Method and system for preparing ceramic raw material

Abstract

Each of one or more ceramic raw materials placed in a container are mixed with round stones and a solvent by means of a rotation-revolution mixer. Alternatively, a manufacturing system including a plurality of devices including such a rotation-revolution mixer or other device and a robot system including one or more robots for at least one of the plurality of devices are operated by a computer in accordance with manufacturing recipe data that represents a ceramic manufacturing recipe, whereby one or more of a plurality of steps for preparing a ceramic raw material are automatically performed.

Description

Ceramic raw material blending method and blending system

[0001] The present invention relates generally to the preparation of ceramic raw materials.

[0002] In the process of producing ceramics (ceramic materials), ceramic raw materials are prepared, and the method disclosed in Patent Document 1 is known as a method of preparing ceramic raw materials. Note that "ceramics" refers to a general term for inorganic materials composed of polycrystals, but may also contain metals or organic compounds. Ceramics may also be composed of single crystals or may be amorphous, such as glass. In this specification, "ceramics" may be polycrystalline, single crystal, amorphous, or a mixture of these.

[0003] Japanese Patent Application Laid-Open No. 2022-006662

[0004] In the creation of ceramics, it is desirable to be able to mix ceramic raw materials quickly, or in other words, to shorten the time required to mix ceramic raw materials.

[0005] One or more types of ceramic raw materials contained in containers are mixed with the pebbles and solvent using a rotation-revolution mixer. Alternatively, a production system including a plurality of devices, including such a rotation-revolution mixer or other device, and a robot system including one or more robots for at least one of the plurality of devices, are operated by a computer in accordance with production recipe data representing a ceramic production recipe, thereby automatically performing one or more of the plurality of steps for blending the ceramic raw materials.

[0006] Ceramic raw materials can be mixed quickly.

[0007] 1 shows an example of a system configuration according to an embodiment of the present invention; 2 shows a part of the experimental system configuration and the flow of blending ceramic raw materials; 3 shows the rest of the experimental system configuration and the flow of blending ceramic raw materials.

[0008] In the following description, an "interface apparatus" may be one or more interface devices. The one or more interface devices may be at least one of the following: - One or more I / O (Input / Output) interface devices. The I / O (Input / Output) interface device is an interface device for at least one of an I / O device and a remote display computer. The I / O interface device for the display computer may be a communication interface device. The at least one I / O device may be a user interface device, for example, either an input device such as a keyboard and a pointing device, or an output device such as a display device. - One or more communication interface devices. The one or more communication interface devices may be one or more homogeneous communication interface devices (e.g., one or more NICs (Network Interface Cards)) or two or more heterogeneous communication interface devices (e.g., a NIC and an HBA (Host Bus Adapter)).

[0009] In the following description, the term "memory" refers to one or more memory devices, which are an example of one or more storage devices, and may typically be a primary storage device. At least one memory device in the memory may be a volatile memory device or a non-volatile memory device.

[0010] In the following description, a "persistent storage device" may refer to one or more persistent storage devices, which are an example of one or more storage devices. A persistent storage device may typically be a non-volatile storage device (e.g., an auxiliary storage device), and more specifically, may be, for example, a hard disk drive (HDD), a solid state drive (SSD), a non-volatile memory express (NVME) drive, or a storage class memory (SCM).

[0011] In the following description, the term "storage device" may refer to at least one of memory and persistent storage device.

[0012] In the following description, a "processor" may refer to one or more processor devices. The at least one processor device may typically be a microprocessor device such as a CPU (Central Processing Unit), but may also be another type of processor device such as a GPU (Graphics Processing Unit). The at least one processor device may be a single-core or multi-core device. The at least one processor device may also be a processor core. At least one processor device may be a processor device in a broad sense, such as a circuit that is a collection of gate arrays written in a hardware description language that performs part or all of the processing (for example, an FPGA (Field-Programmable Gate Array), a CPLD (Complex Programmable Logic Device), or an ASIC (Application Specific Integrated Circuit)).

[0013] Furthermore, in the following description, functions may be described using the expression "yyy unit." However, the functions may be realized by one or more computer programs executed by a processor, by one or more hardware circuits (e.g., FPGAs or ASICs), or by a combination thereof. When a function is realized by a program executed by a processor, the specified processing is performed using a storage device and / or an interface device, etc., as appropriate, and therefore the function may be considered to be at least a part of the processor. Processing described using a function as the subject may be processing performed by a processor or a device having the processor. A program may be installed from a program source. The program source may be, for example, a program distribution computer or a computer-readable recording medium (e.g., a non-transitory recording medium). The description of each function is an example, and multiple functions may be combined into one function, or one function may be divided into multiple functions.

[0014] In the following description, when elements of the same type are described without distinction, common reference symbols are used, and when elements of the same type are described with distinction, reference symbols are used.

[0015] An embodiment of the present invention will be described below with reference to the drawings. In the following description, "MI" stands for materials informatics, and "DB" stands for database.

[0016] 1 shows an example of a system configuration according to one embodiment of the present invention. Note that the description of this embodiment can be based on at least a portion of the disclosures in unpublished prior applications PCT / JP2023 / 009174 and PCT / JP2023 / 009175 filed by the same applicant as the present application. A brief description of FIG. 1 will be given below.

[0017] The material creation support system 10 includes an experiment system 110, a data acquisition unit 60, an MI platform system 100, and a researcher terminal 11 A. The MI platform system 100 includes a data presentation unit 50 and a data conversion unit 70.

