Method and system for controlling tin bath atmosphere to reduce surface defects

Abstract

A controller, process, and glass manufacturing apparatus may be configured to minimize defects. Embodiments may be adapted to control the injection of nitrogen and / or argon, and a mixture of nitrogen and hydrogen, or nitrogen, hydrogen, and argon during glass float manufacturing to promote a pre-selected hydrogen concentration within a tin bath furnace while also minimizing glass surface defects that may be caused by tin condensation and tin bath impurity concentration. Empirical usage data may also be collected and provided to predefined machine learning elements of the host device to update predefined control schemes of the controller for adapting to operating condition setpoints or other target values to account for furnace operating history and performance.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Patent Application No. 63 / 412,937, filed on October 4, 2022. Technical Field

[0003] The present innovation relates to controllers configured to facilitate control of operations of a tin bath float glass process for making glass, glassmaking equipment, glassmaking control systems, and methods of making and using the same. Background Art

[0004] Examples of glass production can be seen in U.S. Patent Application Publication No. 2022 / 0169549 and U.S. Patent No. 5,057,1335. In float glass production, molten glass can be fed onto a bath of molten tin for forming glass.

[0005] The main problem in glass production is surface defects. Surface defects can occur while the glass is being formed in the tin bath. Some examples of tin bath surface defects can be summarized as "Tin Drip", "Tin Drop", "Cassiterite Particle", "Top Tin", "Bottom Surface Tin", "Dross Formation", "Bloom Formation" and any other defect type associated with or originating from the tin bath environment. The defects affect the glass differently, but all defects reduce the quality and yield of glass production. Summary of the invention

[0006] It has been determined that surface defect conditions can be avoided by utilizing an improved control scheme for float glass production processing. In some embodiments, the improved control scheme may include controlling the injection of process gas into a tin bath furnace for float glass manufacturing, which may provide improved control of the concentration of reactants (e.g., hydrogen concentration) in the atmosphere of the tin bath furnace above the tin bath, and maintaining the impurity concentration in the tin bath at or below a preselected impurity level. Some embodiments may include using a process gas injection and control scheme, wherein an inert process gas (e.g., nitrogen, a mixture of nitrogen and argon, etc.) is injected between the formation stage and the transition stage of the glass forming process when the glass is located on the molten tin bath. The injection of the inert gas may be positioned between the positions where a process gas having a reactant (e.g., hydrogen) mixed with an inert gas (e.g., argon and / or nitrogen or only nitrogen) is injected upstream and downstream of the inert injection position to help maintain a more consistent and uniform concentration of reactants (e.g., hydrogen) throughout the tin bath atmosphere for complete processing of the glass manufacturing process. It has been discovered that embodiments can provide a significant reduction in tin condensate formation, which can facilitate reducing surface defects due to tin condensate that forms on or near the top and falls onto the glass as it is formed, while also maintaining tin bath impurity levels at desired levels to help mitigate bottom surface defects.

[0007] It has also been discovered that embodiments can utilize an extraction system to help remove the injected process gas from the atmosphere above the glass body located on the tin bath to help remove entrained particles and process gas for particle removal. The removed gas can be filtered through a mesh, cloth filter or other filter media and recycled back to the tin bath furnace. The removal of particles can help clean the atmosphere above the glass body during glassmaking to help reduce defects that may be caused by such particulate material and any reactions that the particulate material may have that may contribute to defect formation. Examples of such particulate materials can be tin dioxide (SnO 2 ), which may be formed during the glassmaking process and entrained in the hot gases above the glass body. In some cases, the removed process gas may be vented rather than recycled, or a portion of the extracted process gas may be vented and another portion recycled. The extent of recycling may be based on the concentration of reactants in the extracted gas, the temperature of the extracted gas, and other factors.

[0008] Embodiments may also include (or alternatively include) a top heating element power adjustment. A power adjustment capable of controlling the heating provided by the top heating element of the tin bath furnace may be provided to increase the heating provided to help purge condensate of tin or other impurity materials that may form on the top or on the heating element. Such a purge may occur during a preselected operating cycle (e.g., a purge time period) during which lower quality glass may be produced, wherein defects from such a purge may not contribute to significant glass quality degradation. Such a purge may be performed so that the tin bath furnace may be in a cleaner or less impurity-concentrated state for subsequent production of higher quality glass having a higher quality threshold that requires a lower concentration of defects or a lower density of surface defects.

[0009] Power adjustment of the heating elements may also be provided (or alternatively provided) so that different portions of the heating elements are operated at higher powers, while other portions are operated at lower powers depending on the concentration of tin condensate at these different locations. Positions with higher tin condensate concentrations may be controlled so that the heating elements are operated at lower power levels to provide less heating, thereby helping to minimize further tin condensate formation, while other positions with lower levels of tin condensate may have their heaters operated at higher power levels so that the overall heating provided by all heating elements can maintain the desired heating level, while the position control of the heating can be adjusted to minimize the formation of tin condensate on or adjacent to the top heating elements of the tin bath furnace. When some heating elements are operated at lower powers, venting or sweeping gas injection may be provided to help prevent tin condensate accumulation. For example, such venting or sweeping may include injecting process gas to travel along the low power heating elements, thereby promoting the entrainment and removal of tin condensate for subsequent extraction and / or venting.

[0010] Some embodiments may be configured to utilize a particle monitoring device that may utilize one or more sensors or other particle monitoring devices to assess particle accumulation within the atmosphere above the glass body formed on the tin bath. When the particle level is detected to be at a level above a first high threshold, the amount of reactants injected into the furnace atmosphere may be reduced to promote a reduction in particle formation. For example, such a reduction may occur by reducing the flow rate of the injected process gas including the reactants and / or reducing the concentration of the reactants injected into the process gas. When the particle level is detected to be at or below a second low threshold, the amount of reactants injected into the furnace atmosphere may be increased to promote more efficient heating utilization and improve the impurity level in the tin bath. For example, such an increase may be achieved by increasing the flow rate of the injected process gas including the reactants and / or increasing the concentration of the reactants injected into the process gas.

[0011] It has been surprisingly found that embodiments of the controller, glass manufacturing equipment and process of the present application have been able to significantly reduce surface defect formation. For example, it has been found that some embodiments can reduce the surface defect formation rate from a 35% reduction in surface defect formation to a 5% reduction. This type of reduction is substantial and can help avoid the formation of waste glass that must be disposed of and / or recycled, and improve energy utilization in the glass manufacturing process. For example, in a system design that forms 700 tons of glass per day, surface defect reduction can provide a total economic value of up to $17,000 per month. These improvements avoid waste and help improve the environmental impact associated with glass manufacturing, and also improve operational profitability. Further, the embodiments can provide such improvements while being relatively cheap to implement. The relatively low capital and operating costs that may result from the implementation of the embodiments can allow a high return on investment to help provide the above-mentioned improvements.

[0012] As can be appreciated from the above and as discussed elsewhere herein, embodiments of the methods, apparatus, and systems may include, individually or in combination, but may not be limited to, the following control processes and / or systems: (i) a control process for optimizing process gas flow rate by utilizing a correlation between defects and control values ​​of glass thickness; (ii) a control process and system for targeting specific areas based on tin oxygen levels, and / or targeting areas based on glass thickness using locally controlled H2 injection; (iii) a control process and system for optimizing the tin bath furnace atmosphere flow distribution by utilizing an extraction system from the sidewalls of the tin bath; (iv) a control process for utilizing a correlation between defects and top-mounted candle heater power levels at specific sections; and (v) a control process for utilizing a purge of top and heater candle condensate during glass thickness transitions.

[0013] As described above, embodiments of the methods and systems disclosed herein can reduce surface defects generated in the tin bath environment by dynamically modifying the internal atmosphere and adjusting the flow pattern within the tin bath environment, thereby improving the quality and yield of float glass. The methods and systems disclosed herein can also improve and help maintain overall tin bath cleanliness by removing volatile or non-volatile particles and / or defect initiators.

[0014] In some embodiments, glass thickness and defect correlation and segment-specific targeting for process gas control may be employed. The process gas to be controlled may include nitrogen (N 2 ) gas, hydrogen (H 2 ) and nitrogen and hydrogen (N 2 / H 2 ) gases. In some embodiments, a particle and / or gas removal device and / or mechanism may be utilized via an extraction system positioned adjacent to at least one tin bath sidewall. The extracted particles and / or gases may be processed to remove particles and exhaust and / or recycle the extracted gases. Embodiments may also utilize internal purging of the top assembly of the tin bath furnace.

[0015] Embodiments of the methods and apparatus disclosed herein may also include correlating defects with control values ​​of glass thickness to optimize process gas flow rates. This may include, but may not be limited to, correlating glass thickness with process gas flow rates, N 2 / H 2 In some embodiments, the range endpoints are 2±2% H 2 process gas (for 2.2 mm glass thickness) and 6 ± 2% H 2 The process gas (for 5.7 mm glass thickness) has an endpoint in the range of 2 ± 1% H 2 process gas (for 2.2 mm glass thickness) and 6 ± 1% H 2 In such specific embodiments, the balance of the process gas may be nitrogen N 2 In some embodiments, for 2.2 mm glass thickness, the endpoint range of the process gas may be 2 ± 0.5% H 2 , and for 5.7mm glass thickness, the endpoint range of the process gas can be 6±0.5%H 2 Embodiments of the methods, apparatus, and systems may be configured to maintain furnace atmosphere pressure and maintain overall internal atmosphere flow rates to prevent external atmosphere from entering the tin bath, thereby reducing specific defects that may affect specific glass thicknesses.

[0016] Embodiments of the methods, devices, and systems of the present application may include a method that can utilize localized targeted H 2 Injection and / or N 2 Injection control process and / or control system. It has been surprisingly found that this helps reduce surface defects by injecting process gases into specific locations or processing areas in and around the furnace in a pre-selected manner to help minimize tin monoxide (SnO) reactions at certain locations within the furnace, thereby helping to minimize or avoid tin (Sn) condensation at the top area of ​​the tin bath furnace, while also promoting sufficient reaction and hydrogen concentration within the tin bath furnace to maintain the tin bath in a desired state, thereby avoiding impurity accumulation that may contribute to bottom defects or other types of tin bath composition related problems. In some embodiments, a process gas with N2 and / or H2 can be injected into the furnace through one or more side walls between the tin surface and the top of the tin bath, and the process gas (N2) can be injected from the top centerline. This can help to remove any defect initiators, such as H 2Atmospheric reactions with SnO and / or other defect initiators that may be volatile or non-volatile are delivered to the side wall regions of the furnace. This can therefore promote condensation of tin or other defect initiators on the side walls and move tin droplets and / or other defects away from the top and ceiling heater candles; thereby potentially reducing top surface defects. For example, in some embodiments, the process gases may be mixed in an upper region above the tin bath adjacent to a ceiling mounted heater and / or electrical equipment for powering the heater for mixing in this region between the boundaries of the tin bath sides. The mixed process gas stream may then be directed into the tin bath. This type of process gas injection into the tin bath may be configured to produce a directed atmosphere zone around a band formed on the tin bath.

[0017] Embodiments of the methods and systems may include a method that can utilize locally controlled H 2 Injection and / or N 2 Injection control process targeting specific areas based on tin oxygen levels. The method may include using the calculated concentration difference between the tin oxygen sensor measurement and the maximum tin oxygen saturation calculated from the tin bath temperature to increase or decrease the process gas at the specific location. A decrease in the control value concentration difference may infer an increase in the process gas, N 2 and H 2 The concentration of the mixture changes so that the gas includes a higher concentration of H 2 and / or the process gas flow rate has increased. An increase in the control value concentration difference can be inferred from a decrease in process gas, N 2 and H 2 The concentration of the mixture is changed so that the process gas has less H 2 and / or the process gas flow rate is reduced. This can subsequently reduce the level of dissolved tin oxygen, which can reduce specific surface defects at specific locations.

