An on-line risk level quantification evaluation method for float glass spontaneous explosion source

Abstract

The application provides a kind of float glass self-explosion source online risk level quantification evaluation method, relating to glass processing technical field, comprising the following steps: 1) detecting equipment takes a photo to self-explosion defect, samples and tests defect composition to determine type, establishes defect type database, sets the weight of defect induced self-explosion by the expansion coefficient of defect under different temperature conditions;2) determine the number of self-explosion defects;3) determine the influence coefficient of different thickness glass plate on self-explosion;4) calculate the self-explosion coefficient of glass plate;5) establish three-level risk classification according to self-explosion coefficient, connect production line disposal.The application can guide production, reduce cost and improve quality.

Description

Technical Field

[0001] This invention relates to the field of glass processing technology, and in particular to a method for quantitatively evaluating the online risk level of spontaneous breakage sources in float glass. Background Technology

[0002] The internal defects and heterogeneous particles that cause float glass to spontaneously shatter without external force or significant impact, or during deep processing, are collectively referred to as spontaneous breakage sources. Mainstream spontaneous breakage sources include nickel sulfide particles, elemental silicon, alumina, metaaluminosilicates, refractory material debris, and metal inclusions. Industry statistics show that during the tempering and hot-dip immersion stages, spontaneous breakage caused by nickel sulfide particles and elemental silicon accounts for 95% of cases, with nickel sulfide particles being the most dominant.

[0003] In float glass production, nickel is introduced from key raw materials such as silica sand, and it can also be introduced into metal equipment used during processing and transportation. This makes the management of nickel introduction extremely complex and continuously drives up production costs. Currently, there are two main methods for managing the spontaneous explosion of nickel sulfide, both domestically and internationally: The first method involves selecting high-quality mineral raw materials with low nickel content during the float glass production stage, and simultaneously eliminating nickel-containing metal equipment during processing, or using non-metallic materials for physical isolation. This approach can effectively reduce spontaneous breakage, but it will significantly increase production costs.

[0004] The second method involves utilizing the self-explosion mechanism of nickel sulfide during the deep processing stage. Through homogenization (hot dipping), the glass sheets at risk of spontaneous explosion are detonated, eliminating the hazard and preventing potentially hazardous tempered glass from entering the market. This method is costly and results in significant losses. While it is mandated in Europe and the United States, it is not yet required in China. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention proposes a non-destructive self-destruction source risk level quantitative evaluation model for product quality control.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a method for quantitatively evaluating the online risk level of spontaneous breakage sources of float glass, comprising the following steps: 1) The detection equipment photographs the spontaneous explosion defects to confirm the location, quantity, and composition of the defects. The defect composition is determined by correlating the sampling and testing results with the photographed images. A defect type database is established, and the weight of the defect inducing spontaneous explosion is set based on the expansion coefficient of the defect under different temperature conditions. The rules for setting the weight of the defect inducing spontaneous explosion are as follows: the weights a for no obvious stress concentration, small harmless bubbles, and shallow surface defects are 1.1, 1.2, and 1.3, respectively; the weight b for clustered multiple defects is 1.2 to 1.5, and the greater the degree of defect aggregation, the larger the value of b; the weight c for the location of the defect on the plate surface is 1.2 to 1.8, and the closer to the center of the panel, the larger the value of c; the weight d for NiS-type particle defects is 1.3 to 2, and the value of d is proportional to the particle size; if there is no corresponding defect, the corresponding weight is 0.

[0007] 2) Take photos to obtain the number of self-explosion defects on the single board; 3) Determine the influence coefficient of glass plates of different thicknesses on spontaneous breakage; the influence coefficient f of glass plate thickness on spontaneous breakage is 1.2 to 2, and 1.2 for 6mm. The influence coefficient decreases as the glass plate thickness increases.

[0008] 4) Calculate the spontaneous breakage coefficient of the glass plate; the number of defects is n, and the spontaneous breakage coefficient of the glass plate is w = n * f * (a + b + c + d).

[0009] 5) Establish a three-tiered risk classification based on the self-explosion coefficient. The three risk levels are: w < 2 is Level I, 2 ≤ w < 8 is Level II, and 8 ≤ w is Level III. For production line handling: Level I (Very Low): Normal release. Level II (General): Can be used normally, but batches should be closely monitored. Level III (High): Online rejection / isolation, strictly prohibited from entering high-risk applications.

