Horizontal Glass Tempering Products

Transcription

1 Horizontal Glass Tempering Products

2 What is tempered glass? Tempered glass is two or more times stronger than annealed glass. When broken, it shatters into many small fragments which prevent major injuries. This type of glass is intended for glass facades, sliding doors, building entrances, bath and shower enclosures and other uses requiring superior strength and safety properties.

3 Mappi was founded in 1993 with one foot firmly grounded in an Italian tradition of furnace production for tempered glass and one foot planted in innovative ideas and computer driven technology. Mappi currently has: 280 furnaces worldwide

4 Mappi has the Production Facility in Italy, a Branch in the United States: Mappi America Inc

5 Mappi high quality tempering systems for the glass industry stand out for their technologically advanced design and construction and simple use.

6 MAPPI MAKES TWO PRIMARY TYPES OF FURNACES: The FOX Eco Convection Series: is designed to satisfy the demands of the small to medium sized glassworks that are interested to integrating a compact tempering plant but are limited by available space, the Fox series maintains high quality standards while remaining economical The ATS Eco Convection Series is the conventional range of machine know worldwide for they best performances in terms of quality and versatility, designed for glasswork with mixed types of production and applications, like building, interior decoration, automotive

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8 COMPOSITION OF THE FOX AND AU MACHINE 1. Loading roller section 2. Heating section 3. Tempering and forced cooling section 4. Unloading roller section 5. Electric fan 6. Pneumatic system 7. Electrical system 8. Electric board and switchboard

9 1. LOADING ROLLER SECTION Tubular steel structure Steel rollers rubber coated Forward and backward movement controlled by a foot pedal Side rollers to facilitate the loading and unloading of large glass sheets Pneumatic controlled rack with roller casters

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15 2. HEATING SECTION Possibility to open and roll out the lower heating chambers (for the ATS Series) Chamber movements controlled by AC motors The furnace can be turned on and off daily without ceramic rollers problems Equipped with the MHS Multizone Heating System Equipped with the ESS Energy Saving System Equipped with the IHS Intelligent Heating System

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20 Small tightly monitored & controlled heating elements combined with a lower temperature produce a very accurate heat profile for the best optical quality This MAPPI furnace contains many heating elements: on the top and on the bottom

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23 Ceramic Rollers and Heating Chamber Maintenance System for raising the upper heating chamber (Motor reducers, endless screw and rolling on the rails) with easy access to the ceramic rollers, the rollers don t have to be removed for maintenance, this means that the working surface always remains level System for extraction of lower heating chamber (for the AU Series) for facilitate the maintenance of the heating zones

24 Heating System MHS Multizone Finely controlled heating zones insure thermal and energy efficiency Wire resistance controlled by static relay with pulse train (precision, any mechanical relay) Every heating element is equipped with an independently managed thermocouple Wire heating resistence made with special alloy, that is weldable Heating zones movable (because they are interchangeable) in case of emergency If a resistance in one zone burns out it is still possible to continue production Map of the zones on the PLC monitor to check their functioning / integrity ( and the quality of the tempering process)

25 Thermocouple position 35 mm S mm 10 mm

26 Energy Saving System ESS It is possibile to set the temperatures and the power of the heating elements individually because every heating element is supplied by a thermocouple and is controlled autonomously by the PLC supplied by a static reley Self-optimizing heating system with the presence of the glass sheet. Please note: a. Where the glass sheet is located, the air temperature is lower and consequently the software sends more current to that heating zone. b. This system saves energy because during the heating process only the panels that heat the glass sheet are on, while the other panels that don t see the glass sheet are off

27 In the Mappi Oven there are at least 40 heating elements for a furnace with dimension 1050 x 2300 and di 128 heating elements for a furnace with dimension 2500 x 4800, the dimension of each heating element is 300 mm x 600 mm and is equipped with own thermocouple.