[0018] The data presentation unit 50 has an AI (Artificial Intelligence) unit 108 and an IF (Interface) unit 109. The AI ​​unit 108 performs training of the machine learning model and inference using the machine learning model. For example, in response to instructions from the IF unit 109, the AI ​​unit 108 outputs to the IF unit 109 the inference results obtained by inputting organized data obtained from the data mart 107 into the machine learning model. The IF unit 109 receives inquiries from the researcher terminal 11A and presents target data to the researcher terminal 11A in response to the inquiries. The researcher terminal 11A is an information processing terminal (e.g., a personal computer or smartphone) of the materials researcher 5A (an example of a user). The researcher terminal 11A is an example of a sender of an inquiry for target data and also an example of a recipient of the target data. When receiving an inquiry from the researcher terminal 11A (or periodically), the IF unit 109 presents the object represented by the target data (organized data obtained from the data mart 107 and / or data based on inference results obtained by instructing the AI ​​unit 108). The presented object may be, for example, a manufacturing recipe or material properties. In this embodiment, a "manufacturing recipe" refers to a method for creating a material and typically includes a material composition and / or a synthesis process. A "material composition" may be, for example, a blending composition, and a "synthesis process" may refer to raw material types (e.g., different particle sizes) and process conditions. A manufacturing recipe may also include a material development strategy. A "material property" refers to the properties exhibited by a substance (e.g., a structure) as a material and may specifically include, for example, one or more property items (e.g., strength, thermal expansion coefficient, etc.) and values ​​(typically numerical values) for each of the one or more property items.

[0019] The materials researcher 5A creates new materials and conducts experiments based on the presented target data. The target data may be presented (transmitted) to a system such as the experiment system 110 instead of or in addition to the researcher terminal 11A.

[0020] An experiment is conducted using the experimental system 110 based on the presented subject. The experimental system 110 may include a ceramics production system 111 (e.g., an air-fired kiln), a robot system 187 for the production system 111, and a ceramics evaluation system 112 (e.g., a device for evaluating thermal expansion coefficients). Experimental data is output from the experimental devices, such as the production system 111 and the evaluation system 112. The output experimental data is transmitted to and stored in the data server 120. A combinatorial experiment is an example of an experiment, and at least one of a high-throughput experiment, an automated experiment using a robot, and an experiment mainly performed by human labor may be adopted instead of or in addition to a combinatorial experiment. The production system 111 and the robot system 187 may be operated by the MI platform system 100 according to the manufacturing recipe data.

[0021] The data acquisition unit 60 includes a data server 120 and an experiment notebook unit 130. The data server 120 has two databases for storing experimental data from the experiment system 110: a production database 121 for storing experimental data from the production system 111, and an evaluation database 122 for storing experimental data from the evaluation system 112. "Experimental data" may be data related to an experiment, such as a summary, details, results, or evaluation of the experiment. The experiment notebook unit 130 manages the experimental data acquired from the databases managed by the data server 120 as an electronic experiment notebook 131.

[0022] The data conversion unit 70 includes a collection unit 101, a feature calculation unit 103, an image analysis unit 104, a natural language analysis unit 105, and an organization unit 106. The collection unit 101 collects experimental data from the electronic experiment notebook 131 or the database of the data server 120, formats the collected experimental data, and stores the formatted experimental data in the data lake 102. Alternatively, the collection unit 101 collects various data 150 and stores at least a portion of the various data 150 in the data lake 102. The feature calculation unit 103 calculates the feature values ​​of one or more predetermined types of data in the formatted experimental data. For example, the one or more types of data may be image data and text data. The image data is analyzed by the image analysis unit 104, and the feature calculation unit 103 calculates the feature values ​​of the image data based on the results of the analysis. Furthermore, the text data is text-mined by the natural language analysis unit 105, and the feature calculation unit 103 calculates the feature values ​​of the text data based on the results of the text mining. The organizer 106 organizes the data lake 102 into one or more data marts 107 as data sets that meet predetermined conditions.

[0023] The system shown in FIG. 1 is expected to efficiently and quickly execute the cycle of presenting target data → conducting an experiment → collecting experimental data → converting the experimental data into organized data → presenting target data based on the organized data. For example, organized data is prepared based on experimental data collected and formatted in the MI platform system 100, and the target data is presented to the materials researcher 5A by the MI platform system 100 based on the organized data. Data presentation to the materials researcher 5A may also be performed without going through the MI platform system 100. For example, another materials researcher 5B may use the trainee terminal 11B to acquire experimental data from the electronic experiment notebook 131, organize the experimental data, and input it into the AI ​​unit 140. The AI ​​unit 140 may be implemented outside (or within) the trainee terminal 11B.

[0024] The MI platform system 100 provides target data, representing a ceramic manufacturing recipe, and performs experiments by generating ceramics (ceramic materials) according to the manufacturing recipe represented by the manufacturing recipe data. The generation of ceramics according to the manufacturing recipe includes blending ceramic raw materials. While at least some of the steps in blending the ceramic raw materials may be performed manually (e.g., by a materials researcher 5A), in this embodiment, the MI platform system 100 (an example of a computer system) automatically performs multiple steps for blending the ceramic raw materials by operating the manufacturing system 111 and the robot system 187 according to the manufacturing recipe data. This allows for rapid blending of ceramic raw materials. It is sufficient that at least one of the multiple steps is performed automatically. Alternatively, instead of generating the manufacturing recipe data, the MI platform system 100 may receive manufacturing recipe data from an external system and operate the manufacturing system 111 and the robot system 187 according to the received manufacturing recipe data. That is, a computer system such as the MI platform system 100 may generate or receive manufacturing recipe data and operate the fabrication system 111 and the robot system 187 according to the generated or received manufacturing recipe data.

[0025] 2 and 3 show the configuration of the experimental system 110 and the flow of blending ceramic raw materials.

[0026] In the manufacturing system 111, ceramics may be produced through processes such as raw material mixing (compounding of ceramic raw materials) → molding (molding of ceramic powder) → firing → processing, in accordance with the manufacturing recipe represented by the manufacturing recipe data 200. In the manufacturing system 111, at least the raw material mixing (compounding of ceramic raw materials) shown in the figure is performed.