[0010] Traditional online inspection equipment for float glass can detect defects ≥200µm in size but cannot identify their type. Industry statistics show that tempered hot-dip galvanized glass spontaneous breakage defects are concentrated in the 100-600µm range. To address this issue, spontaneous breakage detection equipment was introduced to the float glass production line, capable of identifying heterogeneous defects in the 60-600µm range. After improving the production line's inspection accuracy and capabilities, we found a significant number of spontaneous breakage defects <200µm on the float glass sheets. Companies cannot treat all float glass containing such defects as defective. Since spontaneous breakage is caused by heterogeneous defects involving different types, quantities, glass thickness, depth, and size, these factors were integrated. An algorithm was used to quantify and rate the spontaneous breakage risk of float glass sheets on the production line. The rating data is then connected to the existing optimization system via the spontaneous breakage detection equipment for control, enabling the rejection and isolation of non-conforming products.

[0011] The public safety hazards caused by spontaneous breakage of glass in high-rise buildings are an urgent problem to be solved. In the production of large-scale float glass, there are numerous micro-defects smaller than 400µm. These micro-defects contain a significant number of impurities that are potential sources of spontaneous breakage. Manufacturers cannot completely remove glass sheets containing these sources. This invention integrates all spontaneous breakage factors and develops a quantitative evaluation method for spontaneous breakage. This method evaluates raw glass sheets containing spontaneous breakage sources and determines whether to reject or release the product based on the risk level. Simultaneously, the evaluation model allows for source tracing, tracking and optimizing raw material purity, production processes, and equipment to reduce and eliminate the generation of spontaneous breakage sources, thereby lowering the risk of product spontaneous breakage. Detailed Implementation

[0012] The following are specific embodiments of the present invention, which further describe the technical solution of the present invention, but the present invention is not limited to these embodiments.

[0013] The judgment results were verified by a hot-dip test, which simulates the tempering temperature. The experimental data are shown in the table below.

[0014]

[0015] The first round of hot-dip testing resulted in a Level III (high) test piece with a 100% spontaneous breakage rate, while the Level II (general) spontaneous breakage rate was 13%. To verify its guiding value, multiple rounds of hot-dip testing can be conducted. Level II pieces can be subsequently repaired for defects. This method is used to identify glass plate defects online and guide production.

[0016] The specific embodiments described herein are merely illustrative of the spirit of the invention. Those skilled in the art to which this invention pertains may make various modifications or additions to the described specific embodiments or use similar methods to substitute them, without departing from the spirit of the invention or exceeding the scope defined by the appended claims.

Claims

1. A method for quantitatively evaluating the online risk level of spontaneous breakage sources in float glass, characterized in that, Includes the following steps: 1) The detection equipment takes pictures of the spontaneous explosion defects, samples and analyzes the defect components to determine the type, establishes a defect type database, and sets the weight of the defect in causing spontaneous explosion by using the expansion coefficient of the defect under different temperature conditions. 2) Determine the number of self-explosion defects; 3) Determine the influence coefficient of glass plates of different thicknesses on spontaneous breakage; 4) Calculate the spontaneous breakage coefficient of the glass plate; 5) Establish a three-level risk classification based on the self-explosion coefficient and coordinate with the production line for handling.

2. The method for quantitatively evaluating the online risk level of spontaneous explosion sources of float glass according to claim 1, characterized in that, The weighting rules for defect-induced spontaneous explosion are as follows: the weights a for no obvious stress concentration, small harmless bubbles, and shallow surface defects are 1.1, 1.2, and 1.3, respectively; the weight b for clustered multiple defects is 1.2 to 1.5; the weight c for the location of the defect on the panel surface is 1.2 to 1.8, with the value of c increasing as it approaches the center of the panel; the weight d for NiS-type particle defects is 1.3 to 2, with the value of d being proportional to the particle size; and the weight for no corresponding defect is 0.

3. The method for quantitatively evaluating the online risk level of spontaneous explosion sources of float glass according to claim 1, characterized in that, The influence coefficient f of glass plate thickness on spontaneous breakage is 1.2 to 2, and 1.2 for 6 mm. The influence coefficient decreases as the glass plate thickness increases.

4. The method for quantitatively evaluating the online risk level of spontaneous explosion sources of float glass according to claim 1, characterized in that, The number of defects is n, and the spontaneous breakage coefficient of the glass plate is w = n * f * (a + b + c + d).

5. The method for quantitatively evaluating the online risk level of spontaneous explosion sources of float glass according to claim 1, characterized in that, The three-level risk classification based on the self-destruction coefficient is as follows: w < 2 is Level I, 2 ≦ w < 8 is Level II, and 8 ≦ w is Level III.

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