Ceramic Powder Edge Trimming With In-Motion Abrasive Tracking
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Solution Overview
Problem
Existing ceramic product production plants face inefficiencies in trimming operations due to inaccuracies in cutting, leading to edge burrs, and require complex and space-consuming solutions that are not adaptable to modern production needs.
Innovation Solution
A trimming system with a ring-shaped transport device and abrasive tools mounted on sliding frames, equipped with detectors and drive assemblies, allows simultaneous and precise trimming of all edges while the articles are in motion, adapting to edge imperfections in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple transverse trimming stations are used to finish several articles simultaneously, then productivity is improved, but device complexity and space requirements increase considerably
Solution Approach 1:
The patent employs a robotic manipulator with dynamic positioning capabilities that can move between different articles and trim them sequentially. The robotic system adapts its position and orientation in real-time based on article location, replacing the need for multiple fixed trimming stations. This dynamic approach maintains high productivity while reducing overall system complexity and space requirements.
Solution Approach 2:
A single robotic manipulator is designed to perform trimming operations on multiple articles at different positions and orientations. The robotic system serves as a universal trimming device that can handle both longitudinal and transverse edges of various articles along the conveyor, eliminating the need for dedicated trimming stations for each article position.
2Manufacturing precision
If traditional fixed trimming stations are used, then manufacturing precision is maintained, but productivity decreases due to machine stops
Solution Approach 1:
The robotic manipulator operates continuously alongside the moving conveyor belt, trimming articles as they pass by without requiring the conveyor to stop. The robotic system maintains continuous trimming action by positioning itself appropriately for each article, ensuring both high productivity and manufacturing precision through uninterrupted operation.
Solution Approach 2:
The system incorporates detectors that monitor article positions and dimensions in real-time, providing feedback to the robotic manipulator and control system. This feedback mechanism enables the robotic system to adjust its trimming parameters dynamically, maintaining manufacturing precision while operating continuously at high speed alongside the moving articles.
3Device complexity
If abrasive tools are positioned fixedly, then device complexity is reduced, but adaptability to edge imperfections and alignment errors decreases
Solution Approach 1:
The robotic manipulator provides dynamic positioning and orientation capabilities, allowing the abrasive tools to adapt to variations in article position, orientation, and edge imperfections. The robotic system can adjust its degrees of freedom in real-time to compensate for misalignment errors, providing high adaptability without requiring overly complex fixed positioning mechanisms for each tool.
Solution Approach 2:
Detectors mounted on or near the robotic manipulator continuously monitor article positions, orientations, and edge characteristics, providing feedback that enables real-time adjustments by the robotic control system. This feedback mechanism allows the system to adapt to alignment errors and edge imperfections dynamically, maintaining trimming quality without requiring pre-calibrated complex positioning systems.
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
Enables fast and precise trimming of all edges without additional orientation systems, reducing production time and space requirements, and accommodating geometric and alignment errors.
Implementation Method 1
the trimming operations are generally carried out by means of the abrasive tools that intercept the edge to be treated, remove any excess material and smooth the edges
Data Source
Figure 1
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AI summary
System (1) for trimming an article (2) made of compacted ceramic powder comprising: a transport device (3) for transporting the article (2) in an advancing direction (A); a fixed main frame (9); a secondary frame (10) which is connected to the main frame (9) in the advancing direction (A) in a sliding manner; a trimming assembly (11) which, in turn, comprises two transverse support structures (13) carried by the secondary frame (10); at least two abrasive tools (14) for trimming the edges (B1, B2, B3, B4) of the article (2) and each coupled to a support structure (13) in a sliding manner; two drive assemblies (16) so as to position and/or move the respective abrasive tool (14) along a trimming trajectory (T); detectors (17) to detect the development/outline of the edge (B1, B2, B3, B4) to be trimmed; two deflection units (12) to deflect the ring-shaped transport device (3) so as to define a work space (W); and a control assembly (CU) to control the actuation of the various components as a function of the data detected by the detectors (17) and the format of the article (2) to be trimmed.