System and method for monitoring and controlling glass no-rafts

Abstract

A system, method, and computer program product for monitoring and controlling unmelted compound materials in a glass melting furnace comprises at least one camera configured to capture image data inside the glass melting furnace and at least one processor programmed or configured to receive image data, define a region of interest in the image data, identify a distribution area of ​​unmelted compound materials in the region of interest, compare the distribution area of ​​unmelted compound materials with a predetermined set value, and determine a deviation between the distribution area of ​​unmelted compound materials and the predetermined set value. In response to the deviation between the distribution area of ​​unmelted compound materials and the predetermined set value, the crown temperature distribution in the longitudinal direction inside the glass melting furnace is controlled based on a temperature control model.

Description

Technology Field

[0001] Cross-reference regarding related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 617,440 filed January 4, 2024 and U.S. Application No. 19 / 008,013 filed January 2, 2025, the disclosures of which are incorporated herein by reference in their entirety.

[0003] Technology field

[0004] The present disclosure generally relates to monitoring and controlling the operation of a glass melting furnace to automate the operation of the glass melting furnace, and in some non-limiting embodiments or aspects, to a system, method, and computer program product for controlling and monitoring unmelted compound materials in a glass melting furnace. Background Technology

[0005] Technical considerations

[0006] A continuous glass melting furnace is a critical component of the glass manufacturing process, designed to melt raw materials and maintain a consistent and continuous flow of molten glass for further processing. These furnaces are typically used to manufacture various types of glass, such as flat glass (used for windows and mirrors) or container glass (used for bottles and jars).

[0007] Raw materials, typically comprising silica sand, soda ash, limestone, and other additives, are prepared in precise proportions according to the desired glass composition and fed into the melting tank of a glass melting furnace via a hopper or conveyor system. The mixture of raw materials is heated to very high temperatures [often exceeding 2,000 degrees Fahrenheit (1,100 degrees Celsius)] to melt and fuse the materials together, forming homogeneous molten glass. As the mixture of raw materials passes through the melting tank, the mixture gradually melts, and by the time the molten glass reaches the outlet of the melting tank, any unmelted mixture material is gone.

[0008] Conventional glass melting furnaces typically operate under a control scheme in which a controller modifies the fuel flow rate for one or more burners to maintain a desired furnace temperature profile when measured by one or more temperature sensors. The furnace operator selects the desired furnace temperature profile based on current operating conditions and the desired glass 'manufacturing method'. The furnace temperature profile is determined primarily by empirical rules, where melting behavior is visually observed through one or more ports within the furnace, and the fuel flow rate is adjusted to maintain the desired distribution area of ​​unmelted compound material within the melting tank. The selected furnace temperature profile is determined by considering the balance between efficiency and glass quality. Temperatures that are too high will melt all of the compound material but require too much fuel, whereas temperatures that are too low will not melt all of the compound material, resulting in defects in the glass.

[0009] There is a need in the field for improved systems and methods to control the operation of glass melting furnaces.

[0010] A system, method, and computer program product for controlling and monitoring unmelted compound materials in a glass melting furnace are disclosed.

[0011] According to some embodiments or aspects of the present disclosure, a system for monitoring and controlling unmelted compound materials in a glass melting furnace is provided. The system may include at least one camera configured to capture image data inside the glass melting furnace and at least one processor, wherein the at least one processor is programmed or configured to receive image data from the at least one camera. The at least one processor may be further programmed or configured to define regions of interest in the image data corresponding to one or more zones of the glass melting portion inside the glass melting furnace. The at least one processor may be further programmed or configured to identify the distribution area of ​​unmelted compound materials in each of the one or more zones based on at least one characteristic of the image data, compare the distribution area of ​​the unmelted compound materials with a predetermined set value, and determine the deviation between the distribution area of ​​the unmelted compound materials and the predetermined set value. In response to the deviation between the distribution area of ​​the unmelted compound materials and the predetermined set value, the at least one processor may be further programmed or configured to control the crown temperature distribution in the longitudinal direction inside the glass melting furnace based on a temperature control model. The present model determines a desired temperature change in at least one of one or more zones, wherein the desired temperature change may include corresponding to a desired change in the distribution area of ​​the unmelted compound material. The model may further include using a temperature distribution matrix to convert the desired temperature change into a plurality of crown temperature trim setpoints. A computer program product for monitoring and controlling an unmelted compound material in a glass melting furnace, and a method for monitoring and controlling an unmelted compound material in a glass melting furnace are also disclosed.

[0012] The features and characteristics of the present disclosure, as well as the methods of operation and functions of the relevant elements of the structure, and the combination of parts and manufacturing economics will become more apparent when considering the following description with reference to the accompanying drawings and the appended claims, all of which form part of the present specification, where similar reference numbers designate corresponding parts in various drawings. Brief explanation of the drawing

[0013] FIG. 1 is a representative schematic diagram of a glass melting furnace according to some embodiment or aspect of the present disclosure. FIG. 2 is a diagram of a non-limiting embodiment or aspect of a component of a system for monitoring and controlling the non-melting formulation material shown in FIG. 1. Figures 3 and 4 are schematic plan views of a furnace equipped with a system for monitoring and controlling unmelted compound materials. Figure 5 is a graph showing the area of ​​unmelted compound material in various parts of a glass melting furnace as a function of time. Figure 6 is a graph showing the temperature in various regions of a glass melting furnace as a function of time. Figure 7 is a graph showing the change in the crown temperature profile on the fill side and waist side of the glass melting furnace during the first empirical test. Figure 8 is a graph showing the crown temperature profile during the first empirical test. Figure 9 is a graph showing the change in the crown temperature profile of the charging side and the narrow side of the glass melting furnace during the second empirical test. Figure 10 is a graph showing the crown temperature profile during the second empirical test. Figure 11 is a graph showing the change in the crown temperature profile as a function of time. Figure 12a is a graph showing the deviation of the area of ​​the unmelted mixture material as a function of time. Figure 12b is a graph showing the temperature change of the furnace's charging end as a function of time. Figure 12b is a graph showing the temperature change of the furnace's narrow end as a function of time. Figure 13 is a graph comparing the deviation of the model versus the measured value of the unmelted compound material area as a function of time. FIG. 14 is a screenshot of a representative graphical user interface of a system for monitoring and controlling unmelted compound materials according to some embodiments or aspects of the present disclosure. Figure 15 is a screenshot of another representative graphical user interface of the system for monitoring and controlling unmelted compound materials. FIG. 16 is a flowchart of a non-limiting embodiment or aspect of a process for monitoring and controlling unmelted formulation materials. In FIGS. 1–16, similar characters refer to the same components and elements in some cases, unless otherwise noted. Specific details for implementing the invention

[0014] The following description is provided to enable a person skilled in the art to make and use the described embodiments considered for carrying out the present disclosure. However, various modifications, equivalents, variations, and alternatives will be readily apparent to a person skilled in the art. Any and all modifications, variations, equivalents, and alternatives are intended to fall within the spirit and scope of the present disclosure.