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29 The software is able to manage the power of every single zone in order to check the heating process of the master zone. The thermocouple is able to measure the air temperature consequently where the glass sheet absorbs heat, the air has a lower temperature; so the software in order to check master zone supplies more power to the affected zone. Master Heating element Thermocouple which takes the temperature of warm air Low heating power Thermocouple which takes the temperature of cold air High heating power

30 IHS: Intelligent Management system for the self-organizing heating, allows concentrated heating only in those zones where the glass is present, eliminating overheating of rollers not covered by glass. The specific software manages AUTOMATICALLY all the heating zones. The control precision is ± 1 C Power management of heating elements depends on the position of glass sheets

31 Movement of the Glass in the Heating Chamber The ceramic rollers are driven accurately to within 1/1000 mm by DC drive motor with a friction transmission between iron / rubber (avoids slack time gaps, gear lash, with resulting risks of marks on the glass) This eliminates the need for SO2 Full ceramic rolls, easily replaced Roller drives are controlled by brushless motors to insure accurate roller position and speed To avoid distortions and damage to the surface of the glass, the speed of oscillation of the ceramic rolls is managed automatically : initially speed is slow, progressively increasing as the temperature of the glass rises

32 Mappi glass tempering furnaces provide better glass flatness and optical quality with high precision roller drive with independent drives for each section with frequency converters. The roller drives are accurate to within 1/100 of a millimeter so the furnace does not require SO2 gas. This means there is less cleaning of the rollers in the chamber.

33 Roller oscillation Speed Ceramic roller speed variation during the heating cycle Time in furnace

34 Advantages of the MAPPI Drive System Absence of SO2 Oscillating the rolls accurately so they don't touch the glass at the same point. The position and movement of the ceramic rolls is critical for quality glass Absence of vibrations Reliability and reduced maintenance (greasing chain every 6 months) Effortless access to rolls and heating elements

35 3. TEMPERING AND FORCED COOLING SECTION Single section for tempering and cooling Steel rolls with insulating spiral wound Kevlar covering. Compensation top rollers prevent movement & lifting thin glass (3/4 mm.) with blower air Computer manages the speed of the blowers and quantity and direction of the air automatically Rapid opening of the blowers manually for maintenance and cleaning section of glass fragments

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40 Air ducts and pipes to the blower fan are equipped with automatic valves for opening and closing Air knives with numerous nozzles uniformly distribute air designed to optimize the pressure and the uniformity of the air on the plate of glass to reduce irradesence Air ducts and pipes designed for the maximum efficiency and reduced noise Vibration dumpeners below the pipes Air Ducts Section

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42 4. UNLOADING ROLLER SECTION Structure similar to the loading section but with rollers equipped with spiral rolled Kevlar insulating rope for heat protection Rack with roller casters based on the dimension of the furnace Safe unloading system (in case of lack of unloading consent) Side rollers to facilitate the unloading of big glass sheets Independent rollers movement

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45 5. ELECTRIC FAN Fan body and air ducts / pipes designed to reduce noise level and energy loss Single blower fan is used for both tempering and cooling Blower powered by a D.C. Motor to reduce energy consumption. Blower controlled by a process PC (to improve usage and energy efficiency Anti vibration sensors / anti mechanical resonance sensors Vibration dampers below the fan body

46 Direct Current Motor for the Ventilator It has a precise speed control that reduces electrical consumption according to the required air quantity Recommended electric filter for the harmonics on the electrical supply line if it is not powered directly from a line and transformer dedicated only to the furnace Please note: A.C. motors used by other systems: Have a fixed speed and the electrical consumpion is constant / not adaptable to the need of different glass thickness The air quantity is regulated by closing more or less the air outlet

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51 6. PNEUMATIC SYSTEM o o Servomechanism Electrical valves o Devices for filtering / lubricating / pneumatic regulating

52 Pneumatics control air flow to the quench

53 7. ELECTRICAL SYSTEM C.E. norms Electrical assembling between the control board and the point of use onboard the machine Coated cable ducts Numbered electrical derivation boxes with cable support chains

54 8. ELECTRIC BOARD AND SWITCHBOARD Cabinet Operator interface (for the general machine and process supervision) consisting of a monitor and an IP55 membrane keyboard 24V/DC power supply for the electrical board interior and for the control circuits Hardware and software safety controls for the heating chambers temperature Modem for tele-assistence

55 The furnace is completely managed by a Siemens PLC, the processing variables are set from the keyboard and the global processing its controlled through a monitor. Optical and acustical alarm for the status of the machine and the alarms Actuators for the bushless motors (for the movement control with a precision of a thousand of millimeter Special electronic boards for controlling the heating zones PLC stores of tempering recipes

56 TOUCH SYSTEM Is the new Integrated Quality System for the Automatic Control of Production and Tempering Process in order to meet ANSI and CE Standards of finished products, with automatic archiving of each and every single process cycle. The exclusive TOUCH system enables the immediate control of all process parameters and real-time printing of the Certification Reports. It consists of a special Touch Screen Monitor of the last generation, and a series of instrumental equipment for the control of processing stages

