Automated Float Glass System with Machine Vision Control
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Solution Overview
Problem
The float glass manufacturing process is labor-intensive due to manual adjustments of top rollers in conventional float glass systems, making it difficult to accurately control the thickness and width of the glass ribbon, and to monitor and control the temperature profile within the float bath.
Innovation Solution
A float glass system equipped with machine vision cameras, sensors, and operating devices connected to a control system that automatically or semi-automatically adjusts the top rollers and temperature settings to achieve desired ribbon dimensions and temperature conditions, reducing the need for manual labor and improving precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual adjustment of top rollers is used in conventional float glass systems, then operators can control glass ribbon dimensions, but the process becomes labor-intensive and less precise
Solution Approach 1:
The patent replaces the manual mechanical adjustment system with an automated control system that uses sensors to detect glass ribbon dimensions and machine vision cameras to monitor the floating process. The control system automatically adjusts roller positions and angles, eliminating the need for manual intervention while improving precision and consistency in glass ribbon manufacturing.
Solution Approach 2:
The patent implements feedback control by using sensors to continuously monitor glass ribbon thickness and width, and machine vision cameras to track the glass ribbon's position and dimensions in real-time. This feedback information is fed back to the control system, which automatically adjusts the top rollers to maintain desired dimensions, creating a closed-loop control system that improves manufacturing precision.
2Adaptability or versatility
If manual adjustment of top rollers is used, then operators can change glass ribbon dimensions, but the process is time-consuming and costly
Solution Approach 1:
The patent replaces manual mechanical adjustment with an automated control system that can rapidly adjust roller positions and angles based on pre-programmed parameters. This allows the system to adapt to different glass ribbon dimensions quickly and accurately without the time-consuming manual intervention required in conventional systems.
Solution Approach 2:
The patent uses pre-programmed control parameters and pre-configured sensor settings that allow the system to automatically adapt to different glass ribbon dimensions. The control system has predetermined adjustment sequences and parameters that can be selected or modified to accommodate various production requirements, enabling rapid adaptation without manual reconfiguration.
3Ease of operation
If visual adjustment by operators is used, then top roller position can be controlled, but accuracy varies between operators
Solution Approach 1:
The patent replaces visual estimation and manual adjustment with automated sensors and machine vision cameras that objectively measure and control top roller positions. The sensors provide precise, objective data on roller position and glass ribbon dimensions, eliminating the variability inherent in visual estimation by operators while maintaining ease of operation through automated control.
4Temperature
If manual temperature control is used in float bath, then temperature can be adjusted, but the temperature profile is difficult to control accurately
Solution Approach 1:
The patent implements feedback control for temperature by using sensors to continuously monitor float bath temperature and glass ribbon temperature at multiple points. This temperature data is fed back to the control system, which automatically adjusts heating and cooling elements to maintain precise temperature profiles, eliminating the difficulty of manual temperature control while improving accuracy.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution streamlines the float glass manufacturing process by enabling precise control over the glass ribbon's width and thickness, reducing labor and time requirements, and enhancing the accuracy of temperature management within the float bath, thus improving overall efficiency and reducing operational costs.
Implementation Method 1
At least one machine vision camera is located to view an interior of the float bath
Implementation Method 2
At least one sensor is connected to the float bath to measure an operating parameter of the float bath
Implementation Method 3
The molten glass forms a continuous glass ribbon
Implementation Method 4
molten glass from a furnace is poured onto the top of a bath of molten metal located in a float bath
Implementation Method 5
multiple pairs of opposed top rollers are used to expand and move the glass ribbon through the float bath
Data Source
AI summary
A float glass system includes a float bath having an entrance end and an exit end. At least one machine vision camera is located to view an interior of the float bath. At least one sensor is connected to the float bath to measure an operating parameter of the float bath. At least one operating device is connected to the float bath. The at least one machine vision camera, the at least one sensor, and the at least one operating device are connected to a control system configured to control the operating device based on input from the at least one machine vision camera and/or the at least one sensor.