Compressed Air Injection for Ceramic Slip Level Control

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Current continuous mills for grinding ceramic materials in water suspension face challenges in maintaining a stable filling level, leading to energy inefficiency and inconsistent product characteristics due to fluctuations in the slip level, which existing control systems partially address but require periodic interruptions in slip infeed.

Innovation Solution

A compressed-air injection device and integrated control system that allows for controlled introduction of compressed air to stabilize the filling level by adjusting air and slip ratios, enabling continuous operation without interrupting the slip infeed, and setting preset times and frequencies for air injection based on power input data.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If the filling level is maintained above the rotation axis to reduce energy consumption, then energy efficiency is improved, but the slip level fluctuates causing inconsistent product characteristics

Engineering Contradiction:

Improveenergy consumptionVSAvoidslip level stability

Core Design Contradiction:

Use of energy by moving objectVSStability of the object's composition

Solution Approach 1:

The control system continuously monitors the power input of the motor and automatically activates the compressed air injection device when power consumption exceeds a predetermined threshold, thereby maintaining the filling level within optimal ranges and ensuring consistent product characteristics while energy efficiency is improved

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

Compressed air is injected into the rotating body through a dedicated injection device to increase the filling level of slip, allowing the system to maintain optimal processing conditions above the rotation axis without excessive fluctuations, thus resolving the contradiction between energy efficiency and stability

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Power

If the filling level is increased to optimize power input, then power consumption is reduced, but the grinding effect is reduced

Engineering Contradiction:

Improvepower inputVSAvoidgrinding effect

Core Design Contradiction:

PowerVSProductivity

Solution Approach 1:

The system dynamically adjusts the filling level by injecting compressed air only when power consumption exceeds a threshold, maintaining the filling level within an optimal range that balances power efficiency and grinding effectiveness, preventing both excessive filling and insufficient filling

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The control system monitors power input parameters and uses this data to trigger compressed air injection, changing the physical state of the slip filling level to maintain optimal processing conditions that preserve both power efficiency and grinding effect

Inventive Principle:

Principle #35Parameter changes

3Stability of the object's composition

If a control system with periodic pump interruption is used to stabilize filling level, then filling level stability is improved, but operational continuity is reduced

Engineering Contradiction:

Improvefilling level stabilityVSAvoidoperational continuity

Core Design Contradiction:

Stability of the object's compositionVSProductivity

Solution Approach 1:

Compressed air injection provides a continuous method for adjusting filling level without requiring interruption of the slip infeed pump, maintaining operational continuity while achieving filling level stability through pneumatic pressure adjustments

Inventive Principle:

Principle #29Pneumatics and hydraulics

Solution Approach 2:

The compressed air injection device operates continuously or intermittently without stopping the slip infeed pump, ensuring continuous grinding operation while maintaining stable filling levels, eliminating the periodic interruptions required by previous pump-control methods

Inventive Principle:

Principle #20Continuity of useful action

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution maintains a stable filling level, optimizing energy consumption and product uniformity by continuously regulating the slip level within the mill, ensuring efficient grinding and consistent product quality without interrupting the grinding process.

Implementation Method 1

a compressed-air injection device, adapted to introduce air into the rotating body (1) in a controlled manner

Methodology Applied

Scientific EffectCompressed air pressure: Pressure Increase

Implementation Method 2

a control system (15,16) adapted to regulate the injection of compressed air so as to maintain a pre-established level of liquid inside the hollow body (1)

Methodology Applied

Scientific EffectFeedback control: Feedback

Data Source

PatentEP4389287A1Injecting air into continous mill

Publication Date: 2024.06.26 CERTECH S P A A SOCIO UNICO

Figure 1

AI summary

Continuous mill with compressed-air injection device for grinding ceramic powder in a water solution (slip), comprising: a hollow body (1), rotating about a rotation axis (X) through the action of a motor (3), a predefined mass of grinding bodies (6) contained inside the hollow body (1), an inlet conduit (4) and an outlet opening (7) for the slip, characterised in that it comprises a compressed-air injection device (11) to stabilise the volume of air and slip inside the mill, situated upstream of the hollow body (1); a continuous mill comprising a control system (15,16) for detecting the power input of the motor (3), which determines different actions depending on the detected power input value.