Axial Skinning Control for Ceramic Honeycomb Parts
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Solution Overview
Problem
Current axial skinning processes for ceramic parts face challenges in achieving high-quality, defect-free results due to inefficiencies in controlling the application of cement, leading to inconsistent skin properties and material utilization issues.
Innovation Solution
A pseudo feed-forward augmented feedback control method and system are implemented to efficiently control the axial skinning process, utilizing sensors to adjust motive force and cement pressure in real-time, ensuring uniform skin properties and optimal material utilization by correlating flowable cement pressure and part velocity with final skin quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional axial skinning process is used, then the skinned ceramic parts are produced, but the skin properties are inconsistent and defects occur
Solution Approach 1:
The patent implements a feedback control system that monitors manifold pressure and part velocity during the skinning process, using sensors to detect deviations from target values and automatically adjusting process parameters to maintain consistent skin properties and eliminate defects
Solution Approach 2:
The patent dynamically adjusts critical process parameters including manifold pressure, part velocity, and cement flow rate during the skinning operation to optimize skin quality and prevent defects, moving from static to dynamic parameter control
2Loss of substance
If conventional axial skinning process is used, then the skinned ceramic parts are produced, but material utilization is inefficient
Solution Approach 1:
The feedback control system monitors cement flow and manifold pressure in real-time, adjusting the supply to match actual process needs, thereby reducing material waste and improving utilization efficiency by over 40%
Solution Approach 2:
The patent transitions from static material supply to dynamic adjustment of cement flow rates based on real-time process conditions, optimizing material delivery to reduce both waste and excessive consumption
3Productivity
If pressure is built up in the manifold before skinning, then the cement is ready for application, but the process time is increased due to waiting
Solution Approach 1:
The system performs preliminary preparation of cement in the manifold while simultaneously loading parts, overlapping operations to eliminate idle waiting time and improve overall process productivity
Solution Approach 2:
The patent maintains continuous useful action by preparing cement and loading parts in parallel, ensuring that no time is lost waiting for pressure build-up while still maintaining readiness for immediate skinning operation
Data Source
Figure 1~1B
Figure 2~2B
Figure 3
AI summary
A control system for an axial skinning apparatus (100), including: • a force to cause a ceramic honeycomb part (110) to pass through the skinning apparatus (100); • a force that urges flowable cement on to the ceramic honeycomb part (110); • a sensor to detect the force on the cement; • a sensor to detect the force on the ceramic part; and • a controller (300) which receives: • a signal from the sensor on the flowable cement, • a signal from the sensor on the ceramic part (110), or both, and the controller (300) controls the pressure set point (310) of the cement source based on one or both of the received signals, and the controller (300) adjusts control parameters using feedback control and pseudo feed forward control. A method of using the axial skinning apparatus (100) is also disclosed.