Exit Lock Roller Exchange Mechanism for Continuous Glass Ribbon Support
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Solution Overview
Problem
The existing float glass production lines face challenges in efficiently replacing Lift Out Roll (LOR) rollers without disrupting the glass ribbon support, leading to potential breakage and increased production downtime due to contamination and clogging issues, which complicates cleaning and maintenance.
Innovation Solution
A system for replacing LOR rollers within the exit airlock of the tin bath, utilizing a translation movement mechanism that maintains continuous support of the glass ribbon, allowing for simultaneous operation of old and new rollers to prevent sagging and ensure seamless transition, with individual motorization for each roller and an intermediate table for continuous support during the replacement process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the LOR roller is removed for cleaning or replacement, then the roller can be cleaned offline, but the glass ribbon loses support and risks breakage
Solution Approach 1:
A third roller is introduced as an intermediary element during the replacement process. When replacing a LOR roller, the system transitions through a state where three rollers are present (two original + one new), providing continuous support to the glass ribbon. This intermediary roller ensures the ribbon never loses support during the critical replacement operation.
Solution Approach 2:
The new roller is positioned and prepared in advance before the old roller is completely removed. The replacement process follows a specific sequence: the new roller is inserted while the old one is still in place, support is established, and only then is the old roller fully extracted. This preliminary positioning prevents ribbon breakage.
2Ease of operation
If the roller extraction system lowers the roller below the ribbon level, then the roller assembly can be extracted, but the mechanical drive system becomes complex and time-consuming to operate
Solution Approach 1:
Instead of lowering the roller below the ribbon to extract it (conventional method), the invention inverts the approach by raising the new roller to the operational level while the old roller remains in place. The extraction happens without lowering the roller assembly, simplifying the mechanical drive system and reducing operational complexity.
Solution Approach 2:
The glass ribbon support action continues uninterrupted throughout the roller replacement process. The system maintains continuous support from the rollers to the ribbon at all times during the exchange, eliminating the need to stop the production line or lower rollers to break the support continuity.
3Reliability
If production parameters are modified to prevent breakage during roller replacement, then ribbon breakage risk is reduced, but production time increases and glass is lost
Solution Approach 1:
The roller replacement process is designed to maintain continuous support of the glass ribbon throughout the entire operation. By ensuring the ribbon never loses support or requires parameter modifications, the system maintains normal production speed and eliminates glass loss, achieving both reliability and productivity.
Data Source
Figure 1
Figure 2a~2b
Figure 3a~3b
AI summary
Installation for driving a glass ribbon (2) in a float glass production line, the installation comprising an exit chamber (1) from a tin bath, the exit chamber comprising at least one ribbon (2) lifting roller (3a, 3b), the installation being able to take at least three states: - an initial state in which one table of the roller (3a) to be replaced is able to support the ribbon (2) over its entire width inside the chamber (1), - a final state in which one table of the new roller (3b) is able to support the ribbon (2) over its entire width inside the chamber (1), - an intermediate state in which the tables of the two rollers (3a, 3b) straddle the inside and outside of the chamber (1) and are able to simultaneously at least partially support the ribbon (2).