[0015] The singular forms used herein include multiple referents unless otherwise stated. With respect to the use of any plural and / or singular terms herein, a person skilled in the art may translate from plural to singular and / or singular to plural as appropriate to the context and / or application. Various singular / plural substitutions are not expressly described herein for the sake of clarity.

[0016] Spatial or directional terms such as 'left', 'right', 'inner', 'outer', 'up', 'down', etc. relate to the embodiments or modes depicted in the drawings and should not be construed as limiting, as the embodiments or modes may take various alternative orientations.

[0017] All numbers used in this specification and claims should be understood as being modified by the term “about” in all cases. “About” means plus or minus 25 percent of the stated value, e.g. plus or minus 10 percent of the stated value. However, this should not be construed as being limited to any analysis of the value according to the doctrine of equivalents.

[0018] Unless otherwise indicated, all ranges or ratios disclosed herein shall be understood to encompass starting and ending values ​​and any and all sub-ranges or sub-ratios contained therein. For example, a specified range or ratio of '1 to 10' shall be deemed to include any and all sub-ranges or sub-ratios between (and including) a minimum value of 1 and a maximum value of 10, that is, all sub-ranges or sub-ratios starting with a minimum value of 1 or greater and ending with a maximum value of 10 or less. The ranges and / or ratios disclosed herein represent average values ​​for the specified ranges and / or ratios.

[0019] Terms such as 'first', 'second', etc., are not intended to refer to any specific order or chronology, but rather to refer to different conditions, attributes, or elements.

[0020] All documents mentioned in this document are 'referenced' in their entirety.

[0021] The term 'at least' is synonymous with 'more than'.

[0022] The term 'not greater than' is synonymous with 'less than'.

[0023] In some cases, one or more components may be referred to herein as 'configured,' 'operable,' 'adapted,' etc. A person skilled in the art will recognize that, unless the context otherwise requires, 'configured' may generally encompass active components and / or inactive components and / or standby components.

[0024] Some modalities may be described using the expressions 'combined' and 'connected' along with their derivatives. It should be understood that these terms are not intended to be synonyms for one another. For example, some modalities may be described using the term 'connected' to indicate that two or more elements are in direct physical or electrical contact with each other. In another example, some modalities may be described using the term 'combined' to indicate that two or more elements are in direct physical or electrical contact with each other. However, the term 'combined' can also mean that two or more elements do not come into direct contact with each other but still cooperate or interact with each other.

[0025] The objects described herein exemplify different components that are contained within or connected to different components. It should be understood that the architectures depicted are merely exemplary and that many other architectures may be implemented to achieve virtually the same function. In a conceptual sense, any arrangement of components to achieve the same function is effectively 'associated' so that the desired function is achieved. For this reason, any two components of the present invention combined to achieve a specific function may be seen as 'associated' to each other to achieve the desired function, regardless of the architecture or intermediate components. Likewise, any two components so associated may also be seen as 'operably connected' or 'operably combined' to achieve the desired function, and any two components so associated may also be seen as 'operably combined' to achieve the desired function. Specific examples of components that can be operatedly combined include, but are not limited to, physically combineable and / or physically interacting components.

[0026] Some non-limiting embodiments or aspects may be described herein with respect to thresholds. As used herein, satisfying a threshold may refer to values ​​greater than the threshold, more than the threshold, higher than the threshold, greater than the threshold, less than the threshold, less than the threshold, lower than the threshold, less than the threshold, equal to the threshold, etc.

[0027] Furthermore, even if a specific number of introduced claims are explicitly listed, a person skilled in the art will recognize that such listing should be interpreted to mean at least the number listed (e.g., a basic listing of 'two listings' without other modifiers typically means at least two listings, or two or more listings). Additionally, where conventions similar to 'at least one of A, B, and C, etc.' are used, such configurations are generally intended to have meaning in the sense that a person skilled in the art would understand the convention (e.g., 'a system having at least one of A, B, and C' includes, but is not limited to, a system having A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together). Where conventions similar to ‘at least one of A, B, or C, etc.’ are used, such configurations are generally intended in the sense that a person skilled in the art would understand the convention (e.g., ‘a system having at least one of A, B, or C’ would include, but not be limited to, a system having A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, etc.). It will be further understood by a person skilled in the art that disjunctive words and / or phrases, whether in descriptions, claims, or drawings, which typically present two or more alternative terms, should be understood to include the possibility of one of the terms, either of the terms, or both of the terms, unless the context otherwise indicates. For example, the phrase ‘A or B’ would typically be understood to include the possibility of ‘A’ or ‘B’ or ‘A and B’.

[0028] Where conventions similar to 'A and / or B' are used, such configurations are generally intended to have meaning in the sense that a person skilled in the art will understand the convention (e.g., 'A and / or B' may include, but is not limited to, A alone, B alone, or a system having A and B together).

[0029] The term 'include' is synonymous with 'comprise'.

[0030] It should be noted that any reference to "one embodiment," "one aspect," or "one aspect" implies that a specific feature, structure, or characteristic described in relation to such embodiment or aspect is included in at least one embodiment or aspect. Accordingly, the appearance of the phrases "in one embodiment," "in one aspect," or "in one aspect" in various places throughout this specification does not necessarily refer to the same aspect or embodiment. Furthermore, a specific feature, structure, or characteristic may be combined in any suitable manner in one or more embodiments or aspects.

[0031] A person skilled in the art will recognize that the components (e.g., operations), devices, objects, and accompanying discussions described herein are used as examples for conceptual clarity and that various configuration modifications are considered. Consequently, as used herein, the specific examples and accompanying discussions are intended to represent a more general class. In general, any use of specific examples is intended to represent a class, and the exclusion of specific components (e.g., operations), devices, and objects should not be construed as limiting.

[0032] As used herein, the term “system” may refer to one or more computing devices or combinations of computing devices, such as but not limited to processors, servers, client devices, software applications, and / or other similar components. Additionally, references to “server” or “processor” as used herein may refer to previously cited servers and / or processors, different servers and / or processors, and / or combinations of servers and / or processors, which are specified to perform a prior stage or function. For example, as used in this specification and claims, a first server and / or first processor specified to perform a first stage or function may refer to the same or different servers and / or processors specified to perform a second stage or function.