[0018] Embodiments of the methods, apparatus and systems may also include a method of utilizing locally controlled H 2 Injection control process based on glass thickness targeted areas. The method may include using glass thickness as a control value to target areas that may produce specific defects affecting specific glass thickness by increasing or decreasing process gas flow rate. This may include glass thickness and range endpoints of 2 ± 2% H 2 process gas (for 2.2 mm glass thickness) and 6 ± 2% H 2 Process gas (for 5.7mm glass thickness) Process gas (N 2 / H 2 In some embodiments, for 2.2 mm glass thickness, the endpoint range of the process gas may be 2 ± 1% H 2 , and for 5.7mm glass thickness, the endpoint range of the process gas can be 6±1%H 2In some embodiments, for 2.2 mm glass thickness, the endpoint range of the process gas may be 2 ± 0.5% H 2 , and for 5.7mm glass thickness, the endpoint range of the process gas can be 6±0.5%H 2 . In the target area, a "forming section" can be defined as a collection of tin bath compartments that accommodate top rollers positioned toward the beginning of the rear tin bath where the glass enters. The process gas flow rate can be reduced in proportion to the glass thickness, where the thickness can be <3.9 mm, which can reduce tin droplets and / or potential other defects for these specific glass thicknesses in the forming section. In the target area, a "cooling section" can be defined as a collection of most of the tin bath compartments that accommodate water coolers positioned toward the end of the tin bath where the glass ribbon exits. The process gas flow rate can be increased in proportion to the glass thickness, where the thickness can be >3.9 mm, which can reduce top tin and / or potential other defects for these specific glass thicknesses in the cooler section. Embodiments of the disclosed method and system can be configured to maintain a furnace atmosphere pressure and an overall internal atmosphere flow rate to prevent external atmosphere from entering the tin bath.

[0019] Embodiments of the apparatus, method, and system may include control processes and systems for optimizing the flow distribution of the tin bath furnace atmosphere by utilizing an extraction system from the sidewalls of the tin bath. 2 ) can be injected from the centerline at a higher flow rate at the top of the tin bath, and the process gas (e.g., N 2 and H 2 A mixture of SnO and SnO can be injected at a lower flow rate at the top side. This can create an internal airflow from the top of the tin bath to a vent near the surface of the tin bath. The vent can remove SnO and / or other volatile or non-volatile defect initiators from the surface of the tin bath to a collection tank. SnO in the atmosphere can react with other SnO to form SnO2 (tin dioxide, solid), or react with hydrogen in the process gas to form tin (Sn) and water (H 2 O). Other reactions may also occur in the tank. The collection tank may include a large diameter tube or a dedicated container, wherein the bottom of the tube or container may be opened to remove Sn, SnO2 and / or other solid and particulate accumulations. The collection tank may also include internal metal mesh and / or other materials / types to slow down the process gas to improve internal reactions and particle collection. The process gas may be discharged from the collection tank, recycled back into the furnace, or a combination thereof. If the process gas is recycled, the particles of the process gas may be measured to ensure the quality of the recycled gas and the process gas mixture (N) may be determined based on the particle measurement results. 2 / H 2 ) is the flow rate increasing or decreasing.

[0020] The increase in particles may increase the H in the process gas mixture2 , and the reduction of particles may reduce the H in the process gas mixture 2 The process gas includes hydrogen and nitrogen, which can be 0% H 2 To 10% H 2 The linear range of the 2 ). The recycled process gas may be returned to the side wall of the tin bath between the inlet vent and below the top of the tin bath, which side wall may be before, after, or in the same vertical plane as the inlet vent. 2 and H 2 Removing SnO and / or other volatile defect initiators from the tin bath can reduce overall defects and maintain a clean tin bath environment and atmosphere.

[0021] Embodiments of the apparatus, methods, and systems may further include a control process that utilizes the correlation of defects to the power level of the top mounted candle heaters at specific sections. Generally, as the glass thickness increases, the top mounted heaters may be activated or adjusted to a higher power. Embodiments may utilize a control scheme that includes reducing the power level of the heaters in areas where tin condensate may be highest, and increasing the power level in areas where tin condensate may be lowest, to maintain the desired overall energy input while also attempting to avoid the formation of tin condensate. Embodiments may also include increasing the exhaust or purge gas flow rate when the heater power may be low or deactivated to prevent condensate accumulation.

[0022] Embodiments of the apparatus, methods, and systems may include a control process that utilizes a purge of top and heater candle condensate during glass thickness transitions. This may include increasing the heater power level to a maximum range and increasing the overall process gas flow rate or pulsed process gas flow rate from the top. This may facilitate purging much of the condensate from the top and heater candles onto glass that may not be of the same value, reducing defects on nominal glass that may have a higher value under other operating conditions. This may be associated with defects, and a control alarm may be activated when a purge may be required.

[0023] In some embodiments, the control value glass thickness may be inversely proportional to the lehr speed, which means that the lehr speed may be used as a control value instead of glass thickness, and vice versa. In addition, the control value glass thickness may be inversely proportional to the roller speed, which means that the roller speed may be used as a control value instead of glass thickness, and vice versa. In still other embodiments, the lehr speed, roller speed, and glass thickness parameters may all be used as control parameters, or a combination of these variables may be used as control parameters.

[0024] In some embodiments, adding argon or other gases to the process gas can reduce defects.2 The process gas can be N 2 and Ar mixture interchangeably, and N 2 and H 2 The process gas can be N 2 , H 2 and Ar mixture.

[0025] In a first aspect, a process for controlling the manufacture of float glass on a tin bath is provided. The process may include determining one or more of the following items based on one or more of the following items: (a) the concentration of hydrogen and / or nitrogen included in a first process gas having nitrogen and / or argon for injection into a first zone of the tin bath furnace; (b) the flow rate of the first process gas for injection into the first zone; and / or (c) the atmosphere pressure of the atmosphere in the tin bath furnace in the first zone. The process may also include determining one or more of the following based on one or more of the following: (i) the thickness of the ribbon to be formed on the tin bath; (ii) the atmospheric conditions within the tin bath furnace; (iii) the ribbon speed; (iv) the ribbon width; (v) the tin conditions within the tin bath furnace; and / or (vi) the measured defects of the ribbon: (d) the concentration of hydrogen and / or nitrogen included in a third process gas having nitrogen and / or argon for injection into the second zone and / or the third zone of the tin bath furnace; (e) the flow rate of the third process gas for injection into the second zone and / or the third zone; and / or (f) the atmospheric pressure of the atmosphere in the tin bath furnace in the third zone. The process may also include determining the flow rate of the second process gas containing argon and / or nitrogen for injection adjacent to the interface of the first zone and the second zone, so that hydrogen is not added to the atmosphere of the tin bath furnace via the injection of the second process gas to facilitate maintaining a preselected hydrogen content in the atmosphere of the entire tin bath furnace during the formation of glass from the ribbon.

[0026] It should be understood that the second process gas may be an inert gas (e.g., containing nitrogen and / or argon). The first process gas and the third process gas may include hydrogen mixed with nitrogen and / or argon. In some embodiments, the first process gas and the third process gas may have the same concentration of hydrogen, nitrogen, and argon or the same concentration of hydrogen and nitrogen. In other embodiments, the first process gas may have a concentration of hydrogen and nitrogen that is different from the concentration of hydrogen and nitrogen of the third process gas. In yet other embodiments, the first process gas may have a concentration of hydrogen, argon, and nitrogen that is different from the concentration of hydrogen, argon, and nitrogen of the third process gas. The third process gas may be injected downstream of the location where the second process gas is injected.

[0027] In a second aspect, the injection of the second process gas occurs in the first zone adjacent to the interface, in the second zone adjacent to the interface, or at the interface. For example, some embodiments may inject the second process gas at the interface between the first zone and the second zone. Other embodiments may inject the second process gas near the interface.

[0028] In the third aspect, the first process gas may be injected into the first zone, and the third process gas may be injected into the second zone and / or the third zone downstream of the location where the second process gas is injected.

[0029] In a fourth aspect, the process may include a host device that receives glass manufacturing data for a tin bath furnace to update process modeling, and updates the process modeling to determine whether one or more control parameters should be adjusted. The glass manufacturing data may include, for example: (i) thickness of a ribbon formed on a tin bath; (ii) atmosphere conditions within the tin bath furnace; (iii) ribbon speed; (iv) ribbon width; (v) tin conditions within the tin bath furnace; and / or (vi) measured defects of the ribbon. The data may be provided via sensors of the tin bath furnace and / or at least one computer device.

[0030] In a fifth aspect, the process can include a host device communicating with a controller of a tin bath furnace or an operator device of the tin bath furnace to suggest adjustments to one or more control parameters based on updates to process modeling. In some embodiments, the suggested adjustments can be based on an evaluation of glass manufacturing data receivable by the host device and / or updated process modeling that can be performed based on the received data.

[0031] In a sixth aspect, based on one or more of the following items: (i) the thickness of the strip to be formed on the tin bath; (ii) the atmosphere conditions within the tin bath furnace; (iii) the strip speed; (iv) the strip width; (v) the tin conditions within the tin bath furnace; and / or (vi) measured defects of the strip, determining one or more of the following items: (a) the concentration of hydrogen and / or nitrogen included in a first process gas having nitrogen and / or argon for injection into a first zone of the tin bath furnace; (b) the flow rate of the first process gas for injection into the first zone; and / or (c) the atmosphere pressure of the atmosphere in the tin bath furnace in the first zone, may include determining the concentration of hydrogen to be included in the first process gas and the flow rate of the first process gas.

[0032] In a seventh aspect, based on one or more of the following items: (i) the thickness of the strip to be formed on the tin bath; (ii) the atmosphere conditions within the tin bath furnace; (iii) the strip speed; (iv) the strip width; (v) the tin conditions within the tin bath furnace; and / or (vi) measured defects of the strip, determining one or more of the following items: (d) the concentration of hydrogen and / or nitrogen included in a third process gas having nitrogen and / or argon for injection into the second zone and / or the third zone of the tin bath furnace; (e) the flow rate of the third process gas for injection into the second zone and / or the third zone; and / or (f) the atmospheric pressure of the atmosphere in the tin bath furnace in the third zone, may include determining the concentration of hydrogen to be included in the third process gas and the flow rate of the third process gas.

[0033] In an eighth aspect, the process can include determining a pressure of an atmosphere in the tin bath furnace adjacent an interface of the first zone and the second zone.

[0034] In the ninth aspect, the flow rate for injecting a second process gas adjacent to the interface of the first zone and the second zone may be determined based on one or more of the following: (i) the thickness of the ribbon to be formed on the tin bath; (ii) the atmosphere conditions within the tin bath furnace; (iii) the ribbon speed; (iv) the ribbon width; (v) the tin conditions within the tin bath furnace; and / or (vi) measured defects of the ribbon.

[0035] In a tenth aspect, the process may include exhausting gas extracted from the atmosphere of the tin bath furnace in response to detecting particulate material exceeding or satisfying a first threshold.

[0036] In the eleventh aspect, the process may further include recycling the gas extracted from the atmosphere after removing particulate material entrained within the extracted gas from the extracted gas in response to detecting the particulate material at or below the second threshold.

[0037] In a twelfth aspect, the process can include adjusting the power level of the heating element based on tin condensate detected within the atmosphere and / or one or more heating elements of the tin bath furnace. In some embodiments, the adjustment of the power level can be performed so that when the detected tin condensate is below a preselected low condensate threshold, the heating element has an increased power, and when the detected tin condensate is at or above a preselected high condensate threshold, the heating element has a decreased power.

[0038] In a thirteenth aspect, the process may include determining that the glass to be manufactured from the ribbon has a quality within a preselected low quality threshold; and when the glass to be manufactured from the ribbon has a quality within the preselected low quality threshold, passing a purge flow along a heating element mounted on a top of a tin bath furnace to remove tin condensate from the heating element and / or clean the heating element.

[0039] In the fourteenth aspect, the process according to the first aspect may include one or more features of the second aspect, the third aspect, the fourth aspect, the fifth aspect, the sixth aspect, the seventh aspect, the eighth aspect, the ninth aspect, the tenth aspect, the eleventh aspect, the twelfth aspect and / or the thirteenth aspect. The embodiment may utilize all of the features of all of these aspects or sub-parts of different aspects. Therefore, it should be understood that the embodiment of the process may include one or more other aspects discussed herein. The embodiment of the process of the present application may also include other exemplary features of the exemplary embodiments discussed herein.

