Automatic Tweel Control Using Visual Feedback in Float Glass
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Solution Overview
Problem
Current glass manufacturing techniques rely on manual control of the tweel, leading to errors such as improper opening or closing, resulting in inconsistent molten glass flow and potential waste.
Innovation Solution
A computer-implemented method and system for automatic tweel control using visual data from cameras to measure the dimensions of the molten glass flow, generating control pulse signals to adjust the tweel position and flow rate accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual control of the tweel is used, then the operator can adjust the tweel position, but errors occur in tweel control leading to inconsistent molten glass flow
Solution Approach 1:
The patent replaces manual mechanical control of the tweel with an automated control system that uses visual data from cameras to detect molten glass flow dimensions and automatically adjusts the tweel position through control pulse signals, eliminating human error in tweel operation
Solution Approach 2:
The system continuously receives visual data from cameras monitoring the molten glass flow, processes this data to determine flow dimensions, compares them to target values, and automatically sends control pulse signals to adjust the tweel position, creating a closed-loop feedback control system that maintains consistent flow
2Productivity
If the tweel is opened too wide or left open too long, then more molten glass flows onto the bath, but the floating layer becomes too wide causing waste
Solution Approach 1:
The system uses real-time visual feedback from cameras to monitor the width of the molten glass floating layer and automatically adjusts the tweel position to maintain optimal width, preventing both excessive flow (which causes waste) and insufficient flow (which reduces productivity)
Solution Approach 2:
The automated control system enables the manufacturing process to self-regulate the tweel position based on real-time measurements of molten glass flow characteristics, eliminating the need for manual intervention and consistently maintaining optimal flow conditions
3Loss of substance
If the tweel is not opened wide enough or kept closed too long, then insufficient molten glass leaves the furnace, but the floating layer becomes too narrow reducing throughput
Solution Approach 1:
The system continuously monitors the width of the molten glass floating layer through visual data and automatically adjusts the tweel opening to maintain optimal dimensions, ensuring sufficient glass flow onto the bath without causing excessive width that would lead to waste
4Measurement precision
If automatic control system with cameras is implemented, then tweel control precision is improved, but system complexity increases
Solution Approach 1:
The system uses cameras as intermediary devices to capture visual data of the molten glass flow, which is then processed to determine flow dimensions and control the tweel position, enabling precise measurement without direct physical contact with the hot molten glass
Data Source
AI summary
Systems, methods, and computer program products are provided for automatic tweel control in molten glass manufacturing. An example system includes a processor configured to receive visual data from a camera positioned with a view of a molten glass flow that is spreading from a melting tank into a bath containing molten metal, wherein a flow rate of the molten glass flow is controlled by a tweel. The processor is also configured to process the visual data to determine a value of a dimension of the molten glass flow. The processor is further configured to, in response to the value of the dimension of the molten glass flow satisfying a predetermined threshold value, generate a first control pulse signal to the tweel, wherein the first control pulse signal is configured to incrementally increase or decrease the flow rate of the molten glass flow.