[0033] Float glass furnaces are widely used in the glass industry to produce high-quality flat glass. The basic concept involves melting raw materials such as silicon, soda ash, and limestone in the furnace and 'floating' the molten glass in a melt bath to produce flat, uniform glass ribbons. Traditional float glass furnaces have inherent limitations such as thermal inefficiency, material waste, and structural brittleness, which this patent application aims to address.

[0034] The following numbered provisions exemplify various aspects of the present disclosure.

[0035] Clause 1: A system for monitoring and controlling unmelted compound materials within a glass melting furnace, comprising: at least one camera configured to capture image data inside the glass melting furnace; and at least one processor, wherein the at least one processor receives image data from at least one camera, defines a region of interest in the image data corresponding to one or more zones of the glass melting portion inside the glass melting furnace, identifies the distribution area of ​​unmelted compound materials in each of the one or more zones based on at least one characteristic of the image data, compares the distribution area of ​​the unmelted compound materials with a predetermined set value, determines the deviation between the distribution area of ​​the unmelted compound materials and the predetermined set value, and is programmed or configured to control the crown temperature distribution in the longitudinal direction inside the melting furnace based on a temperature control model in response to the deviation between the distribution area of ​​the unmelted compound materials and the predetermined set value, wherein the temperature control model determines a desired temperature change of at least one of the one or more zones, the desired temperature change corresponds to a desired change in the distribution area of ​​the unmelted compound materials; A system comprising converting the desired temperature change into a plurality of crown temperature trim set values ​​using a temperature distribution matrix.

[0036] Clause 2: In Clause 1, the system comprises a temperature distribution matrix including a plurality of temperature trim multipliers corresponding to a plurality of crown temperature trim set values.

[0037] Clause 3: A system in Clause 1 or 2, wherein the desired temperature change includes a weighted fill-side temperature change and a weighted waist-side temperature change.

[0038] Clause 4: A system in which, in any one of Clauses 1 to 3, controlling the crown temperature distribution includes increasing or decreasing the supply of gas to at least one burner.

[0039] Clause 5: A system further programmed or configured, wherein, in any one of Clauses 1 to 4, at least one processor identifies a melting front of an unmelted compound material in each of one or more zones based on at least one characteristic of image data, compares the melting front of the unmelted compound material with a predetermined melting front setpoint, determines a deviation between the melting front of the unmelted compound material and the predetermined melting front setpoint, and controls a crown temperature distribution using a temperature control model in response to the deviation between the melting front of the unmelted compound material and the predetermined melting front setpoint.

[0040] Clause 6: A system in which, in any one of Clauses 1 through 5, at least one processor is programmed or configured to generate a warning in response to determining that the distribution area of ​​the unmelted compound material is outside a predetermined threshold range.

[0041] Clause 7: In any one of Clauses 1 through 6, the warning is at least one of a visual warning and an auditory warning, the system.

[0042] Clause 8: A system in which, in any one of Clauses 1 through 7, at least one characteristic of the image data is an image contrast value.

[0043] Clause 9: A system in which, in any one of Clauses 1 through 8, at least one characteristic of the image data is an image brightness value.

[0044] Clause 10: In any one of Clauses 1 through 9, one or more zones are defined between the inlet of the glass melting furnace and the bubbler area, in a system.

[0045] Clause 11: In any one of Clauses 1 through 10, a system comprising one or more zones including a charging zone at the inlet of a glass melting furnace, a bubbler zone of a bubbler area of ​​a glass melting furnace, and an intermediate zone between the charging zone and the bubbler zone.

[0046] Clause 12: A system in which, in any one of Clauses 1 through 11, at least one processor is programmed or configured to average image data over a preset period to correct for thermal disturbances in the image data.

[0047] Clause 13: A system in which, in any one of Clauses 1 through 12, at least one camera is a pair of cameras located at the exit of a glass melting furnace.

[0048] Clause 14: A system in which, in any one of Clauses 1 through 13, at least one camera comprises a liquid cooling jacket.

[0049] Clause 15: In any one of Clauses 1 to 14, the liquid cooling jacket comprises a nitrogen purge for cleaning at least one lens of a camera.

[0050] Clause 16: In any one of Clauses 1 through 15, at least one camera is a system operating in the visible light spectrum.

[0051] Clause 17: A system in which, in any one of Clauses 1 through 16, at least one camera is configured to capture black-and-white still or video images inside a glass melting furnace.

[0052] Clause 18: A system in which, in any one of Clauses 1 through 17, at least one camera is configured to capture color still or video images inside a glass melting furnace.

[0053] Clause 19: A computer program product for monitoring and controlling unmelted compound material in a glass melting furnace, comprising at least one non-transient computer-readable medium containing one or more instructions, wherein when executed by at least one processor, said one or more instructions cause the at least one processor to receive image data inside the glass melting furnace from at least one camera, define a region of interest in the image data corresponding to one or more zones of the glass melting portion inside the glass melting furnace, identify the distribution area of ​​the unmelted compound material in each of the one or more zones based on at least one characteristic of the image data, compare the distribution area of ​​the unmelted compound material with a predetermined set value, determine the deviation between the distribution area of ​​the unmelted compound material and the predetermined set value, and, in response to the deviation between the distribution area of ​​the unmelted compound material and the predetermined set value, control the crown temperature distribution in the longitudinal direction inside the glass melting furnace based on a temperature control model, wherein the temperature control model determines a desired temperature change in at least one of the one or more zones, the desired temperature change corresponds to a desired change in the distribution area of ​​the unmelted compound material; A computer program product comprising converting a desired temperature change into multiple crown temperature trim set values ​​using a temperature distribution matrix.

[0054] Clause 20: A computer program product in which, in Clause 19, the temperature distribution matrix comprises a plurality of temperature trim multipliers corresponding to a plurality of crown temperature trim set values.

[0055] Clause 21: A computer program product in Clause 19 or 20, wherein the desired temperature change includes a weighted charging side temperature change and a weighted narrow side temperature change.

[0056] Clause 22: A computer program product in which, in any one of Clauses 19 to 21, controlling the crown temperature distribution includes increasing or decreasing the supply of gas to at least one burner.

[0057] Clause 23: A computer program product wherein, in any one of Clauses 19 to 22, one or more instructions, when executed by at least one processor, cause at least one processor to further identify the melting front of an unmelted compound material in each of one or more zones based on at least one characteristic of image data, compare the melting front of the unmelted compound material with a predetermined melting front setting value, determine the deviation between the melting front of the unmelted compound material and the predetermined melting front setting value, and control the crown temperature distribution using a temperature control model in response to the deviation between the melting front of the unmelted compound material and the predetermined melting front setting value.

