Glass Tank Batch Topography Mapping for Stable Electric Melting
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Solution Overview
Problem
Existing methods for measuring batch thickness in fully electric melting furnaces are inaccurate, risky, and do not account for spatial and temporal variations, leading to inefficiencies and poor glass quality.
Innovation Solution
A method for non-contact data acquisition and evaluation of batch layer and glass level using sensors to create a topographic map, allowing for spatially and temporally adapted insertion rates and melting rates, with optional microwave heating to optimize the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual probing with a rod is used to measure batch thickness, then a local measurement can be obtained, but the measurement is risky for personnel, requires staffing, and is relatively inaccurate due to single-point measurement
Solution Approach 1:
The patent replaces manual mechanical probing with automated optical or electromagnetic sensors (such as laser triangulation sensors, ultrasonic sensors, or radar sensors) to measure batch thickness. This substitution eliminates personnel exposure to high-temperature environments and continuous staffing requirements while providing continuous, multi-point measurements across the entire batch surface, significantly improving both safety and measurement accuracy.
Solution Approach 2:
The invention transitions from single-point measurement to multi-dimensional surface mapping by deploying sensors that can scan or map the entire batch surface. This dimensional expansion allows simultaneous measurement of batch thickness at multiple locations, providing comprehensive spatial information that improves overall measurement accuracy and enables detection of non-uniform batch distribution.
2Loss of energy
If a continuous layer of melt material is maintained across the entire melt bath surface, then thermal insulation is improved, but the energy efficiency and melting capacity are reduced due to excessive cooling of the glass melt
Solution Approach 1:
The patent implements spatially variable batch thickness control by measuring the actual batch thickness at multiple locations and adjusting the batch feed rate locally to achieve the optimal thickness distribution. This allows thick batch layers in areas requiring insulation while maintaining thinner layers in areas needing heat penetration, thereby simultaneously improving thermal insulation efficiency and melting capacity without the trade-off present in uniform batch coverage.
Solution Approach 2:
The system continuously monitors batch thickness using sensors and feeds this information back to the batch feeding mechanism. Based on real-time thickness measurements and predetermined optimal thickness profiles, the system dynamically adjusts batch feed rates to maintain the ideal balance between thermal insulation and heat penetration, maximizing both energy efficiency and melting capacity.
3Ease of operation
If batch thickness is not precisely controlled, then the melting process is simpler to operate, but glass quality deteriorates due to 'volcano' formation and unstable glass flow
Solution Approach 1:
The system implements self-regulating batch thickness control where sensors continuously monitor batch thickness and automatically adjust batch feed rates without operator intervention. The control system compares measured thickness against target profiles and autonomously modifies feeding parameters, maintaining precise batch thickness control while simplifying operation through automation.
Solution Approach 2:
The invention introduces dynamic batch thickness control that adapts to changing melting conditions in real-time. Rather than static uniform thickness, the system continuously adjusts batch thickness distribution based on measured temperature fields, melting rates, and flow patterns, enabling the process to self-optimize and maintain high glass quality while remaining operationally simple through automated adaptation.
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
Improves energy efficiency, reduces 'volcano' formation, stabilizes glass flow, and enhances glass quality by adjusting batch insertion rates and melting rates based on real-time data analysis.
Implementation Method 1
at least one sensor (160) for non-contact acquisition of data on the batch layer (150)
Implementation Method 2
particularly in association with a microwave heater (190)
Implementation Method 3
Transform Electromagnetic Energy to Thermal Energy
Data Source
Figure 1~3
Figure 4
AI summary
The present invention relates to a method for recording and evaluating data on the batch ceiling and/or the glass melt in a fully electric cold-top melting furnace for melting glass, as well as the use of the method in a process for manufacturing glass.