Float Bath Cooling Nozzle Alignment for Glass Quality
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Solution Overview
Problem
Current float glass manufacturing processes face inefficiencies in cooling the bottom casing of float baths, leading to temperature inconsistencies and potential defects in the final product due to random nozzle arrangements in air blower systems, which fail to effectively utilize gaps between bricks for cooling.
Innovation Solution
The implementation of a float bath design with strategically positioned nozzle assemblies that inject cooling air directly into the gaps between bricks, specifically targeting the centers of brick borders and using radial nozzle configurations to enhance cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cooling air is blown to the bottom casing using an air blower with randomly arranged nozzles, then the bottom casing is cooled, but the cooling efficiency is insufficient due to failure to effectively utilize gaps between bricks
Solution Approach 1:
The patent applies local quality by strategically positioning nozzles to target specific high-temperature zones. The nozzle centers are aligned with gap centers between bricks, and nozzle orientations are adjusted to direct cooling air precisely into these gaps where heat accumulation occurs, rather than using uniform random arrangement across the entire bottom casing surface.
Solution Approach 2:
The patent implements preliminary action by pre-calculating and pre-positioning nozzles according to the actual brick layout and gap locations before the cooling operation begins. The nozzle coordinates and orientations are determined in advance based on the brick assembly configuration, ensuring optimal cooling coverage from the start of the cooling process.
2Reliability
If the bottom portion of the float bath is cooled to maintain molten metal temperature, then the base casing is protected from melting, but temperature inconsistencies cause molten metal flow changes and generate bubbles leading to surface defects
Solution Approach 1:
The patent addresses temperature uniformity by distributing nozzles to target multiple brick gaps systematically. Each nozzle is positioned and oriented to cool specific gap regions, ensuring comprehensive and uniform cooling across the entire bottom casing surface, preventing localized overheating that would cause molten metal flow disturbances and bubble formation.
Solution Approach 2:
The patent incorporates feedback by using temperature detection means to monitor the bottom casing temperature and adjusting the cooling air supply accordingly. The air blower operation is controlled based on detected temperature values, allowing dynamic adjustment to maintain optimal temperature distribution and prevent defects in the final glass product.
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 approach improves the cooling efficiency of the bottom casing, stabilizes the temperature distribution, and enhances the quality of the final float glass product by ensuring uniform cooling and preventing defects like Open Bottom Bubbles.
Implementation Method 1
an air blower installed away from the bottom casing to supply a cooling air toward the bottom casing
Implementation Method 2
the cooling air is injected toward gaps between the bricks
Data Source
AI summary
A float bath for manufacturing a float glass includes a brick assembly composed of a plurality of bricks to store a molten metal so that a float glass is capable of moving forward while floating on the molten metal, a bottom casing for forming an outer side of the brick assembly, and an air blower installed away from the bottom casing to supply a cooling air toward the bottom casing. The air blower is disposed so that the cooling air is injected toward gaps between the bricks.