[0058] Clause 24: A computer program product wherein, in any one of Clauses 19 to 23, one or more instructions, when executed by at least one processor, cause at least one processor to generate a warning in response to determining that the distribution area of ​​the unmelted compound material is outside a predetermined threshold range.

[0059] Clause 25: A computer program product in which, in any one of Clauses 19 through 24, the warning is at least one of a visual warning and an auditory warning.

[0060] Clause 26: A computer program product in which, in any one of Clauses 19 through 25, at least one characteristic of the image data is an image contrast value.

[0061] Clause 27: A computer program product in which, in any one of Clauses 19 through 26, at least one characteristic of the image data is an image brightness value.

[0062] Clause 28: In any one of Clauses 19 through 27, one or more zones are defined between the inlet of the glass melting furnace and the bubbler area, in a computer program product.

[0063] Clause 29: A computer program product wherein, in any one of Clauses 19 through 28, one or more zones include a charging zone at the inlet of a glass melting furnace, a bubbler zone of a bubbler area of ​​a glass melting furnace, and an intermediate zone between the charging zone and the bubbler zone.

[0064] Clause 30: A computer program product wherein, in any one of Clauses 19 to 29, one or more instructions are executed by at least one processor, and at least one processor further averages the image data over a preset period to correct for thermal disturbances in the image data.

[0065] Clause 31: A method for monitoring and controlling unmelted compound material in a glass melting furnace, comprising: receiving image data inside the glass melting furnace from at least one camera using at least one processor; defining a region of interest in the image data corresponding to one or more zones of the glass melting portion inside the glass melting furnace using at least one processor; identifying a distribution area of ​​unmelted compound material in one or more zones based on at least one characteristic of the image data using at least one processor; comparing the distribution area of ​​the unmelted compound material with a predetermined set value; determining a deviation between the distribution area of ​​the unmelted compound material and the predetermined set value using at least one processor; and controlling a crown temperature distribution in the longitudinal direction inside the glass melting furnace based on a temperature control model using at least one processor in response to the deviation between the distribution area of ​​the unmelted compound material and the predetermined set value, wherein the temperature control model determines a desired temperature change of at least one of one or more zones, and the desired temperature change corresponds to a desired change in the distribution area of ​​the unmelted compound material. A method comprising converting a desired temperature change into a plurality of crown temperature trim set values ​​using a temperature distribution matrix.

[0066] Clause 32: The method of Clause 31, wherein the temperature distribution matrix comprises a plurality of temperature trim multipliers corresponding to a plurality of crown temperature trim set values.

[0067] Clause 33: The method in Clause 31 or 32, wherein the desired temperature change includes a weighted charging side temperature change and a weighted narrow side temperature change.

[0068] Clause 34: In any one of Clauses 31 to 33, at least one operation is a method of increasing or decreasing the supply of gas to at least one burner.

[0069] Clause 35: A method further comprising, in any one of Clauses 31 to 34, the step of identifying the melting front of an unmelted compound material in each of one or more zones based on at least one characteristic of image data; the step of comparing the melting front of the unmelted compound material with a predetermined melting front set value; the step of determining the deviation between the melting front of the unmelted compound material and the predetermined melting front set value; and the step of controlling the crown temperature distribution using a temperature control model in response to the deviation between the melting front of the unmelted compound material and the predetermined melting front set value.

[0070] Clause 36: A method further comprising the step of generating a warning in response to determining that the distribution area of ​​the unmelted compound material is outside a predetermined threshold range in any one of Clauses 31 to 35.

[0071] Clause 37: In any one of Clauses 31 through 36, the warning is at least one of a visual warning and an auditory warning.

[0072] Clause 38: A method in which, in any one of Clauses 31 through 37, at least one characteristic of the image data is an image contrast value.

[0073] Clause 39: A method in which, in any one of Clauses 31 to 38, at least one characteristic of the image data is an image brightness value.

[0074] Clause 40: In any one of Clauses 31 through 39, one or more zones are defined between the inlet of the glass melting furnace and the bubbler area, method.

[0075] Clause 41: A method in which, in any one of Clauses 31 to 40, one or more zones comprise a charging zone at the inlet of a glass melting furnace, a bubbler zone of a bubbler area of ​​a glass melting furnace, and an intermediate zone between the charging zone and the bubbler zone.

[0076] Clause 42: A method comprising, in any one of Clauses 31 to 41, an additional step of averaging image data over a preset period to correct for heat-related disturbances in the image data.

[0077] Referring to FIG. 1, a float glass furnace (100) [hereinafter referred to as 'furnace (100)'] according to one embodiment or aspect of the present disclosure is illustrated. The furnace (100) has a tank (102) contained within a sealed chamber (104) made of a refractory material resistant to high temperatures. The furnace (100) has an input end (106) (also referred to herein as 'input end' or 'input side') having at least one input opening (108) through which a mixture material is supplied into the tank (102). An output end (110) (also referred to herein as 'narrow end' or 'narrow side') having at least one outlet opening (112) through which molten glass exits the furnace (100) is located opposite the input end (106). A plurality of burners (114) are positioned between the input end (106) and the output end (110) and extend into the interior of the sealed chamber (104). Burners (114) may be provided on both sides of the sealed chamber (104). Each burner (114) is connected to a burner controller (116) configured to control the amount of fuel supplied to the burner (114). The burners (114) are spaced apart along the longitudinal length of the furnace (100) to distribute energy supply over most of the length of the tank (102). One or more sensors (118) are provided to measure the temperature inside the sealed chamber (104). One or more sensors (118) are connected to the burner controller (116) and may provide input signals to the burner controller (116) to control the output of the burner (114). As a result of the positioning of the burner (114) and fuel supply, the temperature profile inside the sealed chamber (104) viewed along the longitudinal length of the furnace (100) between the input end (106) and the output end (110) is typically referred to as the 'crown temperature'.

[0078] Referring again to FIG. 1, the furnace (100) includes a system (200) configured for monitoring and controlling unmelted compound materials within the furnace (100). The system (200) is configured to control the temperature within the sealed chamber (104) in an optimized manner to produce molten glass with minimal or no defects while minimizing energy usage for heating the sealed chamber (104) by using real-time melt measurements and applying a model-based predictive control method. The system (200) includes at least one camera (201) and at least one controller (202) configured to receive image data from at least one camera (201). In some embodiments or aspects, the at least one camera (201) may be a pair of cameras (201) provided on the left and right sides of the discharge end (110) of the furnace (100). Each of the pair of cameras (201) may be connected to a common controller (202). Alternatively, each of the pair of cameras (201) may be connected to a separate controller (202).

