Ceramic sheet casting system and process

Abstract

This invention provides a ceramic sheet casting processing system and process for ceramic sheet processing, and a coordinated production control system, including a production control platform. Multiple AVG trolleys for transporting slurry drums are connected to the production control platform. The production control platform includes a controller, which is connected to a communication module and a data processing module. The production control platform is also connected to raw material processing equipment, sampling and testing equipment, casting processing equipment, and a stacking and laminating device. The casting processing equipment includes a casting device, a cutting device, a stacking and laminating device, and a calcining device. This system completely separates raw material processing from production. Slurry can be quickly sampled and tested before being fed into production. The test results assist in the adjustment of production equipment and slurry. During production, the slurry is fed into the casting equipment in batches, and batch sampling and testing are performed. If abnormalities are detected, the operating mode of the production equipment can be quickly switched for rapid production adjustment. During continuous production, the number of defective products is low.

Description

Technical Field

[0001] This application relates to the field of ceramic sheet processing, and in particular to a ceramic sheet casting processing system and process. Background Technology

[0002] Existing dry-pressed ceramics, through the application of pressure from above and below, suffer from uneven pressure distribution, uneven density, and uneven shrinkage, which can lead to cracking, delamination, and other phenomena, resulting in air leakage problems.

[0003] Casting is a method for forming ceramic products. The specific process includes: first, mixing the pulverized powder with an organic plasticizer solution in an appropriate ratio to form a slurry with a certain viscosity. The slurry flows down from the container and is scraped and pressed onto a special base tape with a certain thickness by a scraper. After drying and curing, it is peeled off from the top to become a thin film of green tape. Then, according to the size and shape requirements of the finished product, the green tape is processed by punching, laminating and other processes to form a blank finished product to be sintered.

[0004] In tape casting equipment, if air bubbles in the slurry cannot be expelled as much as possible, it can easily lead to a large number of pores inside the green body after molding, which will affect the quality of ceramics during drying and sintering. Summary of the Invention

[0005] The purpose of this application is to provide a system and process to ensure that the products are less likely to be defective during the production of ceramic sheets by casting. Compared with the prior art, this application provides a ceramic sheet casting processing system, including a production control platform. Multiple AVG trolleys for transporting slurry drums are connected to the production control platform. The production control platform includes a controller, and the controller is connected to a communication module, a data processing module and an AVG trolley route control module.

[0006] The production control platform is connected to raw material processing equipment, sampling and testing equipment, casting processing equipment, and lamination equipment;

[0007] Raw material processing equipment includes: vacuum mixing equipment, quantitative feeding device, raw material conveying device, and filling device;

[0008] Sampling and testing equipment includes sampling equipment, pre-casting equipment, and green ceramic tape testing equipment;

[0009] Casting equipment includes: casting device, cutting device, laminating device and calcining device; the slurry input ends of the pre-casting equipment and casting device are equipped with auxiliary scrapers and main scraper blades for defoaming the input slurry.

[0010] This solution completely separates raw material processing from production. Sampling and testing can be carried out quickly before the slurry is put into production. The test results can be used to assist in the debugging of production equipment and slurry. During production, the slurry is fed into the casting equipment in batches, and batch sampling and testing are carried out. If abnormalities are detected, the working mode of the production equipment can be quickly switched to quickly adjust the production and ensure that the products are less likely to be defective during continuous production.

[0011] Furthermore, the slurry tank includes a sealed tank with a partition plate installed inside. A sampling head is fixedly connected to the upper end of the sealed tank. The sampling head includes sampling ports on both sides of the partition plate. The output port of the filling device is equipped with a pair of filling output pipes that match the sampling ports. The inlet of the casting device is equipped with a pair of sampling connectors that match the sampling ports. After the raw material is pretreated, the treated slurry is fed into any cavity inside the sealed tank through the filling device. During casting production, the liquid in the two cavities inside the sealed tank can be quickly discharged.

