CN116730592B - Ultra-uniform photovoltaic glass production system and method - Google Patents
Ultra-uniform photovoltaic glass production system and method Download PDFInfo
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- CN116730592B CN116730592B CN202310614060.1A CN202310614060A CN116730592B CN 116730592 B CN116730592 B CN 116730592B CN 202310614060 A CN202310614060 A CN 202310614060A CN 116730592 B CN116730592 B CN 116730592B
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Classifications
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B13/00—Rolling molten glass, i.e. where the molten glass is shaped by rolling
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B13/00—Rolling molten glass, i.e. where the molten glass is shaped by rolling
- C03B13/18—Auxiliary means for rolling glass, e.g. sheet supports, gripping devices, hand-ladles, means for moving glass pots
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- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C17/00—Surface treatment of glass, not in the form of fibres or filaments, by coating
- C03C17/001—General methods for coating; Devices therefor
- C03C17/002—General methods for coating; Devices therefor for flat glass, e.g. float glass
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D21/00—Measuring or testing not otherwise provided for
- G01D21/02—Measuring two or more variables by means not covered by a single other subclass
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q50/00—Information and communication technology [ICT] specially adapted for implementation of business processes of specific business sectors, e.g. utilities or tourism
- G06Q50/04—Manufacturing
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Abstract
The application provides an ultra-uniform photovoltaic glass production system and method, comprising a glass production line device pair roller synchronization device and an anilox roller correction frame; the pair roller synchronizing device is used for synchronously correcting an upper roller and a lower roller in the calender; the anilox roller correcting frame comprises: a support frame body; the application can improve the thickness uniformity of glass and the uniformity of a film coating layer, has higher tempering flatness because of extremely small original sheet, even glass thickness and film coating, can reduce the refractive index, can produce a product with thinner glass thickness under the same refractive index, can realize a photovoltaic glass product with 1.6-3.2mm and light transmittance of 99 percent, and can achieve the light transmittance of more than 96 percent because of extremely small original sheet thickness and even thickness and film coating when in the fields of thickened glass (4-6 mm), explosion-proof glass (8-12 mm) and bulletproof glass (12-20).
Description
Technical Field
The application relates to the field of glass production correction, in particular to an ultra-uniform photovoltaic glass production system and method.
Background
The global solar photovoltaic market is rapidly developing. With the accumulation and advancement of technology, the pursuit of high-power, high-performance solar cells has never ceased. Meanwhile, the solar module is subdivided into different types for different use environments so as to face different customer demands. In this way, higher requirements are also put forward for tempered glass enterprises. Solar module enterprises have proposed the need for high abrasion resistance, AR (Anti Reflection) tempered glass front plates for tempered glass enterprises.
However, the prior AR toughened glass generally passes through the steps of coating, curing and toughening, solution flows into the middle of an anilox roller and a rubber roller during coating, the solution is uniformly smeared on the rubber roller in a dot shape by means of cutting off the four-corner anilox concave lines of the anilox roller body, so that the condition that the concentration of the coating is uneven due to the fact that solution is easily accumulated at the end points of the four-corner anilox concave lines during coating is easy to occur, wire drawing defects are easy to occur, the thickness of a film layer after coating is uneven (the thickness of the film layer can only be controlled to be +/-10 nm), the surface is uneven, the light transmittance is only 93.8% -94%, the thickness of original glass is uneven, the thickness of the finished product after coating, curing and toughening is extremely poor, the consumption of glass liquid is increased, the problem of exceeding standard is caused, and in addition, larger static friction force and pressure are generated in a thicker area during contact friction between the glass and a plane, so that abrasion resistance is easier to reduce.
Disclosure of Invention
The application provides a production system and a production method of ultra-uniform photovoltaic glass, which aim to solve the problems that the glass thickness of a finished product is extremely poor, the consumption of glass liquid is increased after coating, curing and tempering, so that the bending degree and the flatness exceed the standard, and in addition, larger static friction force and pressure are generated in a thicker area when the glass is in contact friction with a plane, so that the glass is easier to wear and the wear resistance is reduced.
An embodiment of a first aspect of the present application provides a glass production system comprising: the glass production line device at least comprises a calender and a coating machine, wherein the calender comprises an upper calendaring roller and a lower calendaring roller which are arranged in pairs, the coating machine comprises an anilox roller, and the glass production system further comprises a pair roller synchronization device and an anilox roller correction frame;
The pair roller synchronizing device is used for synchronizing the linear speed of an upper rolling roller and a lower rolling roller in the calender and is used for pair rollers at the position where the thickness of the original sheet glass is minimum;
The anilox roller correcting frame comprises:
A support frame body having a base;
the anilox roller is rotationally limited on a base on the supporting frame body, a plurality of stress points are arranged on the anilox roller, and the stress points are distributed along the axial direction of the anilox roller;
an electric stretching mechanism for hanging a flexible belt at the stress points to pull the anilox roller upwards; and
And the measuring meter is used for measuring the displacement of the anilox roller after upward traction.
In an alternative embodiment, the pair of roller synchronizing means comprises:
The temperature measurement module is used for measuring the temperatures of set points or all points of the produced glass surface to obtain the temperature distribution of the glass surface;
The calculation module is used for determining the point position with the lowest temperature difference on the surface of the glass as the correction point position of the synchronous counter roll according to the temperature distribution;
And the correction module is used for adjusting the linear speeds of the upper rolling roller and the lower rolling roller so as to synchronize the linear speeds of the upper rolling roller and the lower rolling roller at each correction point.
In an alternative embodiment, the side surface of the anilox roller is provided with a pattern structure which is uniformly arranged and has a concave-convex shape, and the pattern structure comprises:
The first ends of the first main branches and the second main branches are uniformly converged at the first round edge part, the second ends of the first main branches are uniformly distributed at the second round edge part, the first main branches and the second main branches are alternately arranged at intervals, and the diameter of the first round is smaller than that of the second round; and
And the combining part is combined with the first end of the first main branch, the second end of the first main branch, the first end of the second main branch and the second end of the second main branch and is in a closed ring shape.
In an alternative embodiment, the joint of the anilox roller is in the shape of a circular ring or a rectangular ring.
In an alternative embodiment, the tread band structure further comprises:
The auxiliary branch groups comprise at least one auxiliary branch, the first end of each auxiliary branch is connected with one of the first main branches, and the second end of each auxiliary branch is connected with a second main branch adjacent to the one of the first main branches.
In an alternative embodiment, the tread band structure further comprises:
Each auxiliary branch group comprises at least one auxiliary branch, each auxiliary branch group is used for connecting adjacent first main branches and second main branches with preset numbers, and at least one first main branch and one second main branch are separated between two adjacent auxiliary branch groups.
In an alternative embodiment, the pattern structure includes a plurality of auxiliary branches between adjacent first main branches and second main branches, each of the plurality of auxiliary branches having at least one overlapping node with at least one other auxiliary branch.
In an alternative embodiment, in the pattern structure, at least two reinforcing linking stems are connected between the bonding portions where the second ends of the adjacent first main limbs and second main limbs are connected.
In an alternative embodiment, in the pattern structure, the surface of the bonding portion, the surface of the junction between the bonding portion and the first main limb, and the surface of the junction between the bonding portion and the second main limb are hydrophobic surfaces subjected to superhydrophobic treatment, and the surfaces of the first main limb and the second main limb are hydrophilic surfaces.
In an alternative embodiment, in the pattern structure, elongated diffusion ribs are provided on the inner surface of the first main limb and/or the second main limb, and the number of the diffusion ribs in the direction close to the second end of the corresponding main limb is higher than the number of the diffusion ribs in the direction close to the first end of the corresponding main limb.
In an alternative embodiment, in the pattern structure, between each first main limb and the adjacent second main limb, in the radial direction of the first main limb, the number of auxiliary limbs gradually decreases in a direction towards the first end of the first main limb.
In an alternative embodiment, in the pattern structure, the inner surface of the first main limb and/or the second main limb forms a wavy fold or a stepped fold, and the width of the fold gradually decreases along the direction corresponding to the first end of the main limb.
In a second aspect, embodiments of the present application provide a method of glass production, comprising:
Measuring the temperature of a set point position or all point positions of the produced glass surface to obtain the temperature distribution of the glass surface;
According to the temperature distribution, the rolling upper roller and the rolling lower roller determine the point position with the lowest temperature difference on the surface of the glass as a correction point position of the synchronous counter roller;
And adjusting the linear speeds of the upper rolling roller and the lower rolling roller so as to synchronize the linear speeds of the upper rolling roller and the lower rolling roller at each correction point.