[0079] Now, referring to FIG. 2, a diagram of an exemplary component of the system (200) is illustrated. In some embodiments or aspects, the system (200) may include a bus (203), a processor (204), a memory (206), a storage component (208), an input component (210), an output component (212), and a communication interface (214).

[0080] The bus (203) may include components that enable communication between components of the system (200). In some non-limiting embodiments or aspects, the processor (204) may be implemented in hardware, software, or a combination of hardware and software. For example, the processor (204) may include a processor [e.g., a central processing unit (CPU), a graphics processing unit (GPU), an accelerated processing unit (APU), etc.], a microprocessor, a digital signal processor (DSP), and / or any processing component that can be programmed to perform a function [e.g., a field-programmable gate array (FPGA), an application-specific integrated circuit (ASIC), etc.]. The memory (206) may include random access memory (RAM), read-only memory (ROM), and / or another type of dynamic or static storage device (e.g., flash memory, magnetic memory, optical memory, etc.) for storing information and / or instructions for use by the processor (204).

[0081] The storage component (208) may store information and / or software related to the operation and use of the device (200). For example, the storage component (208) may include a hard disk [e.g., magnetic disk, optical disk, magneto-optical disk, solid-state disk, etc.], a compact disc (CD), a digital versatile disc (DVD), a floppy disk, a cartridge, a magnetic tape, and / or another type of computer-readable media along with a corresponding drive.

[0082] The input component (210) may include a component that enables the system (200) to receive information through user input, for example, a touchscreen display, keyboard, keypad, mouse, button, switch, microphone, camera, etc. Additionally or alternatively, the input component (210) may include a sensor [e.g., sensor (118)] and / or a camera [e.g., camera (201)] for detecting information (e.g., temperature information). The output component (212) may include a component that provides output information from the system (200) [e.g., at least one display, speaker, light-emitting diode (LED), etc.].

[0083] The communication interface (214) may include components similar to a transceiver (e.g., a transceiver, a separate receiver and transmitter, etc.) that enable the system (200) to communicate with another device, for example, through a wired connection, a wireless connection, or a combination of a wired connection and a wireless connection. In some embodiments or aspects, the communication interface (214) may be configured to enable communication with the burner controller (116). The communication interface (214) may enable the system (200) to receive information from another device and / or provide information to another device. For example, the communication interface (214) may be an Ethernet interface, an optical interface, a coaxial interface, an infrared interface, a radio frequency (RF) interface, a universal serial bus (USB) interface, or a Wi-Fi interface. ®It may include an interface, a cellular network interface and / or similar. The communication interface (214) may additionally enable the system (200) to receive information from another device and / or provide information to another device through a communication network that may include one or more wired and / or wireless networks. For example, a communication network may include cellular networks [e.g., long-term evolution (LTE) networks, third generation (3G) networks, fourth generation (4G) networks, code division multiple access (CDMA) networks, etc.], public land mobile networks (PLMN), local area networks (LAN), wide area networks (WAN), metropolitan area networks (MAN), telephone networks [e.g., public switched telephone network (PSTN)], private networks, ad hoc networks, intranets, the Internet, fiber-optic-based networks, cloud computing networks, and / or similar ones, and / or some or all of these or other types of networks combined.

[0084] The system (200) may perform one or more of the processes described herein. The system (200) may perform these processes based on the processor (204) executing software instructions stored by a computer-readable medium, such as memory (206) and / or storage components (208). A computer-readable medium (e.g., a non-transient computer-readable medium) is defined herein as a non-transient memory device. A non-transient memory device includes a memory space located within a single physical storage device or a memory space spread across multiple physical storage devices.

[0085] Software instructions may be read into memory (206) and / or storage components (208) from another computer-readable medium or from another device via a communication interface (214). Software instructions stored in memory (206) and / or storage components (208) may cause the processor (204) to perform one or more processes described herein when executed. Additionally, or alternatively, hardwired circuits may be used instead of or in combination with software instructions to perform one or more processes described herein. Accordingly, the embodiments or aspects described herein are not limited to any specific combination of hardware circuits and software.

[0086] The memory (206) and / or storage component (208) may include a data store or one or more data structures (e.g., a database, and / or similar). The system (200) may receive information from the data store or one or more data structures within the memory (206) and / or storage component (208), store information therein, communicate information therein, or retrieve information stored therein. For example, the information may include data associated with a profile set, input data, output data, or any combination thereof.

[0087] The number and arrangement of the components shown in FIG. 2 are provided as examples. In some non-limiting embodiments or aspects, the system (200) may include additional components, fewer components, different components, or differently arranged components than those shown in FIG. 2. Additionally or alternatively, a set of components of the system (200) (e.g., one or more components) may perform one or more functions described as being performed by another set of components of the system (200).

[0088] The number and arrangement of systems and / or devices shown in FIG. 2 are provided as examples. There may be additional systems and / or devices, fewer systems and / or devices, different systems and / or devices, or systems and / or devices arranged differently than those shown in FIG. 2. Additionally, two or more systems or devices shown in FIG. 2 may be implemented within a single system or single device, or a single system or single device shown in FIG. 2 may be implemented as a plurality of distributed systems or devices.

[0089] Referring to FIGS. 3 and 4, a plan view of the furnace (100) is shown with cameras (201) installed on the left and right sides of the discharge end (110). Although FIGS. 3 and 4 show a pair of cameras (201), in some embodiments or aspects, the system (200) may have one or more than two cameras (201). For example, the system (200) may have a single camera (201) installed on the discharge end (110) of the furnace (100) or any other part of the furnace (100).

[0090] Each camera (201) may be a high-temperature camera configured for use in the extreme temperature environment of the furnace (100). In some embodiments or aspects, the camera (201) may have a water-cooling jacket (220) provided within a metal tube (222) inserted through the wall of the discharge end (110) of the furnace (100). In some embodiments or aspects, the metal tube (222) may be made of Inconel. Nitrogen purge may be provided to cool the metal tube (222) and keep the lens of the camera (201) clean. In some embodiments or aspects, the camera (201) may be a visible light camera configured to capture black-and-white or color image data inside the furnace (100). In additional embodiments or aspects, the camera (201) may be an infrared camera configured to capture image data in the infrared light spectrum. In some embodiments or aspects, the camera (201) may be manufactured by JM Canty, Inc. in Buffalo, New York.

