Accurate Thermal Process Control in the Production of Glass Tubes
Optimization of the Process for Forming Glass Tubes at Temperatures above 1000 °C
Challenge
The glass forming process demands precise temperature control to prevent structural defects like uneven wall thickness or breakage due to excessively high or low temperatures. High ambient temperatures, fast-moving glass, variable emissivity, and unsuitable conditions for contact thermometers complicate accurate real-time measurement, necessitating a robust non-contact solution.
Solution
Infrared pyrometers precisely measure glass temperatures in real-time, ensuring optimal temperature control during glass tube formation. Mounted strategically with cooling accessories to withstand harsh conditions, these sensors accurately monitor rapid temperature changes, allowing immediate adjustments to heating processes, effectively reducing defects and enhancing glass quality.
Benefits
- Reduces defects by ensuring uniform glass tube temperature, improving mechanical strength and durability.
- Minimizes downtime through real-time, accurate monitoring and immediate adjustments during production.
- Eliminates risks associated with contact measurement methods, protecting fragile glass surfaces.
- Lowers maintenance and operational costs by preventing overheating-related damages and process interruptions.
- Improves overall process reliability, leading to consistent product quality and higher production efficiency.
Crucial Role of Precise Non-Contact Temperature Control in the Glass Forming Process
An industrial manufacturer in the glass industry requires a reliable and easy-to-integrate temperature measurement solution to monitor and control the temperatures of glass tubes during the forming process, with the ability to regulate heating if necessary.
Precise temperature control during the forming process is crucial. If the temperature is too high, the glass becomes overly liquid and cannot maintain the necessary shape and structure, leading to uneven wall thicknesses and diameters, which compromises the mechanical strength of the glass tubes. Conversely, if the temperature is too low, the glass mass becomes difficult to shape, potentially causing surface defects, incomplete shaping, or even complete breakage of the glass tube.
In tubular glass production, a continuous raw glass strand is drawn from a glass melt, which is slowly cooled and solidified on a straight guide before being divided into sections.
Accurate temperature measurement and the installation of measuring systems are challenging due to the existing process conditions. The high and variable temperatures, caused by heating with gas flames (ranging between 1000 °C and 1200 °C (1832 °F and 2192 °F)), expose the measuring instruments to extreme conditions, with ambient temperatures well above 80 °C (176 °F). Additionally, the moving and forming glass mass requires the measuring instruments to react quickly and precisely to provide real-time data. The emissivity of glass plays a crucial role in non-contact stationary infrared temperature measurement, influencing accuracy.
Given the high temperatures and the risk of damaging the glass, contact thermometers are unsuitable for targeted temperature control. Therefore, the industrial manufacturer seeks a new non-contact measurement solution.
Accurate Temperature Control in Glass Manufacturing with Optris Glass Pyrometer
Optris provides the ideal solution for the industrial manufacturer with the CTLaser G5 infrared pyrometer. This innovative pyrometer is perfect for nearly all glass applications and is easy to integrate, even in challenging environments.
The CTLaser G5 measures in the spectral range of 5 µm and operates in temperature ranges between 100 °C and 1650 °C (212 °F and 3002 °F), making it highly sensitive and ideal for measuring glass surfaces. With a rapid response time of 80 ms, it adeptly detects quick temperature changes.
This pyrometer is exactly what the manufacturer needs to monitor the temperature of glass tubes. Multiple units are acquired and seamlessly integrated into the production process. The CTLaser G5H‘s specialized spectral range of 5.0 µm is crucial for effectively measuring glass temperatures across various industrial processes. Selecting the appropriate wavelength is essential for measuring both surface and deeper layers of glass, with specific recommendations based on temperature levels and material properties.
The pyrometers are mounted at key points at a slight distance from the measuring points using the provided mounting brackets and aligned using the integrated double laser sight.
Additionally, the CTLaser G5 is equipped with a water-cooling housing and an air purge attachment to handle the demanding environmental conditions. The water-cooling system protects the measuring head from overheating, while the air purge attachment keeps the pyrometer lens free from contamination.
Temperature readings are output via the supplied electronic box, allowing signals to be processed as an alarm through an analog output. This setup enables precise control over temperature fluctuations and the heating process.
The manufacturer successfully addresses all challenges with the CTLaser G5. The solution is easy to integrate, even in harsh environments, reliably records temperatures, and quickly provides alarm values. Maintenance efforts are significantly reduced thanks to the Optris accessories, ultimately saving the manufacturer both time and costs.
Reduce Costs and Improve Accuracy in Glass Processing with Optris G5 Pyrometers
The advantages of the Optris solution are clear. Optris pyrometers are easily integrated into processes, with a two-component system consisting of a compact sensor head and an electronic box that simplifies installation. Key process settings can be adjusted directly on the electronic box, and with the affordable USB kit from Optris, configuration via a PC using our free software is quick and straightforward.
The CTLaser G5 series offers models with varying temperature ranges: the G5L model covers 100 °C to 1200 °C (212 °F 2192 °F), the G5H model covers 250 °C to 1650 °C (482 °F to 3002 °F), and the G5HF model covers 200 °C to 1650 °C (392 °F to 3002 °F). With optical resolutions ranging from 45:1 to 70:1, these pyrometers ensure precise measurements. The system accuracy is specified as ±1% or ±1.5 °C, with repeatability of ±0.5% or ±0.5 °C, ensuring reliability in various glass applications.
Emissivity plays a crucial role in non-contact stationary infrared temperature measurement, influencing accuracy. The CTLaser G5 addresses this with its specialized spectral range of 5.0 µm, suitable for measuring glass temperatures effectively across various industrial processes. Wavelength selection is critical for measuring surface and deeper glass layers, with specific recommendations based on temperature levels and material properties.
The CTLaser G5 series features double laser aiming marks, providing precise aiming support and minimizing alignment errors. This system utilizes two laser beams to trace the infrared optical path accurately, indicating the spot’s position and size regardless of distance.
Additionally, digital field bus system outputs provide even more options for process integration. With a two-piece design and advanced signal processing capabilities, the CTLaser G5 offers a wide range of analog and digital outputs, ensuring seamless integration into various industrial processes and control systems.
Optris offers a wide range of accessories, enabling use in virtually any application, regardless of how challenging the process environment. Accessories such as the Optris water cooling housing and air purge attachment protect the pyrometers from high temperatures and contamination, saving customers time and money by significantly reducing commissioning and maintenance efforts.
Thanks to the efficient Optris CTLaser G5H solution, the manufacturer in this application has successfully replaced all previously used competitor pyrometers.
Recommended Products
Other Glass Applications
Talk to us about your IR Temperature Measurement Requirements
There are over 300 different pyrometer variants to choose from in the Optris infrared pyrometer portfolio each optimized for material, spot size, distance from the target, and environmental conditions. Fortunately, there is a trained engineer to phone or chat with to guide you through the process of choosing the perfect infrared sensor for your application.
The same support is available for the extensive IR camera product line.