[0040] In a fifteenth aspect, a device is provided to facilitate control of the operation of a tin bath furnace. An embodiment of the device may be configured as an embodiment for implementing the process of the present application. In some embodiments, the device may include a computer device having a processor and at least one transceiver, the processor being communicatively connected to a non-transitory computer-readable medium. The computer device may be communicatively connected to a sensor of the tin bath furnace to receive data from the sensor. The computer device may be configured to determine one or more of the following items based on one or more of the following items: (i) the thickness of the strip to be formed on the tin bath; (ii) the atmosphere conditions in the tin bath furnace; (iii) the strip speed; (iv) the strip width; (v) the tin conditions in the tin bath furnace; and / or (vi) the measured defects of the strip: (a) the concentration of hydrogen and / or nitrogen included in the first process gas having hydrogen, nitrogen and / or argon for injection into the first zone of the tin bath furnace; (b) the flow rate of the first process gas for injection into the first zone; and / or (c) the atmosphere pressure of the atmosphere in the tin bath furnace in the first zone. The computer device may also be configured to determine one or more of the following based on one or more of the following: (i) the thickness of the ribbon to be formed on the tin bath; (ii) the atmospheric conditions within the tin bath furnace; (iii) the ribbon speed; (iv) the ribbon width; (v) the tin conditions within the tin bath furnace; and / or (vi) the measured defects of the ribbon: (d) the concentration of hydrogen and / or nitrogen included in a third process gas having nitrogen and / or argon for injection into the second zone and / or the third zone of the tin bath furnace; (e) the flow rate of the third process gas for injection into the second zone and / or the third zone; and / or (f) the atmospheric pressure of the atmosphere in the tin bath furnace in the third zone. The computer device may also be configured to determine the flow rate of the second process gas containing argon and / or nitrogen for injection adjacent to the interface of the first zone and the second zone, so that hydrogen is not added to the atmosphere of the tin bath furnace via the injection of the second process gas to facilitate maintaining a preselected hydrogen content in the atmosphere of the entire tin bath furnace during the formation of glass from the ribbon.

[0041] As described above, the second process gas may be an inert gas containing nitrogen and / or argon. The first process gas and the third process gas may include hydrogen mixed with nitrogen or hydrogen mixed with nitrogen and argon. In some embodiments, the first process gas and the third process gas may have the same concentration of hydrogen, nitrogen and argon or the same concentration of hydrogen and nitrogen. In other embodiments, the first process gas may have a concentration of hydrogen and nitrogen that is different from the concentration of hydrogen and nitrogen of the third process gas. In yet other embodiments, the first process gas may have a concentration of hydrogen, argon and nitrogen that is different from the concentration of hydrogen, argon and nitrogen of the third process gas. The third process gas may be injected into the atmosphere of the tin bath furnace downstream of the position where the second process gas is injected into the atmosphere of the tin bath furnace, and the first process gas may be injected upstream of the position where the second process gas is injected into the atmosphere of the tin bath furnace.

[0042] In a sixteenth aspect, the apparatus for facilitating control of the operation of a tin bath furnace can be configured such that the computer device is a host device, and the data from the sensor includes glass manufacturing data for the tin bath furnace (e.g., surface defect data or other data for measured defects of the ribbon). The host device can be configured to update process modeling to determine whether one or more control parameters should be adjusted based on the data from the sensor. The host device can be communicatively connected to a controller of the tin bath furnace and / or an operator device of the tin bath furnace to transmit a suggested adjustment of one or more control parameters based on an update of the process modeling.

[0043] In a seventeenth aspect, the apparatus for facilitating control of tin bath furnace operation may be configured such that the computer device is configured to adjust a power level of a heating element based on tin condensate detected within an atmosphere of the tin bath furnace and / or one or more heating elements of the tin bath furnace.

[0044] In an eighteenth aspect, the apparatus for facilitating control of operation of a tin bath furnace may be configured such that the computer device is configured to adjust the power level of one or more heating elements of the tin bath furnace based on tin condensate detected within the atmosphere such that when the detected tin condensate is below a preselected low condensate threshold, the one or more heating elements have increased power, and when the detected tin condensate is at or above a preselected high condensate threshold, one or more of the heating elements have reduced power.

[0045] In a nineteenth aspect, the apparatus for facilitating control of tin bath furnace operation according to the fifteenth aspect may include one or more features of the sixteenth, seventeenth, and / or eighteenth aspects. Embodiments may utilize all of the features of all of these aspects or sub-parts of different aspects. Therefore, it should be understood that embodiments of the apparatus according to the fifteenth aspect may include features of one or more of the other aspects discussed herein. Embodiments of the apparatus according to the fifteenth aspect may also include other exemplary features of the exemplary embodiments discussed herein.

[0046] In the twentieth aspect, a device for manufacturing glass is provided. The device may include a tin bath furnace having a tin bath and an atmosphere above the tin bath. The tin bath furnace may be configured to form a belt on the tin bath. The tin bath furnace may have a first zone, a second zone, and a third zone, wherein the second zone is located between the first zone and the third zone. The tin bath furnace may be connected to at least one hydrogen source, at least one nitrogen source, and / or at least one argon source, so that a first process gas having hydrogen mixed with nitrogen and / or argon may be injected into the first zone, a second process gas containing argon and / or nitrogen may be injected adjacent to the interface of the first zone and the second zone, so that hydrogen will not be added to the atmosphere of the tin bath furnace via the injection of the second process gas, to facilitate maintaining a preselected hydrogen content in the atmosphere of the entire tin bath furnace during the formation of glass by the belt, and a third process gas having hydrogen mixed with nitrogen and / or argon may be injected into the second zone and / or the third zone of the tin bath furnace upstream of where the second process gas may be injected.

[0047] As described above, the second process gas may be an inert gas containing nitrogen and / or argon. The first process gas and the third process gas may include hydrogen mixed with nitrogen or hydrogen mixed with nitrogen and argon. In some embodiments, the first process gas and the third process gas may have the same concentration of hydrogen, nitrogen and argon or the same concentration of hydrogen and nitrogen. In other embodiments, the first process gas may have a concentration of hydrogen and nitrogen that is different from the concentration of hydrogen and nitrogen of the third process gas. In yet other embodiments, the first process gas may have a concentration of hydrogen, argon and nitrogen that is different from the concentration of hydrogen, argon and nitrogen of the third process gas. The third process gas may be injected into the atmosphere of the tin bath furnace downstream of the position where the second process gas is injected into the atmosphere of the tin bath furnace, and the first process gas may be injected upstream of the position where the second process gas is injected into the atmosphere of the tin bath furnace.

[0048] In a twenty-first aspect, the apparatus for making glass may include heating elements mounted on top of a tin bath furnace. The heating elements may be configured so that the power level of one or more of the heating elements may be adjusted based on the atmosphere and / or tin condensate detected within the heating elements. For example, the heating elements may be configured to adjust the power level so that when the detected tin condensate is at or below a preselected low condensate threshold, the heating element has increased power, and when the detected tin condensate is at or above a preselected high condensate threshold, the heating element has decreased power.

[0049] In a twenty-second aspect, the apparatus for making glass may include a gas extraction system in communication with the atmosphere of the tin bath furnace to extract particles entrained in the atmosphere gas.

[0050] In a twenty-third aspect, the apparatus for making glass may include a plurality of sensors positioned to monitor the operation of a tin bath furnace. The sensors may be communicatively connected to at least one computer device. The at least one computer device may have a processor and at least one transceiver, the processor being communicatively connected to a non-transitory computer-readable medium. The at least one computer device may be configured to determine one or more of the following items based on one or more of the following items: (a) the concentration of hydrogen and / or nitrogen included in a first process gas having nitrogen and / or argon for injection into a first zone of the tin bath furnace; (b) the flow rate of the first process gas for injection into the first zone; and / or (c) the atmosphere pressure of the atmosphere in the tin bath furnace in the first zone. The computer device may also be configured to determine one or more of the following based on one or more of the following: (i) the thickness of the ribbon to be formed on the tin bath; (ii) the atmospheric conditions within the tin bath furnace; (iii) the ribbon speed; (iv) the ribbon width; (v) the tin conditions within the tin bath furnace; and / or (vi) the measured defects of the ribbon: (d) the concentration of hydrogen and / or nitrogen included in a third process gas having nitrogen and / or argon for injection into the second zone and / or the third zone of the tin bath furnace; (e) the flow rate of the third process gas for injection into the second zone and / or the third zone; and / or (f) the atmospheric pressure of the atmosphere in the tin bath furnace in the third zone. The computer device may also be configured to determine the flow rate of the second process gas containing argon and / or nitrogen for injection adjacent to the interface of the first zone and the second zone, so that hydrogen is not added to the atmosphere of the tin bath furnace via the injection of the second process gas to facilitate maintaining a preselected hydrogen content in the atmosphere of the entire tin bath furnace during the formation of glass from the ribbon.

[0051] In a twenty-fourth aspect, the apparatus for making glass may include a plurality of sensors positioned to monitor the operation of the tin bath furnace. The sensors may include sensors positioned and configured to measure the hydrogen concentration in the first zone, the second zone, and the third zone, the tin bath atmosphere dew point, and the tin bath atmosphere oxygen potential.

[0052] In a twenty-fifth aspect, the apparatus for making glass may include a computer device configured as a host device. Data from a sensor positioned to measure data related to the operation of a tin bath furnace may be communicated with the host device and provided to the computer device. The data that the sensor may provide may include glassmaking data of the tin bath furnace. The host device may be configured to update process modeling to determine whether one or more control parameters should be adjusted based on the data from the sensor. The host device may also be communicatively connected to a controller of the tin bath furnace and / or an operator device of the tin bath furnace to transmit a suggested adjustment of one or more control parameters based on an update of the process modeling.

[0053] In the twenty-sixth aspect, the apparatus for manufacturing glass according to the twentieth aspect may include one or more features of the twenty-first aspect, the twenty-second aspect, the twenty-third aspect, the twenty-fourth aspect, the twenty-fifth aspect, and / or the twenty-sixth aspect. Embodiments may utilize all of the features of all of these aspects or sub-parts of different aspects. Therefore, it should be understood that embodiments of the apparatus according to the twentieth aspect may include features of one or more of the other aspects discussed herein. Embodiments of the apparatus according to the twentieth aspect may also include other exemplary features of the exemplary embodiments discussed herein.

[0054] Additional details, objects, and advantages will become apparent as the following description proceeds of certain exemplary embodiments of a controller configured to facilitate control of tin bath float process operations for making glass, glassmaking equipment, glassmaking control systems, and methods of making and using the same. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] In the drawings included herein are shown exemplary embodiments of the controller, glassmaking equipment, glassmaking control system, and methods of making and using the same of the present application configured to facilitate control of tin bath float process operations for making glass. It should be understood that the same reference numerals used in the drawings may identify the same components.

[0056] Figure 1 A schematic block diagram is provided for a side view of a first exemplary embodiment of a glass manufacturing apparatus of the present application having an exemplary embodiment of a control system of the present application for controlling the operation of the glass manufacturing apparatus.

[0057] Figure 2A schematic block diagram is provided for a top view of a first exemplary embodiment of a glass manufacturing apparatus of the present application having an exemplary embodiment of a control system of the present application for controlling the operation of the glass manufacturing apparatus.

[0058] Figure 3 for Figure 1 and Figure 2 A block diagram of an exemplary embodiment of a computer device 10 is illustrated in FIG.

[0059] Figure 4 A flow chart illustrating a first exemplary embodiment of a process for controlling a glass manufacturing or glass manufacturing operation.

[0060] Figure 5 is a flow chart illustrating a second exemplary embodiment of a process for controlling a glass manufacturing or glass manufacturing operation.