[0027] The multiple steps for preparing the ceramic raw materials are the following five steps. In the following five steps, the second container may be the first container or a container separate from the first container. The third container may be the second container or a container separate from the second container. The fourth container may be the third container or a container separate from the third container. The fifth container may be the fourth container or a container separate from the fourth container. The sixth container may be a container separate from the fifth container. (A) A weighing and mixing step of weighing each of one or more ceramic raw materials 211, the solvent 213, and the pebbles 212, and placing the weighed one or more ceramic raw materials 211, the solvent 213, and one or more (typically multiple) pebbles 212 into the first container. (B) A wet mixing process in which one or more types of ceramic raw materials 211, a solvent 213, and one or more balls 212 are wet-mixed in a second container containing the one or more types of ceramic raw materials 211. (C) A drying process in which a slurry (raw materials 211 and solvent 213) obtained by wet mixing in a third container is dried. (D) A dry crushing process in which the dried raw materials (raw materials 290 (typically mixed raw materials) from which the solvent 213 has been evaporated) are crushed in a fourth container. (E) A ball separation process in which one or more balls 212 are separated from the crushed raw materials 290 in a fifth container to obtain ceramic powder in a sixth container.

[0028] These five steps enable rapid preparation of ceramic raw materials. While all five steps in this embodiment are performed manually, at least one of these five steps may be performed manually (e.g., at least a portion of the operations of the robot system 187 may be performed manually). Even if at least one step is performed manually, ceramic raw materials can be prepared quickly (e.g., faster than the comparative examples and modifications described below). Rapid preparation of ceramic raw materials contributes to the rapid creation of ceramics (ceramic materials). Specifically, for example, rapid preparation of ceramic raw materials enables rapid experiments using the ceramic raw materials. As a result, a large amount of experimental data can be accumulated in a short period of time, and this large amount of experimental data can be used to train and / or infer a machine learning model using a manufacturing recipe and material properties as input and output. In other words, further speedup and efficiency of the cycle of presenting target data → experiment → collecting experimental data → learning / inferencing a machine learning model using the experimental data → presenting target data is expected.

[0029] In this embodiment, all of the second to fifth containers are the first container, and the first container is the heat-resistant container 210. That is, in this embodiment, the process can be carried out up to the start of the boulder separation process without changing the container. Therefore, the process up to the start of the boulder separation process can be carried out without transferring the contents of the container, thereby contributing to the high-speed blending of ceramic raw materials. Furthermore, since the container is placed in the dryer 203 as described below (so that it can be used even when the slurry drying temperature is increased), it must be heat-resistant. For example, the heat-resistant container 210 made of Teflon (registered trademark), nylon, or the like is preferable.

[0030] The robots in the robot system 187 may be collaborative robots or other robots (e.g., industrial robots). Furthermore, a robot may be provided for each device in the manufacturing system 111, or one robot may be shared by two or more devices in the manufacturing system 111. The robots in the robot system 187 receive requests directly or indirectly from the MI platform system 100, for example, via a communication network, and operate in accordance with the received requests. In the case where a request is received indirectly, a control device of at least one robot may receive a request from the MI platform system 100 and issue a request based on the received request to the at least one robot. In the case where a request is received directly, a request may be received from the MI platform system 100 without passing through such a control device. Hereinafter, for simplicity of explanation, it is assumed that a request according to the manufacturing recipe data 200 is received from the MI platform system 100 for each robot in the robot system 187, regardless of whether the request is received directly or indirectly. Furthermore, the robot system 187 operates regardless of whether any of the one or more robots in the robot system 187 operates. The robot may send a notification (e.g., a status notification such as completion of the request) to the MI platform system 100 at the start or completion of an operation according to a request.

[0031] The multiple devices in the production system 111 include an automatic weighing machine 201, a rotation-revolution mixer 202 (an example of a wet mixer and a crusher), a dryer 203, and a boulder separator 204. Each of these devices 201-204 receives a request from the MI platform system 100 directly or indirectly, for example, via a communication network, and operates in accordance with the received request. In the case where a request is received indirectly, a control device of at least one of the devices 201-204 may receive a request from the MI platform system 100 and issue a request based on the request to the at least one device. In the case where a request is received directly, a request may be received from the MI platform system 100 without passing through such a control device. For simplicity of explanation, it is assumed below that a request according to the manufacturing recipe data 200 is received from the MI platform system 100 for each device in the production system 111, regardless of whether the request is received directly or indirectly. The device in the production system 111 may send a notification (e.g., a status notification such as completion of the request) to the MI platform system 100 at the timing of starting or completing an operation according to the request.

[0032] In the weighing and mixing step, the robot system 187 sets the heat-resistant container 210 on the automatic weighing machine 201. The automatic weighing machine 201 weighs each of the one or more ceramic raw materials 211, the solvent 213, and the pebbles 212 according to one or more parameter values ​​related to weighing and / or mixing included in the manufacturing recipe represented by the manufacturing recipe data 200, and places the weighed one or more ceramic raw materials 211, the solvent 213, and the one or more pebbles 212 into the heat-resistant container 210. The robot system 187 removes the heat-resistant container 210 from the automatic weighing machine 201. According to the example shown in FIG. 2 , there are three types of ceramic raw materials 211A, 211B, and 211C.

[0033] The "one or more parameter values ​​related to weighing and / or mixing included in the manufacturing recipe" may be specified in a request received by the automatic weighing machine 201 from the MI platform system 100. The "one or more parameter values" may include at least one of the name and weight of each type of ceramic raw material 211, the name and weight of the solvent 213, and the name and weight of the beads 212. The solvent 213 may be an alcohol such as IPA (isopropyl alcohol). The beads 212 must be heat-resistant because they are placed in the dryer 203 as described below. For example, the one or more beads 212 may be at least one of alumina balls, zirconia balls, and nylon balls. While there are no limitations on the type of solvent 213, when using a cohesive material, ethanol or IPA, which has high dispersibility, is preferred as the solvent 213. There is no limitation on the type of balls 212, but examples of balls 212 include stainless steel, steel, carbon steel, chromium steel, tungsten carbide balls, silicon nitride, natural silica, SiC, agate (silicon oxide), polyurethane, Teflon, quartz, etc., and nylon balls are particularly preferred when it is desired to avoid the inclusion of impurities.