[0012] Furthermore, the green ceramic tape testing equipment is used to test the surface quality, tensile strength, and elastic modulus of the green ceramic tape produced by the pre-casting equipment.

[0013] Furthermore, the laminating device includes a laminating mold, a pair of process edges are provided inside the laminating mold, and pressure devices are installed at both the upper and lower ends of the laminating mold.

[0014] Furthermore, the auxiliary scraper includes a scraper body with a vertical guide rail, a defoaming mesh belt with a permanent magnet installed at the bottom of the scraper body, and an electromagnetic generator matching the defoaming mesh belt installed inside the scraper body; the electromagnetic generator drives the defoaming mesh belt to vibrate, thereby assisting in defoaming the slurry surface.

[0015] Optionally, the AVG cart's route specifications include an empty barrel area, a barrel waiting area, and a waiting point. The waiting point is located between the raw material processing equipment and the casting processing equipment, which facilitates the sampling and classification and storage of the slurry barrels after production.

[0016] A ceramic sheet casting process, the specific steps of which are as follows:

[0017] A. Raw material pretreatment;

[0018] A1, After the ceramic slurry is mixed with the dispersant and binder, it is stirred at a constant speed under vacuum;

[0019] A2, after adding a quantitative amount of defoamer, repeat step A1 multiple times to complete the slurry pretreatment, and then fill the slurry into the slurry tank and seal it.

[0020] B, Sampling and processing before casting;

[0021] B1, raw ceramic pieces are obtained by sampling the slurry in the slurry tank and casting it.

[0022] B2, green ceramic belt inspection; if the inspection is qualified, the pulp tank is put into production; if the inspection is unqualified, the auxiliary scraper is adjusted. If the inspection result is still unqualified after the equipment is adjusted, the pretreatment equipment will repeat step A2 to fill the new pulp tank. After filling, the new pulp tank repeats step B until the inspection result is qualified.

[0023] If the equipment passes the inspection after adjustment, the auxiliary scraper at the casting equipment is adjusted simultaneously before proceeding to the next step.

[0024] C, to carry out tape casting production;

[0025] C1, using slurry in a slurry tank to cast green ceramic;

[0026] C2, raw porcelain is cut and blanked to obtain raw porcelain slabs, and the raw porcelain slabs are fired to initially form the body;

[0027] C3, layered co-firing, involves stacking multiple raw ceramic pieces and finally sintering them together to form the final shape.

[0028] Optionally, the specific operation for adjusting the auxiliary scraper in B2 is as follows: adjust the scraper position to fit against the upper surface of the slurry at the input end of the pre-casting equipment, and then turn on the electromagnetic generator with the set power to make the defoaming mesh belt vibrate and impact the air bubbles on the surface of the slurry.

[0029] Optionally, when switching the type of slurry for production, the production control platform controls the production equipment to debug the production mode. When debugging the production mode: each slurry tank is sampled and tested. Before the sampling and testing of a single slurry tank, the next slurry tank is not filled. When filling, only the sampling chamber is filled until the sample in the slurry tank passes the test. At this time, the equipment can continuously fill slurry.

[0030] Optionally, when a single type of pulp is produced continuously, the production control platform controls the production equipment to operate in continuous production mode. In continuous production mode, the raw material processing equipment continuously fills pulp tanks and samples the continuously transported pulp tanks. If the sampling test fails, the production control platform switches the production mode to the debugging mode.

[0031] Compared to existing technologies, the advantages of this application are:

[0032] (1) This solution completely separates raw material processing from production. Sampling and testing can be carried out quickly before the slurry is put into production. The test results can be used to assist in the debugging of production equipment and slurry. During production, the slurry is fed into the casting equipment in batches for production. Batch sampling and testing are carried out. If the test results are abnormal, the working mode of the production equipment can be quickly switched to quickly adjust the production. This ensures that the product is less likely to be defective during continuous production.

