Dynamic Glass Furnace Optimizer for Yield Loss Reduction
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Solution Overview
Problem
Existing glass production lines face inefficiencies due to limitations in dynamic production control, including the inability to accommodate special pieces, high yield loss from handling damage, and the need for batch-specific production schedules, which hinder continuous processing and increase production delays.
Innovation Solution
A glass production line with a dynamic optimizer system that integrates cutting table and tempering furnace control, allowing for real-time scheduling adjustments, incorporation of replacement pieces, and dynamic furnace layouts to optimize work piece placement and minimize handling, thereby enhancing yield and reducing production delays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If batch-specific production schedules are used, then production control is simplified, but productivity decreases due to inability to accommodate special pieces and continuous processing
Solution Approach 1:
The system transitions from static batch-specific schedules to dynamic real-time scheduling that adapts to special pieces and continuous processing requirements. The dynamic optimizer continuously adjusts cutting schedules and furnace layouts based on current production needs, enabling the system to handle both standard and special pieces without batch interruptions.
Solution Approach 2:
The invention changes the scheduling parameters from fixed batch parameters to dynamic parameters that can be adjusted in real-time. The system monitors production flow and modifies cutting patterns, furnace loading sequences, and piece prioritization dynamically, allowing continuous processing while accommodating special pieces without disrupting overall production.
2Ease of operation
If multiple handling operations are performed, then work pieces can be sorted and routed correctly, but yield loss increases due to handling damage
Solution Approach 1:
The system performs preliminary sorting and routing decisions at the cutting table stage using the dynamic optimizer. Work pieces are assigned to specific furnace positions and racks before being loaded, minimizing the need for subsequent handling and repositioning. This preliminary organization reduces the number of handling operations required during furnace loading and processing.
Solution Approach 2:
The invention introduces a buffer system as an intermediary between the cutting table and tempering furnace. The buffer temporarily holds work pieces with assigned routing information, allowing the system to organize pieces for optimal furnace loading without requiring multiple handling operations. The buffer acts as a staging area that preserves piece integrity while enabling efficient routing.
3Device complexity
If replacement pieces are processed separately, then production scheduling is simplified, but production delays occur due to batch-specific constraints
Solution Approach 1:
The invention merges replacement piece processing into the continuous production flow by integrating the dynamic optimizer that schedules both regular and replacement pieces together. Instead of separate batch schedules, the system consolidates all piece types into a unified real-time schedule, allowing replacement pieces to be processed immediately when needed without waiting for batch completion.
Solution Approach 2:
The system maintains continuous useful action by processing replacement pieces within the ongoing production sequence rather than interrupting for separate batch processing. The dynamic optimizer continuously adjusts the schedule to incorporate replacement pieces at optimal points in the production flow, ensuring uninterrupted processing and minimizing delays.
4Loss of substance
If dedicated delivery device is used, then work piece handling is reduced, but device complexity increases
Solution Approach 1:
The dedicated delivery device is designed with multi-functionality to justify its complexity. It serves multiple purposes: transporting work pieces from cutting table to buffer, providing temporary storage, and enabling organized loading to the tempering furnace. This universal device consolidates several functions into one system, reducing overall handling operations and yield loss while maintaining manageable complexity through integrated design.
Data Source
AI summary
A glass production line comprising a cutting table, a tempering furnace having a loading station that includes a changeable set of uniquely identifiable work-piece storage loading locations adjacent the loading station with each storage loading location receiving a work-piece therein for subsequent furnace processing, wherein a subset of the uniquely identifiable work-piece storage loading locations is moved away from the loading station when it is emptied of furnace work-pieces and a new sub-set of uniquely identifiable work-piece storage loading locations is moveable adjacent the loading station to provide the changeable set of uniquely identifiable work-piece storage loading locations adjacent the loading station, and a dynamic optimizer coupled to the furnace for dynamically scheduling furnace layouts for glass work-pieces to be tempered, wherein the dynamic furnace optimizer is adapted to schedule work-pieces from uniquely identifiable work-piece storage loading locations not currently adjacent the unloading station based upon a minimum yield gain.