In an alternative embodiment, the configuration parameters of the upper and lower calender rolls include: the lower roller cooling air angle, the air quantity, the driving roller angle, the upper roller surface temperature and the lower roller surface temperature, the position of an air knife and the angle of a calender auxiliary roller;
According to the temperature distribution of the surfaces of the pair of rolls and the configuration parameters of the upper roll and the lower roll, determining stress coupling influence distribution at each rolling point of each rolling upper roll and each rolling lower roll comprises the following steps:
According to the angle and the air quantity of the lower roller cooling air, and in combination with a preset influence distribution diagram of the angle and the air quantity of the lower roller cooling air on the glass stress, determining first stress distribution formed in the lower roller cooling process;
determining second stress distribution formed by the upper roller and the lower roller in the calendaring process according to the angle of the driving roller, the temperatures of the upper roller surface and the lower roller surface, the position of the air knife and the angle of the auxiliary roller of the calendaring machine;
determining stress coupling influence distribution at each rolling point position of each rolling upper roller and each rolling lower roller according to the first stress distribution and the second stress distribution;
and determining the thickness range of the upper rolling roller and the lower rolling roller according to the stress coupling influence distribution and combining the preset corresponding relation between coupling stress and thickness range.
An embodiment of the third aspect of the present application provides tempered glass, wherein the manufacturing equipment of the tempered glass adopts the glass production system for production.
Advantageous effects
According to the technical scheme, the ultra-uniform photovoltaic glass production system and the ultra-uniform photovoltaic glass production method provided by the application can carry out offline or online correction on a glass production system by configuring the pair roller synchronous device and the anilox roller correction frame, the pair roller synchronous device is used for carrying out synchronous correction on an upper roller and a lower roller in a calender, the anilox roller correction frame carries out upward traction on the anilox roller through the plurality of stress points, then different displacement amounts of the anilox roller after upward traction are measured, so that the influence of dynamic runout (full runout) of the anilox roller can be avoided, the thickness of factory glass is more uniform by synchronizing the pair roller and the correction frame, the correction frame is matched with the anilox roller arranged on the correction frame, the thickness of the glass produced by correction frame is uniform, the flatness of the produced glass is higher, the original glass is small in difference, the glass thickness and the plating film are uniform, the refractive index can be reduced, the product with thinner glass thickness under the same refractive index can be produced, the product with the thickness of 1.6-3.2%, the light transmittance (light transmittance) and the thickness of the original glass is 8-12mm (thickness) and the ultra-12 mm (thickness of the original glass is uniform, and the thickness of the glass is 20-12 mm) is thicker) and the ultra-uniform glass is achieved at the same time.
Drawings
In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the drawings that are required in the embodiments or the description of the prior art will be briefly described, and it is obvious that the drawings in the following description are some embodiments of the present application, and other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a schematic diagram of a glass production system in accordance with an embodiment of the present application.
Fig. 2 is a schematic structural view of an anilox roller correcting frame in an embodiment of the present application.
Fig. 3 is a schematic diagram of the structure of the anilox roller embodying the first circle and the second circle in the anilox structure of the anilox roller in the embodiment of the present application.
Fig. 4 is a topological structure diagram of the anilox roller of fig. 3.
Fig. 5 is one of the schematic diagrams of the anilox structure of the anilox roller in the embodiment of the present application.
Fig. 6 is a second schematic diagram of the texture of an anilox roller in an embodiment of the application.
Fig. 7 is a topological structure diagram of the anilox roller of fig. 6.
Fig. 8 is a schematic structural view of a diffusion rib according to an embodiment of the present application.
Reference numerals: 1-glass production line device, 11-glass production line, 121-upper calendaring roller, 122-lower calendaring roller, 13-anilox roller, 14-rubber roller, 2-pair roller synchronization device and 3-anilox roller correction frame; 23-electric stretching mechanism, 21-supporting base, 22-measuring meter, 202-first round, 203-first main branch, 204-second main branch, 205-auxiliary branch, 201-second round, 2061-first end combined joint, 2062-second end combined joint, 207-reinforced grafting stem, 2031-diffusion rib.
Detailed Description
In order to make the technical problems, technical schemes and beneficial effects to be solved more clear, the invention is further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are for purposes of illustration only and are not intended to limit the scope of the invention.
Furthermore, the terms "first," "second," and the like, are used for descriptive purposes only and are not to be construed as indicating or implying a relative importance or implicitly indicating the number of technical features indicated. Thus, a feature defining "a first" or "a second" may explicitly or implicitly include one or more such feature. In the description of the present application, the meaning of "a plurality" is two or more, unless explicitly defined otherwise. The anilox roller, the manufacturing method and the toughened glass of the toughened glass can be used in the technical field of display and any field except the technical field of display, and the anilox roller, the manufacturing method and the application field of the toughened glass are not limited.
The application provides a production system and a production method of ultra-uniform photovoltaic glass, and aims to solve the problems that the glass thickness of a finished product is extremely poor, the consumption of glass liquid is increased, the bending degree and the flatness exceed the standard, and in addition, larger static friction force and pressure are generated in a thicker area when the glass is in contact friction with a plane, so that the glass is easier to wear and the wear resistance is reduced.
Specifically, in the glass production process, the glass mainly comprises two large blocks, wherein the first block is raw glass production, the second block is raw glass deep processing, and in the raw glass production, the main process steps are melting, calendaring, annealing and cutting of raw glass raw materials after melting or mixing. The raw sheet glass is melted or mixed glass raw materials are melted to obtain glass liquid, the glass liquid is pressed and formed into a hot glass state by calendaring, the hot glass is annealed to eliminate stress of the hot glass, and the raw sheet glass is cut into the raw sheet glass according to the size by cutting. In the compression molding process, certain radial runout inevitably exists in the conventional rolling rollers due to the limitation of the processing technology level in the processing process, after two rolling rollers are paired, the radial runout of the two rolling rollers is increased, the radial runout deformation of the rolling rollers is increased continuously under the high-temperature working state, the extremely poor thickness of the original sheet glass product and the original plate width are directly caused, the thickness uniformity is poor, the annual usage amount of the original sheet glass liquid of the applicant is directly caused to be more than 3000-5000 tons, and the economic benefit loss is more than one hundred million yuan.
In the deep processing of the original glass, the steps of edging, coating and tempering are the most common processes. The edging is to grind the edge defect of the cut original glass, and at the same time, the safe chamfering is carried out, the coating is to increase the reflection-increasing film, increase the incidence of light, and the toughening is to strengthen the surface of the glass. However, when the prior AR toughened glass is coated, the solution flows into the middle of the anilox roller and the rubber roller, and is uniformly smeared on the rubber roller in a dot shape by means of the cutting solution of the anilox concave lines at the four corners of the roller body of the anilox roller, so that the condition that the concentration of the coated film is uneven due to the fact that the solution is easily accumulated at the end points of the anilox concave lines at the four corners during coating is easy to occur, wire drawing defects are easy to occur, the thickness of the coated film is uneven (the thickness of the coated film can only be controlled to be +/-10 nm), the surface is uneven, the performance is poor, and the light transmittance is only 93.8% -94%.
Meanwhile, the total run-out and cylindricity of the anilox roller are also factors directly influencing the uniformity of the thickness of the film layer, specifically, the total run-out refers to the variation of the whole characteristic or curved surface relative to the reference when the part rotates 360 degrees around the reference axis, and the cylindricity refers to the difference between the maximum size and the minimum size of any vertical section. For the anilox roller, if the tolerance range of full run-out is larger, the solution intercepted by the four corners anilox concave lines of the anilox roller body is very uneven when the adhesive roller is smeared in a dot shape, the wiredrawing defect occurs, too much intercepted solution also occurs, the solution is wasted, and meanwhile, a lot of inconvenience and problems are caused for the subsequent liquid scraping operation. The above problems are also caused if the cylindricity tolerance range is large, and as such, the applicant has found that the correction level of the anilox roller is critical.
In summary, under the inhomogeneous circumstances of former glass thickness, the rete thickness of coating film simultaneously, both thickness inhomogeneous lead to the glass thickness of coating film solidification tempering finished product extremely poor great and the consumption of glass liquid increases jointly to lead to crookedness and roughness to exceeding standard, in addition, thicker regional production more static friction force and pressure when glass and plane contact friction, thereby wearing and tearing more easily, the problem that the wearability reduces.
In the process of years of research, the applicant finds that the good control and the bad control on the thickness of the original glass are related to the more and less consumption of glass liquid, and finds that the uniformity of the thickness of the film after coating is related to the smoothness, the wear resistance and the light permeability of the glass surface. Accordingly, the applicant has focused on solving the uniformity of the thickness of the glass and the uniformity of the thickness of the coating film. After years of intensive research, the applicant has proposed the ultra-uniform photovoltaic glass production system and method of the present application.
