Float Bath Cooling Water Spray for Steel Casing Temperature Stability
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Solution Overview
Problem
Conventional float bath systems for manufacturing float glass face temperature instability issues when the air blower for cooling the steel casing breaks down, leading to increased temperatures, alloy formation, bubble creation, and potential surface defects in glass products due to temperature fluctuations.
Innovation Solution
A float bath system equipped with a separate cooling water spray member that can spray cooling water onto the steel casing in a preset pattern, specifically targeting the interfaces between blocks, to maintain temperature stability when the air blower is inoperable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single air blower cooling system is used for the steel casing, then the structure is simple and easy to operate, but the system reliability deteriorates when the air blower breaks down causing temperature increase and quality defects
Solution Approach 1:
The patent introduces a backup cooling method by changing the cooling parameter from air-based (single air blower) to water-based (spray nozzles), providing an alternative cooling mechanism that activates when the primary air cooling system fails, thereby improving reliability without requiring a completely redundant air blower system
Solution Approach 2:
The patent pre-installs spray nozzles and water supply pipes within the steel casing structure, preparing a backup cooling capability in advance. This beforehand cushioning ensures that when the air blower fails, the water spray system can immediately activate to prevent temperature rise, avoiding the need for emergency system installation
2Temperature
If the air blower operation is suddenly stopped, then energy consumption is reduced, but temperature stability deteriorates causing tin to return to liquid state and react with steel casing forming alloys and bubbles
Solution Approach 1:
The patent introduces water spray as an intermediary cooling medium that can quickly compensate for temperature rises when the air blower stops. The water spray system acts as a mediator between the steel casing and the thermal environment, providing rapid heat removal to maintain temperature stability during air blower interruptions
Solution Approach 2:
The patent ensures continuous cooling action by having the water spray system ready to activate immediately when the air blower stops. This continuity of useful cooling action prevents temperature fluctuations that would cause tin to return to liquid state and react with the steel casing, maintaining stable cooling without energy waste from unnecessary continuous air blower operation
3Manufacturing precision
If conventional air blower cooling is used, then the cooling system is simple to install, but manufacturing precision deteriorates due to temperature fluctuations causing bubbles and surface defects in glass products
Solution Approach 1:
The patent applies local quality improvement by installing spray nozzles at specific locations within the steel casing where temperature fluctuations most affect glass quality. The water spray is directed at critical areas prone to hot spots, providing localized cooling enhancement that prevents bubble formation and surface defects without requiring complete system redesign
Solution Approach 2:
The patent creates a composite cooling system combining air cooling and water spray cooling mechanisms. This composite approach leverages the advantages of both cooling methods - the simplicity of air cooling and the rapid response of water spray cooling - to maintain temperature stability and prevent manufacturing defects while adding minimal structural complexity
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
The system effectively prevents temperature increases at the float bath bottom, enhancing the quality and stability of float glass production by ensuring continuous cooling, even during air blower failures.
Implementation Method 1
a cooling water spray member capable of spraying a cooling water onto the steel casing
Implementation Method 2
an air blower capable of supplying air to the steel casing
Data Source
AI summary
Disclosed is a float bath system for manufacturing a float glass, comprising a block assembly having a plurality of blocks connected to each other and configured to store a molten metal therein; a steel casing surrounding the block assembly; an air blower capable of supplying air to the steel casing; and a cooling water spray member capable of spraying a cooling water onto the steel casing. And, a cooling method of said float bath system is disclosed.