Glass Tempering Furnace Discharge Control Using Heater Power Thresholds
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Solution Overview
Problem
In the glass plate tempering process, direct temperature monitoring by sensors is often affected by ambient furnace temperatures, leading to inaccurate measurements and improper discharging of glass plates, resulting in increased waste and resource inefficiency.
Innovation Solution
A method that monitors real-time working parameters of heating elements, such as total power or current, using filtering and comparison with specified thresholds to control the discharging of glass plates, eliminating the need for direct temperature monitoring and relying on operator experience.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If temperature sensors are used to directly monitor the glass plate temperature in the heating furnace, then the discharging control can be automated, but the measurement accuracy deteriorates due to ambient furnace temperature interference
Solution Approach 1:
The patent introduces heating element working parameters (power, current) as an intermediary indicator to indirectly monitor the glass plate heating state. Instead of directly measuring the glass plate temperature in the high-temperature furnace environment, the system monitors the electrical parameters of heating elements, which correlate with the heating process. This intermediary measurement approach avoids the measurement interference from ambient furnace temperature while maintaining automated control capability.
2Reliability
If temperature sensors are placed in the high temperature furnace environment for continuous monitoring, then real-time temperature data can be obtained, but the reliability of detection deteriorates due to furnace temperature interference
Solution Approach 1:
The patent extracts the measurement function from the high-temperature furnace environment by monitoring heating element parameters instead of directly measuring glass plate temperature. The detection is performed on electrical parameters (power, current) of heating elements which are outside the direct thermal field interference, thereby separating the measurement process from the harmful high-temperature environment while maintaining continuous monitoring capability.
3Ease of operation
If the glass plate is moved out after a fixed heating time based on thickness multiplication, then the process is simple to operate, but the heating temperature control accuracy deteriorates causing insufficient heating or over-burning
Solution Approach 1:
The patent implements a feedback control mechanism by continuously monitoring heating element working parameters and comparing them against threshold values. The system adjusts the discharging decision based on real-time parameter feedback rather than relying on fixed time calculations. This feedback approach maintains operational simplicity while significantly improving heating temperature accuracy and preventing both insufficient heating and over-burning conditions.
4Manufacturing precision
If heating time is extended to ensure adequate heating temperature, then heating quality improves, but energy consumption increases and production efficiency deteriorates
Solution Approach 1:
The patent transitions from a static fixed-time heating approach to a dynamic parameter-based control system. The discharging decision is made based on real-time monitoring of heating element working parameters that dynamically reflect the actual heating state. This dynamic approach allows the system to optimize heating time for each specific condition, ensuring adequate heating quality while minimizing energy consumption and avoiding unnecessary extended heating periods.
Data Source
AI summary
A method for controlling discharging of a glass plate in a glass plate tempering technology process is provided. After a glass plate is fed into a heating furnace, a monitoring unit monitors and performs filtering on a working parameter of a heating element in real time, and then transmits the filtered working parameter to a control unit. The control unit compares the filtered working parameter with a specified threshold. After the working parameter reaches a maximum value or a minimum value, and then reaches the specified threshold during a subsequent change, the control unit sends an instruction to a drive mechanism. The drive mechanism acts to move the glass plate out of the heating furnace directly or after a time delay, so as to complete a glass plate heating process. The present disclosure changes a conventional time-based control method, reduces energy consumption, and improves quality of a tempered glass.