Fig. 1 shows a schematic structural view of a glass production system according to an embodiment of the first aspect of the present application, fig. 2 shows a schematic structural view of an anilox roller correction frame, and as shown in fig. 1, the glass production system includes a glass production line device 1, the glass production line device 1 includes at least a calender including a pair of an upper calender roller 121 and a lower calender roller 122, and a coater including an anilox roller 13 and a rubber roller 14.
The glass production system further comprises a counter roller synchronization device 2 and an anilox roller correction frame. The pair roller synchronizing device 2 is used for synchronizing the linear speed of the upper rolling roller 121 and the lower rolling roller 122 in the calender and is used for pair rollers at the position where the thickness of the original sheet glass is minimum.
The anilox roller correcting frame comprises a supporting frame body of a base 21, an anilox roller 13, an electric stretching mechanism 23 and a measuring meter 22, wherein the anilox roller 13 is rotationally limited on the anilox roller base 21 of the supporting frame body, a plurality of stress points are arranged on the anilox roller 13, and the stress points are distributed along the axial direction of the anilox roller 13; the electric stretching mechanism 23 hangs flexible belts at a plurality of stress points to pull the anilox roller 13 upwards; the gauge 22 is used to measure the displacement amount of the anilox roller 13 after the upward drawing.
Opposite ends of the anilox roller 13 are limited on the base 21 of the supporting frame body in a rotating way, so that the anilox roller 13 is limited on the base 21 in a horizontally suspended way.
The application provides a glass production system, which is specially used for carrying out deep research on two processing procedures of film coating and calendaring and provides an creative scheme, in the aspect of calendaring, a roll synchronization device 2 is adopted for carrying out line speed synchronization on an upper calendaring roll 121 and a lower calendaring roll 122, the position of the roll is selected at the position with the smallest thickness range of raw glass, the thickness range of the raw glass is reduced, the thickness uniformity is greatly improved, and the annual usage amount of raw glass liquid is reduced.
The application adopts a specially designed anilox roller correcting frame to correct the anilox roller 13. The existing anilox roller is made of stainless steel pipe, the hollow wall is thin, the engraving processing deformation is large and easy to bend, especially thin wall and slender parts, the phenomenon is more serious, when the anilox roller is corrected, because the anilox roller is made of stainless steel, the stainless steel is poor in heat conductivity compared with common low-carbon steel, the elongation is low, the deformation force required when the anilox roller is corrected is large, the yield point of the stainless steel is high, the deformation and the correction pressure are difficult to control, ellipse, S-bend and the like are easy to occur, and the stainless steel has strong rebound tendency compared with carbon steel. Therefore, various straighters appear on the market, but the existing straightening machine on the market is high in price, complex in operation and low in efficiency, cannot guarantee that fine and precise patterns on the surface of the anilox roller are not damaged, and cannot completely meet the correction requirement of the anilox roller. The applicant has invented a correction frame which is specially used for an anilox roller through long-time research, and the correction is realized by upwards dragging a plurality of stress points which are distributed in the axial direction of the anilox roller 13, so that the multi-point correction is broken through a fixed thinking mode that the traditional shaft and the tube bending correction are all single-point correction by a hydraulic mode, the slender shaft is more quickly and accurately straightened by adopting a mode that the stress points are upwards dragged, the existing hydraulic correction presses one point, the anilox roller is stressed by one point, the anilox roller is easy to deform, the cylindricity is not up to standard, and the surface pattern is damaged, and the scrapping is caused. The correction frame provided by the application is pulled upwards at each stress point through the flexible belt, performs multi-point correction, does not damage patterns and lose circles, is simple and convenient to operate, is low in cost and high in efficiency, and completely meets the correction requirement of an anilox roller.
The anilox roller correcting frame carries out multi-point correction on the anilox roller, and the technical indexes can be as follows: the total run-out tolerance range of the anilox roller is 0.01mm-0.06mm; the rebound quantity is less than or equal to 0.02mm; fine and precise patterns are subjected to nondestructive correction; the cylindricity is less than or equal to 0.04mm; the quality of the anilox roller is improved, and the correction rejection rate is reduced. The corrected anilox roller can intercept the solution in a dot shape, so that the solution is very uniform when the anilox roller is smeared, the wiredrawing defect can not occur, the intercepted solution is proper, the subsequent liquid scraping operation is convenient, and the uniformity of the film thickness of the coating film is ensured.
In summary, the solution proposed by the applicant solves the problems of uniformity of glass thickness and uniformity of film coating thickness, improves the linear speed precision of the upper roller and the lower roller of the calender, improves the linear speed precision from 0.01m/min to 0.001m/min, directly improves the linear speed precision by 10 times, reduces radial runout between the upper roller 121 and the lower roller 122 after the opposite rollers, reduces the thickness of the original glass to be extremely poor, greatly improves the uniformity of the thickness, reduces the annual usage amount of the original glass liquid to 4000-6000 tons, and saves economic losses by more than hundred million yuan.
The anilox roller 13 used in the glass production system can be subjected to offline correction through the configuration of the anilox roller 2 and the anilox roller 13 correction frame, the online pair roller is carried out on the calender, the pair roller synchronization device 2 is used for synchronously correcting an upper roller and a lower roller in the calender, the anilox roller 13 is upwards pulled by the anilox roller 13 correction frame through the stress points, and then different displacement amounts of the anilox roller 13 after the upward pulling are measured, so that the influence of dynamic run-out (full run-out) of the anilox roller 13 can be avoided, the thickness of the glass produced after correction is uniform, and the coating film is uniform, so that the toughened flatness of the produced glass is higher, the original glass thickness and the coating film are uniform due to extremely small, the refractive index can be reduced, the thinner product of the glass with the same refractive index can be produced, the photovoltaic glass product with the light transmittance of 99% can be realized, and meanwhile, the thickness difference of the original glass thickness and the coating film thickness of the glass (4-6 mm), the explosion-proof glass (8-12 mm) and the bulletproof glass (12-20) can be reduced, and the original film thickness can reach extremely uniform thickness and 96% due to the extremely small film thickness.
In the glass production line device 1, a calender and a film plating machine are included, specifically, the calender is one of key devices of the glass production line, and the raw materials are converted into raw glass by extruding and stretching the glass through an upper roller and a lower roller. The calender generally includes a roller table, a deforming mechanism, etc. except for the upper and lower calender rolls 121 and 122, the twin-roll synchronizing device 2, which are present in pairs, and the present application focuses on the twin-roll, other related structures and devices and requirements thereof, which are substantially the same as those in the related art, and a detailed description thereof will be omitted herein, and it is possible to implement the present application in combination with the known technologies.
The coater is a device for coating glass on a glass production line, wherein the anilox roller 13 is one of the key components. The anilox roller 13 is usually made of a metal material, and the surface of the anilox roller is carved with a certain pattern, so that various film layers can be formed on the surface of the glass, and the optical, thermal, electrical and other properties of the glass are changed. Key features of the anilox roller 13 include: the present application provides a solution for making the coating film uniform, and the correction of the anilox roller 13 is performed with great effort.
Of course, besides calenders and coating machines, other devices and apparatuses, such as curing ovens, tempering ovens, cutting machines, cooling machines, etc., are not essential to the application, but may be implemented by those skilled in the art in combination with the solutions and well-known techniques of the application, the specific features and functions of which will vary according to different production requirements and process flows, and are not described in any great detail herein.
The present inventors have found that the problem of non-uniformity in thickness of glass and the problem of non-uniformity in thickness of coating film are separated into two stages, one of which is a calender processing stage and the other of which is a processing stage of a coating machine, and found that the essence of which cannot be solved by the uniformity of the present product is the parameter limitation of the roller assembly, namely the influence of internal stress and surface pattern of the roller assembly on solution diffusion when correcting or using, but no related study is currently found, and no current study has found such essence, and the study direction cannot be found, so that the study is stopped before the uniformity is reached.
Based on the discovery, the application provides a novel ultra-uniform photovoltaic glass production system, which comprises a glass production line device 1, a pair roller synchronization device 2 for performing online pair roller on an upper roller and a lower roller of a calender of the glass production line device 1, and an anilox roller 13 correction frame of a film plating machine.
In the embodiment of the application, the ultra-uniformity refers to the uniformity that the uniformity of the film coating and the original film reaches a certain threshold.
The following describes the pair-roller synchronizing device 2 of the present application in detail, and the pair-roller synchronizing device 2 in the embodiment of the present application is used for synchronous correction of an upper roller and a lower roller in a calender.
