Centrifugal Glass Reserve Monitoring via Image Processing
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Solution Overview
Problem
The existing methods for forming glass fibers in industrial production, such as those used in insulation products, face challenges in controlling the pressure of molten glass, leading to inconsistent fiber quality and potential safety risks due to inadequate monitoring of the glass reserve volume.
Innovation Solution
A method and device that utilize a camera and image processing system to evaluate the volume of the primary glass reserve formed against the centrifuge's annular wall, allowing for real-time adjustment of the fiber-forming process by controlling the centrifugal force and rotation speed, thereby optimizing fiber quality and preventing overheating or overflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the volume of the primary glass reserve is not monitored, then the device complexity is reduced, but the fiber quality consistency deteriorates and safety risks increase
Solution Approach 1:
The patent replaces complex mechanical monitoring systems with optical imaging technology. A camera captures images of the glass reserve, and image processing algorithms automatically calculate the reserve volume, substituting mechanical sensors and complex mechanical measurement systems with a simpler optical-mechanical system that achieves the same monitoring function with fewer moving parts and lower complexity.
Solution Approach 2:
The patent creates an optical copy (image) of the glass reserve volume and processes this copy to determine the actual volume. Instead of directly measuring the physical glass reserve with complex contact sensors, the system captures a visual representation and extracts measurement data from the image, enabling indirect measurement that simplifies the physical measurement system while maintaining accuracy.
2Manufacturing precision
If image processing systems are added to monitor glass reserve volume, then fiber quality control improves, but device complexity increases
Solution Approach 1:
The patent implements a feedback control system where the camera continuously monitors the glass reserve volume, the image processing system calculates the current volume, and this information feeds back to control the glass supply or centrifuge speed to maintain optimal reserve levels. This closed-loop feedback enables automatic pressure control, improving fiber quality while the feedback mechanism itself manages the complexity by providing real-time adjustment capabilities.
Solution Approach 2:
The system enables the fiberizing device to self-monitor and self-regulate the glass reserve volume. The camera and image processing system allow the device to automatically detect and respond to changes in glass reserve levels without external intervention, making the system self-sufficient in maintaining optimal operating conditions and reducing the need for manual monitoring and adjustment.
3Manufacturing precision
If the rotation speed is increased to improve fiber quality, then the centrifugal force increases, but the glass reserve volume decreases leading to potential overheating
Solution Approach 1:
The patent uses the image processing system to continuously monitor glass reserve volume and provides feedback to the control system. When the reserve volume drops below optimal levels (which would cause overheating), the feedback signal triggers adjustments to reduce rotation speed or increase glass supply, preventing temperature rise while maintaining fiber quality within acceptable ranges.
Solution Approach 2:
The patent implements dynamic adjustment of rotation speed based on real-time glass reserve volume measurements. Instead of operating at a fixed high speed, the system continuously adapts the rotation speed to maintain optimal glass reserve levels, allowing the centrifuge to operate dynamically at varying speeds that prevent both quality degradation and overheating conditions.
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 enables precise control of the glass pressure, resulting in improved fiber quality, reduced risk of overheating, and enhanced operational safety by automatically monitoring and adjusting the glass fiber forming process.
Implementation Method 1
under the effect of the centrifugal force resulting from the rotation of the rotary assembly, a primary reserve of glass is formed against the primary annular wall of the centrifuge
Data Source
AI summary
A method for forming glass fibers by a rotary assembly including a shaft rotated about an axis of rotation, a centrifuge secured to the shaft and provided with a primary annular wall including a plurality of primary orifices, and a supply system configured to supply the centrifuge with molten glass, and wherein, under the effect of a centrifugal force resulting from a rotation of the rotary assembly, a primary reserve of glass is formed against the primary annular wall of the centrifuge, the method including a) acquiring, using a camera, of at least one primary image of the centrifuge, b) processing the at least one primary image by an image processing system, and c) evaluating a parameter representative of a volume of the primary reserve by a system for processing the data from the primary image.