Adjustable Plate Flow Control for Honeycomb Extrusion
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Solution Overview
Problem
The existing methods for producing ceramic honeycomb bodies face challenges in adjusting the center-to-outer flow distribution of extrudate source material through an extrusion die, leading to defects such as uneven distribution and reduced production efficiency, as correcting these defects can be time-consuming and costly.
Innovation Solution
A system comprising a first plate with uniformly sized openings and a second plate with openings of varying radial positions, allowing for relative movement between the plates to adjust the flow distribution, ensuring consistent extrusion of honeycomb extrudate by controlling the overlap between corresponding openings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional extrusion die flow distribution control methods are used, then manufacturing simplicity is maintained, but manufacturing precision deteriorates due to inability to adjust center-to-outer flow distribution
Solution Approach 1:
The extrusion die flow control system is segmented into multiple adjustable components: a first plate with first openings, a second plate with second openings, and a third plate with third openings. Each plate can be independently adjusted to control flow distribution at different stages, enabling precise center-to-outer flow control without requiring a completely complex redesign of the entire extrusion die.
Solution Approach 2:
The system introduces dynamic adjustability by allowing relative movement between the plates (lateral translation or rotation) to change the overlap between corresponding openings. This dynamic adjustment capability enables real-time optimization of flow distribution patterns during production, transforming a static die structure into an adaptable system that can correct flow distribution issues on-the-fly.
2Manufacturing precision
If sequential production of honeycomb extrudate is maintained, then production continuity is preserved, but manufacturing precision deteriorates because defects cannot be corrected in real-time
Solution Approach 1:
The system incorporates inspection capabilities that provide feedback on the quality of honeycomb extrudate as it is being produced. This feedback loop enables real-time detection of defects such as voids or uneven distribution, allowing operators to adjust the plate positions or overlaps immediately to correct flow distribution issues before they affect subsequent extrudate, thereby maintaining both production continuity and manufacturing precision.
3Manufacturing precision
If fixed extrusion die design is used, then device simplicity is maintained, but manufacturing precision deteriorates due to inability to optimize flow distribution for different production requirements
Solution Approach 1:
The extrusion die system is designed with multi-functionality through the use of adjustable plates that can be repositioned to serve different production requirements. The same basic plate structure can be adjusted to optimize flow distribution for various honeycomb extrudate types, production volumes, or quality specifications, eliminating the need for multiple specialized dies while maintaining high manufacturing precision across different applications.
Data Source
AI summary
A system for controlling center-to-outer flow distribution of extrudate source material through an extrusion die suitable for production of a honeycomb extrudate, and a method for fabricating a honeycomb extrudate, are provided. Sequentially arranged first and second plates define first and second pluralities of openings through which extrudate source material may flow, wherein at least some openings of the second plurality of openings arranged at different radial positions differ in area. Relative movement between the first plate and the second plate may be effectuated to adjust overlap between corresponding openings of the plates, thereby adjusting a center-to-outer flow distribution of extrudate source material through an extrusion die arranged downstream of the first and second plates.