[0034] In the wet mixing step, the robot system 187 sets the heat-resistant container 210 (heat-resistant container 210 containing one or more types of ceramic raw materials 211, a solvent 213, and one or more balls 212) removed in the weighing and mixing step in the rotation-revolution mixer 202. The rotation-revolution mixer 202 wet-mixes (agitates) the one or more types of ceramic raw materials 211 in the heat-resistant container 210 according to one or more parameter values ​​related to wet mixing included in the manufacturing recipe. The robot system 187 removes the heat-resistant container 210 from the rotation-revolution mixer 202. In this step, the opening of the heat-resistant container 210 may or may not be covered with a lid.

[0035] The "one or more parameter values ​​related to wet mixing included in the manufacturing recipe" may be specified in a request received by the rotation-revolution mixer 202 from the MI platform system 100. The "one or more parameter values" may include at least one of the rotation speed of the rotation-revolution mixer 202 (e.g., the number of rotations per unit time) and the length of rotation time. Furthermore, although wet mixing may be performed using a ball mill or the like instead of the rotation-revolution mixer 202, employing the rotation-revolution mixer 202 as a wet mixing device contributes to high-speed blending of ceramic raw materials.

[0036] In the drying step, the robot system 187 places the heat-resistant container 210 removed in the wet mixing step in the dryer 203. The dryer 203 dries the slurry in the heat-resistant container 210 in accordance with one or more drying parameter values ​​included in the manufacturing recipe. That is, the slurry is dried together with the boulders 212. The robot system 187 removes the heat-resistant container 210 from the dryer 203. By drying the slurry and the boulders 212 together, dry crushing can be performed directly in the next step (without the need to transfer the contents of the container). Note that any drying method that can evaporate the solvent may be used, and for example, any of nitrogen gas drying, vacuum drying, atmospheric drying, microwave drying, induction heating drying, and heating drying using a hot plate may be used.

[0037] The "one or more parameter values ​​related to drying included in the recipe" may be specified in a request received by the dryer 203 from the MI platform system 100. The "one or more parameter values" may include all or part of the parameters related to the operation of the dryer 203, and may include, for example, at least one of the drying time, drying temperature (e.g., temperature per hour from the start of drying), the number of heat-resistant containers 210 to be set, carrier gas, gas flow rate, and vacuum level. The dryer 203 may have space for multiple heat-resistant containers 210. Therefore, the drying process may be performed after the weighing and mixing process and the wet mixing process are performed for multiple heat-resistant containers 210. Both the weighing and mixing process and the wet mixing process may be performed in parallel for multiple heat-resistant containers 210.

[0038] In the dry crushing step, the robot system 187 sets the heat-resistant container 210 removed in the drying step in the rotation / revolution mixer 202. The rotation / revolution mixer 202 crushes the raw material in the heat-resistant container 210 in accordance with one or more parameter values ​​related to dry crushing included in the manufacturing recipe. The robot system 187 removes the heat-resistant container 210 from the rotation / revolution mixer 202. In this step, the opening of the heat-resistant container 210 may or may not be covered with a lid.

[0039] The "one or more parameter values ​​related to dry crushing included in the manufacturing recipe" may be specified in a request received by the rotational / revolutionary mixer 202 from the MI platform system 100. The "one or more parameter values" may include at least one of the rotational / revolutionary mixer 202 rotation speed (e.g., the number of rotations per unit time) and the rotation time length. Dry crushing may be performed by another crushing device instead of the rotational / revolutionary mixer 202, but employing the rotational / revolutionary mixer 202 as a crushing device contributes to high-speed blending of ceramic raw materials. A rotational / revolutionary mixer 202 as a crushing device may be provided separately from the rotational / revolutionary mixer 202 as a wet mixing device, but using the rotational / revolutionary mixer 202 to perform both wet mixing and crushing can conserve equipment resources.

[0040] In the boulder separation step, the robot system 187 sets the heat-resistant container 210 removed in the dry crushing step in the boulder separator 204. The heat-resistant container 210 contains a mixture of crushed raw material 290 and one or more boulders 212. The boulder separator 204 separates the one or more boulders 212 from the crushed raw material 290 in the heat-resistant container 210. As a result, ceramic powder, which is the crushed raw material 290, enters a receiving container 270 (an example of a sixth container). The receiving container 270 is removed from the boulder separator 204 by the robot system 187. In this step, if a lid is placed on the opening of the removed heat-resistant container 210, the robot system 187 may remove the lid and then set the heat-resistant container 210 in the boulder separator 204. Alternatively, the boulder separator 204 may be omitted, and the above-described operation of the boulder separator 204 may be performed by the robot system 187.

[0041] Specifically, in the boulder separation process, the robot system 187 sets a jig 271 having a net 300 on the heat-resistant container 210 and the receiving container 270 so that the net 300 is sandwiched between the opening of the heat-resistant container 210 and the opening of the receiving container 270. At this point, the receiving container 270 is above the heat-resistant container 210. The jig 271 fixes the heat-resistant container 210 and the receiving container 270. For example, the jig 271 has a fixing member 301 on the periphery of the net 300, to which at least a portion of the opening periphery (e.g., flange) of the heat-resistant container 210 and at least a portion of the opening periphery (e.g., flange) of the receiving container 270 are set. The robot system 187 or the boulder separation device 204 turns the heat-resistant container 210 and the receiving container 270 fixed to the jig 271 upside down. In other words, when the receiving container 270 is placed below the heat-resistant container 210 via the mesh 300, the balls 212 fall onto the mesh 300, and the crushed raw material 290 falls as ceramic powder into the receiving container 270 through the mesh 300. To increase separation efficiency, the robot system 187 or the ball separator 204 may vibrate the heat-resistant container 210 fixed to the jig 271. The mesh 300 is a sieve, filter, mesh, or the like, and is an example of a means for physically separating one or more balls 212 from the crushed raw material 290. Therefore, the mesh size is set to a size that prevents the balls 212 from passing through, regardless of their orientation. The material of the mesh 300 (sieve, filter, mesh, etc.) is not limited as long as it can separate the balls. For example, the material may be stainless steel, nylon, Sunline, polyamide, polyester, or fluororesin.

