Non-Equidistant Electrode Kiln for Stable Glass Melting
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Solution Overview
Problem
The existing glass kilns experience fluctuations in the resistivity of molten glass, leading to instability in the melting process and potential electrode power failures, known as the 'power off' phenomenon, which affects the operational stability and product quality.
Innovation Solution
A front-zone dual-electrode non-equidistant kiln design is introduced, featuring a pool wall with a clarification zone, a homogenization zone, and multiple pre-melting zones. The kiln includes dual electrodes with non-equidistant spacing, ultrasonic components, current measuring instruments, a voltage controller, automatic feeding and discharge gates, and a processor for real-time data processing and control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the feed volume of glass is increased to meet production demand, then productivity is improved, but the resistivity fluctuations of molten glass worsen, causing power off phenomenon and reducing operational stability
Solution Approach 1:
The pre-melting zone is divided into multiple sub-zones with different electrode spacings. The front pre-melting zone has smaller electrode spacing to handle higher feed volumes and maintain stable resistivity, while rear zones have larger spacing. This segmentation allows the system to process larger glass feeds without causing power off phenomena, thus improving both productivity and operational stability.
Solution Approach 2:
Different regions of the pre-melting zone are assigned different electrode spacing characteristics. The front zone (where glass is first introduced) has non-equidistant smaller spacing optimized for handling variable feed volumes and resistivity fluctuations, while subsequent zones have larger spacing appropriate for more stable molten glass. This local optimization resolves the contradiction between handling high feed volumes and maintaining stable operation.
2Reliability
If the electrode spacing is reduced to stabilize the melting process, then operational stability is improved, but the melting efficiency and productivity deteriorate
Solution Approach 1:
The electrode system is segmented into front-zone electrodes with smaller spacing (for stability) and rear-zone electrodes with larger spacing (for efficiency). This allows the system to simultaneously achieve operational stability in the feed-sensitive front zone and maintain high melting efficiency in the rear zones where the glass is already molten and stable.
Solution Approach 2:
Each zone of the pre-melting region is equipped with electrode spacing optimized for its specific function. The front zone uses smaller spacing to stabilize resistivity during the critical initial melting phase, while rear zones use larger spacing to maximize melting efficiency. This local quality differentiation resolves the contradiction between stability and efficiency.
3Productivity
If the feed volume of glass is increased, then productivity is improved, but the resistivity of molten glass becomes more unstable, causing electrodes to fail and affecting product quality
Solution Approach 1:
The pre-melting zone is segmented into multiple zones with progressively larger electrode spacings. The front zone with smaller spacing stabilizes the resistivity of molten glass during the critical early melting phase, ensuring consistent quality even at high feed volumes. Subsequent zones with larger spacing continue the melting process, resulting in high-quality molten glass that meets product specifications.
Solution Approach 2:
The front pre-melting zone is equipped with specific electrode spacing characteristics (smaller spacing) optimized for maintaining resistivity stability and thus product quality. This local quality control ensures that even when overall feed volume is increased for high productivity, the critical quality-determining phase of initial melting remains stable and controlled.
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 kiln design significantly reduces the 'power off' phenomenon, enhances the operational stability, and improves the quality of the glass melting process by maintaining consistent electrode power supply and precise control over the melting and homogenization of glass.
Implementation Method 1
pre-melting the glass powder using the plurality of electrodes to form molten glass
Implementation Method 2
The transmitting unit may be configured to emit an ultrasonic wave, and the receiving unit may be configured to collect feedback ultrasonic data
Data Source
AI summary
A front-zone dual-electrode non-equidistant kiln comprises a pool wall that forms a clarification zone, a homogenization zone, and pre-melting zones. The pre-melting zones and the homogenization zone are in communication with the homogenization zone and the clarification zone, respectively. A total width of the pre-melting zones is greater than widths of the clarification zone and the homogenization zone. Electrodes are arranged on the pool wall on two sides of each of the clarification zone, the homogenization zone, and the pre-melting zones. A spacing between electrodes on two sides of the pre-melting zones is less than a spacing between electrodes on two sides of the clarification zone and a spacing between electrodes on the two sides of the homogenization zone. The pool wall is provided with a discharge port and feed ports. The feed ports and the discharge port are in communication with the pre-melting zones and the clarification zone, respectively.