Glass Sheet Shaping via Variable Speed Roll Forming
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Solution Overview
Problem
Existing glass sheet roll forming methods fail to effectively minimize undesired curvature from desired portions of the glass sheet, limiting the flexibility and precision in shaping glass for applications like vehicle windows.
Innovation Solution
A glass shaping system comprising a horizontal first roll shaping zone and an inclined second roll shaping zone, with pairs of shaping rolls having transversely straight and transversely convexly arcuately curved configurations, allowing for variable contact time by adjusting the rotational speed of the rolls to selectively eliminate undesired curvature.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the glass sheet is transported at high velocity through the roll shaping zone, then cycle time is reduced, but undesired curvature cannot be selectively minimized
Solution Approach 1:
The roll shaping zone is divided into multiple independently controllable roll pairs, each capable of different rotational speeds. This segmentation allows different portions of the glass sheet to experience different contact times with the rolls, enabling selective curvature minimization in specific zones while maintaining overall high throughput velocity.
Solution Approach 2:
The rotational speed of the shaping rolls is made variable and adjustable. By dynamically changing the roll speed during the shaping process, the system can optimize contact time for different glass sheet regions, thereby controlling curvature precision without sacrificing overall production cycle time.
2Manufacturing precision
If the contact time between glass sheet and shaping rolls is increased, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
Different portions of the glass sheet receive different contact times with the shaping rolls based on local requirements. Rolls positioned to address specific curvature problems can operate at reduced speeds for longer contact time, while other rolls maintain higher speeds for efficiency, achieving local precision without global productivity loss.
Solution Approach 2:
The system applies extended contact time only where and when needed for curvature correction, rather than uniformly across the entire glass sheet. This partial action approach maintains high productivity for portions of the sheet that don't require extensive shaping while providing sufficient contact time for precision work in problem areas.
3Device complexity
If conventional roll forming methods are used, then the process is simple, but undesired curvature cannot be selectively minimized
Solution Approach 1:
The system introduces variable speed control for the shaping rolls, transforming a static, simple process into a dynamic, adjustable one. This added complexity in control mechanisms enables precise curvature management while maintaining relative simplicity in the physical roll forming structure.
Solution Approach 2:
The rotational speed parameter of the shaping rolls is made variable and adjustable during operation. By changing this key parameter, the system achieves selective curvature minimization without requiring fundamental changes to the roll forming equipment or process architecture, thus balancing precision improvement with maintained simplicity.
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 precise control over glass sheet shaping, reducing undesired curvature while maintaining a reasonable cycle time, allowing for a variety of window shapes without major component changes.
Implementation Method 1
Each set of upper and lower shaping rolls have complementary shapes so as to allow a glass sheet to pass therebetween, and to take the cumulative shape of the entire set of upper and lower shaping rolls
Implementation Method 2
shaping means complementary to the curved surface defined by the rods are pressed down onto the sheet to conform it to the rods
Implementation Method 3
the glass sheet being transported from the horizontal first roll shaping zone, up the slope of the inclined second roll shaping zone
Data Source
Figure 1
Figure 2~3
AI summary
The present invention relates to a method of shaping a glass sheet in one dimension, by roll forming in a manner to selectively minimize/eliminate undesired curvature from the glass sheet. Such shaping is achieved by the selective location in first and second, shaping zones, of shaping rolls having first and second shaping configurations and, optionally, by varying the velocity of the glass sheet as it moves through the shaping zones, thus varying the time portions of the glass sheet are in contact with certain shaping rolls.