Float Glass Distortion Measurement via LED Transillumination
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Solution Overview
Problem
Existing methods for detecting and classifying defects in float glass strips, particularly distortion and inclusions, are not sufficiently rapid or reliable, especially in continuously produced transparent materials like glass, where real-time monitoring and accurate defect identification are crucial for quality control.
Innovation Solution
A device and method utilizing a linear inset LED light source with LEDs of different wavelengths, a cylindrical lens element, and multiple CCD cameras with adjustable positions and filters, enabling precise measurement of thickness and refractive power variations, along with a two-stage parallel signal evaluation and mathematical algorithms for accurate defect detection and classification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional defect detection methods are used in float glass production, then defect detection is possible, but the detection speed and reliability are insufficient for real-time quality control
Solution Approach 1:
The glass strip is divided into multiple measurement zones along the production line, with separate light sources and cameras for each zone. This allows parallel processing of different sections of the glass strip, increasing detection speed while maintaining reliability through comprehensive coverage of the entire strip width and length
Solution Approach 2:
Reference measurements are taken and stored before actual defect detection begins. The system pre-establishes baseline optical properties of the glass strip, enabling rapid comparison during production to quickly identify deviations without requiring complex real-time analysis, thus improving both speed and reliability
2Measurement precision
If multiple measurement parameters are captured simultaneously, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The same optical setup with light sources and cameras serves multiple measurement functions. By capturing images at different wavelengths and processing them through various algorithms, the system simultaneously measures thickness, refractive power, and detects defects without requiring separate dedicated systems for each parameter, thus reducing overall device complexity
Solution Approach 2:
The system uses light sources with different wavelengths (e.g., red and green LEDs) to probe different optical properties of the glass. By changing the wavelength parameter and analyzing the differential responses, the system extracts multiple measurement parameters from a single optical configuration, improving precision without proportionally increasing device 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
Enables rapid and reliable detection and classification of distortion defects in float glass strips with high sensitivity and accuracy, ensuring continuous quality control during the manufacturing process by processing bitmaps from all channels in parallel and incorporating production line data.
Implementation Method 1
a linear inset LED light source (5) transilluminating from below the width of the glass strip (4) to be examined, said light source having LEDs arranged closely alongside one another, wherein at least two types of LEDs having different wavelengths in an arbitrary sequence are used
Implementation Method 2
a cylindrical lens element (8) arranged linearly and parallel to the entire length of the inset LED light source (5), the distance between said cylindrical lens element and the inset LED light source (5) being adjustable in a continuously variable manner
Implementation Method 3
measuring distortion defects in a manufactured float glass strip... whole-area measurement of the thickness variation and of the refractive power variation
Data Source
AI summary
The invention relates to a method and a device for the rapid and reliable measuring of distortion defects in a manufactured float glass strip, having the following features: a) a linear inset LED light source (5) sweeping the breadth of the glass strip (4) to be examined, said light source having LEDs that are tightly packed one next to the other below a glass strip (4) to be examined, b) a linear cylindrical lens 8) which is arranged in parallel to the entire length of the inset LED light source (5) and the distance of which to the inset LED light source (5) is continuously variable, c) a light source (2) arranged above the glass strip (4), d) an array of at least 4 CCD cameras arranged above the glass strip (4), and a two-stage parallel signal evaluation unit.