[0061] Figure 6 is a schematic diagram of an exemplary graphical user interface (GUI) illustrating exemplary suggestions for control parameter adjustments that may be displayed via an operator device. DETAILED DESCRIPTION

[0062] refer to Figures 1 to 5 , the glass manufacturing equipment 1 may include a glass melting furnace 3 (GM), which can melt the material used to form molten glass. The molten material can be any suitable glass material. For example, the glass material melted into molten glass can include sodium carbonate, lime and silica, which is used to form sodium carbonate-lime glass or sodium carbonate-lime-silica glass (for example, lime, sodium carbonate, silica, dolomite, aluminum oxide, a suitable clarifier, or a combination of a finder, silica, natural alkali, sand and / or feldspar, etc.). The molten glass material can alternatively be formulated into another type of glass, such as, for example, borosilicate glass or other types of glass.

[0063] Molten glass may be output from the glass melting furnace 3 to be fed to the tin bath furnace 4 for forming a ribbon 2 which is manipulated in the first zone Z1 of the tin bath furnace 4 via rollers and other glass body forming mechanisms to form an elongated ribbon 2 floating on top of the molten tin (e.g., liquid tin) of the tin bath 6 (TB). The tin bath furnace 4 may include a bath trough lined with a refractory material to maintain the molten tin of the tin bath 6 at a preselected tin bath temperature. The tin bath furnace 4 may also include side walls SW and a roof to maintain a gas atmosphere ATM above the tin bath.

[0064] In some embodiments, the atmosphere ATM of gas may include a mixture of hydrogen and nitrogen or a mixture of argon, nitrogen and hydrogen. The atmosphere ATM may be provided to form a protective atmosphere around the strip 2 to minimize the oxygen in the air that may enter the tin bath furnace 4 through imperfect seals or other inlet paths, thereby oxidizing the material of the strip 2 or the tin of the tin bath.

[0065] The top of the tin bath furnace 4 may include or have a plurality of heating elements HE attached to the top. The heating elements may be electric heaters or other types of heating elements that can provide heating at the top of the tin bath furnace 4. The heating of the heating elements HE can be adjusted between a low heating level and a high heating level, and between a plurality of intermediate heating levels between the low heating level and the high heating level.

[0066] The tin bath furnace 4 may also include a plurality of process gas injection outlets or nozzles. The process gas injection outlets may be defined in the top and / or side walls of the tin bath furnace 4. Figure 1 As shown, at least one process gas may be injected at variously spaced component outlets as shown via process gas injections P1, P2, P3, P4, P5, and P6. It should be appreciated that in various embodiments, less than six injection outlets or injections or more than six injection outlets or process gas injections may be used.

[0067] In some embodiments, a first process gas that is a combination of nitrogen and hydrogen can be injected into the tin bath furnace 4 via multiple spaced top outlets of the equipment (e.g., process gas injection P1, P3, P4, P5, and P6) to form the atmosphere (ATM) of the tin bath furnace 6. In some embodiments, a second process gas consisting of only nitrogen or a mixture of nitrogen and argon can also be injected into the atmosphere (ATM) of the tin bath furnace 4 via one or more outlets (e.g., process gas injection P2). The injection of the second process gas can occur simultaneously with the injection of the first process gas at other outlets. The injected first process gas and the second process gas can mix within the atmosphere to form the atmosphere ATM above the tin bath 6 and below the top of the tin bath furnace 4.

[0068] The tin bath 6 may be located below a formed ribbon 2 that is formed by pouring or otherwise feeding molten glass material from a glass melting furnace 3 onto the tin bath 6 via a feeding device (e.g., a tweel device or other suitable molten glass matrix feeding device) and then being rolled or otherwise manipulated so that the molten glass matrix material forms a desired ribbon 2 having a desired thickness and width on the tin bath 6. For example, the desired thickness and width of the ribbon 2 may be based on the product specifications for forming a particular desired glass sheet and the size and dimensions of the tin bath furnace 4.

[0069] When updating the process to manufacture new sizes of products in a continuous process, the thickness of the ribbon 2 formed in the first zone Z1 can be adjusted. Such thickness adjustments can be made, for example, when manufacturing a ribbon of about 2 mm thickness to forming a ribbon of about 6 mm thickness, and vice versa. In some embodiments, the thickness of the ribbon 2 can be adjusted over time to manufacture different sizes (thicknesses) of glass within a range between 1 mm and 6 mm. In other embodiments, the thickness of the ribbon can be adjusted within other size ranges (e.g., 2 mm to 5.7 mm, 1 mm to 10 mm, etc.).

[0070] The output of the glass matrix material and the formation of the ribbon 2 may be performed in a first zone Z1 of the tin bath furnace 4 and carried out in a continuous manner to provide a continuous glass manufacturing process. The first zone Z1 may be considered a forming zone or a ribbon forming zone.

[0071] The tin bath melting furnace 4 may also include a second zone Z2 and a third zone Z3. The second zone Z2 may be defined between the first zone Z1 and the third zone Z3. The second zone Z2 may be considered as a transition zone, in which the molten glass of the band 2 may be transformed or stretched from a wider width to the final width and thickness of the glass body for making glass. The third zone Z3 may be considered as a cooling zone, and may be configured to cool the band 2 after it has traveled through the second zone Z2, thereby solidifying the band 2 to form a solid glass, which may then be output from the tin bath melting furnace 4 for cutting into a desired size to form glass for mirrors, glass for windows, automotive glass, furniture glass, insulating glass or glass for other devices. The third zone Z3 may include a cooler or other device to promote the cooling of the band 2 to solidify the glass of the band 2, thereby forming glass suitable for feeding to the annealer for annealing. After annealing, the formed glass may be inspected and / or cut into a desired size and / or geometric shape. After the glass is cut into a desired size, the formed glass may be packaged for shipment. The glass output from the tin bath, annealer, and / or cutting process may also undergo optical or other evaluation by one or more quality sensors to provide glass manufacturing quality metric data to the local controller CTRL, the operator device OPD, and / or the remote host device HD. This type of glass manufacturing quality metric data may include measured surface defect data, which may be obtained from the glass ribbon 2 before the ribbon is cut into a desired size or geometry. The measured surface defect data may be data of measured defects of the ribbon 2 obtained via optical evaluation via one or more quality sensors. As discussed herein, the host device HD, the operator device OPD, and / or the local controller CTRL may be configured to receive this measured surface defect data and utilize the data of measured defects of the ribbon 2 in a feedback loop to evaluate empirical data of the tin bath furnace operation to determine adjustments to one or more target parameter values ​​of the tin bath furnace operation.

[0072] The tin bath furnace may include a plurality of sensors S. The sensor S may be a measuring device, a concentration sensor, a temperature sensor, a pressure sensor, a composition sensor, a quality sensor configured to detect surface defects in the strip 2, and / or other sensors. The sensor may be communicatively connected to a local controller (CTRL), an operator device OPD, and / or a host device HD. The local controller may be a computer device 10, which is communicatively connected to the sensor S to receive sensor data from the sensor, thereby facilitating automated process control of the operation of the tin bath furnace. The local controller CTRL may be communicatively connected to the operator device OPD and / or the remote host device HD, which may be configured to provide process control implementation supervision and / or control adjustment recommendations for updating control parameters used by the local controller CTRL and / or the operator device OPD. The operator device OPD and the host device HD may also be computer devices 10, and may be communicatively connected to the sensor S and / or the local controller CTRL to receive sensor data from the sensor S. Controller data from the local controller CTRL may also be provided to the operator device OPD and / or the host device HD via a communication connection between these devices.

[0073] As from Figure 3 As best seen, each computer device 10 may include a processor (Proc.) that is communicatively connected to at least one transceiver (Trcvr) and at least one non-transitory computer-readable medium (Mem). The transceiver may include one or more communication interfaces, such as at least one network transceiver, at least one near field communication transceiver, and / or at least one wireless transceiver. The transceiver (Trcvr) may be configured to facilitate the computer device 10 to have a communication connection to other computer devices 10, input devices (Input), output devices (Output), and / or sensors. The non-transitory computer-readable medium (Mem) may have one or more applications (App) stored thereon and one or more data storage devices (DS), such as files, databases, or other types of data storage devices. The code of the application may be run by the processor (Proc.) to enable the computer device 10 to perform various actions and / or processes. The execution of the application code may also result in the use of one or more data storage devices DS during the execution of the application (App).

[0074] One or more input devices (Input) may include a keyboard, a keypad, a pointer device, a touch screen, a microphone, or other types of input devices communicatively connected to the processor or computer device 10. One or more output devices (Output) may include a speaker, a display, a printer, or other types of output devices communicatively connected to the processor or computer device 10. Other computer devices 10 may be communicatively connected to the computer device 10 via a network connection (e.g., a local area network connection, a wide area network connection, a cellular network connection, an Internet connection, etc.). The communication connection between computer devices 10 (e.g., the communication connection between the local controller CTRL and the operator device OPD and / or any of these devices and the host device HD) may involve an intermediate device, such as a border control device, an access point, or other types of intermediate nodes between the communicatively connected computer devices 10.

[0075] The controller CTRL, the operator device OPD and / or the remote host device HD may be configured to implement one or more control schemes for controlling the operation of the glass manufacturing process used by the tin bath furnace 4. Examples of these control schemes are Figure 4 and Figure 5 As illustrated. For example, in the first step S1, the thickness of the glass ribbon 2 can be determined, and the initial hydrogen and nitrogen injection concentrations of different zones of the tin bath melting furnace can be determined. The hydrogen and nitrogen injection concentrations can be defined as a mixture of hydrogen included in the nitrogen injected into the process gas for the process gas injection streams included in the first zone Z1, the second zone Z2, and the third zone Z3. In some embodiments, the hydrogen concentration of the process gas may range from more than 0 volume percent (vol%) hydrogen to 10 vol% hydrogen. Each outlet may have its own specific hydrogen concentration setting, or multiple outlets may utilize the same setting. The determination of the hydrogen concentration may also include determining that at least one process gas injection may utilize a second process gas provided by a second gas source (inert) and composed of nitrogen and / or argon. The second gas source may be a nitrogen source and / or an argon source (e.g., an argon and nitrogen storage container, in which nitrogen and argon may be mixed into argon and nitrogen of pre-selected concentrations to be provided as a second process gas), or a nitrogen source that may provide a second process gas of nitrogen (e.g., composed of nitrogen or almost entirely composed of nitrogen). In some embodiments, the injection of the inert second process gas may occur at least at a position between the first zone Z1 and the second zone Z2. For example, such an injection of the inert second process gas may be a second process gas injection P2 located at the interface of the first zone Z1 and the second zone Z2 or within one of these zones and near such an interface. The second process gas injection P2 position may be between at least one first process gas injection position within the first zone Z1 and a plurality of downstream first process gas and / or third process gas injection positions P3, P4, P5, and P6 in the second zone Z2 and the third zone Z3 downstream of the second process gas injection position.

[0076] Each implantation location may utilize the implantation of a process gas having a preselected concentration of nitrogen, argon, and / or hydrogen, so that each zone has a different concentration of hydrogen. For example, the first zone Z1 may have a hydrogen concentration ranging from 3 vol% to 10 vol%, or from above 0 vol% to 10 vol%. The second zone Z2 may have a hydrogen concentration range of 0 vol% to 5 vol% or 0 vol% to 10 vol% hydrogen, and the third zone may have a hydrogen concentration ranging from above 0 vol% to 6 vol% or 1 vol% to 10 vol%.