[0033] (2) The slurry tank includes a sealed tank with a partition plate installed inside. A sampling head is fixedly connected to the upper end of the sealed tank. The sampling head includes sampling ports on both sides of the partition plate. A pair of filling output pipes matching the sampling ports are installed at the output port of the filling device. A pair of sampling connectors matching the sampling ports are installed on the feed port of the casting device. After the raw material is pretreated, the treated slurry is fed into any cavity inside the sealed tank through the filling device. During casting production, the liquid in the two cavities inside the sealed tank can be quickly discharged.

[0034] (3) Both the pre-casting equipment and the casting device are equipped with auxiliary scrapers and main scraper blades for defoaming the input slurry. The auxiliary scraper includes a scraper body with a vertical guide rail. The bottom of the scraper body is equipped with a defoaming mesh belt with a permanent magnet. An electromagnetic generator matching the defoaming mesh belt is installed inside the scraper body. The electromagnetic generator drives the defoaming mesh belt to vibrate, thereby assisting in defoaming the surface of the slurry.

[0035] (4) When switching the production of slurry type, the production control platform controls the production equipment to debug the production mode. When debugging the production mode: each slurry tank is sampled and tested. Before the sampling and testing of a single slurry tank, the next slurry tank is not filled. When filling, only the sampling chamber is filled until the sample in the slurry tank is qualified. At this time, the equipment can continuously fill slurry.

[0036] (5) When a single type of slurry is produced continuously, the production control platform controls the production equipment to operate in continuous production mode. In continuous production mode, the raw material processing equipment continuously fills the slurry tanks and samples the slurry tanks being transported continuously. If the sampling test fails, the production control platform switches the production mode to the debugging mode. Attached Figure Description

[0037] Figure 1 This is a system architecture diagram for this application;

[0038] Figure 2 This is a process flow diagram for this application;

[0039] Figure 3 This is a mind map of the application;

[0040] Figure 4 This is a diagram showing the state changes of this application;

[0041] Figure 5 This is a perspective view of the pulp tank in this application;

[0042] Figure 6 This is a cross-sectional view of the slurry tank in this application;

[0043] Figure 7 This is a schematic diagram illustrating the scenario of transporting the pulp drum according to this application;

[0044] Figure 8 This is a partial cross-sectional view of the auxiliary scraper in this application;

[0045] Figure 9 for Figure 8 Schematic diagram of the structure at point A;

[0046] Figure 10 This is a top view of the stacked mold of this application.

[0047] Explanation of the labels in the diagram:

[0048] 1. Sealed container, 2. Divider plate, 3. Sampling head, 4. Scraper body, 5. Defoaming mesh belt, 6. Electromagnetic generator. Detailed Implementation

[0049] The embodiments will be described clearly and completely with reference to the accompanying drawings. All other embodiments obtained by those skilled in the art based on the embodiments in this application without creative effort are within the scope of protection of this application.

[0050] Example 1:

[0051] Please see Figure 1-4 and Figure 7 A ceramic sheet casting processing system includes a production control platform. Multiple AVG (Automated Guided Vehicle) trolleys for transporting slurry drums are connected to the production control platform. The AVG trolley route specifications include an empty drum area, a drum to be processed area, and a waiting point. The waiting point is located between the raw material processing equipment and the casting processing equipment, facilitating the sampling and post-production classification and storage of the slurry drums. The production control platform includes a controller for controlling the operation of the raw material processing equipment, sampling and testing equipment, casting processing equipment, and sheet lamination device. The controller is connected to a communication module, a data processing module, and an AVG trolley route control module.

