Glass Sheet Positioning for Windshield Forming
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Solution Overview
Problem
Conventional methods for forming glass sheets fail to centrally position them on forming molds due to size variations and curvature requirements, leading to inconsistent glass sheet sizes and shapes, especially in manufacturing vehicle windshields.
Innovation Solution
A method involving a conveyor system with detectors to measure the glass sheet's extremities and generate control signals for central positioning on a forming mold with a curved face, using conveyance deceleration and transfer apparatus like continuous or segmented rings, vacuum, or gas lift to ensure precise alignment and transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If switches are used to sense the approach of a glass sheet to initiate transfer from a conveyor for forming, then the transfer can be initiated, but the glass sheet is not necessarily positioned centrally on the forming mold due to size variations
Solution Approach 1:
The patent replaces mechanical switch-based detection with an optical detection system using a light source and detector array. This optical system measures the actual position and size of the glass sheet by detecting light reflection or transmission patterns, enabling precise positioning calculations that account for size variations while maintaining automated transfer initiation.
Solution Approach 2:
The patent implements a feedback control system where the detected glass sheet position and size information is fed back to a control mechanism. This feedback enables real-time adjustment of the conveyor speed and transfer timing to ensure the glass sheet is centrally positioned on the forming mold, compensating for manufacturing tolerances and size variations.
2Adaptability or versatility
If glass sheets of different sizes are used for outer and inner windshield layers, then the curvature requirements can be met, but the positioning precision becomes difficult to maintain
Solution Approach 1:
The patent changes the detection and control parameters dynamically based on the detected glass sheet size. The system adjusts the detection window size, detector sensitivity, and conveyor speed parameters according to the actual glass sheet dimensions, enabling precise positioning control across different glass sheet sizes without compromising accuracy.
Solution Approach 2:
The patent introduces dynamic adjustment capabilities to the positioning system, allowing real-time modification of conveyor speed, transfer timing, and detector sensitivity based on the detected glass sheet characteristics. This dynamic control enables the system to adapt to size variations while maintaining consistent positioning precision across different glass types.
3Productivity
If the conveyor continues at constant speed through the forming mold, then productivity is maintained, but the glass sheet cannot be centrally positioned below the forming portion
Solution Approach 1:
The patent implements dynamic conveyor speed control that adjusts the conveyance speed based on the detected glass sheet position. When the glass sheet is detected to be off-center, the system modulates the conveyor speed to compensate for the positioning error, ensuring the glass sheet reaches the central position below the forming portion while maintaining overall productivity through minimal speed variations.
Solution Approach 2:
The patent performs preliminary positioning adjustments before the glass sheet reaches the forming mold by detecting and correcting position deviations in advance. The system calculates the required correction based on detected glass sheet position and applies compensatory conveyance adjustments ahead of time, ensuring central positioning is achieved just before transfer without requiring speed reduction at the critical forming zone.
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
Ensures accurate central positioning of glass sheets of varying sizes, maintaining consistent curvature and size alignment during forming, effectively addressing size discrepancies and curvature needs for both outer and inner windshield glass sheets.
Implementation Method 1
A light source and detector array are positioned to detect the downstream and upstream extremities of the conveyed glass sheet
Implementation Method 2
vacuum, or gas lift to ensure precise alignment and transfer
Implementation Method 3
vacuum, or gas lift to ensure precise alignment and transfer
Data Source
AI summary
A method having particular utility for making outer and inner formed windshield glass sheets is performed by glass sheet positioning centrally on a forming face (34) of a forming mold (32) to form each glass sheet to a design shape regardless of any size difference between the glass sheets from one cycle to the next.