[0077] In some embodiments, for example, the first process gas injection position P1 may inject a gas having a hydrogen content of 3 vol% to 10 vol% hydrogen, wherein the remainder of the gas is nitrogen (e.g., 97 vol% nitrogen to 90 vol% nitrogen) or a mixture of argon and nitrogen (e.g., from 80 vol% nitrogen to less than 97 vol% nitrogen and greater than 0 vol% argon to 10 vol% argon). The second process gas injection position P2 may inject a gas having a hydrogen concentration of 0 vol% and being all nitrogen, or a mixture of 90 vol% to 100 vol% nitrogen and 0 vol% to 10 vol% argon. The third process gas injection position P3 can inject a gas with a hydrogen content of 1 vol% to 10 vol% hydrogen, wherein the remainder of the gas is nitrogen (e.g., 99 vol% nitrogen to 90 vol% nitrogen) or a combination of nitrogen and argon, wherein argon can be provided so that it is between 0 vol% and 10 vol% of the gas (e.g., the injected gas is between 98 vol% nitrogen, 1 vol% hydrogen, and 1 vol% argon and 80 vol% nitrogen, 10 vol% argon, and 10 vol% hydrogen). The fourth process gas injection position P4 can inject a gas with a hydrogen content of 1 vol% to 10 vol% hydrogen, wherein the remainder of the gas is nitrogen (e.g., 99 vol% nitrogen to 90 vol% nitrogen) or a combination of nitrogen and argon, wherein argon can be provided so that it is between 0 vol% and 10 vol% of the gas (e.g., the injected gas is between 98 vol% nitrogen, 1 vol% hydrogen, and 1 vol% argon and 80 vol% nitrogen, 10 vol% argon, and 10 vol% hydrogen). The fifth process gas injection position P5 can inject a gas with a hydrogen content of 1 vol% to 10 vol% hydrogen, wherein the remainder of the gas is nitrogen (e.g., 99 vol% nitrogen to 90 vol% nitrogen) or a combination of nitrogen and argon, wherein argon can be provided so that it is between 0 vol% and 10 vol% of the gas (e.g., the injected gas is between 98 vol% nitrogen, 1 vol% hydrogen, and 1 vol% argon and 80 vol% nitrogen, 10 vol% argon, and 10 vol% hydrogen). The sixth process gas injection position P6 can inject a gas with a hydrogen content of 1 vol% to 10 vol% hydrogen, wherein the remainder of the gas is nitrogen (e.g., 99 vol% nitrogen to 90 vol% nitrogen) or a combination of nitrogen and argon, wherein argon can be provided so that it is between 0 vol% and 10 vol% of the gas (e.g., the injected gas is between 98 vol% nitrogen, 1 vol% hydrogen, and 1 vol% argon and 80 vol% nitrogen, 10 vol% argon, and 10 vol% hydrogen).

[0078] As another example, some embodiments may be configured such that the first process gas injection position P1 may inject a gas having a hydrogen content of 3 vol% to 10 vol% hydrogen, wherein the remainder of the gas is nitrogen (e.g., 97 vol% nitrogen to 90 vol% nitrogen) or a combination of nitrogen and argon (e.g., from 80 vol% nitrogen to less than 97 vol% nitrogen and greater than 0 vol% argon to 10 vol% argon). The second process gas injection position P2 may inject a gas having a hydrogen concentration of 0 vol% and being all nitrogen (e.g., 100 vol% nitrogen), or being a mixture of 90 vol% to 100 vol% nitrogen and 0 vol% to 10 vol% argon. The third process gas injection position P3 can inject a gas with a hydrogen content of 0 vol% to 5 vol% hydrogen, wherein the remainder of the gas is nitrogen (e.g., 100 vol% nitrogen to 95 vol% nitrogen) or a combination of nitrogen and argon, wherein argon can be provided so that it is between 0 vol% and 10 vol% of the gas (e.g., the injected gas is between 100 vol% nitrogen, 0 vol% hydrogen and 0 vol% argon and 85 vol% nitrogen, 10 vol% argon and 5 vol% hydrogen). The fourth process gas injection position P4 can inject a gas with a hydrogen content of 0 vol% to 5 vol% hydrogen, wherein the remainder of the gas is nitrogen (e.g., 100 vol% nitrogen to 95 vol% nitrogen) or a combination of nitrogen and argon, wherein argon can be provided so that it is between 0 vol% and 10 vol% of the gas (e.g., the injected gas is between 100 vol% nitrogen, 0 vol% hydrogen and 0 vol% argon and 85 vol% nitrogen, 10 vol% argon and 5 vol% hydrogen). The fifth process gas injection position P5 can inject a gas with a hydrogen content of 1 vol% to 6 vol% hydrogen, wherein the remainder of the gas is nitrogen (e.g., 99 vol% nitrogen to 94 vol% nitrogen) or a combination of nitrogen and argon, wherein argon can be provided so that it is between 0 vol% and 10 vol% of the gas (e.g., the injected gas is between 99 vol% nitrogen, 1 vol% hydrogen, and 0 vol% argon and 84 vol% nitrogen, 10 vol% argon, and 6 vol% hydrogen). The sixth process gas injection position P6 can inject a gas with a hydrogen content of 1 vol% to 6 vol% hydrogen, wherein the remainder of the gas is nitrogen (e.g., 99 vol% nitrogen to 94 vol% nitrogen) or a combination of nitrogen and argon, wherein argon can be provided so that it is between 0 vol% and 10 vol% of the gas (e.g., the injected gas is between 99 vol% nitrogen, 1 vol% hydrogen, and 0 vol% argon and 84 vol% nitrogen, 10 vol% argon, and 6 vol% hydrogen).

[0079] The first process gas and the second process gas injection may be consistent with the determined concentrations and flow rates and data related to tin condensate, bath composition and / or glass quality metric data that may be evaluated in the second step S2 during the process. In a third step S3, the processing guidelines for the operation of the tin bath furnace 4 may be updated based on the evaluated empirical data. For example, the host device HD may receive the data and update the processing model via a predefined machine learning algorithm to update the control parameter set values ​​for the gas injection flow rate and the gas injection concentration, as well as other process control parameters (e.g., heating element power level, lehr speed, etc.). In the third step, the local controller CTRL and / or the operator device OPD may also or alternatively receive such data and perform the evaluation. In a fourth step S4, one or more changes to the automated process control parameter target values ​​may then be recommended to adjust the process of glass manufacturing performed by the tin bath furnace 4. Such recommendations may be made via the host device HD sending communications for display and / or other outputs at the operator device OPD, so that the operator may receive the recommendations and enter inputs into the control parameters to be transmitted to the local controller CTRL, thereby adjusting one or more control parameters based on the recommended changes transmitted by the host device HD. Alternatively, the operator device OPD may make such recommendations via its output devices or communications with the output devices to facilitate the operator providing input related to those changes. As a further alternative, it is contemplated that the local controller CTRL may also or alternatively perform such evaluations and provide communications to the operator device OPD to facilitate changes to at least one control parameter based on the transmitted recommendations.

[0080] An operator may utilize his or her operator device OPD to provide input for adjusting control parameters. For example, such input may be facilitated by a graphical user interface (GUI) of an automated process control program running at the operator device and a communication connection of the operator device OPD with a local controller CTRL and / or a host device HD. Examples of adjustment of control parameters may include adjusting the concentration of hydrogen, nitrogen, and / or argon in one or more process gases or injection points of process gases.

[0081] from Figure 5The exemplary process shown can be understood as a glass manufacturing process that can be supervised and / or adjusted via a host device HD, an operator device OPD, and / or a local controller CTRL. In a first step ST1, molten glass can be fed into a tin bath 6 to form a ribbon 2 having a desired width and / or thickness. In a second step ST2, a first process gas can be injected into a first zone Z1 at a first flow rate to form a ribbon. The first flow rate can be a suitable flow rate, and the first process gas can have a preselected concentration of hydrogen mixed with nitrogen (e.g., hydrogen between 1 vol% and 10 vol%, with the balance being nitrogen or a combination of nitrogen and argon, etc.). In a third step ST3, a second process gas (e.g., nitrogen or a mixture of nitrogen and argon) can be injected into the second zone Z2 at a second flow rate, injected into the interface between the first zone Z1 and the second zone Z2, or near such an interface within the first zone Z1 or within the second zone Z2 (e.g., at a second gas injection P2 downstream of the first gas injection P1 and upstream of the subsequent third, fourth, fifth, and sixth gas injections P3-P6). The second process gas may be an inert gas provided via at least one inert gas source (inert). The first process gas and / or the third process gas may be provided via a hydrogen (H2) source, a nitrogen (N2) source, and / or an argon (Ar) source, which may be mixed via a mixing device MD to form a first process gas and / or a third process gas having a preselected concentration of hydrogen and a remaining amount of nitrogen or nitrogen and argon. For the first process gas and the third process gas, the hydrogen concentration may be in the range of greater than 0 vol% hydrogen to 10 vol% hydrogen. When argon is present, argon may also be provided in the gas so that the argon concentration in the injected gas is between 0 vol% and 10 vol%. In contrast, the second process gas provided by at least one inert gas source (inert) may not have any hydrogen mixed therein (e.g., may be only nitrogen or may include nitrogen mixed with argon). For example, the inert gas of the second process gas may be 100 vol% nitrogen or a mixture of nitrogen and argon, wherein nitrogen is less than 100 vol% to 90 vol% of the inert gas, and argon is greater than 0 vol% of the injected inert gas and does not exceed 10 vol%.

[0082] In the fourth step ST4, the first process gas and / or the third process gas may be injected into the second zone Z2 downstream of the injection of the second process gas and / or injected into the third zone Z3 downstream of the injection of the second process gas to increase the hydrogen content in the atmosphere ATM in these zones or maintain the hydrogen content in the atmosphere ATM. The injection of the first process gas, the second process gas and / or the third process gas in the second step ST2, the third step ST3 and the fourth step ST4 may be performed simultaneously. Figure 5In an optional fifth step ST5, shown in dashed lines, the injection of these process gases may be adjusted based on glass thickness, ribbon thickness, ribbon speed, ribbon width, tin conditions, tin bath atmosphere conditions, glass manufacturing quality feedback data (e.g., glass quality metric data, measured defects of the ribbon, etc.), and / or empirical processing data collected by the sensor S. Adjustments in the injection of process gases may include adjustments to the concentrations of hydrogen, nitrogen, and / or argon and adjustments to the flow rates of the injected gases at one or more injection points in one or more zones. These adjustments may all occur at the same time, or may occur at different times (e.g., adjustments to the concentrations and / or flow rates may occur for a first injection point location, and subsequently other adjustments may occur at other injection points for different zones or other injection locations).

[0083] It has been surprisingly discovered that the injection of an inert second process gas near the interface between the first zone Z1 and the second zone Z2 can have a significant effect on reducing the formation of defects on the ribbon 2 during manufacturing via the tin bath furnace 4. In some evaluations conducted, it was determined that this injection at this location (e.g., at or near the location of the process gas injection P2) can contribute to, for example, a 5% to 35% reduction in surface defects. It has been determined that this improvement can be at least partially attributed to the inert gas injection helping to offset hydrogen accumulation within the atmosphere ATM downstream of the first zone Z1. It is believed that the injection of the inert gas helps to better maintain the hydrogen concentration within the atmosphere ATM, making the hydrogen concentration more uniform by avoiding hydrogen accumulation, which can occur due to the unreacted hydrogen in the first zone Z1 accidentally increasing the hydrogen concentration within the atmosphere ATM in the second zone Z2 and / or the third zone Z3 as the gas flows within the atmosphere ATM during the formation, cooling and / or annealing of the glass ribbon 2. By allowing the hydrogen concentration in the atmosphere to be more uniform throughout the different zones, tin condensation can be greatly reduced, and other chemical interactions that may contribute to the generation of defects can also be reduced or avoided.

[0084] It has also been surprisingly discovered that this injection of the inert gas is provided near or at the first region / second region interface without causing any type of damage or significant damage to the tin bath components. The impurity level within the tin bath can be maintained using the inert second process gas injection so that bottom defects are not generated at a higher rate and so that the tin bath components can be maintained within the desired impurity content level. The accumulation of oxygen and tin condensate and tin oxides (e.g., Sn y O x , such as SnO, SnO 2 The formation of tin condensate and solid tin oxide (SnO) can be avoided or at least not aggravated by injecting an inert second process gas (e.g., oxygen from air traveling into the atmosphere due to imperfect sealing and other constraints, oxygen diffusing into the bath via oxygen that may remain in the glass matrix material of ribbon 2, etc.). y O x) can avoid particulate material that may contribute to surface defects.

[0085] In some embodiments, the inert gas and / or first process gas may also include argon (Ar). Including argon may allow for more inert levels of argon to be positioned closer to the ribbon adjacent to the tin bath 6 because argon is heavier than nitrogen or hydrogen. It is contemplated that argon may be able to provide a protective inert barrier around the perimeter of the ribbon 2 to help further mitigate the formation of surface defects. For example, argon may be a heavier gas that may collect closer to the ribbon 2 and help prevent SnO from forming. 2 Formed adjacent to the belt 2, such particulate material is prevented from contacting or interacting with the belt to form defects.

