Ceramic Composite Fiber Catalytic Filter Tube Grouting Parameter Adjustment
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Solution Overview
Problem
Current methods lack a systematic approach to adjust preparation parameters of ceramic composite fiber-based catalytic filter tubes, making it difficult to determine a loading reference value based on actual slurry parameters, which hinders efficiency in their preparation.
Innovation Solution
A method and device that utilize a central control unit to input fiber length, pH value, and solid phase content to determine loading reference values, grouting pressure, and suction parameters, allowing for real-time adjustments based on actual grouting amounts and thickness measurements to optimize the preparation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional fixed preparation parameters are used, then the preparation process is simple, but the preparation efficiency and quality consistency deteriorate due to inability to adapt to actual slurry parameter variations
Solution Approach 1:
The patent implements dynamic parameter adjustment by establishing a mathematical model that calculates loading reference values based on real-time slurry parameters (fiber length, pH value, solid phase content). The grouting pressure and holding time are dynamically adjusted according to the calculated loading reference value, transforming the static preparation process into a dynamic adaptive system that responds to actual material conditions.
Solution Approach 2:
The patent employs feedback control mechanisms where the actual grouting amount is monitored during the process and compared with the preset grouting amount. Based on the difference, the grouting pressure holding time is automatically adjusted. Additionally, the thickness of the blank tube is detected and fed back to adjust suction pressure, creating closed-loop control that continuously optimizes preparation parameters.
2Manufacturing precision
If loading reference value is determined without considering actual slurry parameters, then the preparation process is straightforward, but the manufacturing precision and quality consistency deteriorate
Solution Approach 1:
The patent changes the determination method of loading reference value from a fixed empirical approach to a parameter-based calculation approach. The loading reference value is calculated using a mathematical model that incorporates three key slurry parameters: fiber length (L), pH value (pH), and solid phase content (G). This transforms the loading reference value from a constant to a variable that adapts to actual slurry conditions, significantly improving accuracy.
Solution Approach 2:
The patent performs preliminary measurement and calculation of slurry parameters before the actual grouting process. The fiber length, pH value, and solid phase content are measured in advance, and the loading reference value is calculated beforehand based on these measurements. This preliminary action ensures that the correct parameters are ready before production begins, avoiding delays during the grouting process.
3Manufacturing precision
If grouting pressure holding time is fixed, then the control process is simple, but the grouting quality and thickness consistency deteriorate
Solution Approach 1:
The patent implements feedback control for grouting pressure holding time by monitoring the actual grouting amount during the process. A grouting meter measures the real-time grouting amount and compares it with the preset grouting amount. Based on the difference, the control system automatically adjusts the grouting pressure holding time to ensure the actual grouting amount matches the target, thereby guaranteeing thickness consistency.
Solution Approach 2:
The patent replaces manual monitoring and adjustment of grouting parameters with automated detection and control systems. A grouting meter automatically measures the grouting amount, and an ultrasonic thickness gauge detects the blank tube thickness. These measurements are fed back to the control system, which automatically adjusts the grouting pressure holding time without manual intervention, improving both precision and ease of operation.
4Manufacturing precision
If suction pressure is not adjusted based on thickness detection, then the process is simple, but the blank tube quality and density uniformity deteriorate
Solution Approach 1:
The patent implements feedback control for suction pressure by using an ultrasonic thickness gauge to detect the thickness of the blank tube during the suction process. The detected thickness is compared with the gap inside the mold, and based on the difference, the suction pressure is automatically adjusted. This ensures that the blank tube achieves the desired thickness and quality consistency while maintaining efficient production.
Solution Approach 2:
The patent performs thickness detection and suction pressure adjustment in a continuous manner during the blank tube formation process. The ultrasonic thickness gauge continuously monitors the blank tube thickness, and the suction pressure is adjusted in real-time without interrupting the production flow. This continuous action ensures quality consistency while minimizing additional time consumption.
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 improves the precision and efficiency of ceramic composite fiber-based catalytic filter tube preparation by dynamically adjusting grouting and suction parameters, ensuring consistent quality and performance through self-learning adjustments.
Implementation Method 1
determining a grouting pressure and a grouting pressure holding time... as well as a suction pressure and a suction time of a vacuum pump
Implementation Method 2
receiving an ultrasonic thickness gauge that is arranged on a right side of the mold by the central control unit, to detect a thickness of a blank tube
Data Source
AI summary
The present disclosure relates to a method for adjusting grouting parameters in preparation of a ceramic composite fiber-based catalytic filter tube, and a method and a device for preparing a ceramic composite fiber-based catalytic filter tube. In the present disclosure, a loading reference value of a slurry is determined by a fiber length, a pH value, and a solid phase content of the slurry, thus evaluating a performance value of the slurry; initial working parameters for preparation are determined by comparing the loading reference value of the slurry with a preset value. During the actual preparation, a grouting amount is introduced to conduct conversion check on a quality of the slurry, so as to ensure a grouting pressure and a grouting pressure holding time during the grouting.