Parallel Insulated Glass Manufacturing Line
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Solution Overview
Problem
The existing manufacturing processes for insulated glass units are inefficient, requiring longer cycle times and more labor, with energy consumption issues and ergonomic challenges due to the need for heating entire units and manual handling of glass in horizontal orientations.
Innovation Solution
A high-speed parallel process manufacturing line that includes a vertically oriented washer, double shuttle for efficient conveyor management, servo-driven suction cups for continuous glass movement, a temperature-controlled spacer supply, infrared heating for localized heating, and a double gas press for rapid gas filling, reducing cycle time and energy consumption while improving ergonomics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing processes are used for insulated glass units, then production can be maintained with conventional equipment, but cycle time is extended and production rate is reduced
Solution Approach 1:
The manufacturing process is divided into parallel work cells (washing cell, heating cell, spacer application cell, assembly cell) that operate simultaneously on different glass units. This segmentation allows multiple units to be processed at different stages at the same time, doubling the production rate from one unit per cycle to two units per cycle while reducing overall cycle time.
Solution Approach 2:
Glass units are pre-washed in the washing cell before reaching the assembly cell, and pre-heated in the heating cell before spacer application. This preliminary action ensures that when units reach the assembly cell, they are ready for immediate processing, eliminating waiting time and reducing overall cycle time.
2Reliability
If entire glass units are heated in traditional ovens, then spacer adhesive can be properly activated, but energy consumption increases significantly
Solution Approach 1:
Instead of heating entire glass units in traditional ovens, the patent uses targeted heating methods such as heat guns or heating elements positioned at specific locations (corners or edges) where the spacer adhesive needs activation. This localized heating approach provides sufficient thermal energy for reliable sealing while consuming significantly less energy than heating entire units.
Solution Approach 2:
The heating function is extracted from the main assembly process and performed separately in a dedicated heating cell before units reach the assembly cell. This allows heating to be optimized for the specific requirement of adhesive activation rather than general unit heating, reducing energy consumption while maintaining seal quality.
3Ease of operation
If manual handling of glass panes is used, then flexibility in processing can be maintained, but labor requirements increase and ergonomic challenges arise
Solution Approach 1:
Manual handling of glass panes is replaced with automated conveying systems including conveyors, robotic manipulators, or automated transfer mechanisms. These systems provide consistent, repeatable handling operations that reduce labor requirements and eliminate ergonomic challenges associated with manual glass handling while maintaining processing flexibility through programmable control.
Solution Approach 2:
The manufacturing system is designed to automatically transfer glass units between work cells and perform operations without manual intervention. Units are self-conveyed through the process on conveyors, and operations such as spacer application and sealing are performed by automated equipment, reducing the need for human operators while maintaining operational flexibility.
4Device complexity
If glass panes are processed in horizontal orientation, then equipment design is simplified, but ergonomic challenges increase for workers
Solution Approach 1:
The patent transitions from processing glass panes exclusively in horizontal orientation to vertical or angled orientations in certain work cells. This dimensional change allows workers to perform operations at ergonomic heights and angles, reducing strain and improving comfort while equipment design adapts to accommodate the new orientation through vertically mounted conveyors and processing equipment.
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 solution significantly reduces cycle time, doubles production rates, minimizes labor, and reduces energy consumption by half, while improving the quality and safety of the manufacturing process through continuous glass movement and localized heating, enabling faster and more efficient production of insulated glass units.
Implementation Method 1
a heating station including a plurality of infrared heating units positioned to heat the edges of the insulated glass unit
Implementation Method 2
a servo-driven suction cup assembly structured to grip the glass pane and advance it slightly
Data Source
AI summary
A high speed parallel manufacturing line for manufacturing insulated glass units, the manufacturing line including a gas filling topping press that mates a spacer applied lite supplied to the topping press and a topping lite supplied to the topping press to create an insulated glass unit and fills the insulated glass unit with a non-air gas. A heating station applies localized heat to adhesive of the spacer material. A sealing press applies pressure to the insulated glass unit and facilitates further sealing of the spacer material to the spacer applied lite and the topping lite. The line may include a fourth corner sealer that completes sealing of the airspace of the IGU prior to finishing of the IGU.