Molten Glass Viscosity Control via Magnetic Torque Sensing
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Solution Overview
Problem
In glass manufacturing processes, controlling the flowrate of molten material at downstream locations is challenging due to variability in viscosity and temperature, leading to inconsistencies in glass ribbon thickness, width, and quality.
Innovation Solution
A method involving mixing molten material at an upstream location with a shaft having protrusions, measuring torque and level to calculate viscosity, and adjusting temperature at a midstream location to control the flowrate at the downstream location, using a wireless torque sensor and level sensor for accurate measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If viscosity and temperature are controlled to maintain consistent flowrate, then glass ribbon quality improves, but measurement and control complexity increases
Solution Approach 1:
The patent replaces complex mechanical viscosity measurement systems with a magnetic torque sensor that uses magnetic fields to measure torque on the mixing shaft. This substitution reduces mechanical complexity while maintaining measurement accuracy for controlling glass ribbon quality
Solution Approach 2:
The patent introduces a magnetic coupling system as an intermediary between the mixing shaft and torque sensor, allowing torque measurement without direct mechanical contact. This intermediary enables precise viscosity measurement while simplifying the overall measurement system architecture
2Stability of the object's composition
If temperature is adjusted at midstream location to control downstream flowrate, then flowrate consistency improves, but energy consumption increases
Solution Approach 1:
The patent applies temperature adjustment at a midstream location before the downstream forming area, proactively controlling viscosity and flowrate before they reach the glass formation zone. This preliminary action prevents flowrate variations rather than correcting them, reducing the energy needed for continuous adjustment
Solution Approach 2:
The patent implements a feedback control system where downstream flowrate measurements are used to adjust upstream temperature and mixing parameters. This closed-loop feedback optimizes energy consumption by making adjustments only when and where needed to maintain flowrate consistency
3Measurement precision
If torque measurement is used to calculate viscosity, then viscosity measurement accuracy improves, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical torque measurement devices with a magnetic torque sensor that measures torque through magnetic field interaction. This substitution maintains high measurement precision for viscosity calculation while reducing mechanical complexity and maintenance requirements
Solution Approach 2:
The magnetic torque sensor system is designed to automatically measure torque and provide viscosity calculations without requiring complex external measurement equipment or manual intervention, making the system self-sufficient while maintaining high precision
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 ensures a consistent and uniform flowrate, improving the quality of the glass ribbon by reducing stress concentrations and variability, while increasing production efficiency and output.
Implementation Method 1
measuring a torque of the shaft, measuring a level of the molten material at the upstream location, and calculating a viscosity of the molten material at the upstream location based on the measured torque and the measured level
Implementation Method 2
measuring the torque of the shaft can include rotating a rotor mounted to the shaft relative to a stator. In some embodiments, the stator can be positioned to receive a signal from the rotor without physically contacting the rotor
Implementation Method 3
adjusting a temperature of the molten material at a midstream location positioned between the upstream location and the downstream location based on the estimated flowrate
Data Source
AI summary
A method of controlling a flowrate of molten material at a downstream location in a glass manufacturing process can include mixing the molten material at an upstream location positioned upstream from the downstream location relative to a flow direction of the molten material with a shaft including a plurality of protrusions. The method can also include measuring a torque of the shaft, measuring a level of the molten material at the upstream location, and calculating a viscosity of the molten material at the upstream location based on the measured torque and the measured level. In addition, the method can include estimating the flowrate based on the calculated viscosity, and controlling the flowrate at the downstream location based on the estimated flowrate.