[0091] Referring continuously to FIGS. 3 and 4, each camera (201) is configured to capture image data inside the furnace (100). In some embodiments or aspects, the left camera (201) may be configured to capture image data of the left portion inside the furnace (100), and the right camera (201) may be configured to capture image data of the right portion inside the furnace (100). In additional embodiments or aspects, the left camera (201) may be configured to capture image data of the right portion inside the furnace (100), and the right camera (201) may be configured to capture image data of the left portion inside the furnace (100). In various embodiments or aspects, the image data captured by the camera (201) may be combined into a single image using a controller (202).

[0092] Image data can be used to determine the unmelted portion of the compound material within the glass melting portion (120) of the furnace (100). Various characteristics of the image data, such as image contrast, brightness, and other characteristics, can be analyzed by the controller (202) to determine at least one characteristic of the melting state, such as the melting distribution area and / or melting front, which affects fuel usage and glass quality. The controller (202) can use the image data to determine the optimal fuel combustion rate for the burner (114), for example, to prevent the unmelted material from flowing too far downstream of the glass melting portion (120) and causing defects in the final glass product. The presence of unmelted compound material passing through a predetermined longitudinal area within the furnace may be correlated with an increase in the number of glass defects.

[0093] In some embodiments or aspects, the distribution area / melt front value may be averaged over a preset period to correct for heat-related disturbances in the image data. During the ignition of one or more burners (114), the image data may be distorted to show a higher or lower distribution area for the unmelted mixture material relative to the actual value of the unmelted mixture material due to the heat output of one or more burners (114). By averaging the distribution area / melt front value over a specific period, such heat-related disturbances during the ignition of one or more burners (114) are removed from the image data. In an embodiment or aspect where two cameras (201) are used, the image data of the left camera may be averaged during the period when the right burner (114) is ignited, and the image data of the right camera may be averaged during the period when the left burner (114) is ignited.

[0094] In some embodiments or aspects, the controller (202) may be configured to receive image data from at least one camera (201) and to define a region of interest in the image data. In some embodiments or aspects, the minimum number of regions of interest in the image data is 1. In additional embodiments or aspects, the maximum number of regions of interest in the image data may be based on the number of burners. For example, and referring to FIGS. 3 and 4, the region of interest may correspond to at least one zone (e.g., Z0, Z1, Z2, etc.) of the glass melting portion (120) inside the furnace (100). In some embodiments or aspects, at least one zone includes a charging zone (Z2) at the input end (106) of the furnace, a bubbler zone (Z0) at the bubbler area (126) of the furnace, and an intermediate zone (Z1) between the charging zone (Z2) and the bubbler zone (Z0). In additional embodiments or aspects, at least one zone may correspond to a region adjacent to each burner (114). In the embodiments or aspects illustrated in FIG. 3 and 4, the charging zone (Z2) may be defined in the space between the second and third burners (114) (P2, P3), the intermediate zone (Z1) may be defined in the space between the fourth burner (114) (P4) and the second and third burners (114) (P2, P3), and the bubbler zone (Z0) may be defined between the fourth and fifth burners (114) (P4, P5).

[0095] Image data of the region of interest may be used by a controller (202) to monitor and control one or more aspects of the furnace (100) as described herein. Generally, the presence of unmelted compound material passing through the bubbler zone (Z0) is undesirable, as such presence may be associated with an increase in a number of glass defects. As illustrated in FIGS. 5 and 6, changes in the furnace crown temperature have a direct effect on the distribution of unmelted compound, also referred to as the 'raft area'. An increase in the raft area within a specific zone of the furnace (100) is associated with a decrease in the crown temperature within that specific zone. Conversely, a decrease in the raft area is associated with an increase in the crown temperature. Therefore, monitoring the distribution of unmelted compound is an important factor in controlling the operation of the furnace (100).

[0096] Referring again to FIGS. 3 and 4, the unmelted compound material (122) is shown in the shaded area of ​​the drawing, while the molten glass (124) is shown without shading. The distribution area of ​​the unmelted compound material (122) decreases from the input end (106) of the furnace (100) to the discharge end (110). As shown in FIGS. 3 and 4, the charging zone (Z2) is almost completely filled with the unmelted compound material (122), and the distribution of the unmelted compound material (122) gradually decreases in zone (Z1) and zone (Z2).

[0097] The unmelted compound material (122) appears in the image data as having a different shade compared to the molten glass (124). In this way, the image data can be analyzed by the controller (202) to identify the distribution area of ​​the unmelted compound material (122) in the region of interest. For example, each pixel within the image data may be assigned a value based on the characteristics of the image data (e.g., brightness, contrast), and this value may be assigned to correlate with the unmelted compound material (122) or the molten glass (124). By summing all pixels of the image data having the same assigned value, the total distribution area of ​​the unmelted compound material (122) can be determined relative to the total distribution area of ​​the molten glass (124). The total distribution area may be further subdivided into zones such as the zones (Z0–Z2) discussed herein. Additionally, image data can be analyzed by a controller (202) to identify the leading edge (also referred to herein as the ‘raft leading edge’) of the non-melting compound material (122) in the region of interest.

[0098] The distribution area of ​​the unmelted compound material (122) in at least one specific zone, such as the bubbler zone (Z0), may be used by the controller (202) to control the crown temperature distribution of the furnace (100) using a temperature control model as described herein. In some embodiments or aspects, the distribution area of ​​the unmelted compound material (122), e.g., the total distribution area or the distribution area in one or more zones, may be compared with a predetermined set value configured to optimize fuel usage while minimizing glass defects. That is, the temperature control model is configured to balance efficiency and glass quality. Using the distribution area of ​​the unmelted compound material (122) as an input, the controller (202) may be configured to output a control signal, such as a signal to the burner controller (116), to control the operation of one or more burners (116) to achieve a desired crown temperature profile.

[0099] Referring to Figures 5 and 6, for example, in 2 The raft area, denoted by , and the crown temperature, denoted by °F, for example, are each plotted as a function of time. FIGS. 5 and 6 illustrate the correlation between the raft area and the furnace temperature. In FIG. 5, data are plotted in three zones within the region of interest, where the 'charging zone' corresponds to the raft area of ​​Zone 2 described herein, the 'intermediate zone' corresponds to the raft area of ​​Zone 1 described herein, and the 'bubbler zone' corresponds to the raft area of ​​Zone 0 described herein. Similarly, in FIG. 6, data are plotted in three zones within the region of interest, where 'TC charging' corresponds to the temperature of Zone 2 described herein, 'TC peak' corresponds to the temperature of Zone 1 described herein, and 'TC isthmus' corresponds to the temperature of Zone 0 described herein. In the circular area (126) of FIGS. 5 and 6, it is evident that an increase in the raft area generally correlates with a decrease in temperature. Similarly, in the circular area (128) of FIGS. 5 and 6, it is evident that a decrease in the raft area generally correlates with an increase in temperature.