[0052] The transportation routes of multiple AVG vehicles can be controlled through the AVG vehicle route control module;

[0053] The production control platform is connected to raw material handling equipment, sampling and testing equipment, casting processing equipment, and lamination device; the loading and unloading of the slurry tanks during the operation of the raw material handling equipment, sampling and testing equipment, and casting processing equipment are all carried out by automated robotic arms;

[0054] The raw material processing equipment includes: vacuum mixing equipment, quantitative feeding device, raw material conveying device and filling device; the quantitative feeding device is used for quantitative addition of defoamer, and the filling device is used for filling the processed raw materials into the slurry tank;

[0055] The filling device has a pair of filling output pipes that match the sampling port installed at the output port, and the casting device has a pair of sampling connectors that match the sampling port installed at the feed port. After the slurry tank is connected to the sampling connectors, the slurry in the two cavities of the slurry tank can be discharged to the feed end of the casting device.

[0056] After the raw materials are pretreated, the treated slurry is fed into any cavity in the sealed barrel 1 through a filling device. During the casting production, the liquid in the two cavities in the sealed barrel 1 can be quickly discharged.

[0057] The sampling and testing equipment includes a sampling device, a pre-casting device, and a green ceramic tape testing device. The sampling device is used to extract the sample liquid stored in the slurry tank and output it to the pre-casting device for green ceramic tape production. The green ceramic tape testing device is used to test the surface quality, tensile strength, and elastic modulus of the green ceramic tape produced by the pre-casting device, and to test whether the quality of the green ceramic tape produced by the slurry is qualified.

[0058] The casting processing equipment includes: casting device, cutting device, stacking and laminating device and calcining device. The cutting device is used to cut the green ceramic tape produced by casting to obtain green ceramic sheets. The stacking and laminating device is used to stack multiple green ceramic sheets. The calcining device is used for firing and calcining the green ceramic sheets.

[0059] Please see Figure 8-9 Both the pre-casting equipment and the casting device are equipped with auxiliary scrapers and main scraper blades for defoaming the input slurry at the slurry input end. The auxiliary scraper includes a scraper body 4 with a vertical guide rail. A defoaming mesh belt 5 with a permanent magnet is installed at the bottom of the scraper body 4. An electromagnetic generator 6 matching the defoaming mesh belt 5 is installed inside the scraper body 4. A permanent magnet is installed on the defoaming mesh belt 5. A compression spring is connected between the electromagnetic generator 6 and the permanent magnet. The electromagnetic generator 6 intermittently attracts the permanent magnet, causing the defoaming mesh belt 5 to vibrate and assist in defoaming the slurry surface.

[0060] Please see Figure 10 The lamination device includes a lamination mold, a pair of process edges are provided inside the lamination mold, and pressure devices are installed at both the upper and lower ends of the lamination mold.

[0061] Please see Figure 5-6 The slurry tank includes a sealed tank 1, a partition plate 2 installed inside the sealed tank 1, and a sampling head 3 fixedly connected to the upper end of the sealed tank 1. The sampling head 3 includes sampling ports set on both sides of the partition plate 2. The partition plate 2 divides the sealed tank 1 into two chambers. One chamber is used for storing slurry for production; the other chamber is used for storing slurry for sampling. This chamber can store enough slurry for at least two samplings.

[0062] Please see Figure 4 A ceramic sheet casting process, the specific steps of which are as follows:

[0063] A. Use raw material processing equipment to pre-treat the raw materials;

[0064] A1, After the ceramic slurry is mixed with the dispersant and binder, it is stirred at a constant speed under vacuum;

[0065] A2, after adding a quantitative amount of defoamer, repeat step A1 multiple times to complete the slurry pretreatment, and then fill the slurry into the slurry tank and seal it.

[0066] B. Before casting, use sampling and testing equipment to sample the slurry in the slurry tank;

[0067] B1, sample the slurry in the slurry tank, and use a pre-casting equipment to cast green ceramic tiles;

[0068] B2, green ceramic belt inspection; if the inspection is qualified, the pulp tank is put into production; if the inspection is unqualified, the auxiliary scraper is adjusted. The specific operation of the auxiliary scraper adjustment is as follows: adjust the scraper position to fit the upper surface of the pulp at the input end of the pre-casting equipment, and then turn on the electromagnetic generator 6 with the set power to make the defoaming mesh belt 5 vibrate and impact the air bubbles on the surface of the pulp; if the inspection result is still unqualified after the equipment adjustment, the pretreatment equipment will repeat step A2 to fill the new pulp tank. After filling, the new pulp tank repeats step B until the inspection result is qualified.

