The unique jet flow increasing technology must be adopted in the leveling tempering device. By mixing the hot air sucked into the furnace with the compressed air preheated in the nozzle, the temperature of the air sprayed from the nozzle to the glass surface is greatly increased, the convection circulation of the hot air in the furnace is forcibly strengthened, the uniformity and stability of the furnace temperature are improved, and the heating effect of the glass in the furnace is better. Compared with the general compressed air convection model, the compressed air consumption is reduced by more than half.
The transmission of each part of the unit adopts AC frequency conversion technology, driven by motor, and the reciprocating driving speed is adjustable; department
The drill operation is automatically completed by the control system composed of industrial computer and PLC; The air pressure of the air supply system is automatically adjusted, the upper and lower air grids are electrically opened and closed, the air volume is electrically balanced, and the main air valve is automatically opened and closed; The main drive of furnace body and grille adopts O-belt drive, in which the furnace body adopts triple composite drive synchronization technology, namely orthogonal annular drive belt and interconnected annular drive belt; The main drive in and out of the film table adopts chain drive, which is simple and reliable in structure;
When the main drive of furnace body and grille is in power failure state, manual emergency film release function can be used, and emergency power can also be increased according to customer needs.
The power supply device ensures the low-speed operation of the furnace body ceramic roller table after power failure. 1. The front end of the film release section is driven by steel rubber roller, and the rubber surface is made of high-density NBR natural rubber, so as to slow down the impact of the roller on the glass during film release and avoid scratching the original glass. According to the method suggested in the process manual, the original glass sheet is placed on the section and transported to the heating furnace through the roller table. For large pieces of glass, there is also an auxiliary lifting mechanism to facilitate film pasting. The auxiliary lifting mechanism adopts cylinder connecting rod mechanism and is equipped with famous universal wheel to ensure the smooth lifting of the lifting mechanism; When releasing the film, the auxiliary lifting mechanism rises, and the film can be released easily by using the edge roller; The auxiliary lifting mechanism falls, and the glass falls on the roller table. Then press the film feed button, and the glass will be automatically transported forward. When the glass is transported to a predetermined position in front of the furnace, the photoelectric switch installed near the transition roller table in front of the furnace acts, the roller stops rotating, and the glass is in a standby state. According to the size of the placed glass, the distance that the glass moves each time can also be set through the operation terminal, which is convenient for placing glasses with different specifications. The length of glass can also be measured by photoelectric switch in front of the furnace and rotary encoder installed on the transmission mechanism.
2. Lifting platform: single-cylinder linkage mechanism is adopted to ensure the smooth and synchronous lifting of the four corners of the lifting platform.
3. Edge roller system: the upper bus bar is higher than the side cover, which is convenient for loading and unloading the glass plate and is beneficial to observing the quality of the original glass plate or tempered glass.
4. The diameter of the roller table ￠54mm (rubber roller+rope winding roller) is mainly composed of heating furnace body, transmission system and lifting system.
The frame of heating furnace body is welded by national standard high-quality steel and steel plate, with high strength, good rigidity and compact and firm structure. The furnace body is divided into upper and lower parts, and the upper part can be lifted by remote control, which is convenient for the installation, replacement, maintenance and furnace cleaning of the roller table. The furnace lining is made of high-quality aluminum silicate refractory fiber compression board, which has the characteristics of low thermal conductivity, good thermal insulation effect, low density and small heat storage loss. The unique pre-tightening anchorage technology can significantly reduce the heat dissipation and thermal short circuit of the furnace body, effectively reduce the surface temperature of the furnace body and improve the thermal efficiency.
The ceramic roller table in the furnace adopts world-famous products, and the transmission mechanism adopts circular transmission belt and linkage synchronous transmission belt, which greatly improves the transmission accuracy, reduces the impact of the vibration of the transmission system on the ceramic roller table, eliminates the deviation and minimizes the scratches caused by asynchronous transmission. There is a high-performance patented heater in the furnace, which has more heating zones and more uniform temperature in the furnace; The heating element has low surface energy, good thermal shock resistance and long service life.
When the glass enters the furnace, the furnace door is opened, and the segmented conveying roller table and the ceramic roller table in the furnace are synchronously driven to feed the glass into the furnace; After that, close the oven door. The glass is driven by the roller table in the furnace body and swings back and forth within the set effective range, so that the glass is evenly heated and the heating quality is better; At the same time, it ensures that the ceramic roller table is not deformed and bent, and the overall life of the furnace is long.
Features of heating furnace:
1. Unique ceramic roller drive synchronization device: Although the orthogonal belt drive reduces the impact on the ceramic roller during the transmission process, the synchronization of the roller drive cannot be fully guaranteed due to the wrap angle of single-stage drive of 180 degrees and the influence of manufacturing and installation errors. Because the ceramic roller table is not synchronous, when the glass moves back and forth in the furnace, there will be relative sliding between the glass and the roller table, which will cause small scratches on the lower surface of the glass; When multiple pieces of glass are heated at the same time, position deviation or collision will occur; In order to solve this problem, we adopt the synchronous technology of roller compound drive, that is, orthogonal endless drive belt plus interconnected endless drive belt. In this way, the wrap angle of the belt on each ceramic roller table reaches 540 degrees (and it is triple-driven), so even if some belts break, there will be no quality accident, which completely solves the synchronization and reliability of transmission, ensures the synchronous transmission of all roller tables, and greatly improves the heating quality and output. There is no glass slipping on the roller table, and the bearing of the ceramic roller table can not have the problem of running the inner ring, and it can reduce ① white fog; (2) accurate walking, smooth front and back steering, effectively reducing comet-like wear caused by friction between the lower surface of glass and the roller table, (3) prolonging the service life of the ceramic roller table;
2. Roller conveying mechanism: This equipment is equipped with a special ceramic roller conveying mechanism. With this mechanism, people can disassemble the ceramic roller without entering the furnace, which is fast and convenient, and the maintenance time is saved by more than half.