It can be understood that in the currently commonly used synchronous correction mode, the pair roller synchronization device 2 detects the distance difference and the alignment error between the upper roller and the lower roller through a laser interferometer or other high-precision sensors, then the pair roller synchronization device 2 automatically adjusts the relative positions of the upper roller and the lower roller according to the detection result to achieve a synchronous state, in this process, the adjustment can be achieved by controlling the movement speed (i.e. the linear speed) and the position of the upper roller and the lower roller, and also can be achieved by controlling the motor and the transmission system of the calender, finally, the upper roller and the lower roller are in a synchronous state after the correction of the pair roller synchronization device 2, so that the thickness uniformity (the thickness range is reduced) of the glass in the pressing process is ensured.
Meanwhile, the inventor creatively discovers that certain radial runout exists in the processing process of the calendaring roller, the deformation of the calendaring roller can be further increased under the high-temperature working state, and the thickness of the product and the width of the original plate are directly affected. According to the application, the accuracy of the linear speeds of the upper roller and the lower roller of the calender is improved, and the synchronous linear speeds of the upper roller and the lower roller are realized in the operation system of the calender, so that the paired rollers are synchronously arranged at the position with the minimum thickness, the uniformity of the thickness of the product is further improved, the weighing of a unit original plate is reduced, and the consumption of molten glass is reduced.
After the application is implemented, the uniformity of the thickness of the product can be further improved, meanwhile, the weighing of a unit original plate is lightened, the consumption of glass liquid is reduced, and the yield is improved. In addition, the synchronous pair roller for calendaring molding can reduce the sliding friction of the upper roller and the lower roller, reduce the abrasion of a chromium layer and prolong the service life of the calendaring roller.
The application creatively discovers that the upper roller and the lower roller in the calender are in a continuous high-temperature environment, the temperatures of different points are different, the higher the temperature of the rotating roller is creatively discovered, the higher the radial runout is generated, the larger the thickness difference is caused, namely the difference of the temperature of the rotating roller is an important reason for the thickness difference, the application is based on the creative discovery (the theory is not reported at present), the temperature factor is taken as a key factor for correcting the thickness difference, the core concept is that the calendering point with the lowest temperature difference of the same point of the upper roller and the lower roller is found, and then the calendering point at the position is taken as a reference for synchronous correction, so that the extremely poor of the thickness of glass is minimized, not only the cost of a raw sheet is reduced, but also the benefit is realized for toughening warp, when the wind pressure and the temperature are regulated by toughening, if the thickness of the raw sheet is uniform and is different, the raw sheet is easy to warp, the thickness is easy to reduce the thickness (for example, the thickness can be 2.0-2.15 is 2.0-2.08 at present before), the standard thickness is satisfied, the extremely poor, the melting cost is reduced, the rolling frequency is extremely low, the rolling resistance caused by the upper roller and the lower runout of the calender is reduced, the abnormal, the service life of the calender is greatly prolonged, and the service benefit is prolonged.
In the present preferred embodiment, the pair-roller synchronizing device 2 of the present application includes:
The temperature measurement module is used for measuring the temperatures of set points or all points of the produced glass surface to obtain the temperature distribution of the glass surface;
The calculation module is used for determining the point position with the lowest temperature difference on the surface of the glass as the correction point position of the synchronous counter roll according to the temperature distribution;
And the correction module is used for adjusting the linear speeds of the upper rolling roller and the lower rolling roller so as to synchronize the linear speeds of the upper rolling roller and the lower rolling roller at each correction point.
Specifically, when toughened glass is produced, quenching treatment is required to be performed after heating so as to realize the toughening process, the process is realized through an annealing kiln, and in order to ensure the smooth proceeding of the quenching process, a cooling air grid is required to be installed, and cooling air is conveyed by a fan to reach the surface of a glass substrate through the cooling air grid so as to realize the toughening treatment.
In the embodiment of the application, the temperature measuring module can be an infrared sensor, and the point with the minimum temperature difference is selected for synchronization according to the infrared temperature fluctuation curve of the inlet of the annealing kiln, for example, the surface temperature of an object can be measured by detecting heat radiation. When using an infrared sensor for temperature measurement at the annealing furnace inlet, a suitable infrared wavelength range is selected, and the measurement range of the infrared sensor is typically between 2 and 14 μm, and different wavelength ranges correspond to different temperature ranges and measurement accuracy.
The calculation module can adopt an upper computer or a computer to input temperature distribution data, then calculate the rolling point position with the lowest temperature difference between the same point positions of the rolling upper roller and the rolling lower roller, specifically, the temperature data measured by the infrared sensor are usually presented in the form of a fluctuation curve, after the data are measured by the infrared sensor, the temperature fluctuation curve is analyzed and an optimal calibration point is selected, and when the calibration point is selected, the point with the smallest temperature change in the fluctuation curve is found, so that the influence of radial runout can be reduced to the greatest extent, and the synchronization is more accurate.
Further, the inventors of the present application have found that there is a factor influence of the difference in the temperature of the rolls, that is, the change in the temperature directly causes the internal stress distribution of the rolls, and that when the rolls contact the glass material, the internal stress easily affects the rolled glass, which is the first example in the industry, that is, whether the stress influence is delayed to the thickness of the glass is unknown although there is a well-known technology of stress, so there is no research report in the related aspect, and the inventors have creatively found that the change in the internal stress is caused by the temperature of the rolls, and the stress change is directly transmitted to the rolled glass during rolling, thereby causing the non-uniform thickness of the glass.
Meanwhile, the inventor further pioneers to convert the calculation of the stress in the rotating roller to the calculation of the stress of the rotating roller on the glass, because the calculation of the stress in the rotating roller cannot be directly and quantitatively prolonged to the influence of the thickness of the glass, the stress applied to the glass can be directly measured through a thermal expansion and contraction simulation model of the pressure and the temperature, the embodiment of the application firstly converts the calculation of the stress in the rotating roller to the calculation of the stress on the glass, so that the thickness of the glass under the influence of external stress can be calculated through the simulation model, and the calculation of the stress influence is more accurate, and the embodiment of the application further comprises:
The stress coupling influence distribution module is used for determining stress coupling influence distribution at each rolling point position of each rolling upper roller and each rolling lower roller according to the temperature distribution of the surfaces of the pair rollers and the configuration parameters of the upper roller and the lower roller;
And the thickness influence difference determining module is used for determining the thickness influence difference caused by stress of the upper rolling roller and the lower rolling roller according to stress coupling influence distribution at each rolling point position of each upper rolling roller and each lower rolling roller and combining a preset corresponding relation between coupling stress and the thickness influence difference.
In this embodiment, the stress coupling influence distribution is the distribution after the stress influence coupling caused by all factors in the whole process, and the stress influence is mainly from the cooling process of the rotating roller and the rolling process of the rotating roller at present, so the stress coupling influence distribution is the combination of the stress formed by the cooling process of the rotating roller and the rolling process of the rotating roller.
In this embodiment, the difference in thickness influence due to stress specifically refers to the difference in thickness influence on glass due to the above-described stress coupling influence distribution, that is, the difference in thickness influence due to stress=glass thickness in no stress (ideal glass thickness) -glass thickness in the presence of stress coupling influence distribution.
According to the embodiment, stress coupling influence distribution is formed by combining stress formed in the cooling process of the counter-rotating roller and the rolling process of the counter-rotating roller, and then the corresponding relation between the stress coupling influence distribution and the thickness influence difference caused by stress is combined, so that the thickness difference caused by stress is determined, and the problem of uneven and unknown reasons of the current thickness is solved.
The corresponding relation between the preset coupling stress and the thickness influence difference can be obtained through three-dimensional mechanical simulation calculation, specifically, the stress simulation is firstly carried out on the cooling process of the rotating roller and the rolling process of the rotating roller, and then the thickness influence is simulated under the simulation model, so that the thickness influence difference is obtained.
