Glass Hot Forming Control for Stable Alkali Emissions
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Solution Overview
Problem
Existing hot forming systems for glass elements suffer from unreproducible and unstable thermal effects due to variable heating power of gas burner units, leading to non-stable glass properties and high reject rates, particularly from excessive surface alkalinity.
Innovation Solution
A method and system that continuously senses light emissions from the glass element and burner flames using adapted sensor units, compares these signals with reference signals, and adjusts burner unit parameters to maintain alkali emissions within a pre-defined interval, ensuring stable and reproducible glass forming.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gas burner units are used for heating glass elements, then heating function is provided, but heating power is unreproducible and unstable leading to variable thermal effects
Solution Approach 1:
The system continuously monitors light emissions from the glass element and burner flame using sensor units, compares these signals with reference signals, and automatically adjusts burner parameters (air flow, gas flow, burner position) to maintain optimal heating conditions. This closed-loop feedback control ensures reproducible heating power and stable glass properties across different production sites.
Solution Approach 2:
The system dynamically adjusts multiple burner parameters including air flow rate, gas flow rate, and burner position based on real-time light emission measurements. By changing these parameters in response to measured conditions, the system maintains consistent thermal effects on the glass element despite variations in equipment or production site.
2Measurement precision
If conventional photoelectric detection methods are used, then alkali release can be forecast, but only after the hot forming process is completed
Solution Approach 1:
The system performs alkali emission detection during the hot forming process itself rather than after completion. By measuring light emissions from the glass element in real-time during heating, the system enables preliminary detection and immediate control adjustments, preventing excessive alkali release before it occurs rather than detecting it afterward.
Solution Approach 2:
The sensor units continuously monitor light emissions throughout the entire hot forming process, providing ongoing measurement of alkali release conditions. This continuous detection enables real-time control adjustments rather than discrete post-process measurements, maintaining optimal conditions throughout the forming operation.
3Adaptability or versatility
If burner units with variable heating power are used, then flexibility in heating is provided, but temperature conditions and glass viscosity become undefined and varying
Solution Approach 1:
The system uses sensor units to continuously measure light emissions that indicate glass temperature and viscosity conditions. These measurements feed back to the control system which automatically adjusts burner parameters to maintain precise temperature control, ensuring defined and reproducible manufacturing conditions while retaining heating flexibility.
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 approach provides a flexible, cost-effective, and robust system for precise online control of alkali emissions during hot forming, reducing reject rates and ensuring consistent glass properties across different machines and production sites.
Implementation Method 1
Sensing light emissions of the heated glass element and light emissions of burner flames of said one or more burner units via one or more sensor units
Data Source
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AI summary
The present invention provides a method for controlling alkali emissions of a glass element during hot forming, comprising the steps of - Heating of the glass element by using one or more burner units each providing a burner flame, - Sensing light emissions of the heated glass element and light emissions of burner flames of said one or more burner units via one or more sensor units, preferably at least periodically, in particular continuously, wherein said one or more sensor units being adapted such that the total light emitting areas of the glass element and burner flame areas are sensed, - Providing one or more signals by said sensor units when sensing said light emissions, - Comparing said one or more signals with one or more reference signals, - Determining, based on said compared one or more signals with said one or more reference signals, alkali emissions of said glass element, and - Controlling said one or more burner units based on the determined alkali emissions such that the determined alkali emissions are in a pre-given interval.