Low-E Glass Shaping With Camera-Guided Alignment
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Solution Overview
Problem
Glass sheets with low emissivity coatings experience uneven heating in furnaces, leading to curvature and rotation on conveyors, causing misalignment and incorrect shaping during press bending operations.
Innovation Solution
A roller conveyor system with a frame having a fixed wall and three movable walls, combined with a camera and control system, adjusts the position of the glass sheet to correct for uneven heating and ensure accurate shaping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a glass sheet with low emissivity coating is heated in a furnace, then the glass sheet can be shaped, but the coating causes uneven heating and curvature
Solution Approach 1:
The patent applies preliminary action by positioning the glass sheet correctly before heating occurs. The method includes positioning the coated glass sheet at the furnace entrance and transferring it to a shaping ring at a specific location to ensure proper alignment before thermal processing begins, thereby preventing misalignment caused by subsequent curvature during heating
2Productivity
If the coated glass sheet is heated unevenly, then shaping can proceed, but the glass sheet rotates and misaligns on the conveyor
Solution Approach 1:
The patent implements feedback by using a camera to monitor the position of the glass sheet during conveying and heating, with the camera output fed to a control system that automatically adjusts the positioning of subsequent glass sheets based on detected deviations, thereby correcting for rotation and misalignment in real-time
Solution Approach 2:
The patent applies parameter changes by dynamically adjusting the positioning parameters of the glass sheet based on temperature-induced curvature variations. The system modifies the position where the glass sheet is transferred to the shaping ring according to the degree of curvature observed, compensating for thermal deformation effects
3Device complexity
If the glass sheet position is not corrected, then the process is simple, but the bent product geometry is incorrect
Solution Approach 1:
The patent replaces complex mechanical positioning systems with an automated optical-mechanical system. Instead of using complex mechanical devices to physically adjust each glass sheet position, the system uses a camera for detection and a control system to automatically adjust positioning, substituting mechanical complexity with automated control
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 precise alignment and shaping of coated glass sheets by correcting positional deviations caused by uneven heating, preventing rotation and ensuring consistent product geometry.
Implementation Method 1
glass to be shaped is carried out using heated transferred to the glass by radiation and/or convection and/or conduction
Implementation Method 2
glass to be shaped is carried out using heated transferred to the glass by radiation and/or convection and/or conduction
Implementation Method 3
glass to be shaped is carried out using heated transferred to the glass by radiation and/or convection and/or conduction
Implementation Method 4
A glass sheet with low emissivity coating thereon undergoes uneven heating in the furnace due to the difficulty of getting heat into the coated surface
Implementation Method 5
The camera output is fed to a control system to adjust the positioning of the coated glass sheet
Implementation Method 6
The camera output is fed to a control system to adjust the positioning of the coated glass sheet
Data Source
Figure 1
AI summary
The invention relates to a method for shaping a glass sheet having a reflective low emissivity coating thereon comprising the steps: (i) positioning the coated glass sheet at a furnace entrance; (ii) conveying the coated glass sheet through the furnace to heat the glass sheet to a temperature suitable for shaping; (iii) transferring the coated glass sheet on to a first bending tool for supporting the coated glass sheet, the first bending tool having a fixed wall and first, second and third movable walls; (iv) moving at least one of the first, second and third movable walls to adjust the position of the coated glass sheet on the first bending tool ring from a first position to a second position; and (v) shaping the coated glass sheet between the first bending tool and a die. Apparatus for carrying out the method is also disclosed.