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58 Quality Components P.L.C. & electronic controls : SIEMENS Pneumatic controls : FESTO Ceramic rollers: VESUVIUS Brushless motors for the rollers movement (precision of 1 thousandth millimeter). EASY TO FIND ON THE MARKET EVERYWHERE

59 Quality Standards A) Planimetric Distortion Overall: Less than 0.3% In case of a continuous production cycle and using the convection system GHBS, we can reduce the maximum limit since 0.1%. B) Surfacing waves Not exceeding 0,08 mm. (8 hundredths) as the dimension from the top to the bottom of the wave, measured over a space of 250 mm., with the exception of the distance from the front and rear edges of the glass of 300 mm., where it can be 0,25 mm. (25 hundredths)

60 Production Efficiency Completely automated machine, easy to use Change of glass thickness and shapes, managed by the software without interrupting production Percent of glass breakage and defective glass, less than 1%

61 Safety EC certification Reduced noise No use of SO2 Automatic blocking / alarm for the incomplete unloading of the unloading section

62 GHBS CONVECTION SYSTEM (GLAVERBEL HEAT BALANCE SYSTEM) The GLAVERBEL HEAT BALANCE SYSTEM is the result of the recent developments of the convection tecnology designed and patented by Glaverbel Group, it greatly enhances the performance of Mappi furnaces in terms of quality of the tempered product and increased production. Quality and flexibility of the MHS (Multizone Heating System) technology and, MAPPI s standard heating system, with the use of convection system allows the following: Tempering all coated glass of the last generation on the market including the LowE with 0,01 Emissivity. Improving the quality of the tempered product in terms of: Optical Distortion. Glass sheet flatness. Surface defects. Increasing the maximum dimensions of temperable sheet. Reducing cycle time, and increasing the productivity.

63 GHBS system GHBS system involves: A compressor. Compressed air treatment device. A distributing circuit of air inside the chamber. A set of devices located in the upper and lower chamber allow the preheating of compressed air blowing on both surfaces of glass. Thanks to an elaborate management program of sensors and operations involved in the convection system it s possible to do the following: Managing the air entering in the upper and lower chamber separately; Blowing the air only in the zones where the glass is present; Setting up the timing/timer law of the blowing air; Modulating the intensity of the pressured air in every single zone inside the chamber; Managing the distribution of the pressure along the extension of the loading present in the chamber.

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67 Generator Power Supply Mappi furnaces can be powered with a Generator that the customer can purchase following the specfifications provided by MAPPI

68 IMPROVED ENERGY EFFICIENCY 25% ENERGY SAVING Less installed electrical power (influence on fix costs) Fast switch-on (45-60 minutes to reach the working temperature) Possibility to switch-off the furnace every evening thanks to the perfect insulation of the heating chamber.

69 MAPPI Technical Personnel for the Installation 2 mechanics 2 electricians 1 software engineer 1 process engineer for training

70 Reference Norms Ansi Z UNI 7142 EN tempered glass EN 1863 heat strenghtened ECE R 43

71 Heat Soak Test Furnace

72 The Heat Soak Test is done to reduce the risk of spontaneous breakages due to Nickel Sulphide inclusions (Nis)

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74 The form of the stand who support the glasses is an A and is possible to place on this 30 panes of glasses (15 on each side)

75 The Heat Soak Test is a thermal cycle, which contains a heating phase to 290 C, a holding phase of 2 hours at 290 C and a cooling phase to ambient temperature. The total cycle time is approx. 8-9 hours

76 The heating resistance are placed in the two side of the oven at full lenght. The fans for the air stirring are placed in the arch of the oven at full lenght also in order to better the homogeneity of the temperature on the glasses and to better the energizing efficiency of the oven.

77 In the cooling phase, the oven opens chimneys on the top in order to allow at the hot air to go out. In the same time it push fresh air in oven

78 Glass Laminating Furnace

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80 Lammiflex the new furnace for glass laminating. Thanks to an innovative system which allows laminating with PVB film without an autoclave, it allows for excellent results in quality, production output and cost effectiveness.

81 Lammiflex for the assembling of PVB on the glass sheet is not necessary any Climate

82 The furnace include five extractable tray each equipped with a silicone bag where the glass sheet are placed for laminating. The process do a special dry programme and by a double vacuum system laminate with PVB film.

83 Lamina is the simple furnace for glass laminating with EVA film. The furnace in equipped with a single tray or more up to five different trays for more production.

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85 The glass sheet placed inside the silicone bags to be laminated by vacuum and to be heated to a appropriate temperature.

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