Quench Station Segmentation for Glass Sheet Cooling Efficiency
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Solution Overview
Problem
Existing quench stations are inefficient when handling smaller glass sheets or multiple sheets side-by-side, as pressurized air used for cooling often does not effectively impinge on the glass, resulting in wasted energy and reduced cooling efficiency.
Innovation Solution
A quench station design featuring lower and upper quench head assemblies with laterally spaced quench manifolds, programmable valve control to direct pressurized air only where needed, and adjustable supports for various glass shapes, ensuring targeted air flow and reduced air wastage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the quench station is constructed large enough to quench large formed glass sheets, then it can handle larger glass sheets, but pressurized air used for quenching at lateral extremities does not impinge on smaller glass sheets to provide cooling, resulting in wasted energy
Solution Approach 1:
The quench station is divided into multiple independently controllable quench zones along the direction of conveyance, with each zone having its own pressurized air supply. This segmentation allows the system to activate only the zones where glass sheets are present, avoiding waste of pressurized air in empty zones while maintaining the capability to handle various glass sheet sizes.
Solution Approach 2:
The quench station employs dynamic control of pressurized air supply through sensors and programmable logic controllers that detect the presence and position of glass sheets. The system dynamically adjusts which quench zones are active based on real-time conditions, optimizing energy usage while adapting to different glass sheet sizes and configurations.
2Productivity
If two or more smaller sheets are moved side-by-side in a spaced relationship, then multiple glass sheets can be processed simultaneously, but pressurized air flow is wasted at central and lateral outward locations where no glass is present
Solution Approach 1:
The quench station is divided into multiple independently controllable quench zones along the direction of conveyance, with each zone having its own pressurized air supply. This segmentation allows the system to activate only the zones where glass sheets are present, avoiding waste of pressurized air in empty zones while maintaining the capability to handle various glass sheet sizes.
Solution Approach 2:
Each quench zone can be independently activated or deactivated based on the local presence of glass sheets. The system applies pressurized air only to the specific lateral locations where glass sheets are positioned, creating a localized cooling effect precisely where needed rather than uniformly across the entire quench station width.
3Reliability
If pressurized air is supplied across the entire quench station width, then all areas are prepared for quenching, but energy is wasted in areas unoccupied by glass sheets
Solution Approach 1:
The quench station employs dynamic control of pressurized air supply through sensors and programmable logic controllers that detect the presence and position of glass sheets. The system dynamically adjusts which quench zones are active based on real-time conditions, optimizing energy usage while adapting to different glass sheet sizes and configurations.
Solution Approach 2:
The quench station incorporates sensors that automatically detect the presence and position of glass sheets, triggering the activation of appropriate quench zones without manual intervention. The system self-regulates the pressurized air supply based on actual processing needs, eliminating waste while ensuring reliable quenching where required.
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
Enhances cooling efficiency by directing pressurized air precisely to the glass sheets, reducing energy consumption and improving the quenching process for both single and multiple glass sheets, including those of different shapes.
Implementation Method 1
pressurized air flows to the formed glass sheet for quenching
Data Source
AI summary
A glass sheet quench station (16) and method for quenching glass sheets includes quench control valves (55, 57) that are operated to reduce unnecessary quenching air and thereby provide efficiency in the quenching.