BrainWave float glass
The solution for fully controlling furnace temperature to improve glass quality
Control stabilization with BrainWave
ANDRITZ BrainWave is a patented advanced controller that outperforms traditional Proportional-Integral-Derivative (PID) control because of its two main components: an adaptive model and a predictive controller. BrainWave builds its own live models during normal plant operations, a powerful feature not offered by traditional Model Predictive Control (MPC) systems.
BrainWave’s predictive controller accurately forecasts process responses and accounts for multiple objectives. It adapts to process conditions, such as changes in production rate, keeping the process on target. BrainWave can also accept measured disturbance inputs, like raw materials properties, and takes corrective action before the process is pushed off target (PID, by comparison, must wait for the error to occur, and then react).
BrainWave easily integrates with existing control systems and its patented Laguerre technology means an average implementation time of just a few weeks. Best of all, the plant’s own staff can support and deploy BrainWave.
Control stabilization for glass manufacturing
BrainWave stabilizes the glass manufacturing process, resulting in improved operation, increased production, and reduced energy consumption. BrainWave float glass precisely controls glass temperature in the canal and the glass level in the furnace by adjusting the energy input and the batch feeding system.
Traditionally, these loops have wasted energy due to the high variability in their control. BrainWave float glass is proven to reduce canal temperature variation by up to 85%. This precise control reduces energy costs and improves the quality of the glass. Customers have reported additional production of up to 20 tons per day, while others have reported reductions (up to 40%) in scrap.
The first step in the application of a BrainWave patented controller is to hold the critical variables on target. BrainWave allows the furnace to operate at its most efficient operating point, while considering the effects of all measured and controlled variables. It permits consistent automatic control, without burdening the operators with the variation of conventional controls. BrainWave keeps the critical loops of the process closed and running in automatic. Stabilizing the level of glass in the furnace (using a patented BrainWave algorithm for just this type of response), ensures a uniform mass of material in the furnace at all times. This stabilized temperature control (which can predict and react to changes in the process) helps realize a consistent melt for the batch.