Glass Tank Batch Blanket Mapping for Precise Thickness Control
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Solution Overview
Problem
Existing methods for measuring batch blanket thickness in all-electric melting tanks are imprecise, require manual intervention, and lack comprehensive data acquisition, hindering optimization of the melting process and glass production efficiency.
Innovation Solution
A method involving contactless data capture and evaluation of batch blanket thickness using sensors mounted on a charger's boom, compiling a topographic map for spatial and temporal changes, and optionally using microwave heating for localized adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual pointwise measurement with a rod is used, then batch thickness can be measured locally, but measurement precision and reliability are poor and personnel safety is at risk
Solution Approach 1:
The patent replaces manual mechanical measurement with a rod with an automated optical measurement system using cameras and image processing. The camera system captures images of the batch blanket surface, and software algorithms automatically calculate thickness based on surface topography, eliminating the need for personnel to physically probe the hot environment while significantly improving measurement precision and reliability.
Solution Approach 2:
The patent creates a visual copy (image) of the batch blanket surface using cameras, then processes this copy through image analysis to determine thickness. Instead of direct physical measurement, the system captures optical information and derives thickness measurements from the image data, enabling non-contact, high-precision measurement without personnel exposure to hazardous conditions.
2Device complexity
If only pointwise local measurement is performed, then measurement complexity is low, but comprehensive data acquisition for process optimization is insufficient
Solution Approach 1:
The patent divides the batch blanket measurement into multiple discrete measurement points across the surface. The camera system captures images at various locations, and the image processing software segments the batch blanket area into multiple measurement zones, analyzing each region separately to build a comprehensive topographic map of the entire batch blanket surface.
Solution Approach 2:
The patent transitions from one-dimensional point measurements to two-dimensional surface mapping. By using camera imaging and image processing, the system captures the entire batch blanket surface area and generates a topographic map that provides spatial distribution information across the surface, enabling comprehensive process optimization based on regional variations in batch thickness.
3Productivity
If extensive data acquisition from multiple positions is implemented, then process optimization capability is improved, but measurement system complexity increases
Solution Approach 1:
The patent employs a multi-functional camera system that serves multiple purposes: capturing batch blanket topography for thickness measurement, monitoring batch blanket surface conditions, and providing spatial mapping information. This universal measurement approach consolidates multiple measurement functions into a single integrated system, improving productivity through comprehensive data acquisition while controlling complexity through system integration.
Solution Approach 2:
The patent implements automated image processing algorithms that self-correct and self-calibrate during operation. The software automatically processes captured images, calculates thickness values, generates topographic maps, and provides feedback for process adjustment without requiring complex manual intervention or calibration procedures, thereby improving productivity while keeping the control system manageable.
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 optimized batch charging and melting rates, improving energy efficiency, glass quality, and detecting process anomalies, thereby stabilizing the operation of all-electric melting tanks.
Implementation Method 1
providing at least one sensor for contactlessly capturing data on the batch blanket
Implementation Method 2
at least one microwave heater, able to generate energy in the form of microwave radiation
Data Source
AI summary
A method for capturing and evaluating data on a batch blanket on a glass melt in a cold-top melting tank for the melting of glass includes: providing at least one sensor for contactlessly capturing data on the batch blanket at least at an end of a boom of a charger at which batch is applied to the glass melt; repeatedly capturing and storing (a) data of the batch blanket during operation of the melting tank with at least the at least one sensor, data being captured from at least 10 different positions of the batch blanket, and (2) respectively assigning the data to a position of the end of the boom and/or the at least one sensor; and processing the captured data and compiling a topographic map of the batch blanket.