[0042] As described above, the wet mixing step is followed by the drying step, and then the dry crushing step and the boulder separation step are carried out, thereby enabling the ceramic raw material to be mixed at high speed.

[0043] Data representing the performance of the robot system 187 and the production system 111 and the details of the actual mixing of raw materials (e.g., actual weighing values, drying times, start times and end times of each process, etc.) is recorded in the production DB 11 by at least one of the robot system 187, the production system 111, and other devices. At least a portion of the data may be components of the experimental data.

[0044] The heat-resistant container 210 and / or the receiving container 270 may have a label for identifying the container. This allows the container 210 or 270 (specifically, for example, the contents of the container 210 or 270) to be identified from the label. For example, the label may record a recipe or a summary thereof instead of or in addition to the container ID.

[0045] As a comparative example, there is a ceramic raw material preparation method that includes the following six steps: (1) a weighing and mixing step in which each of one or more types of ceramic raw materials, a solvent, and pebbles is manually weighed, and the weighed one or more types of ceramic raw materials, solvent, and one or more pebbles are manually placed in a first container; and (2) a wet mixing step in which a second container containing one or more types of ceramic raw materials, a solvent, and one or more pebbles is manually placed in a wet mixing device (e.g., a ball mill), the second container containing one or more types of ceramic raw materials, a solvent, and one or more pebbles is wet-mixed in the wet mixing device, and the second container is manually removed from the wet mixing device. (3) A cobble slurry separation process in which a third container containing one or more cobble stones and a slurry obtained by wet mixing is manually set in a cobble slurry separator, the cobble stone slurry separator separates one or more cobble stones from the slurry to obtain a slurry in a fourth container, and the fourth container is manually removed from the cobble stone slurry separator. (4) A drying process in which a fifth container containing the slurry is manually set in a dryer, the dryer dries the slurry in the fifth container, and the fifth container is manually removed from the dryer. (5) A crushing process in which the raw material resulting from the solvent volatilizing from the slurry by drying is manually placed in a mortar and crushed with a pestle. (6) A sieving process in which the crushed raw material is manually transferred from the mortar to a sieve and the crushed raw material is manually rubbed against the sieve with a spatula or other object to obtain ceramic powder.

[0046] In this comparative example, the second container may be the first container or a container separate from the first container, and the third container may be the second container or a container separate from the second container (i.e., the first container may be used until the start of the cobble slurry separation process). The fourth container is a container separate from the third container. The fifth container may be the fourth container or a container separate from the fourth container. The mortar is a container separate from the fifth container. Thus, in the comparative example, unlike the embodiment, multiple container changes are required, and manual work is required.

[0047] There may be a variation in which at least some of the six steps in the comparative example are automated. Specifically, for example, the multiple devices in the production system 111 may include an automatic weighing machine, a wet mixer, a boulder slurry separator, a dryer, a crusher, and a sieving machine. The multiple steps may be the following six steps. Furthermore, the automatic weighing machine described below may be the same as the automatic weighing machine 201, and at least a part of the robot system may be the same as at least a part of the robot system 187. (a) A weighing and mixing step in which a first container is set in the automatic weighing machine by the robot system, and the automatic weighing machine weighs each of one or more ceramic raw materials, a solvent, and boulders according to one or more parameter values ​​related to weighing and / or mixing included in the manufacturing recipe, and places the weighed one or more ceramic raw materials, the solvent, and one or more boulders into the first container, and the robot system removes the first container from the automatic weighing machine. (b) a wet mixing step of setting a second container containing one or more ceramic raw materials, a solvent, and one or more balls in a wet mixing device (e.g., a ball mill) using a robot system, wet-mixing the second container containing one or more ceramic raw materials, the solvent, and one or more balls using the wet mixing device in accordance with one or more parameter values ​​related to wet mixing included in the manufacturing recipe, and removing the second container from the wet mixing device using the robot system; (c) a ball slurry separation step of setting a third container containing one or more balls and a slurry obtained by wet mixing in a ball slurry separator using the robot system, separating the one or more balls from the slurry using the ball slurry separator in accordance with one or more parameter values ​​related to ball slurry separation included in the manufacturing recipe to obtain a slurry in a fourth container, and removing the fourth container from the ball slurry separator using the robot system. (d) a drying step of loading the fifth container having the slurry into a dryer using a robotic system, drying the slurry in the fifth container using the dryer according to one or more parameter values ​​related to drying included in the recipe, and removing the fifth container from the dryer using the robotic system.(e) a crushing step in which a robot system is used to set a sixth container (e.g., a mortar) containing raw material resulting from evaporation of the solvent from the slurry by drying to a crushing device, and the crushing device crushes the raw material in accordance with one or more crushing parameter values ​​included in the manufacturing recipe and photographed images of the raw material in the sixth container, and the robot system is used to remove the sixth container from the crushing device; (f) a sieving step in which a robot system is used to set a seventh container to a sieving device, and the sieving device sieves the raw material (e.g., by rubbing a spatula or other member against the sieve) in accordance with one or more sieving parameter values ​​included in the manufacturing recipe and photographed images of the crushed raw material (e.g., the raw material in the sieve) to obtain ceramic powder in the seventh container.

[0048] In this modification, the second container may be the first container or a container separate from the first container, and the third container may be the second container or a container separate from the second container (i.e., the first container may be used until the start of the cobble slurry separation process). The fourth container is a container separate from the third container. The fifth container may be the fourth container or a container separate from the fourth container. The sixth container is a container separate from the fifth container, and the seventh container is a container separate from the sixth container. In this modification, unlike the embodiment, multiple container replacement is required.

[0049] In addition, in the modified example, in the crushing and sieving steps, it is desirable to refer to visual information for crushing or sieving the areas where powder has accumulated (for example, by rubbing a mortar or spatula against the area, or by moving powder that has accumulated at the edges toward the center, etc.), and the crushing and sieving steps are performed by referring to images captured by a camera as the visual information. In the embodiment, it is not necessary to refer to such visual information (for example, captured images), and therefore it is expected that the configuration and function of the device for performing the steps will be simpler than in the comparative example and modified example.