[0069] If the equipment passes the inspection after adjustment, the auxiliary scraper at the casting equipment is adjusted simultaneously, and then the next step C is carried out.

[0070] C. Casting production is carried out using casting equipment;

[0071] C1, The casting device uses the slurry in the slurry tank to cast green ceramic to obtain a green ceramic tape;

[0072] C2, the raw porcelain belt is cut by the cutting device to obtain raw porcelain pieces, and the raw porcelain pieces are fired to form the initial shape.

[0073] C3, layered co-firing, involves stacking multiple raw ceramic pieces and finally sintering them together to form the final shape.

[0074] If the green ceramic tape produced by the slurry is found to be substandard during sampling and testing, this solution can promptly adjust the auxiliary defoaming equipment and the amount of defoamer to achieve self-regulation during the production process, ensuring that the slurry used for casting production meets the production requirements when it is put into production.

[0075] Example 2:

[0076] For simplicity, only the differences from Example 1 will be described below. The difference between Example 2 and Example 1 is as follows:

[0077] When switching the type of slurry for production, the production control platform controls the production equipment to debug the production mode. When debugging the production mode: each slurry tank is sampled and tested. Before the sampling and testing of a single slurry tank, the next slurry tank is not filled. When filling, only the sampling chamber is filled until the sample in the slurry tank passes the test. At this time, the equipment can continuously fill slurry.

[0078] This implementation facilitates automatic equipment adjustment when switching between different slurry production processes, allowing for rapid adjustments to the production equipment when switching slurry for production.

[0079] Example 3:

[0080] For simplicity, only the differences from Example 1 will be described below. The difference between Example 3 and Example 1 is as follows:

[0081] When a single type of slurry is produced continuously, the production control platform controls the production equipment to operate in continuous production mode. In continuous production mode, the raw material processing equipment continuously fills slurry buckets. The filled slurry buckets are transported to the casting processing equipment in batches of N via AVG carts. During continuous production, a sample is randomly taken from one slurry bucket in a certain batch. During sampling, the slurry buckets in the same batch are transferred to the waiting point to await the test results.

[0082] If the test results are satisfactory, the batch of slurry drums will continue to be transported to the casting processing equipment.

[0083] If the sampling inspection fails, the production control platform switches the production mode to the debugging mode, and at the same time, the batch of pulp barrels in which the sampled pulp barrel is located is transferred to the waiting barrel area for recycling and processing by those skilled in the art.

[0084] Once a green ceramic belt meeting production standards is obtained during the debugging process, the production control platform controls the production equipment to resume continuous production.

[0085] This embodiment is applicable to the continuous production process of casting equipment. During the production process, random sampling and testing of the filling slurry are carried out to ensure production quality. At the same time, when abnormalities in the slurry are found, the production mode can be switched in time to adjust the equipment, which can easily reduce the defect rate during production and ensure production quality.

[0086] The above description is merely the best implementation method adopted in light of current practical needs, but the scope of protection of this application is not limited thereto.

