Handling Large Thin Glass Sheets in Clean-Room Loading

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Solution Overview

Problem

The challenge lies in efficiently loading and unloading thin sheets of glass with large surface areas in clean-room conditions, particularly for the production of TFT screens and photovoltaic modules, where small particles can cause line interruptions and production failures, and existing technologies do not adequately address the handling of such sheets in ultraclean environments without requiring separate power sources.

Innovation Solution

A device and method for loading and unloading a container with thin sheets of glass, utilizing conveyor belts and sensors to identify and remove defective sheets, with a system that includes a displacement carriage, transverse conveying device, and removal device, all designed to operate within clean-room conditions without a separate power source, ensuring reliable handling and detection of defects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If thin sheets of glass of large surface area are handled in clean-room conditions, then production of TFT screens and photovoltaic modules can proceed, but the complexity of the handling device increases due to requirements for particle-free operation and precise defect detection

Engineering Contradiction:

Improvehandling reliability in clean-room conditionsVSAvoidcomplexity of conveying and detection system

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The handling system is divided into separate functional modules: a conveying device for transporting glass sheets, a detection device for identifying defects, and a removal device for extracting defective sheets. This segmentation allows each component to be optimized independently while maintaining overall reliability in clean-room conditions.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A support structure serves as an intermediary element that holds the glass sheets during conveying and detection operations. This intermediary mechanism enables precise control and positioning of the glass sheets without direct manual handling, reducing the risk of particle contamination while maintaining handling reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If defective sheets are identified and removed, then production quality improves, but the time required for inspection and removal increases

Engineering Contradiction:

Improvequality control of glass sheetsVSAvoidtime for defect detection and removal

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The detection device continuously monitors glass sheets during the conveying process, identifying defects before the sheets reach the removal device. This preliminary detection allows for immediate removal of defective sheets from the production line, minimizing time loss while maintaining high manufacturing precision.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The detection device provides real-time feedback about the condition of glass sheets to the removal device, enabling dynamic adjustment of the removal process. This feedback mechanism ensures that only defective sheets are removed while minimizing interruptions to the overall production flow, balancing quality control with time efficiency.

Inventive Principle:

Principle #23Feedback

3Stability of the object's composition

If a support structure is used for conveying glass sheets, then handling stability improves, but the risk of particle accumulation and contamination increases

Engineering Contradiction:

Improvestability of glass sheet positioningVSAvoidparticle contamination from support structure

Core Design Contradiction:

Stability of the object's compositionVSObject-affected harmful factors

Solution Approach 1:

The support structure is designed to be easily removable from the clean-room environment after use. This extraction approach allows the support structure to be taken out and cleaned or replaced, preventing particle accumulation and contamination while maintaining stability during the conveying process.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The support structure is designed as a disposable or easily replaceable component that can be quickly removed and replaced if contaminated. This approach prioritizes maintaining a particle-free environment over the permanence of the support structure, allowing for rapid replacement rather than extensive cleaning of the support elements.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Data Source

PatentUS8757355B2Method and device for loading a container with products comprising thin sheets of glass of a large surface area

Publication Date: 2014.06.24 GRENZEBACH MASCHINENBAU GMBH

AI summary

Method and device for loading a container with products which are made up of individual thin sheets of glass (1) of a large surface area or with individual sheets of glass (1), in particular photovoltaic modules, TFT screens or component parts thereof, comprising the following features: a) means for respectively bringing into place individual sheets of glass (1) or products made up of various sheets of glass (1), b) a vertical adjuster with a sliding carriage (16) and supporting forks (12), c) a transverse transporting device (18) for loading, d) a device for transferring force from the transverse transporting device (18) to a transporting belt (8) respectively of the container.