Glass Ribbon Thickness Control via Laser Viscosity Adjustment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing glass ribbon manufacturing methods face challenges in accurately controlling the thickness of glass ribbons during production, as they often require adjustments based on real-time measurements and account for time delays and process disturbances.
Innovation Solution
A control device that utilizes a thickness sensor to monitor the glass ribbon's thickness and adjusts using a laser apparatus for localized heating or a cooling tube for precise viscosity control, correlating thickness changes with laser power and accounting for time delays to maintain target thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If real-time thickness measurement and adjustment is implemented, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The system performs preliminary action by measuring thickness at multiple locations upstream and calculating required adjustments before the glass ribbon reaches the adjustment zone. This allows the control system to prepare and apply corrections in advance, improving thickness control precision while managing device complexity through proactive rather than reactive control.
Solution Approach 2:
The glass ribbon width is segmented into multiple measurement locations, with independent thickness measurements and control adjustments for each location. This segmentation allows targeted corrections at specific problem areas rather than uniform adjustment across the entire ribbon, improving manufacturing precision while reducing overall system complexity by focusing control efforts where needed.
2Manufacturing precision
If multiple measurement locations are used, then manufacturing precision is improved, but measurement precision requirements increase
Solution Approach 1:
The measurement system is divided into multiple independent sensing locations across the glass ribbon width, with each sensor measuring thickness at its specific position. This segmentation allows the system to capture spatial variations in thickness while using relatively simple individual sensors, achieving high manufacturing precision through distributed measurement rather than requiring a single highly complex precision instrument.
Solution Approach 2:
The system implements feedback by continuously monitoring thickness at multiple locations and using this information to adjust processing parameters. The feedback loop compensates for measurement uncertainties by using multiple data points to determine overall thickness trends and make corrective adjustments, thereby maintaining manufacturing precision without requiring each individual measurement to be extremely precise.
3Manufacturing precision
If time delays are accounted for, then manufacturing precision is improved, but processing time increases
Solution Approach 1:
The system performs preliminary measurement and calculation upstream, determining required thickness adjustments before the glass ribbon arrives at the adjustment zone. By accounting for travel time and preparing control actions in advance, the system maintains high manufacturing precision without adding significant processing delay, as the control decisions are made while the ribbon is still in transit.
Solution Approach 2:
The system applies preliminary anti-action by anticipating thickness deviations and applying corrective heating or cooling before the deviations fully manifest. By measuring upstream and applying corrections in advance, the system counteracts potential thickness problems before they affect final product quality, improving precision without requiring excessive response time.
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 method provides more accurate and efficient thickness control of glass ribbons by addressing deviations in real-time, ensuring consistent production and minimizing the impact of process disturbances.
Implementation Method 1
directing a laser beam at the laser power toward the ribbon of glass-forming material to decrease a viscosity at the location
Implementation Method 2
directing a cooling fluid toward the ribbon of glass-forming material to increase a viscosity at the second location
Data Source
AI summary
Methods of manufacturing a glass ribbon include moving a ribbon of glass-forming material along a travel path in a travel direction. Methods include sensing a thickness of the ribbon of glass-forming material at a plurality of locations of the ribbon of glass-forming material. Methods include identifying a location of the plurality of locations in which a corresponding thickness at the location exceeds a target thickness. Methods include correlating a rate of thickness change and a thickness difference between the corresponding thickness and the target thickness to a laser power. Methods include directing a laser beam at the laser power toward the ribbon of glass-forming material to decrease a viscosity at the location and attain the target thickness at the location.