Claims

1. A ceramic sheet casting system, characterized in that, It includes a production control platform, on which multiple AVG trolleys for transporting pulp drums are connected. The production control platform includes a controller, which is connected to a communication module, a data processing module, and an AVG trolley route control module. The production control platform is connected to raw material processing equipment, sampling and testing equipment, casting processing equipment and lamination device; The raw material processing equipment includes: a vacuum mixing device, a quantitative feeding device, a raw material conveying device, and a filling device; The sampling and testing equipment includes sampling equipment, pre-casting equipment, and green ceramic tape testing equipment; The casting processing equipment includes: a casting device, a cutting device, a stacking and laminating device, and a calcining device; the slurry input ends of the pre-casting device and the casting device are equipped with auxiliary scrapers and main scraper blades for defoaming the input slurry. The slurry tank includes a sealed tank (1), a partition plate (2) is installed inside the sealed tank (1), a sampling head (3) is fixedly connected to the upper end of the sealed tank (1), the sampling head (3) includes sampling ports on both sides of the partition plate (2), a pair of filling output pipes matching the sampling ports are installed at the output port of the filling device, and a pair of sampling connectors matching the sampling ports are installed on the feed port of the casting device; the green ceramic tape testing equipment is used to test the surface quality, tensile strength and elastic modulus of the green ceramic tape generated by the pre-casting equipment; The auxiliary scraper includes a scraper body (4) with a vertical guide rail. A defoaming mesh belt (5) with a permanent magnet is installed at the bottom of the scraper body (4). An electromagnetic generator (6) matching the defoaming mesh belt (5) is installed inside the scraper body (4). When switching the type of slurry for production, the production control platform controls the production equipment to debug the production mode. During the debugging of the production mode, each slurry tank is sampled and tested. Before the sampling and testing of a single slurry tank, the next slurry tank is not filled. When filling, only the sampling chamber is filled until the sample in the slurry tank passes the test. At this time, the equipment can continuously fill slurry.

2. The ceramic sheet casting system according to claim 1, characterized in that, The laminating device includes a laminating mold, a pair of process edges are provided inside the laminating mold, and a pressure device is installed at both the upper and lower ends of the laminating mold.

3. The ceramic sheet casting system according to claim 1, characterized in that, The route specifications of the AVG trolley include an empty barrel area, a barrel waiting area, and a waiting point, with the waiting point located between the raw material processing equipment and the casting processing equipment.

4. A ceramic sheet casting process, comprising the ceramic sheet casting system of claim 1, characterized in that, The specific steps are as follows: A. Raw material pretreatment; A1, After the ceramic slurry is mixed with the dispersant and binder, it is stirred at a constant speed under vacuum; A2, after adding a quantitative amount of defoamer, repeat step A1 multiple times to complete the slurry pretreatment, and then fill the slurry into the slurry tank and seal it. B, Sampling and processing before casting; B1, raw ceramic pieces are obtained by sampling the slurry in the slurry tank and casting it. B2, green ceramic belt inspection; if the inspection is qualified, the pulp tank is put into production; if the inspection is unqualified, the auxiliary scraper is adjusted. If the inspection result is still unqualified after the equipment is adjusted, the pretreatment equipment will repeat step A2 to fill the new pulp tank. After filling, the new pulp tank repeats step B until the inspection result is qualified. If the equipment passes the inspection after adjustment, the auxiliary scraper at the casting equipment is adjusted simultaneously before proceeding to the next step. C, to carry out tape casting production; C1, using slurry in a slurry tank to cast green ceramic; C2, raw porcelain is cut and blanked to obtain raw porcelain slabs, and the raw porcelain slabs are fired to initially form the body; C3, layered co-firing, involves stacking multiple raw ceramic pieces and finally sintering them together to form the final shape.

5. The ceramic sheet casting process according to claim 4, characterized in that, The specific operation of the auxiliary scraper adjustment in B2 is as follows: adjust the scraper position to fit the upper surface of the slurry at the input end of the pre-casting equipment, and then turn on the electromagnetic generator (6) with the set power to make the defoaming mesh belt (5) vibrate and impact the air bubbles on the surface of the slurry.

6. The ceramic sheet casting process according to claim 4, characterized in that, When a single type of pulp is produced continuously, the production control platform controls the production equipment to operate in continuous production mode. In continuous production mode, the raw material processing equipment continuously fills pulp tanks and samples the continuously transported pulp tanks. If the sampling test fails, the production control platform switches the production mode to the debugging mode.

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