The stress coupling influence distribution of the present application will be described in detail, specifically, the configuration parameters of the upper calender roll and the lower calender roll include: lower roller cooling air angle, amount of wind, driving roller angle, upper and lower roller surface temperature, the position of air knife and the angle of calender auxiliary roller, stress coupling influences distribution module and includes:
The first stress distribution determining unit is used for determining first stress distribution formed in the cooling process of the lower roller according to the angle and the air quantity of the cooling air of the lower roller and combining a preset influence distribution diagram of the angle and the air quantity of the cooling air of the lower roller on the glass stress;
a second stress distribution determining unit for determining second stress distribution formed by the upper roller and the lower roller in the calendaring process according to the angle of the driving roller, the temperatures of the upper roller surface and the lower roller surface, the position of the air knife and the angle of the auxiliary roller of the calendaring machine;
And the stress coupling influence distribution determining unit is used for determining the stress coupling influence distribution at each rolling point position of each rolling upper roller and each rolling lower roller according to the first stress distribution and the second stress distribution. Specifically, the stress on the glass corresponding to the angle and the air quantity of the lower roller cooling air is found by comparing the angle and the air quantity of the lower roller cooling air with the influence distribution graph of the angle and the air quantity of the lower roller cooling air on the glass stress, so that the first stress distribution in the lower roller cooling process is obtained, and the second stress distribution formed by the temperature and the pressure between the components can be obtained by the position of the air knife and the angle of the auxiliary roller of the calender according to the angle of the driving roller, the temperature of the upper roller surface and the lower roller surface.
The stress coupling influence distribution at each calendering point can be obtained by combining the first stress distribution and the second stress distribution, specifically, the stress coupling influence distribution can be obtained by directly accumulating or weighting accumulating, or the stress coupling accumulating can be performed by a simulation model through a stress superposition model, and the stress coupling influence distribution is not limited in the application.
According to the embodiment, the problem that the thickness of a product is extremely poor and the width of a raw plate is directly influenced because the deformation of the rolling roller is continuously increased under the high-temperature working state due to the fact that certain radial runout exists in the processing process of the rolling roller is solved. According to the embodiment of the application, the linear speed synchronization of the upper roller and the lower roller is realized in the calender operating system, so that the paired rollers are synchronized at the position with the minimum thickness, the uniformity of the thickness of the product is further improved, meanwhile, the weighing of a unit original plate is lightened, the consumption of glass liquid is reduced, in addition, the synchronous paired rollers for calendering can reduce the sliding friction of the upper roller and the lower roller, reduce the abrasion of a chromium layer, prolong the service life of the calender rollers, and simultaneously, the paired rollers are automatically synchronized through the calender, so that the friction resistance generated by abnormal jumping of the upper roller and the lower roller is reduced, the service life of the calender rollers is greatly prolonged, the frequency of changing the calender is reduced, and the benefit is improved.
In some optional embodiments, the application can also improve the precision of the linear speed, specifically, improve the precision of the linear speed of the upper roller and the lower roller in a PLC operation system of the calender, improve the precision by 10 times from 0.01m/min to 0.001m/min, adjust the speeds of the upper roller and the lower roller of the calender at any time to make the linear speeds of the upper roller and the lower roller the same, pair the calender rollers in the assembling process of the calender, ensure that the diameter of the lower roller is 5-10mm larger than that of the upper roller according to the line, and finally adjust the cooling air angle, the air quantity and the angle of the driving roller of the lower roller and the temperature of the roller surface of the upper roller and the lower roller in the debugging synchronous pair rollers in the embodiment, so that the product has no longitudinal deformation and no impact on the roller mark and reduces the stress influence, and the appearance quality of the product meets the requirements.
In the preferred embodiment, the method can optimize the PLC operating system program of the calender and improve the linear speed precision of the upper roller and the lower roller; the matching of the roller diameters of the upper roller and the lower roller of the pairing calender during installation avoids direct influence on synchronous pair rollers, and meanwhile, the position of the air knife of the calender and the angle of the auxiliary roller of the calender have higher requirements, so that the position of the air knife of the calender and the angle of the auxiliary roller of the calender can be further adjusted, and the problem of appearance of a certain plate surface caused by the subsequent pair rollers is prevented.
In addition, in an alternative embodiment, the calender rolls are paired in the assembly process of the calender, the lower roll diameter is ensured to be 5-10mm larger than the upper roll diameter according to the line, meanwhile, the lower roll cooling air angle, the air quantity, the driving roll angle and the upper and lower roll surface temperature are adjusted in the debugging synchronous paired rolls, so that the product is free from longitudinal deformation and roll marks, and the appearance quality of the product meets the requirements. After the above treatment, the direct economic benefit of the present application is illustrated, table 1 below is an effect comparison illustration, the maximum weighing of 1m original plate is 2.2% of the difference before and after the twin-roll, the current five-kiln pulling amount is 930 tons, the weight of glass liquid can be saved after the twin-roll by = { 930/(100% -2.2%) -930}/2 x 363=3797 tons, the benefit=the cost of glass liquid is reduced by =3797 tons, 1600 yuan/ton= 607.5 ten thousand yuan/year, the frequency of twin-roll can be reduced, the original possible 20 minutes is needed to be paid once, and the twin-roll can now be paid once a day.
TABLE 1 comparative table of roll-to-roll synchronization
The anilox roller 13 correcting frame of the present application is described in detail below, specifically, as shown in fig. 2, the anilox roller correcting frame includes a supporting frame body of a base 21, an anilox roller 13, an electric stretching mechanism 23 and a measuring surface 22, the anilox roller 13 is rotationally limited on the anilox roller base 21 of the supporting frame body, a plurality of stress points are configured on the anilox roller 13, and the stress points are distributed along the axial direction of the anilox roller 13; the electric stretching mechanism 23 hangs flexible belts at a plurality of stress points to pull the anilox roller 13 upwards; the gauge 22 is used to measure the displacement amount of the anilox roller 13 after the upward drawing.
As shown in fig. 3, the side surface of the anilox roller 13 is provided with a pattern structure which is uniformly arranged and has a concave-convex shape, and the pattern structure comprises: a first main limb 203, a second main limb 204, and a joint; the first ends of the main branches are uniformly converged at the edge of the first round 202, and the second ends of the main branches are uniformly spread at the edge of the second round 201; the first main branches 203 and the second main branches 204 are alternately arranged at intervals; the diameter of the first circle 202 is smaller than the diameter of the second circle 201; the combination part is combined with the first end of the first main limb 203, the second end of the first main limb 203, the first end of the second main limb 204 and the second end of the second main limb 204, and has a closed ring shape.
Specifically, the reason why the uneven thickness of the coating film is caused in the coating process is creatively found out in the embodiment of the present application that the pattern structure of the coating film belongs to a square topological structure under normal conditions, for example, as shown in fig. 4, the inventor creatively found that the direct reason that the uneven thickness of the coating film is influenced is that a large number of corners exist in the topological structure, and the corners have larger limiting acting force on the solution, when the coating film is coated, the anilox roller 13 and the rubber roller 14 are required to be matched, the solution in the rubber roller 14 is sunk into the pattern structure of the anilox roller 13, so that the solution is uniformly distributed to the surface of the glass through diffusion in the coating film, and because the patterns are uneven, when the corners contain the solution, the corners are always concave 'ends', the solution is easy to accumulate at the corners, the corners are required to be bonded and extruded with the glass in the coating film, and the solution in the concave corners is limited to diffuse the solution due to the existence of the concave walls, and the setting angle of the two concave walls is lower than 90 degrees, so that the limitation of the two concave walls is multiplied under the same area, as shown in fig. 5, and the thickness difference between each corner and the non-corner of the scheme is extremely large.
The existing anilox roller is made of stainless steel pipes, is thin in hollow wall, and is large in embossing deformation and easy to bend. Particularly, the thin wall and slender parts are more serious, the film coating roller is a hollow thin wall slender shaft, and stainless steel has low elongation due to poor heat conductivity compared with common low carbon steel, so that the required deformation force is large. Stainless steel has high yield point, high deformation and correction pressure, is difficult to control, and is easy to generate ellipse, S-bend and the like. And compared with carbon steel, the machine has stronger rebound tendency, and is universal for long-axis bending correction, universal cold-temperature hydraulic correction, punching method, flame correction and shaft correction in machining lines. The punching method and the flame correction method are difficult to correct without damaging the surface patterns, and have poor precision, low efficiency and high operation difficulty. And carrying out common Leng Wen hydraulic correction after the embossing and bending of the domestic anilox roller.
In the preferred embodiment, the application designs the anilox roller total run-out correction frame according to the defects of the traditional anilox roller cold temperature hydraulic correction, has simple operation and high efficiency, can well protect the surface patterns of the anilox roller, has high precision and easy control, has high price and low operation efficiency of the existing straightening machine in the market, can not guarantee that fine and precise patterns on the surface of the anilox roller are not damaged, and can not completely meet the correction requirement of the anilox roller. The full-jump correction frame is simple and convenient to operate, low in cost and high in efficiency, and completely meets the correction requirement of the anilox roller. The whole correction workbench is just free from bending down, correction is visually embodied by a dial indicator, efficiency and quality are improved, and cost is saved. The traditional shaft and tube bending correction is carried out by using a hydraulic correction point, and the existing correction frame can correct a plurality of positions at a time, so that the slender shaft is more quickly and accurately straightened. In the past, a point is pressed by hydraulic correction, and the stress of the point is easy to deform, so that the roundness is not up to standard and the surface pattern is damaged, and the point is scrapped. The correction is flexible suspender multipoint correction, patterns and out-of-round cannot be damaged, the correction process is redesigned according to the coating characteristics, the integrated portal frame is designed, and the electric hoist with lower cost is adopted as the upward traction force. And designing a special fixture, and continuously optimizing and improving the magnetic gauge stand and the dial indicator. The correction is performed by selecting a special treatment modified sling.