[0100] Empirical data is collected to learn process reactions in order to develop a predictive temperature control model configured to trim the desired crown temperature based on the molten state. Referring to FIGS. 7–10, a furnace ‘bump’ test is performed in which the furnace crown temperature is intentionally changed in a manner that maximizes the potential influence on the molten behavior. FIG. 7 is a graph of a temperature change of 10 °F on the charging side reduced to 0 on the isthmus side. FIG. 7 further includes a graph of a temperature change of 10 °F on the isthmus side reduced to 0 on the charging side. The generated crown temperature profile is shown in FIG. 8, where it can be observed that when the furnace temperature is gradually ‘bumped’ at the charging end, the temperature distribution on the charging side (crown numbers 1–4) gradually increases, while the temperature distribution on the isthmus side (crown numbers 4–7) remains substantially unchanged. Similarly, FIG. 8 illustrates that when the furnace temperature is gradually 'bumped' at the narrow end, the crown temperature profile at the charging end does not substantially change but gradually increases at the narrow end. FIG. 9 and 10 illustrate a gradual increase in temperature at both the charging end and the narrow end when the crown temperature profile is 'bumped' at both ends.

[0101] FIG. 11 illustrates the change in temperature on the charging side and the narrow side as a function of time in multiple 'bump' tests. FIG. 11 illustrates the temperature change for both the charging side and the narrow side, whereas FIG. 12b and FIG. 12c illustrate the temperature change for each side individually. During these tests, the deviation of the total raft area is measured and is displayed as a function of time in FIG. 12a and FIG. 13. In FIG. 13, the measured change in the total raft area is displayed, and a simulated model output is fitted to this data using first-order and delayed-time dynamic modeling strategies. In this way, a control technique is developed using a mathematical model of the system and the future behavior of the raft area is predicted in response to changes in the temperature on the charging side and the narrow side. Through this prediction, the system (200) is configured to determine a control action to control the operation of the furnace (100). Therefore, instead of adjusting individual temperatures at each set value of the crown temperature, the temperature control model relies on two manipulated variables (desired temperature changes on the charging side and the isthmus side).

[0102] In some embodiments or aspects, based on the distribution area of ​​the unmelted compound material and / or the melting front and the deviation from a predetermined set value, the system (200) may be configured to control the crown temperature distribution based on a temperature control model that determines a desired temperature change in at least one of the zones that will produce a desired effect in reducing or increasing the distribution area and / or the melting front. The desired temperature change corresponds to a desired change in the distribution area of ​​the unmelted compound material and / or the melting front, as determined by the model using empirical data. In some embodiments or aspects, the temperature control model may consider two variables, the first variable being a weighted charging side temperature distribution toward the charging end of the furnace, and the second variable being a weighted narrow side temperature distribution toward the narrow end of the furnace. The desired temperature change may be converted into a plurality of crown temperature trim set values ​​using a temperature distribution matrix. In some embodiments or aspects, the temperature distribution matrix may include a plurality of temperature trim multipliers corresponding to a plurality of crown temperature trim set values.

[0103] An exemplary equation for determining the crown temperature trim setting value based on the desired temperature change can be expressed as a square matrix as shown in equation (1) below.

[0104] Equation (1)

[0105] In the exemplary equation above, for example, 7 possible crown temperature trim settings (△T1) corresponding to 7 burners SP At △T7 SP ...is present. In other systems, the number of crown temperature trim settings may be higher or lower depending on the number of burners. For example, in a furnace (100) having 7 burners (114), there are 7 possible adjustments for the crown temperature. The crown temperature trim setting is a manipulated variable (△T 장입 and △T 협부It is the product of a temperature distribution matrix containing a plurality of temperature trim multipliers corresponding to the number of crown temperature trim set values ​​(i.e., 7). The temperature distribution matrix is ​​weighted toward the charging side in the first column and toward the isthmus side in the second column. In some embodiments or aspects, the multipliers of the temperature distribution matrix are dimensionless values ​​between 0 and 1 and are selected by an operator based on the desired weight toward the charging side or the isthmus side.

[0106] In some embodiments or aspects, the temperature control model may be configured to trim the desired temperature based on the melt state and / or melt front determined from image data of one or more cameras (201). For example, a controller (202), such as a processor (204), may receive image data from one or more cameras (201) and identify the distribution area of ​​the unmelted compound material and / or the melt front of the unmelted compound material in each of one or more zones based on at least one characteristic of the image data. For example, the identification of the distribution area and / or melt front may be based on contrast, brightness, or other characteristics in the image data of the area of ​​interest. Then, the controller (202), such as a processor (204), is configured to compare the calculated distribution area and / or melt front of the unmelted compound material with a predetermined set value and to determine the deviation between the distribution area and / or melt front of the unmelted compound material and the predetermined set value. The predetermined set value may be pre-set based on prior experience. In response to determining the distribution area of ​​the unmelted compound material and / or the degree of deviation from a predetermined set value with respect to the melting front, a controller (202), such as a processor (204), may be configured to control the crown temperature distribution based on the temperature control model discussed herein. In some embodiments or aspects, a controller (202), such as a processor (204), may be programmed or configured to generate a warning in response to determining that the distribution area of ​​the unmelted compound material and / or the melting front is outside a predetermined threshold range. The warning may be a visual warning, such as a message output on an output component (212) that is a display, and / or an auditory warning, such as a sound output on an output component (212) that is a speaker.

[0107] Referring to FIGS. 14 and 15, an exemplary graphical user interface (GUI) (300) for monitoring and controlling non-melting formulation materials is illustrated according to some embodiments or aspects. The GUI (300) may consist of an input component (210) (illustrated in FIG. 2) for inputting information to a controller (202) (illustrated in FIG. 2) and / or an output component (212) (illustrated in FIG. 2) for outputting information from the controller (202). In some embodiments or aspects, the GUI (300) may be displayed on a display such as a touchscreen display.

[0108] Referring further to FIGS. 14 and 15, the GUI (300) includes an operation control section (302) in which the control of the crown temperature setpoint is enabled or disabled. The operation control section (302) may include one or more buttons for enabling or disabling the crown temperature control. The GUI (300) may additionally include a setting section (304), in which the user may choose to reset the melt control settings to default values ​​or specify custom melt control settings. By clicking the 'Set' button in the setting section (304), the user is provided with an adjustment screen (306) (Fig. 15), in which the melt area and / or melt tip setpoint and / or threshold value may be adjusted.

