Multispectral Inclusion Detection in Float Glass
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Solution Overview
Problem
Conventional methods for detecting inclusions in soda-lime-silica based glass, such as nickel sulfide inclusions, are inefficient and unable to accurately differentiate between different types of inclusions due to their similar shapes and intensities, leading to potential catastrophic failures in thermally tempered glass.
Innovation Solution
A multispectral imaging system that directs energy, such as infrared and visible light, towards the glass and analyzes the spectral reflectance across various wavelengths to identify and differentiate inclusions by capturing their respective spectral reflectance curves, allowing for the detection of nickel sulfide and other micro-defects within specific size ranges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional detection methods are used to identify inclusions in glass, then the detection process is simple, but the detection precision is insufficient and cannot differentiate between different types of inclusions
Solution Approach 1:
The patent transitions from conventional single-wavelength or narrow-band detection to multispectral imaging across a broad spectral range (400-2500 nm). This dimensional expansion in spectral space enables differentiation of inclusions based on their unique spectral reflectance curves, directly resolving the contradiction by adding spectral dimensionality to the detection process
Solution Approach 2:
The system varies the wavelength parameter across a broad spectral range (400-2500 nm) to capture different spectral reflectance characteristics of various inclusions. By changing the spectral parameter and analyzing reflectance at multiple wavelengths, the system achieves precise differentiation between inclusion types that appear identical under conventional single-wavelength detection
2Reliability
If all glass products undergo thermal tempering to ensure safety, then the safety of glass products is improved, but nickel sulfide inclusions cause spontaneous breakage in tempered glass
Solution Approach 1:
The system performs preliminary detection of nickel sulfide inclusions in annealed glass before the thermal tempering process. By identifying and rejecting glass containing NiS inclusions prior to tempering, the system prevents the subsequent spontaneous breakage that would occur during or after tempering, thus resolving the contradiction between achieving safety through tempering and avoiding NiS-related failures
Solution Approach 2:
The detection system takes preliminary anti-action by identifying and eliminating glass products containing nickel sulfide inclusions before they undergo thermal tempering. This preventive measure counteracts the potential harmful effect of NiS expansion during tempering, thereby ensuring reliability without suffering from spontaneous breakage
3Productivity
If nickel sulfide inclusions are detected and rejected in annealed glass, then production yields during tempering are improved, but the detection system must accurately differentiate NiS from other inclusions
Solution Approach 1:
The system changes the detection parameter from single-wavelength intensity measurement to multispectral reflectance measurement across 400-2500 nm. This parameter transformation enables accurate differentiation of nickel sulfide inclusions from other inclusion types based on their distinct spectral signatures, ensuring high-precision identification for yield improvement
Solution Approach 2:
The patent replaces conventional mechanical or simple optical detection methods with multispectral imaging analysis. By substituting the detection mechanism with spectral analysis, the system achieves the measurement precision required to accurately differentiate NiS inclusions, thereby enabling productivity improvement through precise defect identification
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
The system effectively detects and differentiates nickel sulfide inclusions from inclusion-free glass and other types of inclusions, enhancing glass quality control and reducing the risk of glass failures by identifying defects during or after the glass-making process, thereby improving production yields and safety.
Implementation Method 1
different wavelengths of reflected energy from the at least one light source are analyzed and compared and inclusions can be detected based on detected spectral reflectances at various wavelengths
Data Source
AI summary
A method and/or system is provided for detecting and/or identifying inclusions (e.g., nickel sulfide based inclusions/defects) in glass such as soda-lime-silica based float glass. In certain example instances, during and/or after the glass-making process, following the stage in the float process where the glass sheet is formed and floated on a molten material (e.g., tin bath) and cooled or allowed to cool such as via an annealing lehr, energy such as infrared (IR) energy is directed at the resulting glass and reflectance at various wavelengths is analyzed to detect inclusions.