Through the multi-point correction and multi-point traction of the pattern structure and the correction frame, the following technical indexes can be achieved:
the total run-out of the anilox roller is 0.01-0.06mm;
The rebound quantity is less than or equal to 0.02mm;
Fine and precise patterns are subjected to nondestructive correction;
The cylindricity is less than or equal to 0.04mm;
The quality of the anilox roller is improved, and the correction rejection rate is reduced.
According to the application, the first ends of the first main branches 203 and the second main branches 204 are uniformly converged at the edge of the first circle 202, the second ends of the first main branches are uniformly distributed at the edge of the second circle 201, the first main branches 203 and the second main branches 204 are alternately arranged at intervals, the diameter of the first circle 202 is smaller than that of the second circle 201, so that the number of corners is greatly reduced, the number of corners is reduced to zero, the problem that great difference exists between the thickness of the corners and the thickness of the non-corners is avoided, and in addition, more containing paths are provided for the places where the solution is easy to pool at the two ends of the main branches through the combination part, so that the influence caused by solution pool is dispersed as much as possible for the places where the thickness difference is easy to cause.
In an alternative embodiment, the joint is annular or rectangular ring-shaped.
In an alternative embodiment, the method further comprises: a plurality of auxiliary branches 205, each auxiliary branch 205 comprising at least one auxiliary branch 205, each auxiliary branch 205 having a first end connected to one of the first main branches 203 and a second end connected to a second main branch 204 adjacent to said one of the first main branches 203.
In the embodiment of the present application, since the nodes formed by the auxiliary branches 205 and the main branches do not belong to the "concave end", they do not belong to the corners, and when the solution is deposited, the solution is dispersed along the auxiliary branches 205 or the main branches, so that the phenomenon of solution deposition is not generated, meanwhile, the first end of the auxiliary branch 205 is connected with one of the first main branches 203, and the second end is connected with the second main branch 204 adjacent to the one of the first main branches 203, so that the auxiliary branch and the main branch form a cross, and more lines are provided, so that a more uniform reticulate pattern can be formed.
In an alternative embodiment, the method further comprises: each auxiliary branch 205 group comprises at least one auxiliary branch 205, each auxiliary branch 205 group is used for connecting adjacent first main branches 203 and second main branches 204 with set numbers, and at least two main branches are spaced between two adjacent auxiliary branch 205 groups.
In the embodiment of the application, a plurality of adjacent first main branches 203 and second main branches 204 form a larger 'basic unit', and the same number of auxiliary branches 205 are configured, so that on one hand, the uniformity of the whole body can be ensured, and on the other hand, the topology can be performed.
In an alternative embodiment, the auxiliary branches 205 between adjacent first and second main branches 203, 204 comprise a plurality, each auxiliary branch 205 of the plurality of auxiliary branches 205 having at least one overlapping node with at least one other auxiliary branch 205. In the embodiment of the present application, the auxiliary branches 205 also have intersection points, and because the nodes formed by the auxiliary branches 205 and the auxiliary branches 205 do not belong to the "concave end", the nodes do not belong to the above corners, and when the solution is deposited, the solution is dispersed along the auxiliary branches 205 or the main branches, so that the phenomenon of solution deposition is not generated, and meanwhile, the auxiliary branches 205 and the auxiliary branches 205 form intersection points, so that more free flow paths are provided for the solution flow, so that more lines can be provided, and more uniform reticulation can be formed.
In an alternative embodiment, at least two reinforcing graft stems 207 are connected between the junctions where the second ends of adjacent first and second main limbs are connected.
The reinforcing continuous grafted stems 207 can increase the density of the branches at the scattering end, so that the density at the second end of the main branches can be the same as that at the first end, and meanwhile, as the annular structure of the joint can lock more solution, after the reinforcing continuous grafted stems are provided, the locked solution can flow between the reinforcing continuous grafted stems, thereby improving the uniformity of the whole coating film.
In addition, the present application creatively contemplates that certain positions of the concave-convex structure can be subjected to hydrophobic and hydrophilic treatment, taking a solution as an aqueous solution as an example, the hydrophilic position can lock the solution, so that the solution can flow more stably during film plating, the hydrophobic position can diffuse the solution more quickly, and thus the solution can be adapted to nodes or end parts with higher solution density, and in the preferred embodiment, the surface of the combination part and the surface of the connection part of the combination part and the main limb are hydrophobic surfaces subjected to superhydrophobic treatment, and the surface of the main limb is hydrophilic. Therefore, the solution in the joint can flow on the branches more easily, and the condition that the solution is uneven due to excessive locking of the joint can be avoided.
In an alternative embodiment, elongated diffusing ribs 2031 are provided on the inner surface of the first main limb 203 and/or the second main limb 204, and the number of diffusing ribs 2031 in the direction of the main limb (203 or 204) near the second end is higher than the number of directions near the first end. The arrangement of the diffusion ribs can control the coating speed when the solution in the branch overflows to coat, so that the coating uniformity is improved, meanwhile, the diffusion ribs can also improve the flow of the solution in the branch, and further improve the uniformity of the solution in the branch, so that the solution is more uniform in the reticulate pattern structure. The inventor of the application creatively combines the diffusion ribs on the hydrophilic surface, so that the combination of the diffusion ribs and the hydrophilic surface controls the overflow speed of the solution during coating, thereby achieving the synergistic effect of uniform coating on microcosmic scale.
In an alternative embodiment, the number of auxiliary limbs 205 decreases gradually along the first end of the main limb between each first main limb 203 and the adjacent second main limb 204. As can be seen from the figure, the space at the first end is reduced, so that the number of auxiliary branches 205 is gradually reduced along the first end of the main branches, specifically, a unit area can be taken as a basic unit, the density (i.e. the total length x width/area) of the branches in each basic unit is the same, so that although the microstructure of each basic unit is different, the macroscopic coating effect actually appears is consistent, the problem that the solution amount at the nodes of the reticulate pattern is too high cannot be solved in the prior art, and therefore, no matter what reticulate pattern cannot essentially solve the problem, the application considers the density of the branches from the side index, ignores the microstructure difference, evaluates the actual macroscopic coating effect, forms a branched scattered-leaf reticulate pattern structure, and can ensure the uniformity of the coating of the whole reticulate roller 13 by taking the singular structure as the basic unit of the topological structure to carry out topology.
In an alternative embodiment, the inner surface of the first main limb 203 and/or the second main limb 204 forms a wave-shaped or stepped pleat, the width of which gradually decreases in the direction of the first end of the main limb.
In this embodiment, the inner surfaces of the first main limb 203 and/or the second main limb 204 form wavy folds or stepped folds, the folds can form turbulence on the solution, the solution performs microscopic passive turbulence on the solution at any time when flowing in the limb, uniformity of each component in the solution is improved, a phenomenon that local concentration of a certain component is too high is avoided, meanwhile, when the width of the folds is gradually reduced, the formed turbulence effect is finer, the density of the limb combined at the first end is higher, the flowing path of the solution is shorter, and meanwhile, the combination part and the connection part at the first end are hydrophobic surfaces, so that turbulence is formed in a finer mode, and reverse escape interference of larger turbulence on the solution is avoided.
