Gas Filling Lance with Local Switch and Sensor Feedback
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Solution Overview
Problem
Single operators face challenges in efficiently and accurately filling large numbers of insulated glass units with inert gas, as existing gas filling machines can lead to confusion and incorrect filling due to the complexity of managing multiple lances.
Innovation Solution
A gas filling apparatus with a lance featuring a manually operable switch and a control unit that includes a vacuum port and gas sensor, allowing for automatic termination of gas dispensing based on concentration, along with a visual indicator to simplify operation and ensure correct filling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple lances are used to increase filling capacity, then productivity is improved, but device complexity and ease of operation deteriorate due to operator confusion
Solution Approach 1:
Each lance is equipped with an individual foot pedal switch that provides direct local control, and the control unit monitors gas concentration in real-time to automatically terminate filling when the target concentration is reached. This feedback mechanism allows the operator to control multiple lances independently without confusion, as each lance's status and control are clearly distinguished through dedicated controls and automatic monitoring.
2Productivity
If multiple lances are used to increase filling capacity, then productivity is improved, but ease of operation worsens due to operator confusion
Solution Approach 1:
The system provides immediate feedback through individual foot pedal switches for each lace, allowing the operator to independently control each lance's filling process. The automatic termination based on real-time gas concentration monitoring eliminates the need for the operator to manually track filling status of multiple lances, significantly improving ease of operation while maintaining high productivity.
3Manufacturing precision
If gas filling time is extended to ensure accurate concentration, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The control unit continuously monitors gas concentration in real-time during the filling process and automatically terminates filling when the target concentration is achieved. This feedback-controlled approach ensures accurate gas concentration while minimizing filling time, eliminating the need for extended filling periods or manual concentration checks.
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 solution enables a single operator to efficiently fill multiple insulated glass units by minimizing confusion and ensuring accurate gas concentration, reducing filling time and gas usage while allowing for quick operation and easy monitoring of filling status.
Implementation Method 1
a gas sensor for determining the concentration of the dispensed gas type received at the vacuum port
Implementation Method 2
The provision of such a vacuum port enables air to be drawn out of the glass unit
Data Source
AI summary
A gas filling apparatus comprising a lance and control unit remote from the lance is disclosed. The lance has a dispensing nozzle for dispensing gas through an aperture. The lance additionally has a manually operable switch for sending a signal to the control unit to commence dispensing of gas. The provision of the manually operable switch on the lance should result in less errors being made during the filling process, particularly where a plurality of lances are simultaneously operated by a single operator. The lance may additionally comprise a visual indicator indicating the state reached in the dispensing cycle.