[0086] It has also been determined that embodiments of the control system and apparatus 1 of the present application may utilize additional features and control schemes to help further mitigate surface defect formation during glass manufacturing. For example, the particle concentration within the atmosphere ATM may be detected and / or monitored by one or more sensors S, and the controller CTRL may be configured to adjust the hydrogen mixture within the nitrogen of the first process gas injected into different zones of the tin bath furnace 4 in response to the detected particles. For example, the hydrogen concentration within the first process gas and / or the third process gas injected into the atmosphere ATM of the tin bath furnace 4 may be reduced in response to the particle concentration detected within the atmosphere ATM being at or above a preselected high particle threshold. As another example, the hydrogen concentration within the first process gas and / or the third process gas injected into the atmosphere ATM of the tin bath furnace 4 may be increased in response to the particle concentration being at or below a preselected low particle threshold.

[0087] Each collecting device CD may utilize at least one filter cloth, mesh or other particle filtering device that can separate particles from the extracted gas to remove particles from the gas. The extracted gas may then be exhausted via an exhaust conduit 2v or recirculated back into the atmosphere via a recirculation conduit connected to the collecting device CD, which may output the recirculated gas after it has been cleaned or filtered by at least one recirculation flow path 2r.

[0088] The recycling or exhaustion of the process gas extracted from the atmosphere can be determined based on the particle concentration of the extracted gas. In the event that a particle concentration above a high particle concentration threshold is detected in the extracted gas obtained via the extraction flow path 2p, this may indicate that a high concentration of hydrogen is present in the extracted gas. The gas may then be recycled if a higher concentration of hydrogen is desired in the atmosphere, or the gas may be exhausted if the hydrogen concentration is at a desired level or a high level. In the event that the detected particle concentration is above a low particle concentration threshold detected in the extracted gas obtained via the extraction flow path 2p, this may indicate that a low concentration of hydrogen is present in the extracted gas. The gas may then be recycled if a lower concentration of hydrogen is desired in the atmosphere ATM, or the gas may be exhausted if the hydrogen concentration is at a desired level or a low level.

[0089] The number of collection devices, extraction conduits, and recirculation conduits for the extraction flow paths 2p and recirculation flow paths 2r can be adjusted to meet a set of pre-selected design criteria. It is contemplated that each zone may have one or more extraction flow paths 2p and / or recirculation flow paths 2r to facilitate recirculation and extraction in different zones as desired. There may also be multiple exhaust conduits or a single common exhaust conduit arrangement for exhausting the extracted gas.

[0090] In some arrangements, the extraction system 8 may be configured to promote the extraction flow path 2p by using a central injection of an inert gas in a central region aligned with the center of the strip 2, while a process gas including a mixture of hydrogen and nitrogen may be injected near the side wall SW at a lower flow rate than the injected inert gas (e.g., nitrogen or nitrogen mixed with argon). This type of process gas injection may promote the formation of the extraction flow path 2p and may help create an internal gas flow path within the atmosphere ATM to promote the extraction flow path to approach the top surface of the strip 2 and / or the tin bath 6.

[0091] Embodiments may also (or alternatively) include control elements for the heating elements HE to promote the reduction of surface defects. For example, a top-mounted heating element HE (e.g., a top-mounted candle heater, etc.) may be positioned to operate at multiple power levels, ranging from a highest power level that provides the maximum amount of heating to a lowest power level that provides the least amount of heating and intermediate levels between the highest position and the lowest position. The power levels of the heating elements HE in different zones may be adjusted or activated. For example, if a low level of tin condensate is detected via one or more sensors, the heating element HE may be adjusted to increase power to provide additional heating, while other heating elements in locations where a higher level of tin condensate is detected may be adjusted to deactivate or operate at a lower heating level to provide reduced heating to reduce the formation of tin condensate in those locations. This type of power adjustment for the heating elements HE may be provided so that the overall heating input provided by all the heating elements HE is cumulatively within a desired pre-selected heating level or within a pre-selected heating input range for glass manufacturing, so that when the overall heating input provided by the heating elements HE is still within the desired heating range or heating input level, a local adjustment may be provided to minimize tin condensate.

[0092] Additionally (or alternatively), the controller CTRL, the operator device OPD, and / or the host device HD may be configured to cause the operation of the tin bath furnace 4 to be adjusted so that one or more process gas purge streams may also be injected to flow along the heating elements to assist in removing condensate to clean the heating elements. This may be actuated during the manufacture of low quality glass so that an increase in defects that may occur from such purges may be accommodated without adversely affecting the overall suitability of the formed glass, so that the heating elements may be cleaner and contribute to lower levels of surface defect formation during high quality glass manufacturing cycles.

[0093] Embodiments may also (or alternatively) be adapted such that the local controller CTRL, the operator device OPD, and / or the host device HD may be configured such that the location at which the first process gas having a mixture of hydrogen and nitrogen is injected is more lateral relative to the center of the belt to define an injected first process gas flow and / or a third process gas flow that promotes the formation of defect initiators (e.g., SnO, SnO 2 , water, etc.) to the side wall regions of the tin bath furnace. By promoting the formation of such defective agents near the side walls SW, it is expected that tin condensates and other undesirable byproducts produced by undesirable effects that may occur in the atmosphere ATM may have higher concentrations at the side regions away from the peripheral edge of the strip 2 to avoid contact with the strip 2 and the formation of any defects thereon. Such lateral concentration of defective agents may also help prevent the formation of tin condensates also on the heating elements HE in some configurations.

[0094] Embodiments may also (or alternatively) be adjusted such that the local controller CTRL, the operator device OPD, and / or the host device HD may be configured such that the amount of hydrogen injected into the atmosphere ATM via process gas injection is based on the desired glass thickness. In some embodiments, the relationship between hydrogen injection and glass thickness may be a linearly dependent control parameter. Such controls may also adjust the process gas injection flow rates for different zones of the tin bath furnace and the hydrogen concentration used in the injected process gas.

[0095] For example, the injection of process gas may be lower in the first zone Z1 where the formed ribbon may be at its widest width compared to the hydrogen concentration and / or flow rate of the downstream process gas injection (e.g., in the third zone Z3). For example, for thick ribbons exceeding a preselected thickness threshold, the injection of process gas mixed with hydrogen may be at a higher flow rate and / or higher hydrogen concentration in the third zone Z3 compared to the first zone Z1. Such adjustments may be provided to avoid tin condensate formation and other defect contributors in the first zone Z1, while also being used to help reduce the formation of such condensate, particle formation, or other defect conditions in the cooler third zone Z3 where the ribbon undergoes cooling.

[0096] As another example, the flow rate and / or hydrogen concentration of the process gas may be adjusted based on the desired thickness of the strip 2. For a strip 2 that will be thicker, a higher concentration of hydrogen may be used and / or a higher flow rate of a hydrogen-containing process gas may be injected into the first zone. For a strip 2 that will have a lower thickness, a lower concentration of hydrogen may be used and / or a lower flow rate of a hydrogen-containing process gas may be injected.

[0097] Data from the sensor S may also be provided to trigger locally controlled hydrogen injection into different zones of the tin bath furnace 4. For example, a determined difference between a tin-oxygen measurement from a sensor S and a predefined maximum tin-oxygen saturation level that can be calculated based on the temperature of the tin bath that can be detected by another sensor S may be used to increase and / or decrease process gases in different zones. A decrease in the difference between the tin-oxygen measurement from the sensor S and the predefined maximum tin-oxygen saturation level that can be calculated based on the temperature of the tin bath may be used to trigger an increase in the hydrogen concentration within the injected process gas and / or an increase in the flow rate of the injected first process gas and / or third process gas, the first process gas and / or third process gas comprising hydrogen to be injected into the atmosphere ATM of the tin bath furnace 4. An increase in the difference between the tin-oxygen measurement from the sensor S and the predefined maximum tin-oxygen saturation level that can be calculated based on the temperature of the tin bath may be used to trigger a decrease in the hydrogen concentration within the injected process gas and / or a decrease in the flow rate of the injected first process gas and / or third process gas comprising hydrogen to be injected into the atmosphere ATM of the tin bath furnace 4. This type of monitoring and adjustment can help provide a more uniform hydrogen content within the atmosphere ATM throughout the different zones of the tin bath furnace 4, and can also be performed in conjunction with the inert gas injection process discussed above.

[0098] The processing and control that may be provided via the local controller CTRL and / or the operator device OPD may be further enhanced by the host device HD, which may be configured to provide suggested changes to operating parameters for use by the operator and / or the local controller CTRL. For example, sensor data and glass quality metric data may be transmitted from the local controller CTRL, the operator device OPD, and / or the sensor S of the tin bath furnace to the host device HD. The host device may utilize a machine learning application or other control processing program to update the control modeling based on the received empirical furnace performance data and glass quality data to update the control parameter values ​​for the operation of the tin bath furnace. The updated control parameters may then be transmitted to the operator via communication between the host device HD and the operator device OPD to facilitate the transmission of at least one suggested process control parameter change to be implemented by the operator. The operator may then provide input via an input device (Input) using the operator device OPD to adjust one or more process parameters based on the suggestion. The adjusted process parameters may then be transmitted to the local controller CTRL, or utilized by the operator device OPD in the case where the operator device is also a local controller CTRL and directly performs control operations on different elements of the tin bath furnace 4.

[0099] In some embodiments, the host device HD may have a predefined model control program (App) stored thereon that is run with the new data received to further update the control parameter values. The machine learning component of the program or other machine learning program (App) may be configured to process the received data so that high-quality data is taken into account and data that may be of low quality may be ignored. For example, the received data may be analyzed and if it is determined that the data is related to atypical processing (e.g., a tin bath maintenance issue exists or other atypical processing issues are being addressed during processing), the data may be omitted or given a lower weight when processing the data to determine whether one or more updated control parameters should be recommended to the operator device OPD and / or the local controller CTRL.

[0100] Data that may be provided to the host device HD via the sensor S and / or the local controller CTRL and / or the operator device OPD may include lehr speed, roller speed data, tin bath temperature data from different areas of the tin bath, dew point data from different areas of the tin bath furnace 4, glass thickness, ambient temperature, ambient dew point, run time for a particular thickness of glass being manufactured, width of the ribbon, oxygen concentration of the tin bath and / or oxygen concentration within the atmosphere ATM, and hydrogen concentration detected in different areas of the tin bath furnace. Additional data may include process gas injection rates and nitrogen, hydrogen and / or argon concentrations within the injected process gas and the location where the process gas is injected. Other data may also be provided to the host device for updating model control parameters to take into account empirical performance of the tin bath furnace 4 that may be obtained from data received from the host device.

[0101] The host device HD may be configured to determine changes to control parameters for flow rates and / or concentrations of hydrogen, nitrogen, and / or argon included in the process gas injected into the tin bath furnace 4 based on a variety of different data received from the sensor S and / or other criteria or data. The control parameters that may be determined for change may include: (a) the concentration of hydrogen and / or nitrogen included in the first process gas having nitrogen and / or argon for injection into the first zone of the tin bath furnace; (b) the flow rate of the first process gas injected into the first zone; and / or (c) the atmosphere pressure of the atmosphere in the tin bath furnace in the first zone. The control parameters to be determined for change may also include: (d) the concentration of hydrogen and / or nitrogen included in the third process gas having nitrogen and / or argon for injection into the second zone and / or the third zone of the tin bath furnace; (e) the flow rate of the third process gas injected into the second zone and / or the third zone; and / or (f) the atmosphere pressure of the atmosphere in the tin bath furnace in the third zone. The control parameters to be determined for change may also include the atmospheric pressure adjacent to the interface between the first zone Z1 and the second zone Z2, and / or the flow rate of the second process gas containing argon and / or nitrogen for injection adjacent to the interface between the first zone Z1 and the second zone Z2, so that hydrogen is not added to the atmosphere ATM of the tin bath furnace via the injection of the second process gas to facilitate maintaining a preselected hydrogen content in the atmosphere of the entire tin bath furnace during the formation of glass from the ribbon 2. For example, (i) the thickness of the ribbon to be formed on the tin bath; (ii) the atmospheric conditions within the tin bath furnace (e.g., the atmospheric pressure, the concentration of the gas within the atmosphere, and / or the flow rate of hydrogen and / or inert gas); (iii) the ribbon speed; (iv) the ribbon width; (v) the tin conditions in the tin bath furnace; and / or (vi) the measured defects of the ribbon can be used to determine the set point of one or more control parameters or adjustments to the set point. In some embodiments, all of items (i) to (vi) can be utilized. In other embodiments, only one of items (i) to (vi) can be utilized. In yet other embodiments, combinations of items (i) to (vi) may be utilized (e.g., two or more of items (i) to (vi) may be utilized, three or more of these items may be utilized, four or more of these items may be utilized, or five or more of these items may be utilized).

