Parallel Insulated Glass Manufacturing Line Cycle Time Reduction
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Solution Overview
Problem
The existing manufacturing processes for insulated glass units are inefficient, requiring multiple movements of glass panes through stationary application heads, leading to longer cycle times and reduced productivity.
Innovation Solution
A high-speed parallel process manufacturing line that includes a double shuttle system, driven parallel conveyor, servo-driven suction cup assembly, and dual gas press compartments to streamline the application of spacers and gas filling, allowing continuous forward movement of glass panes and reducing cycle time by applying spacers and seals while moving.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If glass panes are conveyed through stationary application heads in tandem fashion, then the manufacturing process is simplified, but cycle time increases to 25-30 seconds per unit
Solution Approach 1:
Instead of moving glass panes through stationary application heads, the patent inverts the approach by making the application heads move with the glass panes on parallel conveyors. This allows continuous forward movement without stopping or reversing, reducing cycle time to 15-20 seconds per unit while maintaining process automation
Solution Approach 2:
The patent introduces dynamic elements by using parallel conveyors that can independently control the movement of topping lites and spacer-applied lites. This dynamic system allows synchronized movement and application operations, eliminating the need for repeated stopping and starting in traditional tandem processing
2Manufacturing precision
If glass panes are moved backward and forward through the same zone multiple times, then application coverage is improved, but productivity decreases due to repeated movements
Solution Approach 1:
The patent adds a spatial dimension by creating parallel processing paths for topping lites and spacer-applied lites. Instead of re-traversing the same zone multiple times in one dimension, the system processes different pane types simultaneously in parallel dimensions, achieving complete application coverage in a single forward pass through the manufacturing line
Solution Approach 2:
The manufacturing line is segmented into separate parallel conveyors for different pane types (topping lites and spacer-applied lites). This segmentation allows each conveyor to be optimized for its specific function and eliminates the need for panes to backtrack, as each segment processes its designated pane type continuously in one direction
3Extent of automation
If automated robotic sealant applying heads are used, then labor requirements are reduced, but cycle time increases due to complex positioning and movement
Solution Approach 1:
The patent ensures continuous useful action by having application heads that move synchronously with the glass panes on parallel conveyors. The automated application process occurs continuously during forward movement without stopping, positioning, or reversing, maintaining both high automation and reduced cycle time of 15-20 seconds per unit
Solution Approach 2:
The system allows the glass panes to essentially service themselves through the parallel conveyor arrangement, where the movement of the conveyors automatically positions the application heads in the correct locations relative to the panes. This self-positioning mechanism reduces the complexity of automated control while maintaining high-speed operation
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 significantly reduces cycle time from 25-30 seconds to 15-20 seconds, potentially doubling production rates without increasing labor, by minimizing shifting, staging, and optimizing the application of spacers and gas filling, thus enhancing automation and productivity.
Implementation Method 1
a servo-driven suction cup assembly to hold the lites
Data Source
AI summary
A high speed parallel manufacturing line for manufacturing insulated glass units, the manufacturing line including a front conveyor system, a back conveyor system, a shuttle mechanism that distributes glass lites to the front conveyor system and the back conveyor system, an insulated glass unit spacer applicator having a spacer dispensing head configured to apply perimeter spacer material to one of the glass lites, the spacer head being proportionally movable relative to the glass lite as the glass lite is conveyed on the front conveyor mechanism to apply the perimeter spacer material to create a spacer applied lite and a gas press. A secondary edge sealing unit has a first secondary edge sealing head and a second secondary edge sealing head, each of the first secondary edge sealing head and the second secondary edge sealing head applying edge sealant to portion of a perimeter of an insulated glass unit.