The glass toughening equipment unit is mainly composed of four parts: discharge section, convection heating section, flat toughening section, and extraction section, as well as high-pressure centrifugal fan, air supply pipeline, air collection box, air circuit, electrical control cabinet, operation console, etc.
The forced convection tempering unit adopts a unique spray flow increasing technology, which mixes hot air from the furnace with preheated compressed air in the nozzle, greatly increasing the temperature of the airflow sprayed towards the glass surface by the nozzle. The forced convection circulation of hot air in the furnace is enhanced, and the uniformity and stability of the furnace temperature are improved, resulting in better heating effect of the glass in the furnace. Compared with general compressed air convection models, compressed air consumption is reduced by more than half.
The transmission of each part of the unit adopts AC frequency conversion technology, with motor drive and adjustable reciprocating drive speed; Each department
Tempering Equipment Atlas (7 sheets)
The operation of the bit is automatically completed by a control system composed of an industrial computer and PLC; The air pressure of the air supply system is automatically adjusted, the upper and lower air grilles are electrically opened and closed, the air volume is electrically balanced, and the main air valve is automatically turned on and off; The main drive of the furnace body and air grille adopts an O-ring belt drive, among which the furnace body adopts a triple composite drive synchronous technology, namely an orthogonal circular drive belt and an interconnected circular drive belt; The main transmission of the input and output stages adopts chain transmission, with a simple and reliable structure;
When the main transmission of the furnace body and air grille is in a power outage state, manual emergency discharge function can be added, and emergency power can also be added according to customer needs
The source device ensures the low-speed operation of the ceramic roller table of the furnace body after a power outage.
Heating section
It mainly consists of heating furnace body, transmission system, lifting system, etc.
The framework of the heating furnace body is welded from high-quality section steel and steel plates according to national standards, with high strength, good rigidity, compact and firm structure. The furnace body is divided into upper and lower parts, and the upper furnace body can be remotely raised to facilitate roller installation, replacement, maintenance, and furnace cleaning. The furnace lining is made of high-quality aluminum silicate refractory fiber compression board, which has characteristics such as low thermal conductivity, good insulation effect, low density, and low heat storage loss. It also adopts unique pre tightening anchoring technology, significantly reducing heat dissipation and thermal short circuit of the furnace body, effectively reducing the surface temperature of the furnace body, and improving thermal efficiency.
The ceramic roller table in the furnace adopts world-renowned products, and the transmission mechanism adopts circular transmission belt and linkage synchronous transmission belt, greatly improving transmission accuracy, reducing the impact of transmission system vibration on the ceramic roller table, eliminating deviation, and minimizing scratches caused by asynchronous transmission. There is a high-performance patented heater inside the furnace, with more heating zones and more uniform temperature inside the furnace; The surface power of the heating element is low, and the thermal shock resistance is good, with a longer lifespan.
When the glass enters the furnace, the furnace door opens, and the conveyor roller for placing fragments and the ceramic roller in the furnace synchronously drive the glass into the furnace; Afterwards, the furnace door closed. The glass is driven by a roller in the furnace and oscillates back and forth within the set effective range, ensuring uniform heating of the glass and better heating quality; At the same time, it ensures that the ceramic roller table does not deform or bend, and the overall service life of the furnace is long.
Heating furnace features:
1. Unique ceramic roller drive synchronization device: Although the orthogonal belt drive reduces the impact of the transmission process on the ceramic roller drive, the synchronization of the roller drive cannot be fully guaranteed due to the 180 degree wrap angle of the single stage drive, as well as manufacturing and installation errors. Due to the asynchrony of the ceramic roller table, when the glass moves back and forth in the furnace, there will be relative sliding between the glass and the roller table, causing small scratches on the lower surface of the glass; When heating multiple pieces of glass at the same time, position deviation or collision may occur; In order to solve this problem, we adopted the synchronous technology of roller table composite transmission, which is an orthogonal circular transmission belt and an interconnected circular transmission belt. In this way, the belt wrap angle on each ceramic roller table reaches 540 degrees (and is subject to triple drive), even if there is a problem of individual transmission belt breakage, there will be no quality accidents, so that the synchronization and reliability of the transmission are completely solved, ensuring synchronous transmission of all rollers, thereby greatly improving heating quality and yield. The glass has no slip on the roller table, and the ceramic roller table bearings must not have the problem of running the inner ring, and can reduce ① white fog; ② Accurate positioning, smooth forward and reverse steering, effectively reducing comet like scratches caused by friction between the lower surface of the glass and the roller table Extend the service life of the ceramic roller table;
2. Roller transport mechanism: The equipment is equipped with a specialized ceramic roller transport mechanism. With this mechanism, people can complete the disassembly of the ceramic roller without entering the furnace, which is fast and convenient, and saves more than half of the furnace maintenance time.