[0050] Although one embodiment has been described above, this is merely an example for explaining the present invention, and the scope of the present invention is not limited to this embodiment. The present invention can be implemented in various other forms.

[0051] For example, a method according to one aspect for rapidly compounding ceramic raw materials involves operating a production system (e.g., production system 111) including a plurality of devices and a robot system (e.g., robot system 187) including one or more robots for at least one of the plurality of devices by a computer in accordance with production recipe data representing a ceramic production recipe, thereby automatically performing at least one or more steps among a plurality of steps for compounding ceramic raw materials.

[0052] The method according to any one or more of the other aspects can contribute to the rapid preparation of ceramic raw materials. Specifically, for example, according to the method according to another aspect, by mixing one or more types of ceramic raw materials, one or more balls, and a solvent contained in a container using a planetary mixer, the method can contribute to the rapid preparation of ceramic raw materials. For example, even if a wet mixing process is simply employed as a process, the method can contribute to the rapid preparation of ceramic raw materials.

[0053] More specifically, for example, the multiple steps may be the following five steps. One or more of the following five steps may be performed automatically by operating the device with a robot. Furthermore, in the following, the third container may be the second container, and the second container may be a heat-resistant container. The fourth container may be the third container or a container separate from the third container. The fifth container may be the fourth container or a container separate from the fourth container. The sixth container may be a container separate from the fifth container. (A) A weighing and mixing step of weighing each of one or more ceramic raw materials and a solvent, and placing one or more balls, the weighed one or more ceramic raw materials, and the solvent into a first container. (B) A wet mixing step of wet-mixing one or more ceramic raw materials in a second container containing one or more ceramic raw materials, a solvent, and one or more balls using a rotation-revolution mixer. (C) a drying step of drying the slurry obtained by wet mixing in the third vessel, (D) a dry crushing step of crushing the dried raw material in the fourth vessel, and (E) a ball separation step of separating the one or more balls from the crushed raw material in the fifth vessel to obtain ceramic powder in a sixth vessel.

[0054] For example, the same heat-resistant container may be used in steps (B) to (E) without replacement, and a rotation-revolution mixer may be used in step (B) and a rotation-revolution mixer may be used in step (D). The rotation-revolution mixers used in steps (B) and (D) may be the same.

[0055] 10...Material creation support system 100...MI platform system 111...Fabrication system 187...Robot system

Claims

1. A method for preparing ceramic raw materials, comprising: a first step of placing each of one or more types of ceramic raw materials, one or more boulders, and a solvent in a first container; and a second step of mixing the one or more types of ceramic raw materials, the one or more boulders, and the solvent contained in a second container using a rotation-revolution mixer, wherein the second container is the first container or a container separate from the first container.

2. A method for preparing ceramic raw materials as set forth in claim 1, wherein at least one or more steps out of a plurality of steps for preparing ceramic raw materials, including the first step and the second step, are automatically performed by operating a production system including a plurality of devices including the rotation / revolution mixer, and a robot system including one or more robots for at least one of the plurality of devices, by a computer in accordance with production recipe data representing a ceramic production recipe.

3. A method for preparing ceramic raw materials, comprising: operating a production system including a plurality of devices; and a robot system including one or more robots for at least one of the plurality of devices by a computer in accordance with recipe data representing a ceramic manufacturing recipe, thereby automatically performing at least one or more steps among a plurality of steps for preparing ceramic raw materials, the plurality of steps being the following five steps: (A) a weighing and mixing step of weighing each of one or more types of ceramic raw materials, a solvent, and pebbles, and placing the weighed one or more types of ceramic raw materials, the solvent, and the one or more pebbles in a first container; (B) a wet mixing step of wet-mixing the one or more types of ceramic raw materials in a second container containing the one or more types of ceramic raw materials, the solvent, and the one or more pebbles; (C) a drying step of drying a slurry obtained by wet mixing in a third container; and (D) a dry crushing step of crushing the dried raw materials in a fourth container. (E) a boulder separating step of obtaining ceramic powder in a sixth container by separating the one or more boulders from the crushed raw material in a fifth container, the second container being the first container or a container separate from the first container, the second container being a heat-resistant container, the third container being the second container, the fourth container being the third container or a container separate from the third container, the fifth container being the fourth container or a container separate from the fourth container, and the sixth container being a container separate from the fifth container, and the drying step being a drying step of drying the slurry and the boulders in the heat-resistant container together.

4. The method for preparing ceramic raw materials according to claim 3, wherein in the dry crushing step, the slurry is crushed using the heat-resistant container containing the slurry and the boulders that have been dried together.

5. The method for preparing ceramic raw materials according to claim 4, wherein all of the second to fifth containers are the first container, and the first container is a heat-resistant container.

6. A method for preparing ceramic raw materials, comprising: operating a production system including a plurality of devices; and a robot system including one or more robots for at least one of the plurality of devices by a computer in accordance with recipe data representing a ceramic manufacturing recipe, thereby automatically performing at least one or more steps among a plurality of steps for preparing ceramic raw materials, the plurality of steps being the following five steps: (A) a weighing and mixing step of weighing each of one or more types of ceramic raw materials, a solvent, and pebbles, and placing the weighed one or more types of ceramic raw materials, the solvent, and the one or more pebbles in a first container; (B) a wet mixing step of wet-mixing the one or more types of ceramic raw materials in a second container containing the one or more types of ceramic raw materials, the solvent, and the one or more pebbles; (C) a drying step of drying a slurry obtained by wet mixing in a third container; and (D) a dry crushing step of crushing the dried raw materials in a fourth container. (E) a marble separating step of obtaining ceramic powder in a sixth container by separating the one or more marbles from the crushed raw material in the fifth container; all of the second to fifth containers are the first container, the first container is a heat-resistant container, and the sixth container is a container different from the first to fifth containers.

