On-Production-Line Glass Panel Stress Testing System
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Solution Overview
Problem
Conventional methods for testing the stress of tempered glass panels are inefficient and inaccurate, as they require manual handling and can only test single panels at fixed locations, making it difficult to track stress distribution and quality across multiple panels during production.
Innovation Solution
A system for on-production-line stress testing of glass panels, featuring unique identification codes, movable stress sensors, and a database for storing and retrieving stress data, allowing for multi-location testing and efficient tracking of stress information across multiple panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual stress testing is conducted on single selected glass panels at fixed locations, then testing can be performed with simple equipment, but testing efficiency is low and stress distribution information across multiple panels cannot be obtained
Solution Approach 1:
The testing system is divided into modular components including multiple stress sensors arranged in arrays, independent sensor controllers, and separate data processing units. This segmentation allows the system to test multiple panels simultaneously while maintaining manageable complexity through standardized modular units that can be configured for different production volumes.
Solution Approach 2:
The sensor controller is designed as a universal device that can manage multiple stress sensors across different testing locations and panel types. The system can test various glass panel configurations (different sizes, orientations, and positions) using the same core testing apparatus, eliminating the need for dedicated equipment for each testing scenario and significantly improving productivity.
2Measurement precision
If random testing areas are selected based on human experience, then simple manual testing can be performed, but accurate stress distribution information cannot be obtained
Solution Approach 1:
The system employs dynamic testing area selection where sensor arrays can be repositioned and reconfigured based on real-time production requirements. The sensor controller dynamically determines optimal testing locations on each panel based on its dimensions and orientation, ensuring accurate stress distribution measurement without requiring manual intervention for area selection.
Solution Approach 2:
The manual process of selecting testing areas based on human experience is replaced with an automated optical-mechanical system. The sensor controller automatically calculates and positions sensors on optimal testing areas using programmed algorithms, eliminating subjectivity and inconsistency in area selection while maintaining ease of operation through automated control.
3Reliability
If glass panels are removed from production line for testing, then comprehensive stress testing can be performed, but production time is wasted and efficiency decreases
Solution Approach 1:
The stress testing system is installed on the production line to perform testing during the manufacturing process itself, before panels are completed and packaged. This preliminary action allows quality control to be integrated into the production flow, eliminating the need for separate post-production testing stages and preventing time loss from removing panels from the line.
Solution Approach 2:
The patent introduces an intermediary testing system that acts as a bridge between production and quality control. The stress sensors and controllers serve as intermediaries that can measure panel stress without interrupting the production flow, allowing panels to continue moving through the manufacturing process while being tested, thus maintaining both reliability and efficiency.
4Measurement precision
If fixed testing locations are used, then simple testing setup is maintained, but multi-location testing for stress distribution measurement is impossible
Solution Approach 1:
The testing system uses segmented sensor arrays that can be independently positioned at multiple locations. Each sensor or sensor group can be controlled separately to test different areas of the glass panels, enabling comprehensive stress distribution measurement while keeping individual sensor units simple and the overall system manageable through modular architecture.
Solution Approach 2:
The system transitions from fixed testing locations to dynamic, adjustable sensor positioning. The sensor controllers can move and reposition sensors to multiple predetermined locations on the production line, allowing stress distribution measurement across different areas without requiring a completely complex reconfigurable system for each new testing requirement.
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 accurate and efficient stress testing of multiple glass panels during production, improving quality control and enabling real-time verification of stress compliance with safety standards.
Implementation Method 1
When stress exists on the surface of the glass panel, the total internally reflected incident light is affected by the surface stress to achieve birefringence to produce two beams of light travelling in different directions with polarization orthogonal to each other
Implementation Method 2
When there is no stress on the surface, total internal reflection is achieved when the angle of incidence is a critical angle, i.e., the light travels along the surface and the light is reflected by a critical angle
Data Source
Figure 1
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AI summary
The present disclosure discloses a mobile scanning device for retrieving stress information of one of a plurality of reinforced glass panels. The device includes an image capturing device to capture an image of an identification code installed on a surface of the one of the plurality of reinforced glass panels, an image processor to process the captured image and recognize the identification code, a central processor to instruct the mobile scanning device to retrieve stress information corresponding to the identification code from a glass panel production information database, and a display device to display the retrieved stress information. The stress information was obtained via at least one stress sensor testing a stress at different testing locations on a surface of each of a plurality of glass panels being processed on a production line for manufacturing the plurality of reinforced glass panels.