Automated Rigid Spacer Frame Application for Large Insulating Glass
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Solution Overview
Problem
Existing methods for manufacturing and applying conventional spacer frames to large insulating glass units, such as Superjumbo or Jumbo sizes, are labor-intensive, inaccurate, and pose safety risks due to ergonomic challenges and manual handling, leading to reduced productivity in production lines.
Innovation Solution
A method and device that allows for the manufacturing and application of large spacer frames in a horizontal or slightly tilted position, using servomechanisms and automatisms to align and apply the frames to glass plates, ensuring ergonomic conditions and uninterrupted production line operation, even for unmanageable sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual handling methods are used for applying spacer frames to large insulating glass units, then flexibility in handling is maintained, but labor intensity increases and positioning accuracy deteriorates
Solution Approach 1:
The patent replaces manual mechanical handling with an automated positioning system that uses mechanical conveyors and positioning mechanisms to transport and place spacer frames. This substitution maintains handling precision while eliminating manual labor, directly resolving the contradiction between ease of operation and productivity.
2Adaptability or versatility
If manual positioning of spacer frames is performed, then adaptability to different positions is maintained, but positioning accuracy deteriorates
Solution Approach 1:
The patent incorporates feedback mechanisms through programmable control systems that receive positioning data and adjust the spacer frame placement accordingly. This feedback loop ensures high positioning accuracy while maintaining adaptability to different glass unit sizes and configurations through programmable parameters.
Solution Approach 2:
The system changes operational parameters through programmable control, allowing the same positioning mechanism to adapt to different glass unit dimensions and spacer frame sizes. This parameter-based adaptability maintains versatility while ensuring consistent positioning accuracy through controlled adjustments.
3Device complexity
If manual handling of large spacer frames is used, then equipment complexity is reduced, but safety risks increase due to ergonomic challenges
Solution Approach 1:
The patent introduces intermediary automated handling mechanisms that act as mediators between the spacer frames and the final placement position. These intermediary devices bear the weight and handle the large frames, eliminating direct human contact with heavy components and thereby reducing safety risks while adding controlled complexity to the system.
4Device complexity
If conventional manual application methods are used for all spacer frame sizes, then device complexity remains low, but manufacturing precision deteriorates for large units
Solution Approach 1:
The patent segments the application process into distinct automated stages: spacer frame preparation, positioning calculation, controlled transport, and precision placement. This segmentation enables high manufacturing precision for large units by breaking down the complex task into manageable, precisely controlled steps, justifying the increased device complexity.
Data Source
AI summary
The present invention deals with integrating methods for manufacturing and applying a spacer frame to a glass plate, particularly in the circumstance of increased sizes thereof, of the rigid type, i.e. which profiles essentially are formed by a hollow body having cross section close to the rectangular, micro-perforated in the wall facing the chamber of the insulating glass, where at least the wall facing the outer cavity intended for the secondary sealant is made of solid metal material or with a metal liner, the remaining walls or all the walls being capable of being made of plastic or metal, e.g. aluminum or stainless steel. Certain innovative elements of the devices implementing such methods are also claimed.