In addition, the existing photovoltaic toughened glass coating process adopts glass inclined-feeding type coating. The oblique feeding type coating film is easy to have the quality problems of roll marks, blue edge lines, edge folding width of a rear short edge, coating film edge lines, uneven film thickness and the like, the service life of the rubber roller is short, and the yield of the coating film is directly affected by frequent replacement of the rubber roller. The direct-feeding type coating film is easy to collide with rollers (rubber rollers) and slide on glass, so that the roller marks on the plate surface are caused, the product quality cannot be ensured, and the rubber rollers need to be replaced frequently. According to the application, an adjustable pressing device (the surface is made of PU material and has Shore hardness of 40) can be additionally arranged at the inlet of the coating machine, so that glass slipping is avoided, the original PDEM material of the coating main carrier roller is changed into PU material, the Shore hardness is changed from 55 to 30, and the Shore hardness of the PU rubber roller is unchanged; by changing the physical property of the carrier roller through the principle, the suction force of the carrier roller is increased, the roller marks and the collision roller (rubber roller) on the surface of the plate are avoided, the quality of a coated product is improved (the roller marks of the front short side are eliminated, the blue edge lines of 3 mm on the front two long sides are eliminated, the edge folding of the rear short side is improved from the original 6mm to the current 2-3 mm, the edge coated line is eliminated, the thickness difference of the film is improved from the original 8-10nm to the current 5-6 nm), the product quality and the yield are improved, and the service life of the rubber roller is prolonged. An adjustable pressing device (the surface is made of PU material and has Shore hardness of 40) is additionally arranged at the inlet of the coating machine, so that glass slipping is avoided, the coating main carrier roller is changed from the previous PDEM material to the PU material, the Shore hardness of 55 is changed to 30, and the Shore hardness of the PU rubber roller is unchanged; when the improved coating film is in straight movement, the material of the carrier roller is properly softened, so that the collision roller (rubber roller) is avoided, the yield loss caused by rubber roller replacement is reduced, and glass products with the thickness of 8-10mm and the light transmittance reaching 96% can be produced.
In a second aspect, embodiments of the present application provide a method of glass production, comprising:
s1: measuring the temperature of a set point position or all point positions of the produced glass surface to obtain the temperature distribution of the glass surface;
S2: according to the temperature distribution, the rolling upper roller and the rolling lower roller determine the point position with the lowest temperature difference on the surface of the glass as a correction point position of the synchronous counter roller;
And S3, adjusting the linear speeds of the upper rolling roller and the lower rolling roller so as to synchronize the linear speeds of the upper rolling roller and the lower rolling roller at each correction point.
Specifically, the temperature measurement can be an infrared sensor, and according to an infrared temperature fluctuation curve of an inlet of the annealing kiln, a point with the minimum temperature difference is selected for synchronization, for example, the surface temperature of an object can be measured by detecting heat radiation. When using an infrared sensor for temperature measurement at the annealing furnace inlet, a suitable infrared wavelength range is selected, and the measurement range of the infrared sensor is typically between 2 and 14 μm, and different wavelength ranges correspond to different temperature ranges and measurement accuracy.
After the temperature distribution data is input by an upper computer or a computer, the rolling point position with the lowest temperature difference between the same point positions of the rolling upper roller and the rolling lower roller is calculated, specifically, the temperature data measured by the infrared sensor is usually presented in the form of a fluctuation curve, after the data is measured by the infrared sensor, the temperature fluctuation curve is analyzed and the optimal calibration point is selected, and when the calibration point is selected, the point with the smallest temperature change in the fluctuation curve is found, so that the influence of radial runout can be reduced to the greatest extent, and the synchronization is more accurate.
Further, the inventors of the present application have found that there is a factor influence of the difference in the temperature of the rolls, that is, the change in the temperature directly causes the internal stress distribution of the rolls, and that when the rolls contact the glass material, the internal stress easily affects the rolled glass, which is the first example in the industry, that is, whether the stress influence is delayed to the thickness of the glass is unknown although there is a well-known technology of stress, so there is no research report in the related aspect, and the inventors have creatively found that the change in the internal stress is caused by the temperature of the rolls, and the stress change is directly transmitted to the rolled glass during rolling, thereby causing the non-uniform thickness of the glass.
Meanwhile, the inventor further pioneers to convert the calculation of the stress in the rotating roller to the calculation of the stress of the rotating roller on the glass, because the calculation of the stress in the rotating roller cannot be directly and quantitatively prolonged to the influence of the thickness of the glass, the stress applied to the glass can be directly measured through a thermal expansion and contraction simulation model of the pressure and the temperature, the embodiment of the application firstly converts the calculation of the stress in the rotating roller to the calculation of the stress on the glass, so that the thickness of the glass under the influence of external stress can be calculated through the simulation model, and the calculation of the stress influence is more accurate, and the embodiment of the application further comprises:
s01, determining stress coupling influence distribution at each rolling point of each rolling upper roller and each rolling lower roller according to the temperature distribution of the surfaces of the pair rollers and the configuration parameters of the upper roller and the lower roller;
s02, according to stress coupling influence distribution at each rolling point position of each rolling upper roller and each rolling lower roller, and combining a corresponding relation between preset coupling stress and thickness influence difference, determining the thickness influence difference of the rolling upper roller and the rolling lower roller caused by stress.
In the preferred embodiment, the stress coupling influence distribution is the distribution after the stress influence coupling caused by all factors in the whole process, and the stress influence is mainly from the cooling process of the rotating roller and the rolling process of the rotating roller, so that the stress coupling influence distribution is the combination of the stress formed by the cooling process of the rotating roller and the rolling process of the rotating roller.
In this embodiment, the difference in thickness influence due to stress specifically refers to the difference in thickness influence on glass due to the above-described stress coupling influence distribution, that is, the difference in thickness influence due to stress=glass thickness in no stress (ideal glass thickness) -glass thickness in the presence of stress coupling influence distribution.
According to the embodiment, stress coupling influence distribution is formed by combining stress formed in the cooling process of the counter-rotating roller and the rolling process of the counter-rotating roller, and then the corresponding relation between the stress coupling influence distribution and the thickness influence difference caused by stress is combined, so that the thickness difference caused by stress is determined, and the problem of uneven and unknown reasons of the current thickness is solved.
The corresponding relation between the preset coupling stress and the thickness influence difference can be obtained through three-dimensional mechanical simulation calculation, specifically, the stress simulation is firstly carried out on the cooling process of the rotating roller and the rolling process of the rotating roller, and then the thickness influence is simulated under the simulation model, so that the thickness influence difference is obtained.
The stress coupling influence distribution of the present application will be described in detail, specifically, the configuration parameters of the upper calender roll and the lower calender roll include: the utility model provides a lower roller cooling wind angle, amount of wind, driving roller angle, upper and lower roller surface temperature, the position of air knife and the angle of calender auxiliary roller, according to the temperature distribution on pair roller surface and the configuration parameter of upper roller and lower roller, confirm every the calendering upper roller with the stress coupling influence distribution of each calendering point position department of calendering lower roller includes:
s021: according to the angle and the air quantity of the lower roller cooling air, and in combination with a preset influence distribution diagram of the angle and the air quantity of the lower roller cooling air on the glass stress, determining first stress distribution formed in the lower roller cooling process;
s022: determining second stress distribution formed by the upper roller and the lower roller in the calendaring process according to the angle of the driving roller, the temperatures of the upper roller surface and the lower roller surface, the position of the air knife and the angle of the auxiliary roller of the calendaring machine;
S023: and determining stress coupling influence distribution at each rolling point position of each rolling upper roller and each rolling lower roller according to the first stress distribution and the second stress distribution.
Specifically, the stress on the glass corresponding to the angle and the air quantity of the lower roller cooling air is found by comparing the angle and the air quantity of the lower roller cooling air with the influence distribution graph of the angle and the air quantity of the lower roller cooling air on the glass stress, so that the first stress distribution in the lower roller cooling process is obtained, and the second stress distribution formed by the temperature and the pressure between the components can be obtained by the position of the air knife and the angle of the auxiliary roller of the calender according to the angle of the driving roller, the temperature of the upper roller surface and the lower roller surface.
The stress coupling influence distribution at each calendering point can be obtained by combining the first stress distribution and the second stress distribution, specifically, the stress coupling influence distribution can be obtained by directly accumulating or weighting accumulating, or the stress coupling accumulating can be performed by a simulation model through a stress superposition model, and the stress coupling influence distribution is not limited in the application.
According to the embodiment, the problem that the thickness of a product is extremely poor and the width of a raw plate is directly influenced because the deformation of the rolling roller is continuously increased under the high-temperature working state due to the fact that certain radial runout exists in the processing process of the rolling roller is solved. According to the application, after the embodiment is adopted, the linear speed synchronization of the upper roller and the lower roller is realized in the calender operation system, so that the paired rollers are synchronized at the position with the minimum thickness, the uniformity of the thickness of the product is further improved, meanwhile, the weighing of a unit original plate is lightened, the consumption of glass liquid is reduced, in addition, the synchronous paired rollers for calendering can reduce the sliding friction of the upper roller and the lower roller, reduce the abrasion of a chromium layer, and prolong the service life of the calender rollers.