7. A method for preparing ceramic raw materials, comprising: operating a production system including a plurality of devices; and a robot system including one or more robots for at least one of the plurality of devices by a computer in accordance with recipe data representing a ceramic manufacturing recipe, thereby automatically performing at least one or more steps among a plurality of steps for preparing ceramic raw materials, the plurality of steps being the following five steps: (A) a weighing and mixing step of weighing each of one or more types of ceramic raw materials, a solvent, and pebbles, and placing the weighed one or more types of ceramic raw materials, the solvent, and the one or more pebbles in a first container; (B) a wet mixing step of wet-mixing the one or more types of ceramic raw materials in a second container containing the one or more types of ceramic raw materials, the solvent, and the one or more pebbles; (C) a drying step of drying a slurry obtained by wet mixing in a third container; and (D) a dry crushing step of crushing the dried raw materials in a fourth container. (E) a boulder separating step of obtaining ceramic powder in a sixth container by separating the one or more boulders from the crushed raw material in the fifth container; all of the second to fifth containers are the first container, the first container is a heat-resistant container, and the sixth container is a container separate from the first to fifth containers; and in the drying step, the slurry and the boulders in the heat-resistant container are dried together.

8. A method for preparing ceramic raw materials, comprising: operating a production system including a plurality of devices; and a robot system including one or more robots for at least one of the plurality of devices by a computer in accordance with recipe data representing a ceramic manufacturing recipe, thereby automatically performing at least one or more steps among a plurality of steps for preparing ceramic raw materials, the plurality of steps being the following five steps: (A) a weighing and mixing step of weighing each of one or more types of ceramic raw materials, a solvent, and pebbles, and placing the weighed one or more types of ceramic raw materials, the solvent, and the one or more pebbles in a first container; (B) a wet mixing step of wet-mixing the one or more types of ceramic raw materials in a second container containing the one or more types of ceramic raw materials, the solvent, and the one or more pebbles; (C) a drying step of drying a slurry obtained by wet mixing in a third container; and (D) a dry crushing step of crushing the dried raw materials in a fourth container. (E) a marble separating step of obtaining ceramic powder in a sixth container by separating the one or more marbles from the crushed raw material in a fifth container, the second container being the first container or a container separate from the first container, the third container being the second container or a container separate from the second container, the fourth container being the third container or a container separate from the third container, the fifth container being the fourth container or a container separate from the fourth container, and the sixth container being a container separate from the fifth container, and at least one of the wet mixing device used in the wet step and the crushing device used in the dry crushing step is a planetary centrifugal mixer.

9. The plurality of devices include an automatic weighing machine, a wet mixing machine, a dryer, and a crushing machine, and in the weighing and mixing step, the heat-resistant container is set in the automatic weighing machine by the robot system, and the automatic weighing machine weighs each of the one or more ceramic raw materials, the solvent, and the pebbles according to one or more parameter values ​​related to weighing and / or mixing included in the manufacturing recipe, and the weighed one or more ceramic raw materials, the solvent, and the one or more pebbles are placed in the heat-resistant container, and the heat-resistant container is removed from the automatic weighing machine by the robot system; in the wet mixing step, the heat-resistant container removed by the robot system in the weighing and mixing step is set in the wet mixing device by the robot system, and the one or more ceramic raw materials in the heat-resistant container are wet-mixed according to one or more parameter values ​​related to wet mixing included in the manufacturing recipe, and the heat-resistant container is removed from the wet mixing device by the robot system; 4. The method for preparing a ceramic raw material according to claim 3, wherein in the drying step, the heat-resistant container taken out by the robot system in the wet mixing step is set in the dryer by the robot system, the dryer dries the slurry in the heat-resistant container according to one or more parameter values ​​related to drying included in the manufacturing recipe, and the heat-resistant container is taken out of the dryer by the robot system; in the dry crushing step, the heat-resistant container taken out by the robot system in the drying step is set in the crushing device by the robot system, the raw materials in the heat-resistant container are crushed by the crushing device according to one or more parameter values ​​related to dry crushing included in the manufacturing recipe, and the heat-resistant container is taken out of the crushing device by the robot system; and in the boulder separating step, the heat-resistant container taken out by the robot system in the dry crushing step is set by the robot system, and the one or more boulders are separated from the crushed raw materials in the heat-resistant container.

10. The plurality of devices include an automatic weighing machine, a wet mixing device, a dryer, and a crushing device, and in the weighing and mixing step, the heat-resistant container is set in the automatic weighing machine by the robot system, and the one or more types of ceramic raw materials, the solvent, and the pebbles are weighed by the automatic weighing machine according to one or more parameter values ​​related to weighing and / or mixing included in the manufacturing recipe, and the weighed one or more types of ceramic raw materials, the solvent, and the one or more pebbles are placed in the heat-resistant container, and the heat-resistant container is removed from the automatic weighing machine by the robot system, In the wet mixing step, the heat-resistant container taken out by the robot system in the weighing and mixing step is set in the wet mixing device by the robot system, the one or more types of ceramic raw materials in the heat-resistant container are wet-mixed by the wet mixing device according to one or more parameter values ​​related to wet mixing included in the manufacturing recipe, and the heat-resistant container is taken out from the wet mixing device by the robot system; in the drying step, the heat-resistant container taken out by the robot system in the wet mixing step is set in the dryer by the robot system, the slurry in the heat-resistant container is dried by the dryer according to one or more parameter values ​​related to drying included in the manufacturing recipe, and the heat-resistant container is taken out from the dryer by the robot system; 7. The method for preparing ceramic raw materials according to claim 6, wherein in the dry crushing step, the heat-resistant container taken out by the robot system in the drying step is set in the crushing device by the robot system, the raw materials in the heat-resistant container are crushed by the crushing device according to one or more parameter values ​​related to dry crushing included in the manufacturing recipe, and the heat-resistant container is taken out of the crushing device by the robot system; and in the boulder separating step, the heat-resistant container taken out by the robot system in the dry crushing step is set by the robot system, and the one or more boulders are separated from the crushed raw materials in the heat-resistant container.

