Comprehensive Analysis of the Use and Maintenance of Tempering Furnace Flat Air Grids: The Key Process to Ensure Glass Quality
In the glass deep-processing industry, the tempering furnace serves as a core piece of equipment, and the stable operation of its flat air grid system directly determines the strength and safety of glass products. Recently, our reporters conducted an in-depth investigation into the critical role of flat air grid technology in the glass tempering process and explored scientific maintenance solutions to provide systematic technical guidance for industry professionals.
Structural Analysis of Flat Air Grids: Zoned Design Adapts to Glass of Different Thicknesses
It is understood that modern tempering furnaces employ an innovative zoned design for their flat air grids, consisting of a quenching section (high-pressure zone) and a cooling section (low-pressure zone). A technical expert explained to our reporters: "This partitioned structure precisely meets the processing needs of glass with different thicknesses. When handling ultra-thin glass of 4–5mm, the high-speed airflow from the large fan in the quenching section, combined with slow-speed conveying, achieves rapid tempering. For glass thicker than 6mm, the material quickly enters the cooling section, where the entire quenching and cooling process is completed."
Notably, the system features electrically adjustable upper and lower air grids with synchronized movement, while the lower air grid supports independent fine-tuning. The interior of the air grid is composed of multiple parallel air distribution boxes, working in tandem with continuously oscillating conveyor rollers to ensure uniform cooling across the glass surface. This design effectively addresses stress distribution issues caused by uneven cooling in traditional processes.
Three Key Points for Routine Maintenance: Preventive Management Ensures Production Safety
During an on-site visit, the equipment supervisor of a large glass processing plant shared their experience in maintaining flat air grids: "Maintaining the integrity of the air grid system is fundamental to ensuring glass quality. We have identified three common failure sources and their corresponding solutions."
First, residual broken glass is considered the primary hazard. Technicians demonstrated the standard cleaning procedure: manually removing large fragments first, followed by a thorough cleaning of the roller surfaces using compressed air. The supervisor emphasized: "Particularly for fine glass particles trapped in the gaps of the polyester ropes, complete removal is essential to prevent scratches on subsequent products."
Second, the stability of the polyester rope system directly affects cooling uniformity. Reporters observed maintenance personnel regularly checking rope tension, securing loose sections with specialized adhesive, and immediately replacing ropes with more than 30% wear. This preventive maintenance approach has reduced related failures by over 60%.
Regarding air grid flatness deviations, the factory introduced laser calibration devices for adjustments. "We measure the chain lengths at each suspension point monthly to ensure the upper and lower air grids remain perfectly parallel," explained a technician while operating the device. "This guarantees consistent cooling intensity on both surfaces of the glass."
Intelligent Adjustment Technology: Digital Control Enhances Glass Quality Stability
In terms of control systems, modern tempering furnaces have achieved a high degree of digitization. Reporters observed at the control panel that air grid height can be precisely adjusted via pulse values. The factory’s automation engineer demonstrated two adjustment modes: "In manual mode, operators can fine-tune settings on-site and record optimal parameters. In automatic mode, pulse values are directly input, and the system automatically positions itself to the preset working state."
This digital control significantly improves the consistency of glass products across batches. According to factory data, intelligent adjustment has reduced visible stress marks on glass by 45%, while flatness compliance rates have risen to 99.2%. Particularly when processing glass of varying specifications (3–19mm), parameter switching time has been reduced by 70%.
Industry Outlook: Continuous Upgrades in Flat Air Grid Technology Drive High-Quality Development of the Glass Industry
With growing demand for safety glass in industries such as construction and automotive, flat air grid technology continues to evolve. Industry experts predict that the next generation of intelligent air grids will integrate temperature sensing and adaptive adjustment systems, dynamically regulating air pressure parameters based on real-time glass surface temperature monitoring. This will further enhance the processing capabilities for ultra-thin glass and shaped glass.
"The flat air grid, as the core component of a tempering furnace, directly impacts a company’s profitability," summarized a technical committee representative from an industry association. "Standardized daily maintenance, combined with intelligent upgrades, will be key to improving the market competitiveness of glass products."
This investigation revealed that enterprises prioritizing scientific maintenance of flat air grids achieve an average product yield rate 8–12 percentage points higher than industry standards. This reaffirms the importance of meticulous management in glass manufacturing. Moving forward, as regulations such as the Building Safety Glass Management Standards become increasingly stringent, ongoing optimization and innovation in flat air grid technology will continue to support the industry’s high-quality development.