According to the toughened glass, the manufacturing equipment of the toughened glass is manufactured by adopting the glass manufacturing system, the toughened glass can be used in the photovoltaic field or other high-end manufacturing fields, the toughened glass is not limited by the manufacturing system, the toughened glass has uniform glass thickness and uniform coating, particularly, the surface film layer can be controlled to be +/-3 nm, the glass thickness is uniform and can be controlled to be +/-0.1 mm, the effect is remarkable, so that the toughened flatness of the manufactured glass is higher, the original sheet is extremely poor, the glass thickness and the coating are uniform, the refractive index can be reduced, a photovoltaic glass product with the glass thickness being thinner under the same refractive index can be manufactured, the photovoltaic glass product with the light transmittance of 1.6-3.2mm and the light transmittance of 99% can be realized, and meanwhile, when the toughened glass (4-6 mm), the explosion-proof glass (8-12 mm) and the bulletproof glass (12-20) fields are thickened, the light transmittance can be higher and reach more than 96% due to the fact that the original sheet thickness is extremely poor, the thickness and the coating is uniform.
It should be noted that, the embodiments of the glass production system, the embodiment of the manufacturing method and the embodiment of the tempered glass provided by the embodiments of the present application can be referred to each other, the embodiments of the present application are not limited to the above embodiments, and any person skilled in the art can easily think about the changing method within the technical scope of the present application, and should not be repeated, so that the above embodiments are merely optional embodiments of the present application, and are not intended to limit the present application, and any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application should be included in the protection scope of the present application.
Claims (14)
1. An ultra-uniform photovoltaic glass production system, comprising: the glass production line device at least comprises a calender and a coating machine, wherein the calender comprises an upper calendering roller and a lower calendering roller which are arranged in pairs, and the coating machine comprises an anilox roller;
The pair roller synchronizing device is used for synchronizing the linear speed of an upper rolling roller and a lower rolling roller in the calender and is used for pair rollers at the position where the thickness of the original sheet glass is minimum;
The anilox roller correcting frame comprises:
A support frame body having a base;
the anilox roller is rotationally limited on a base on the supporting frame body, a plurality of stress points are arranged on the anilox roller, and the stress points are distributed along the axial direction of the anilox roller;
an electric stretching mechanism for hanging a flexible belt at the stress points to pull the anilox roller upwards; and
The measuring meter is used for measuring the displacement of the anilox roller after upward traction;
The side surface of anilox roller has seted up the pattern structure of even range and being concave-convex shape, the pattern structure includes:
The first ends of the first main branches and the second main branches are uniformly converged at the first round edge part, the second ends of the first main branches are uniformly distributed at the second round edge part, the first main branches and the second main branches are alternately arranged at intervals, and the diameter of the first round is smaller than that of the second round; and
And the combining part is combined with the first end of the first main branch, the second end of the first main branch, the first end of the second main branch and the second end of the second main branch and is in a closed ring shape.
2. The glass production system of claim 1, wherein the pair of roller synchronizing device comprises:
The temperature measurement module is used for measuring the temperatures of set points or all points of the produced glass surface to obtain the temperature distribution of the glass surface;
the calculation module is used for determining the point position with the lowest temperature difference on the glass surface as the correction point position of the synchronous pair roller according to the temperature distribution;
And the correction module is used for adjusting the linear speeds of the upper rolling roller and the lower rolling roller so as to synchronize the linear speeds of the upper rolling roller and the lower rolling roller at each correction point.
3. The glass production system of claim 1, wherein the joint of the anilox roller is annular or rectangular ring-shaped.
4. The glass production system of claim 1, wherein the patterned structure further comprises:
The auxiliary branch groups comprise at least one auxiliary branch, the first end of each auxiliary branch is connected with one of the first main branches, and the second end of each auxiliary branch is connected with a second main branch adjacent to the one of the first main branches.
5. The glass production system of claim 1, wherein the patterned structure further comprises:
Each auxiliary branch group comprises at least one auxiliary branch, each auxiliary branch group is used for connecting adjacent first main branches and second main branches with preset numbers, and at least one first main branch and one second main branch are separated between two adjacent auxiliary branch groups.
6. The glass production system of any of claims 1-5, wherein the secondary branches between adjacent first and second primary branches in the pattern structure comprise a plurality of secondary branches, each secondary branch of the plurality of secondary branches having at least one overlapping node with at least one other secondary branch.
7. The glass production system of any of claims 1-5, wherein at least two reinforcing tie stems are connected between the joined portions of the second end connections of adjacent first and second main limbs in the pattern structure.
8. The glass production system according to claim 1, wherein in the pattern structure, the surfaces of the joint portions, the first main limbs, and the joints of the joint portions and the second main limbs are hydrophobic surfaces subjected to superhydrophobic treatment, and the surfaces of the first main limbs and the second main limbs are hydrophilic surfaces.
9. The glass production system according to any one of claims 1 to 5, wherein the pattern structure is provided with elongated diffusing ribs on the inner surface of the first main limb and/or the second main limb, the number of the diffusing ribs being higher in the direction near the second end of the corresponding main limb than in the direction near the first end of the corresponding main limb.
10. The glass production system of claim 4 or 5, wherein in the pattern structure, between each first main limb and an adjacent second main limb, in a radial direction of the first main limb, the number of auxiliary limbs gradually decreases in a direction toward the first end of the first main limb.
11. The glass production system of claim 8, wherein in the pattern structure, the inner surface of the first main limb and/or the second main limb forms a wavy fold or a stepped fold, the width of the fold gradually decreasing in a direction corresponding to the first end of the main limb.
12. A method of glass production using the ultra-uniform photovoltaic glass production system of any of claims 1-11, comprising:
Measuring the temperature of a set point position or all point positions of the produced glass surface to obtain the temperature distribution of the glass surface;
According to the temperature distribution, determining the point position with the lowest temperature difference on the surface of the glass as a correction point position of a synchronous pair roller, wherein the synchronous pair roller comprises an upper roller and a lower roller;
And adjusting the linear speeds of the upper rolling roller and the lower rolling roller so as to synchronize the linear speeds of the upper rolling roller and the lower rolling roller at each correction point.
13. The method of glass production according to claim 12, further comprising:
according to the temperature distribution of the surfaces of the pair of rolls and the configuration parameters of the upper roll and the lower roll, determining stress coupling influence distribution at each rolling point of each rolling upper roll and each rolling lower roll;
And determining the thickness influence difference caused by stress of the upper rolling roller and the lower rolling roller according to stress coupling influence distribution at each rolling point position of each upper rolling roller and each lower rolling roller and combining a corresponding relation of preset coupling stress and thickness influence difference.
14. The method of glass production according to claim 13, wherein the configuration parameters of the upper and lower rollers comprise: the lower roller cooling air angle, the air quantity, the driving roller angle, the upper roller surface temperature and the lower roller surface temperature, the position of an air knife and the angle of a calender auxiliary roller;
According to the temperature distribution of the surfaces of the pair of rolls and the configuration parameters of the upper roll and the lower roll, determining stress coupling influence distribution at each rolling point of each rolling upper roll and each rolling lower roll comprises the following steps:
According to the angle and the air quantity of the lower roller cooling air, and in combination with a preset influence distribution diagram of the angle and the air quantity of the lower roller cooling air on the glass stress, determining first stress distribution formed in the lower roller cooling process;
determining second stress distribution formed by the upper roller and the lower roller in the calendaring process according to the angle of the driving roller, the temperatures of the upper roller surface and the lower roller surface, the position of the air knife and the angle of the auxiliary roller of the calendaring machine;
and determining stress coupling influence distribution at each rolling point position of each rolling upper roller and each rolling lower roller according to the first stress distribution and the second stress distribution.
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| CN114538755A (en) * | 2022-02-25 | 2022-05-27 | 泰州索拉特特种玻璃有限公司 | Photovoltaic glass production process |
| CN115156305A (en) * | 2022-06-14 | 2022-10-11 | 太原理工大学 | Rolling method capable of realizing axial variable tension |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| DE50112183D1 (en) * | 2000-05-30 | 2007-04-26 | Andritz Kuesters Gmbh & Co Kg | rolling device |
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| US5154117A (en) * | 1990-01-16 | 1992-10-13 | Saint-Gobain Vitrage International | Device for the assembly of laminated glazing by pressing |
| JP2003136132A (en) * | 2001-10-30 | 2003-05-14 | Kawasaki Heavy Ind Ltd | Pinch roll device |
| WO2006070077A1 (en) * | 2004-12-31 | 2006-07-06 | Jari Pekka Juhanko | Method of improvement of quality and runnability of production machine for a weblike product |
| CN201704194U (en) * | 2010-04-16 | 2011-01-12 | 信义光伏产业(安徽)控股有限公司 | Glass rolling device |
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