3. First-class thermal insulation technology: special high-density thermal insulation board and thermal insulation anchorage are adopted to eliminate thermal short circuit, which makes the thermal insulation effect better. At normal temperature, the outer surface temperature of the furnace does not exceed 50℃. After power failure 12 hours, the temperature drop of the furnace is only 150℃, and the set temperature can be reached after heating for 30 minutes.
4, the best roller design
Because the glass keeps swinging back and forth on the ceramic roller table during heating, the material, surface state and specifications of the ceramic roller table all affect the heating quality of the glass. In the whole tempering process, the quality of ceramic roller has an important influence, so we adopt imported high-precision silicon ceramic roller table, which has fine workmanship, high surface machining accuracy, strong bending resistance and large effective load, so there are few heating defects. The flat tempering section consists of a cooling grid, a conveying roller table and a wind collecting box.
The tuyere of the grille is made of alloy, and the cooling grille is divided into upper and lower parts, which are respectively connected with the gas distribution center. Intelligent control is realized, and the distance between the grille and the glass can be automatically adjusted according to the different thickness of the glass, so that the spraying distance is always at the best value and the cooling effect is the best. The upper and lower air grids are respectively formed by connecting a plurality of air distribution grids in parallel. Cold air is sprayed to the glass at high speed from the air grid nozzle, and then spreads quickly and smoothly. By changing the frequency of the fan motor through the frequency converter, the velocity and pressure of the wind can be adjusted to the required values for tempering different glasses. At the same time, the glass still swings back and forth on the roller table, so the cooling efficiency is greatly improved and the problem of glass wind spots is greatly improved. Features of cooling device:
1. Steel roller table: The specially treated steel roller table has an imitation surface, which can prevent the glass from being scratched on the roller table, ensure that the glass does not deviate, and effectively improve the surface quality and yield of the glass.
2. Air nozzle structure: The air nozzle structure is the best size, the best hole spacing and the best spraying distance obtained through a lot of calculations and experiments according to the principle of fluid mechanics. Therefore, the tempering quality is better and the wind spot defects are less.
3. Structure of air grates: gaps and slideways are left between the air grates, which not only can evenly and effectively radiate hot air, but also once the glass is broken in the air grates, glass fragments will fall to the ground along the slideway gaps, which is very convenient for maintenance.
4. Air collection box
The upper and lower cavities are controlled by differential pressure valves, and the upper and lower wind pressures can be adjusted and displayed respectively. The computer shows that the wind pressure and pressure difference of the upper and lower wind grids are good, and the overall stiffness of the bellows is good.
5. Roller diameter: ~ ~ ￠54mm (rope winding roller) The gas path system is mainly composed of fan, air supply pipeline, gas collecting box and control valve.
Features of air duct system: Fan system is adopted for flat glass tempering and curved glass tempering.
Reasonable air duct system: With rich experience and fluid mechanics principles, the design of air duct system is continuously optimized, so that the system resistance is significantly reduced and the wind noise is greatly reduced. Therefore, the power of the fan selected by the system is correspondingly reduced, which is more energy-saving. The control system consists of upper and lower computers.
The upper computer is a famous industrial computer. The operation screen is more friendly and humanized. At the same time, it has the characteristics of reliable operation and strong anti-interference ability. The lower computer is OMRONR PLC system, and its high electromagnetic compatibility makes it have high industrial adaptability, allowing the highest environmental temperature to reach 60℃, and has the ability of earthquake resistance and impact resistance.
The upper computer is installed on the console, and the display screen can provide users with a good man-machine interface: help page, process monitoring, temperature curve, process parameters, temperature display, alarm file, equipment maintenance (input test page, output test page, four simulation test pages) and other pages. System process parameters reading and writing, system automatic control, single machine operation debugging and self-diagnosis, prompt alarm and other functions.
It mainly consists of the following subsystems:
Transmission control system
The transmission control system is a continuous production process, including film loading, heating, cooling and film taking. The process parameters of its transmission program change with the thickness of glass, and all of them are automatically controlled by PLC. The status of the transmission process can be monitored through the terminal display screen.
temperature control system
Temperature control adopts Omron special temperature control module, each heating zone is equipped with thermocouple, and the temperature is set on the operation terminal according to the different glass thickness and variety. The temperature control module calculates and outputs a control signal to the solid state relay according to the measured temperature, thereby controlling the output power of the heater. It adopts advanced automatic temperature optimization algorithm, which can realize PID self-tuning function, fuzzy control function and very accurate temperature control. Solid state relay has stable performance and reliable operation, so the temperature control system is very reliable.