High-pressure autoclaves for laminated glass, precisely matching customer production needs.
I. Project Background
A large glass deep-processing enterprise specializes in the research and development and production of architectural safety glass and automotive laminated glass. With the surge in market demand for high-end laminated glass, existing equipment suffers from problems such as small batch processing capacity, insufficient temperature and pressure control precision, and high energy consumption, resulting in a product qualification rate of only 88%, which cannot meet the requirements of mass production and high quality. To address these pain points, the enterprise decided to introduce a customized high-performance autoclave system for laminated glass, used to achieve precise lamination of glass with interlayer films such as PVB/EVA/TPU/SGP, suitable for the production of products in various scenarios such as building curtain walls, high-speed rail windows, and automotive windshields.
II. Core Technology Requirements
1. The equipment must be compatible with various specifications of laminated glass, ensuring the maximum processing size meets the needs of high-end products;
2. The working pressure and temperature control accuracy must meet high industry standards, ensuring no bubbles or delamination in the laminate;
3. Equipped with a complete safety protection system, meeting the requirements of the National Regulations for Safety Supervision of Pressure Vessels;
4. Compared with existing equipment, energy consumption should be reduced by ≥20%, and the single-batch production cycle shortened by ≥15%.
III. Customized Technical Solutions
(I) Precision Control System
Utilizing a PLC color touchscreen, it supports closed-loop control of temperature, pressure, holding time, and heating/cooling rates, achieving industry-leading control precision. Equipped with an industrial Ethernet interface, it enables remote monitoring, parameter adjustment, and fault alarms, facilitating production management for enterprises.
(II) Safety Assurance System
- Multiple safety interlocks: Automatic alarms and emergency pressure relief for over-temperature and over-pressure events, with a relief time ≤3 minutes;
- Mechanical protection: Equipped with explosion-proof doors and a manual emergency pressure relief valve. The vessel body uses pressure vessel-specific steel plates and has passed non-destructive testing;
- Monitoring device: Real-time monitoring of oxygen concentration and pressure fluctuations within the vessel; automatic shutdown and fault data recording in case of abnormalities.
(III) Energy-Saving Optimization Design
- Insulation Layer: Utilizes composite insulation material, 150mm thick, surface temperature ≤50℃, reducing heat loss by 30%;
- Intelligent Temperature Control: Equipped with a PID fuzzy control algorithm, automatically adjusts the heating and cooling rates according to different glass specifications to avoid energy waste;
- Waste Heat Recovery: Utilizes waste heat from the cooling stage to preheat the feed material, reducing energy consumption by 22% compared to the previous model.
(IV) Auxiliary Systems
Equipped with an automatic feeding and discharging device, linked with the production line for automated integration; a uniform air/oil distribution device is installed inside the vessel to ensure uniform temperature and pressure field distribution, with a temperature difference ≤2℃.
IV. Project Implementation and Commissioning
1. Installation Phase: Assemble a professional installation team, strictly adhere to pressure vessel installation specifications, and complete processes such as vessel positioning, pipeline connection, and electrical commissioning. 2. Commissioning Phase: Commissioning is conducted in three phases: first, no-load testing of pressure and temperature control accuracy; second, small-batch trial production; and finally, parameter optimization and finalization to ensure stable equipment operation.
3. Personnel Training: Training is provided to customers on equipment operation and maintenance, ensuring operators master parameter setting and troubleshooting skills.
V. Implementation Results
1. Increased Production Efficiency: Significant improvements in single-batch processing capacity, production cycle, and daily output, with an efficiency increase of 83.3%.
2. Optimized Product Quality: Significantly reduced bubble rate and delamination rate in laminated glass; product qualification rate increased from 88% to 99.7%; and the proportion of high-end products increased by 40%.
3. Energy Consumption and Cost Control: Significantly reduced energy consumption per ton of glass production, saving approximately 360,000 RMB in electricity costs annually; equipment maintenance cycle extended to 6 months; and maintenance costs reduced by 35%.
4. Customer Feedback: The equipment operates stably, meeting the production needs of multiple product specifications. It has passed ISO 9001 quality system and CE certification, receiving high praise from customers for its "high efficiency, precision, and energy saving," providing core equipment support for their expansion into the high-end market.
VI. Conclusion
This project, through the research and application of a customized autoclave system, precisely matched the customer's production needs. From core parameter optimization and safety system upgrades to energy-saving design modifications, it comprehensively solved the pain points of the original equipment. Moving forward, we will combine customer feedback and industry technological developments to further optimize the automation level and energy consumption indicators of the equipment, providing glass deep processing enterprises with more efficient, reliable, and intelligent pressure vessel solutions.