[0102] The following provides examples of exemplary processing and adjustment of one or more control parameters to help further illustrate adjustments that can be provided to reduce surface defects. For example, a tin bath furnace process can be performed so that during the operation of the tin bath furnace, an adjustment of the thickness of the ribbon 2 occurs, so that the thickness of the ribbon 2 to be formed is changed to produce glass of different thicknesses and / or widths. For example, the thickness of the ribbon 2 can be adjusted to reduce by 0.3 mm to transform into a new glass thickness for the manufacture of glass products of different sizes. Based on an evaluation of empirical data, the host device HD can determine that top surface defects are more likely to occur in such a transition change, and therefore recommend an overall set point change for the hydrogen concentration in the atmosphere ATM. Via the operator accepting such a recommended change (via providing input for the change via the operator device OPD), the set point of the hydrogen concentration can be changed due to the change, and the operator device OPD can transmit one or more control parameter changes to the controller CTRL based on the input received from the operator.

[0103] For example, taking into account the new thickness, the overall hydrogen concentration of the entire atmosphere above the tin bath can be 0.5 vol% lower. This adjustment can be provided by adjusting the flow rate of nitrogen and / or argon entering the tin bath furnace and / or adjusting the flow rate of hydrogen entering the tin bath furnace. For example, the flow rate of nitrogen can be increased and / or the flow rate of hydrogen can be reduced to adjust the overall hydrogen concentration in the atmosphere. Such adjustments can be achieved by increasing the flow rate of the inert gas used as the second process gas injected at the second process gas injection P2 point and / or increasing the flow rate of nitrogen and / or argon injected at other injection points. The hydrogen concentration in the injected first process gas and the third process gas and / or the flow rate of the first process gas and the second process gas can also be adjusted to reduce the hydrogen content in the tin bath atmosphere.

[0104] As another example, the thickness of ribbon 2 may be adjusted to increase by 0.3 mm to transition to a new glass thickness for manufacturing glass products of different sizes. Based on an evaluation of empirical data, the host device HD may determine that bottom surface defects are more likely to occur in such transition changes, and therefore recommend an overall set point change for the hydrogen concentration within the atmosphere ATM. Via the operator accepting such a recommended change (via providing input for the change via the operator device OPD), the set point for the hydrogen concentration may be changed as a result of the change, and the operator device OPD may communicate the various set point changes to the controller CTRL based on the input received from the operator.

[0105] For example, the overall hydrogen concentration of the entire atmosphere above the tin bath may be 0.5 vol% higher to take into account the new thickness. This adjustment may be provided by adjusting the flow rate of nitrogen and / or argon entering the tin bath furnace and / or adjusting the flow rate of hydrogen entering the tin bath furnace. For example, the flow rate of nitrogen may be reduced and / or the flow rate of hydrogen may be increased to adjust the overall hydrogen concentration within the atmosphere. Such adjustments may be implemented by reducing the flow rate of an inert gas used as a second process gas injected at the second process gas injection location point P2 and / or reducing the flow rate of nitrogen and / or argon injected at other injection points. The hydrogen concentration in the injected first process gas and the third process gas and / or the flow rate of the first process gas and the second process gas may also be adjusted to increase the hydrogen content within the tin bath atmosphere.

[0106] As yet another example, the host device HD may evaluate empirical data received from a tin bath furnace system and determine that top surface defects are exceeding a preselected quality threshold. The host device HD may determine that the flow rates and / or concentrations of hydrogen, nitrogen, and / or argon may be adjusted to inject process gases into different zones to reduce the top surface defect formation rate. For example, the host device HD may suggest, via a communication sent to the operator device OPD, that the set point for the hydrogen concentration in the second zone and / or near the initial portion of the second zone closest to the first zone Z1 be reduced by a preselected top surface defect reduction change (e.g., 0.5 vol% hydrogen, etc.). Via the operator accepting such a suggested change (via providing input for the change via the operator device OPD), the set point for the hydrogen concentration for injecting process gases into the first zone and / or the second zone may be changed due to the change, and the operator device OPD may transmit one or more control parameter changes to the controller CTRL based on the input received from the operator. For example, such a change can be achieved by adjusting the flow rate of the inert gas provided at the second process gas injection point P2 to increase the flow rate of the gas and / or reduce the flow rate of hydrogen and / or increase the flow rate of nitrogen, thereby injecting the process gas into the second process gas injection point P2 and / or the second zone Z2 downstream of the first zone Z1.

[0107] As yet another example, the host device HD may evaluate empirical data received from a tin bath furnace system and determine that bottom surface defects are exceeding a preselected quality threshold. The host device HD may determine that the flow rates and / or concentrations of hydrogen, nitrogen, and / or argon may be adjusted to inject process gases into different zones to reduce the top surface defect formation rate. For example, the host device HD may suggest, via a communication sent to the operator device OPD, that the set point for the hydrogen concentration in the second zone and / or near the initial portion of the second zone closest to the first zone Z1 be increased by a preselected bottom surface defect reduction change (e.g., an increase in hydrogen concentration of 0.5 vol%, etc.). By the operator accepting such suggested adjustments (via providing input for the adjustment via the operator device OPD), the set point for the hydrogen concentration for injecting process gases into the first zone and / or the second zone may be changed due to the change, and the operator device OPD may transmit one or more control parameter changes to the controller CTRL based on the input received from the operator. For example, such a change can be achieved by adjusting the flow rate of the inert gas provided at the second process gas injection point P2 to reduce the flow rate of this gas and / or increase the flow rate of hydrogen and / or reduce the flow rate of nitrogen, thereby injecting the process gas into the second process gas injection point P2 and / or the second zone Z2 downstream of the first zone Z1.

[0108] It should be appreciated that the above examples may also include other types of adjustments. For example, instead of a hydrogen concentration set point adjustment, the proposed adjustments may include changing the flow rate set points of hydrogen and nitrogen and / or the partial pressure set points of hydrogen and / or nitrogen. Other types of adjustments consistent with the examples discussed above and for different control parameters may also (or alternatively) be provided.

[0109] The host device HD may also be configured to evaluate the overall defect formation rate of top and bottom defects and select and adjust to reduce top or bottom surface defects that may be appropriate to provide the highest economic return for reducing such defects (e.g., it may be desirable to avoid bottom surface defects as opposed to top surface defects, or vice versa, depending on glass quality metric data for the product to be manufactured, etc.) The selected adjustment metric may then be communicated to the operator via communications sent to the operator device for consideration by the operator in adjusting the tin bath furnace operating control parameters.

[0110] from Figure 6 As can be appreciated in the example of the type of communication that may provide a suggested change via communications exchanged between the host device HD and the operator device OPD. The exemplary GUI may also be a GUI of an embodiment in which the operator device OPD may directly perform an evaluation of the data and suggest changes based on the data received by the operator device OPD from the sensor S and / or the controller CTRL.

[0111] Figure 6A graphical user interface (GUI) is illustrated that may be displayed via a display of an operator device OPD, the graphical user interface being generated based on communication of data received from a host device HD or data received by the operator device from a sensor S and / or a controller CTRL. The GUI may include flow rate and concentration indicia, which may be illustrated as indicating hydrogen, nitrogen, and / or argon flow rates and / or flow rate set points for one or more zones or compartments of a tin bath furnace. The GUI may also include a representation of the tin bath (tin bath representation), which may be a visual representation of the tin bath furnace with indicia identifying different zones (IZ) of the tin bath furnace. The visual representation may include coloring and / or other features to indicate different conditions of the tin bath or tin bath furnace atmosphere, and may be configured to facilitate display of other information or indicia via interaction with an operator using a pointer device or a keyboard, electric pen, or other type of input device.

[0112] The GUI may include suggested changes to various set points or other control parameters. This may be displayed, for example, via communications that the operator device OPD may receive from the host device HD as discussed above. Such adjustment suggestions may be provided via one or more adjustment indicia and / or displayed flow rate and concentration indicia that may be illustrated adjacent to the tin bath representation in the GUI to help indicate the suggested changes, and / or indicate where in the tin bath furnace the suggested changes may be implemented if accepted.

[0113] Figure 6 The example of the first adjustment mark, the second adjustment mark, and the third adjustment mark are illustrated as adjustment mark A, adjustment mark B, and adjustment mark C. Based on the data received from the host device HD, more than three or less than three (e.g., only two or only one) adjustment marks may be displayed instead. As can be appreciated from the above, the suggested changes provided by the host device HD may be based on the evaluation of empirical data and other data evaluations performed by the host device HD (examples of which are discussed above).

[0114] The operator may utilize the operator device OPD to provide input via a pointer device, keyboard, light pen or other input device for interacting with the displayed GUI to accept one or more suggested changes. Such selection may trigger the operator device OPD to communicate with the controller CTRL to adjust one or more control parameters so that the operation of the tin bath furnace is adjusted to be consistent with the changed control parameters.

[0115] It will be appreciated that the format and layout of the GUI can be configured in a variety of different ways to convey relevant information to the operator and facilitate receiving input from the operator. The types of representations to be displayed, the indicia to be displayed, and / or the look and feel of such displayed indicia can be adjusted to meet a particular set of design criteria. Additionally, the types of control parameters or other information that can be displayed via the GUI can also be defined to facilitate operator use and oversight according to different sets of design criteria or operating criteria.

[0116] For the sake of brevity, only certain ranges are explicitly disclosed herein. However, the range from any lower limit can be combined with any upper limit to list the range that is not explicitly listed, and the range from any lower limit can be combined with any other lower limit to list the range that is not explicitly listed, and similarly, the range from any upper limit can be combined with any other upper limit to list the range that is not explicitly listed. In addition, when the numerical range with lower limit and upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. Specifically, even if not explicitly listed, each value range disclosed herein (in the form of "from about a to about b", or equivalently, "from about a to b", or equivalently, "from about ab") should be understood to be included in the wider range of values. Each number and range. Therefore, each point or individual value can be used as the lower limit or upper limit of itself and any other point or individual value or any other lower limit or upper limit combination to list the range that is not explicitly listed.

[0117] It should be understood that the embodiments explicitly shown and discussed herein can be modified to meet a set of specific design goals or a set of specific design criteria. For example, valves, pipes, sensors, controllers, communication connection elements (e.g., wiring, intermediate network nodes, network layout, etc.), furnace and sensor arrangements and other elements can be arranged, sized and designed to meet the specific equipment layout design considering the available area of ​​the equipment, the specific sensor array, the controller hardware and furnace operating requirements and other design considerations. It should be understood that the embodiment can be configured to include various process control elements (e.g., temperature sensors; pressure sensors; flow sensors; target element concentration sensors, automated process control systems with at least one workstation, the system including a processor, a non-transient memory and at least one transceiver for communicating with the sensor element; valves; and controllers for providing a user interface for an automated process control system that can be run at a workstation and / or another computer device; etc.) that are positioned and configured to monitor and control operations.

[0118] As another example, it is contemplated that specific features described individually or as part of an embodiment may be combined with other individually described features or parts of other embodiments. Thus, the elements and actions of the various embodiments described herein may be combined to provide further embodiments. Thus, while certain exemplary embodiments of a controller, glassmaking equipment, glassmaking control system, and methods of making and using the same configured to facilitate control of operations of a tin bath float glass process for making glass have been shown and described above, it should be clearly understood that the invention is not limited thereto, but may be embodied and practiced in other ways within the scope of the following claims.