3. First-class insulation technology: The use of high-density insulation boards, coupled with the use of insulation anchoring to eliminate thermal short circuits, makes the insulation effect even better. At room temperature, the temperature of the outer surface of the furnace does not exceed 50 ℃. After a power outage for 12 hours, the temperature drop of the furnace is only 150 degrees, and the set temperature can be reached after 30 minutes of heating.
4. Optimal roller table design
Due to the continuous oscillation of glass on the ceramic roller table during heating, the material, surface condition, and specifications of the ceramic roller table all affect the quality of glass heating. During the entire tempering process, the quality of ceramic rollers has a significant impact. Therefore, we use imported high-precision siliceous ceramic rollers with fine workmanship, high surface processing accuracy, strong bending resistance, and large effective load, resulting in fewer heating defects.
Flat tempered section
The flat steel section is composed of a cooling air grid, a conveying roller track, and a collecting box.
The nozzle of the actual shot air grille of the tempering furnace is made of alloy, and the cooling air grille is divided into upper and lower parts, which are respectively connected to the air distribution center. Intelligent control is achieved, and the distance between the air grille and the glass can be automatically adjusted according to the thickness of the glass, so that the spraying distance is always at the optimal value, thus achieving the best cooling effect. The upper and lower air grilles are respectively composed of several air distribution grilles in parallel. Cold air is sprayed out of the air grille nozzle at high speed towards the glass, and then rapidly and smoothly diffuses. The flow rate and pressure of the air can be changed by the frequency converter of the fan motor to adjust to the required values for toughening different glass. At the same time, the glass is still swinging back and forth on the roller table, greatly improving cooling efficiency and greatly improving the problem of glass wind spots.
Characteristics of the cooling device:
1. Steel roller table: A specially treated steel roller table with a simulated protective surface, which can avoid scratches on the glass on the roller table and ensure that the glass does not deviate, effectively improving the surface quality and yield of the glass.
2. Air nozzle structure: The air nozzle structure is the optimal size, hole spacing, and spray distance obtained through extensive calculations and experiments based on the principles of fluid mechanics. Therefore, the tempering quality is better and there are fewer wind spot defects.
3. Wind grid structure: There are gaps and slides between the wind grids, which not only evenly and effectively dissipate hot air, but also once the glass breaks inside the wind grid, the glass fragments will fall onto the ground along the slide gaps, making maintenance very convenient.
4. Air collection box
The upper and lower chambers are controlled by differential valves, and the upper and lower air pressures are individually adjustable and displayed. The computer displays the air pressure values and pressure differences of the upper and lower air grilles, and the overall stiffness of the air collection box is good.
5. Roller table diameter: ¥ 54mm (rope winding roller)
Take a fragment
Taking segments is basically the same as releasing segments, forming a horizontal roller section. A photoelectric switch is installed at the end of the segment. When the glass reaches the predetermined position, the photoelectric switch senses, the roller table stops rotating, and the sheet is manually unloaded. Similarly, large-sized glass can be unloaded using an auxiliary lifting mechanism.
Air duct system
The air duct system mainly consists of fans, air supply pipelines, air collection boxes, and control valves.
The characteristics of the air duct system: flat glass tempered and curved glass tempered share a common fan system.
Reasonable air duct system: With rich experience and the application of fluid mechanics principles, we continuously optimize the design of the air duct system, significantly reducing system resistance and wind noise. Therefore, the power of the fan selected for the system is correspondingly reduced, making it more energy-efficient.
control system
The control system consists of upper and lower computers.
The upper computer is a well-known industrial control computer. The operation screen is more user-friendly and user-friendly. At the same time, it also has the characteristics of reliable operation and strong anti-interference ability. The lower computer is OMRONR's PLC system, which has high electromagnetic compatibility and industrial adaptability, allowing a maximum ambient temperature of 60 ℃, and has seismic and impact resistance.
The upper computer is installed on the operating console, and the display screen can provide users with a good human-machine interface: help page, process monitoring, temperature curve, process parameters, temperature display, alarm file, equipment maintenance (input test page, output test page, four analog test pages), and other pages. System process parameter reading and writing, system automatic control, single machine operation debugging, self diagnosis, and alarm prompt functions.
It mainly consists of the following subsystems:
Transmission Control System for Glass Tempering Furnace
The transmission control system is a continuous production process that includes loading, heating, cooling, and taking. The process parameters of its transmission program vary depending on the thickness of the glass, and are all automatically controlled by PLC. The status of the transmission process can be monitored through the terminal display screen.
Temperature control system
The temperature control adopts OMRON dedicated temperature control module, and each heating zone is equipped with thermocouples. According to the thickness and variety of glass, the temperature is set on the operating terminal. The temperature control module calculates and outputs control signals to the solid-state relay based on the measured temperature, thereby controlling the output power of the heater. It adopts an advanced automatic optimization temperature algorithm, which can achieve PID self-tuning function and fuzzy control function, The temperature control is very precise. Solid state relays have stable performance and reliable operation, making the temperature control system very reliable.