[0109] Referring further to FIGS. 14 and 15, the GUI (300) additionally includes camera status sections (308a, 308b) for displaying status information of the camera (201) (shown in FIG. 1). The camera status sections (308a, 308b) may be configured to display information regarding the camera's on / off status and characteristics of image data regarding the distribution area of ​​the unmelted compound material and / or the melting edge of the unmelted compound material. The GUI (300) additionally includes a crown temperature information section (310), wherein information regarding the crown temperature measured by one or more sensors is displayed in addition to the crown temperature trim setting value. In some embodiments or aspects, the GUI (300) includes a graphic output section (312) configured to output a graph of selected measured values ​​as a function of time. For example, the graphic output section (312) may be configured to display the charging side and the narrow side temperature trim as a function of time.

[0110] Now, referring to FIG. 16, a flowchart of a non-limiting aspect or embodiment of a process (400) for monitoring and controlling unmelted compound materials in a glass melting furnace is illustrated. In some non-limiting embodiments or embodiments, one or more of the functions described in relation to the process (400) may be performed (e.g., entirely, partially, etc.) by a system (200) such as at least one camera (201) and a controller (202). In some non-limiting embodiments or embodiments, one or more of the steps of the process (400) described below may be performed (e.g., entirely, partially, etc.) by another device or group of devices that is separate from and / or includes the system (200) such as at least one camera (201) and a controller (202).

[0111] Referring to FIG. 16, in step (402), the method (400) may include the step of receiving image data inside the furnace (100) from at least one camera (201) using a processor (204). In step (404), the processor (204) is configured to define a region of interest in the image data, wherein the region of interest corresponds to one or more zones inside the furnace (100). In step (406), the processor (204) is configured to identify the distribution area of ​​the unmelted compound material in one or more zones based on at least one characteristic of the image data. Then, in step (408), the processor (204) is configured to compare the distribution area of ​​the unmelted compound material with a predetermined threshold range. In step (410), the processor (204) is configured to determine whether the distribution area of ​​the unmelted compound material is outside the predetermined threshold range. In response to determining that the distribution area of ​​the non-melting compound material is outside a predetermined threshold range, the processor (204) is configured to control the crown temperature distribution based on the temperature control discussed herein in step (412). For example, in step (414), the processor (204) may be configured to determine a desired temperature change in at least one of one or more zones, and the desired temperature change corresponds to a desired change in the distribution area of ​​the non-melting compound material. In step (416), the processor (204) is configured to use a temperature distribution matrix to convert the desired temperature change into a plurality of crown temperature trim set values. In step (418), the processor (204) is further programmed or configured to generate a warning in response to determining that the distribution area of ​​the non-melting compound material is outside a determined threshold range.

[0112] Although the above methods, systems, and computer program products have been described in detail for illustrative purposes based on what is currently considered to be the most practical and desirable embodiments or modes, it should be understood that such details are for that purpose only and the present disclosure is not limited to the disclosed embodiments or modes, but rather is intended to include modifications and equivalent configurations within the spirit and scope of the appended claims. For example, it should be understood that the present disclosure takes into account that, as far as possible, one or more features of any embodiment or mode may be combined with one or more features of any other embodiment or mode.

Claims

Claim 1 A system for monitoring and controlling unmelted compound materials in a glass melting furnace, comprising: at least one camera configured to capture image data inside the glass melting furnace; A system comprising at least one processor, wherein the at least one processor receives image data from the at least one camera, defines a region of interest in the image data corresponding to one or more zones of a glass melting portion inside the glass melting furnace, identifies a distribution area of ​​the unmelted compound material in each of the one or more zones based on at least one characteristic of the image data, compares the distribution area of ​​the unmelted compound material with a predetermined set value, determines a deviation between the distribution area of ​​the unmelted compound material and the predetermined set value, and is programmed or configured to control a crown temperature distribution in the longitudinal direction inside the glass melting furnace based on a temperature control model in response to the deviation between the distribution area of ​​the unmelted compound material and the predetermined set value, wherein the temperature control model determines a desired temperature change of at least one of the one or more zones, wherein the desired temperature change corresponds to a desired change in the distribution area of ​​the unmelted compound material; and converts the desired temperature change into a plurality of crown temperature trim set values ​​using a temperature distribution matrix. Claim 2 A system according to claim 1, wherein the temperature distribution matrix comprises a plurality of temperature trim multipliers corresponding to the plurality of crown temperature trim set values. Claim 3 A system according to claim 1, wherein the desired temperature change includes a weighted fill side temperature change and a weighted waist side temperature change. Claim 4 A system according to claim 1, wherein controlling the crown temperature distribution includes increasing or decreasing the gas supply to at least one burner. Claim 5 A system according to claim 1, wherein the at least one processor identifies a melting front of the unmelted compound material in each of the one or more zones based on at least one characteristic of the image data, compares the melting front of the unmelted compound material with a predetermined melting front setting value, determines a deviation between the melting front of the unmelted compound material and the predetermined melting front setting value, and further programs or is configured to control the crown temperature distribution using the temperature control model in response to the deviation between the melting front of the unmelted compound material and the predetermined melting front setting value. Claim 6 A system according to claim 1, wherein at least one processor is programmed or configured to generate a warning in response to determining that the distribution area of ​​the unmelted compound material is outside a predetermined threshold range. Claim 7 In paragraph 1, the system wherein the warning is at least one of a visual warning and an auditory warning. Claim 8 A system according to claim 1, wherein at least one characteristic of the image data is an image contrast value. Claim 9 A system according to claim 1, wherein at least one characteristic of the image data is an image brightness value. Claim 10 In paragraph 1, the system, wherein one or more zones are defined between the inlet of the glass melting furnace and the bubbler area. Claim 11 A system according to claim 10, wherein the one or more zones include a charging zone at the inlet of the glass melting furnace, a bubbler zone in the bubbler area of ​​the glass melting furnace, and an intermediate zone between the charging zone and the bubbler zone. Claim 12 A system according to claim 1, wherein at least one processor is programmed or configured to average the image data over a preset period to correct for thermal disturbances in the image data. Claim 13 A system according to claim 1, wherein at least one camera is a pair of cameras located at the exit of the glass melting furnace. Claim 14 A system according to claim 1, wherein at least one camera comprises a liquid cooling jacket. Claim 15 In claim 14, the system comprises a liquid cooling jacket including a nitrogen purge for cleaning the lens of at least one camera.

Images