln body (1), and the detection end is located in the combustion chamber inside the kiln body (1).

3. The digital kiln according to claim 1, characterized in that, It also includes a hot flue pipe (3), which is heat exchanged with the combustion-supporting pipe (2) to increase the temperature of the combustion-supporting gas.

4. The digital kiln according to claim 3, characterized in that, The temperature sensor includes a combustion air duct thermocouple (20), a hot flue thermocouple (30), and a furnace top thermocouple (10). The combustion air duct thermocouple (20) is installed on the combustion air duct (2), the hot flue thermocouple (30) is installed on the hot flue pipe (3), and the furnace top thermocouple (10) is installed on the outer wall of the kiln body (1), with the detection end located inside the kiln body (1).

5. The digital kiln according to claim 1, characterized in that, The material weight sensor is located below the kiln body (1).

6. The digital kiln according to claim 1, characterized in that, The gas regulating valve is an electromagnetic regulating valve, and the combustion-supporting gas regulating valve is an electric regulating valve. The opening signals of the electromagnetic regulating valve and the electric regulating valve are output by the control module.

7. The digital kiln according to claim 1, characterized in that, It also includes a dust collection component (5), which is disposed above the hydraulic furnace door (4) of the kiln body (1).

8. The digital kiln according to claim 7, characterized in that, Below the dust collection assembly (5) is a screw conveyor (53) for conveying and collecting the absorbed material.

Images