Ceramic Extrusion Molding Temperature Control for Dimensional Accuracy
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Solution Overview
Problem
Existing methods for improving dimensional accuracy of ceramic molded bodies before firing are inefficient, as they either fail to account for deformation during cutting or require lengthy adjustments to the kneading material, leading to unstable and time-consuming processes.
Innovation Solution
A method that involves measuring the dimensions of cut ceramic molded bodies and controlling the temperature of the extrusion molding machine's temperature control portion based on a previously established relationship between temperature and dimension, allowing for real-time adjustment to improve dimensional accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If extrusion process parameters are controlled by measuring shape signal immediately after extrusion molding, then dimensional accuracy can be improved, but cutting deformation cannot be considered leading to unstable results
Solution Approach 1:
The patent performs dimension measurement after cutting (preliminary action) to account for cutting deformation, and then adjusts extrusion parameters in advance for the next production cycle. This ensures that the measurement reflects the actual final dimension including cutting effects, leading to more reliable and stable dimensional accuracy control.
Solution Approach 2:
The patent implements a feedback mechanism where dimensions of cut ceramic molded bodies are measured, compared against target dimensions, and used to adjust extrusion process parameters for subsequent production. This closed-loop feedback system continuously improves dimensional accuracy by learning from actual cutting deformation effects.
2Manufacturing precision
If liquid is added to kneading material to adjust dimension, then dimensional accuracy can be improved, but the process becomes time-consuming and inefficient
Solution Approach 1:
The patent changes the extrusion process parameters (pressure, temperature, speed) instead of adding liquid to the kneading material. This parameter adjustment approach achieves dimensional correction without modifying the material composition, thus avoiding additional processing time and maintaining high production efficiency while improving dimensional accuracy.
Solution Approach 2:
The patent replaces the chemical/material adjustment method (adding liquid to kneading material) with a mechanical process parameter adjustment method (modifying extrusion pressure, temperature, or speed). This substitution eliminates the time-consuming material preparation step while achieving the same dimensional correction goal.
3Manufacturing precision
If extrusion pressure is increased to improve dimensional accuracy, then manufacturing precision improves, but energy consumption increases
Solution Approach 1:
The patent dynamically adjusts extrusion parameters (pressure, temperature, speed) based on actual dimension measurement results rather than using fixed high pressure. This dynamic optimization allows the system to use only the necessary amount of energy required to achieve target dimensional accuracy, avoiding excessive energy consumption while maintaining precision.
Solution Approach 2:
The patent uses multiple extrusion parameters (pressure, temperature, speed) that can be adjusted independently. By optimizing the combination of these parameters, the system can achieve high dimensional accuracy without necessarily increasing pressure, thus reducing energy consumption while maintaining manufacturing precision.
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 approach enables quick and stable improvement in the dimensional accuracy of both ceramic molded and fired structures by optimizing the temperature control during the molding process, reducing waste and enhancing productivity.
Implementation Method 1
a relationship between a temperature of the temperature control portion and the dimension of the cut ceramic molded body is previously obtained, and based on the relationship, an appropriate temperature of the temperature control portion is calculated
Data Source
AI summary
A method for producing a ceramic molded body, the method including: a molding step of subjecting a ceramic molding material to extrusion molding using an extrusion molding machine equipped with a temperature control portion to provide a ceramic molded body; a cutting step of cutting the ceramic molded body to have a predetermined length; and a dimension measuring step of measure a dimension of the cut ceramic molded body. A relationship between a temperature of the temperature control portion and the dimension of the cut ceramic molded body is previously obtained, and based on the relationship, an appropriate temperature of the temperature control portion is calculated from the dimension of the ceramic molded body measured in the dimension measuring step, and the temperature control portion is controlled to the appropriate temperature in the molding step.