Claims

1. A process for controlling the manufacture of float glass on a tin bath, comprising: Based on one or more of the following: (i) the thickness of the ribbon to be formed on the tin bath; (ii) the atmosphere conditions within the tin bath furnace; (iii) the ribbon speed; (iv) the ribbon width; (v) the tin conditions within the tin bath furnace; and / or (vi) the measured defects of the ribbon, determine one or more of the following: (a) the concentration of hydrogen and / or nitrogen included in a first process gas having nitrogen and / or argon for injection into a first zone of the tin bath furnace; (b) the flow rate of the first process gas for injection into the first zone; and / or (c) the atmosphere pressure of the atmosphere in the tin bath furnace in the first zone; Based on one or more of the following items: (i) the thickness of the tape to be formed on the tin bath; (ii) the atmosphere conditions within the tin bath furnace; (iii) the tape speed; (iv) the tape width; (v) the tin conditions within the tin bath furnace; and / or (vi) the measured defects of the tape, determine one or more of the following items: (d) the concentration of hydrogen and / or nitrogen included in a third process gas having nitrogen and / or argon for injection into the second zone and / or the third zone of the tin bath furnace; (e) the flow rate of the third process gas for injection into the second zone and / or the third zone; and / or (f) the atmosphere pressure of the atmosphere in the third zone of the tin bath furnace; and A flow rate of a second process gas comprising argon and / or nitrogen injected adjacent the interface of the first zone and the second zone is determined so that hydrogen is not added to the atmosphere of the tin bath furnace via the injection of the second process gas to facilitate maintaining a preselected hydrogen content in the atmosphere throughout the tin bath furnace during glass formation from the ribbon.

2. The process according to claim 1, comprising: The second process gas is injected adjacent to the interface in the first zone, adjacent to the interface in the second zone, or at the interface.

3. The process according to claim 2, comprising: injecting the first process gas into the first zone; as well as The third process gas is injected into the second zone and / or the third zone downstream of the location where the second process gas is injected.

4. The process according to claim 1, comprising: receiving glass manufacturing data for the tin bath furnace at a host device to update process modeling, and updating the process modeling to determine whether one or more control parameters should be adjusted; and The host device communicates with a controller of the tin bath furnace or an operator device of the tin bath furnace to suggest adjustments to the one or more control parameters based on the updates to the process modeling.

5. The process according to claim 1, wherein: The method of determining one or more of the following items based on one or more of the following items: (a) the concentration of hydrogen and / or nitrogen included in a first process gas having nitrogen and / or argon for injection into a first zone of the tin bath furnace; (b) the flow rate of the first process gas for injection into the first zone; and / or (c) the atmosphere pressure of the atmosphere in the tin bath furnace in the first zone, comprising: determining a concentration of hydrogen to be included in the first process gas and a flow rate of the first process gas; and wherein based on one or more of the following items: (i) the thickness of the ribbon to be formed on the tin bath; (ii) the atmosphere conditions in the tin bath furnace; (iii) the ribbon speed; (iv) the ribbon width; (v) the tin conditions in the tin bath furnace; and / or (vi) the measured defects of the ribbon, one or more of the following items are determined: (d) the concentration of hydrogen and / or nitrogen included in a third process gas having nitrogen and / or argon for injection into a second zone and / or a third zone of the tin bath furnace; (e) the flow rate of the third process gas for injection into the second zone and / or the third zone; and / or (f) the atmosphere pressure of the atmosphere in the tin bath furnace in the third zone, comprising: A concentration of hydrogen to be included in the third process gas and a flow rate of the third process gas are determined.

6. The process according to claim 1, comprising: determining an atmosphere pressure of the tin bath furnace adjacent the interface of the first zone and the second zone; and The determination of the flow rate of the second process gas injected adjacent the interface of the first zone and the second zone is based on one or more of: (i) the thickness of the ribbon to be formed on the tin bath; (ii) the atmosphere conditions within the tin bath furnace; (iii) the ribbon speed; (iv) the ribbon width; (v) the tin conditions within the tin bath furnace; and / or (vi) the measured defects of the ribbon.

7. The process according to claim 1, comprising: exhausting gas extracted from the atmosphere in response to detecting particulate material exceeding or satisfying a first threshold; as well as Gas extracted from the atmosphere is recirculated after removing from the extracted gas particulate material entrained within the extracted gas in response to detecting the particulate material at or below a second threshold.

8. The process according to claim 1, comprising: The power level of one or more heating elements of the tin bath furnace is adjusted based on tin condensate detected within the atmosphere and / or the tin bath furnace.

9. The process of claim 8, wherein the adjusting of the power level is performed such that the heating element has increased power when the detected tin condensate is below a preselected low condensate threshold, and the heating element has decreased power when the detected tin condensate is at or above a preselected high condensate threshold.

10. The process according to claim 1, comprising: determining that glass to be produced from the ribbon has a quality within a preselected low quality threshold; as well as When the glass to be produced from the ribbon has the quality within the preselected low quality threshold, a purge flow is passed along heating elements mounted on top of the tin bath furnace to remove tin condensate from the heating elements and / or clean the heating elements.

11. An apparatus for facilitating control of tin bath furnace operation, comprising: a computer device having a processor and at least one transceiver, the processor being communicatively connected to a non-transitory computer-readable medium; The computer device is communicatively connected to a sensor of the tin bath furnace to receive data from the sensor; The computer device is configured to: Based on one or more of the following: (i) the thickness of the ribbon to be formed on the tin bath; (ii) the atmosphere conditions within the tin bath furnace; (iii) the ribbon speed; (iv) the ribbon width; (v) the tin conditions within the tin bath furnace; and / or (vi) the measured defects of the ribbon, determine one or more of the following: (a) the concentration of hydrogen and / or nitrogen included in a first process gas having nitrogen and / or argon for injection into a first zone of the tin bath furnace; (b) the flow rate of the first process gas for injection into the first zone; and / or (c) the atmosphere pressure of the atmosphere in the tin bath furnace in the first zone; Based on one or more of the following items: (i) the thickness of the tape to be formed on the tin bath; (ii) the atmosphere conditions within the tin bath furnace; (iii) the tape speed; (iv) the tape width; (v) the tin conditions within the tin bath furnace; and / or (vi) the measured defects of the tape, determine one or more of the following items: (d) the concentration of hydrogen and / or nitrogen included in a third process gas having nitrogen and / or argon for injection into the second zone and / or the third zone of the tin bath furnace; (e) the flow rate of the third process gas for injection into the second zone and / or the third zone; and / or (f) the atmosphere pressure of the atmosphere in the third zone of the tin bath furnace; and A flow rate of a second process gas comprising argon and / or nitrogen injected adjacent the interface of the first zone and the second zone is determined so that hydrogen is not added to the atmosphere of the tin bath furnace via the injection of the second process gas to facilitate maintaining a preselected hydrogen content in the atmosphere throughout the tin bath furnace during glass formation from the ribbon.

12. The apparatus of claim 11, wherein the computer device is a host device and the data from the sensor includes glass manufacturing data for the tin bath furnace, the host device being configured to update process modeling to determine whether one or more control parameters should be adjusted based on the data from the sensor; The host device may be communicatively coupled to a controller of the tin bath furnace or an operator device of the tin bath furnace to communicate suggested adjustments to the one or more control parameters based on the updates to the process modeling.

13. The apparatus of claim 11, wherein the computer device is configured to: The power level of one or more heating elements of the tin bath furnace is adjusted based on tin condensate detected within the atmosphere and / or the tin bath furnace.

14. The apparatus of claim 11, wherein the computer device is configured to adjust a power level of one or more heating elements of the tin bath furnace based on tin condensate detected within the atmosphere such that when the detected tin condensate is below a preselected low condensate threshold, the one or more heating elements have increased power, and when the detected tin condensate is at or above a preselected high condensate threshold, one or more of the heating elements have reduced power.

15. An apparatus for manufacturing glass, comprising: a tin bath furnace having a tin bath and an atmosphere above the tin bath, the tin bath furnace being configured to form a strip on the tin bath, the tin bath furnace having a first zone, a second zone, and a third zone, the second zone being between the first zone and the third zone; The tin bath furnace is connected to a hydrogen source, a nitrogen source and / or an argon source, such that: A first process gas having hydrogen mixed with nitrogen and / or argon may be injected into the first zone; a second process gas comprising argon and / or nitrogen may be injected adjacent an interface of the first zone and the second zone such that hydrogen is not added to the atmosphere of the tin bath furnace via the injection of the second process gas to facilitate maintaining a preselected hydrogen content in the atmosphere throughout the tin bath furnace during formation of glass from the ribbon; and A third process gas having hydrogen mixed with nitrogen and / or argon may be injected into the second zone and / or the third zone of the tin bath furnace upstream of where the second process gas may be injected.

16. The apparatus of claim 15, comprising heating elements mounted on top of the tin bath furnace, the heating elements being configured such that the power level of one or more of the heating elements can be adjusted based on tin condensate detected within the atmosphere and / or the heating elements.

17. The apparatus of claim 16, wherein the heating element is configured to adjust the power level such that when the detected tin condensate is at or below a preselected low condensate threshold, the heating element has increased power, and when the detected tin condensate is at or above a preselected high condensate threshold, the heating element has decreased power.

18. The apparatus of claim 15, comprising: A gas extraction system is in communication with the atmosphere of the tin bath furnace to extract particles entrained in the atmosphere gas of the tin bath furnace.

19. The apparatus according to claim 18, comprising: a plurality of sensors positioned to monitor the operation of the tin bath furnace, the sensors being communicatively connected to at least one computer device, The at least one computer device has a processor and at least one transceiver, the processor being communicatively connected to a non-transitory computer-readable medium; The at least one computer device is configured to: Based on one or more of the following: (i) the thickness of the ribbon to be formed on the tin bath; (ii) the atmosphere conditions within the tin bath furnace; (iii) the ribbon speed; (iv) the ribbon width; (v) the tin conditions within the tin bath furnace; and / or (vi) the measured defects of the ribbon, determine one or more of the following: (a) the concentration of hydrogen and / or nitrogen included in the first process gas having nitrogen and / or argon for injection into the first zone of the tin bath furnace; (b) the flow rate of the first process gas for injection into the first zone; and / or (c) the atmosphere pressure of the atmosphere in the tin bath furnace in the first zone; Based on one or more of the following items: (i) the thickness of the tape to be formed on the tin bath; (ii) the atmosphere conditions within the tin bath furnace; (iii) the tape speed; (iv) the tape width; (v) the tin conditions within the tin bath furnace; and / or (vi) the measured defects of the tape, determine one or more of the following items: (d) the concentration of hydrogen and / or nitrogen included in the third process gas having nitrogen and / or argon for injection into the second zone and / or the third zone of the tin bath furnace; (e) the flow rate of the third process gas for injection into the second zone and / or the third zone; and / or (f) the atmosphere pressure of the atmosphere in the third zone of the tin bath furnace; and The flow rate of the second process gas comprising argon and / or nitrogen injected into the interface adjacent the first zone and the second zone is determined so that hydrogen is not added to the atmosphere of the tin bath furnace via the injection of the second process gas to facilitate maintaining the preselected hydrogen content in the atmosphere throughout the tin bath furnace during glass formation from the ribbon.

20. The apparatus of claim 19, wherein the sensor comprises a sensor positioned and configured to measure hydrogen concentration, tin bath atmosphere dew point, and tin bath atmosphere oxygen potential in the first, second, and third zones.

21. The apparatus of claim 19, wherein the computer device is a host device, and the data from the sensor communicable with the host device includes glass manufacturing data for the tin bath furnace, the host device being configured to update process modeling to determine whether one or more control parameters should be adjusted based on the data from the sensor; The host device may be communicatively coupled to a controller of the tin bath furnace or an operator device of the tin bath furnace to communicate suggested adjustments to the one or more control parameters based on the updates to the process modeling.

Images