11. A manufacturing system including a plurality of devices and a robot system including one or more robots for at least one of the plurality of devices are operated by a computer in accordance with manufacturing recipe data representing a ceramic manufacturing recipe, thereby automatically performing one or more steps among a plurality of steps for preparing ceramic raw materials, the plurality of devices including an automatic weighing machine, a wet mixing machine, a boulder slurry separating machine, a dryer, a crushing machine, and a sieving machine, the plurality of steps being the following six steps: (a) a weighing and mixing step of setting a first container in the automatic weighing machine by the robot system, weighing each of one or more types of ceramic raw materials, a solvent, and boulders by the automatic weighing machine in accordance with one or more parameter values ​​related to weighing and / or mixing included in the manufacturing recipe, placing the weighed one or more types of ceramic raw materials, the solvent, and one or more boulders into the first container, and removing the first container from the automatic weighing machine by the robot system; (b) a wet mixing step of setting a second container containing the one or more ceramic raw materials, the solvent, and the one or more granules in the wet mixing device by the robot system, wet-mixing the second container containing the one or more ceramic raw materials, the solvent, and the one or more granules in the wet mixing device according to one or more parameter values ​​related to wet mixing included in the manufacturing recipe, and removing the second container from the wet mixing device by the robot system; (c) a boulder slurry separation step of setting a third container containing the one or more granules and a slurry obtained by wet mixing in the boulder slurry separation device by the robot system, obtaining the slurry in a fourth container by separating the one or more granules from the slurry in the boulder slurry separation device according to one or more parameter values ​​related to boulder slurry separation included in the manufacturing recipe, and removing the fourth container from the boulder slurry separation device by the robot system;(d) a drying step of setting a fifth container having the slurry in the dryer by the robot system, drying the slurry in the fifth container by the dryer according to one or more parameter values ​​related to drying included in the manufacturing recipe, and removing the fifth container from the dryer by the robot system; (e) a crushing step of setting a sixth container having the dried raw material in the crushing device by the robot system, crushing the dried raw material in the crushing device according to one or more parameter values ​​related to crushing included in the manufacturing recipe and a photographed image of the raw material in the sixth container, and removing the sixth container from the crushing device by the robot system; (f) a sieving step of setting a seventh container in the sieving device by the robot system, and sieving the raw material in the sieving device according to one or more parameter values ​​related to sieving included in the manufacturing recipe and a photographed image of the crushed raw material to obtain ceramic powder in the seventh container; The second container is the first container or a container separate from the first container, the third container is the second container or a container separate from the second container, the fourth container is a container separate from the third container, the fifth container is the fourth container or a container separate from the fourth container, the sixth container is a container separate from the fifth container, and the seventh container is a container separate from the sixth container, 12. A ceramic raw material preparation system comprising: a production system including a plurality of devices including a rotation / revolution mixer; a robot system including one or more robots for at least one of the plurality of devices; and a computer system that performs one or more of a plurality of steps for preparing ceramic raw materials by operating the production system and the robot system in accordance with production recipe data representing a ceramic production recipe, wherein the plurality of steps include a first step of placing each of one or more types of ceramic raw materials, pebbles, and a solvent in a first container; and a second step of mixing the one or more types of ceramic raw materials, the pebbles, and the solvent in a second container by the rotation / revolution mixer, wherein the second container is the first container or a container separate from the first container.

13. A manufacturing system including a plurality of devices; a robot system including one or more robots for at least one of the plurality of devices; and a computer system for operating the manufacturing system and the robot system according to manufacturing recipe data representing a ceramic manufacturing recipe, thereby performing at least one or more steps among a plurality of steps for preparing ceramic raw materials, wherein the plurality of devices include an automatic weighing machine, a wet mixing machine, a boulder slurry separating machine, a dryer, a crushing machine, and a sieving machine, and the plurality of steps are the following six steps: (a) a weighing and mixing step of setting a first container in the automatic weighing machine by the robot system, weighing each of one or more types of ceramic raw materials, a solvent, and boulders by the automatic weighing machine according to one or more parameter values ​​related to weighing and / or mixing included in the manufacturing recipe, placing the weighed one or more types of ceramic raw materials, the solvent, and the one or more boulders into the first container, and removing the first container from the automatic weighing machine by the robot system; (b) a wet mixing step of setting a second container containing the one or more ceramic raw materials, the solvent, and the one or more granules in the wet mixing device by the robot system, wet-mixing the second container containing the one or more ceramic raw materials, the solvent, and the one or more granules in the wet mixing device according to one or more parameter values ​​related to wet mixing included in the manufacturing recipe, and removing the second container from the wet mixing device by the robot system; (c) a boulder slurry separation step of setting a third container containing the one or more granules and a slurry obtained by wet mixing in the boulder slurry separation device by the robot system, obtaining the slurry in a fourth container by separating the one or more granules from the slurry in the boulder slurry separation device according to one or more parameter values ​​related to boulder slurry separation included in the manufacturing recipe, and removing the fourth container from the boulder slurry separation device by the robot system;(d) a drying step of setting a fifth container having the slurry in the dryer by the robot system, drying the slurry in the fifth container by the dryer according to one or more parameter values ​​related to drying included in the manufacturing recipe, and removing the fifth container from the dryer by the robot system; (e) a crushing step of setting a sixth container having the dried raw material in the crushing device by the robot system, crushing the dried raw material in the crushing device according to one or more parameter values ​​related to crushing included in the manufacturing recipe and a photographed image of the raw material in the sixth container, and removing the sixth container from the crushing device by the robot system; (f) a sieving step of setting a seventh container in the sieving device by the robot system, and sieving the raw material in the sieving device according to one or more parameter values ​​related to sieving included in the manufacturing recipe and a photographed image of the crushed raw material to obtain ceramic powder in the seventh container; A ceramic raw material mixing system, wherein the second container is the first container or a container separate from the first container, the third container is the second container or a container separate from the second container, the fourth container is a container separate from the third container, the fifth container is the fourth container or a container separate from the fourth container, the sixth container is a container separate from the fifth container, and the seventh container is a container separate from the sixth container.

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