Ceramic Honeycomb Extrusion Viscosity Control via Dried Dimension Feedback
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Solution Overview
Problem
Conventional ceramic structure manufacturing methods face challenges in maintaining dimensional accuracy due to drying and firing shrinkages, leading to inefficiencies and increased torque during extrusion, as the amount of liquid added during wet-mixing is often restricted, causing viscosity issues and requiring frequent adjustments or machine stoppages.
Innovation Solution
A method that adjusts the amount of liquid added to the kneaded material based on the dry dimension of the ceramic dried body, allowing for continuous extrusion and viscosity control without stopping the machine, using a combination of image analysis and laser measurements to determine the necessary liquid addition for maintaining stable dimensions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the amount of liquid added during wet-mixing is restricted, then the viscosity of the forming material is reduced, but the dimensional accuracy of the ceramic structure deteriorates due to drying and firing shrinkages
Solution Approach 1:
The patent applies preliminary action by measuring the dry dimension of the ceramic dried body before extrusion and using this measurement to determine the appropriate amount of liquid to add to the forming material. This advance measurement and adjustment prevents dimensional inaccuracies caused by drying and firing shrinkages, allowing the extrusion process to proceed with optimal viscosity control without compromising final dimensional accuracy.
2Manufacturing precision
If the amount of liquid added during wet-mixing is increased to maintain dimensional accuracy, then the viscosity of the forming material increases, but the mechanical load and torque on the extrusion machine increases
Solution Approach 1:
The patent implements feedback control by measuring the dry dimension of the ceramic dried body and using this information to adjust the amount of liquid added to the forming material. This feedback mechanism ensures that the optimal amount of liquid is added to achieve the desired dimensional accuracy while maintaining appropriate viscosity levels, thereby preventing excessive torque and mechanical load on the extrusion machine.
3Ease of manufacture
If the viscosity of the forming material is adjusted by adding more liquid, then the extrusion process becomes easier, but the liquid content ratio increases causing excessive drying shrinkage
Solution Approach 1:
The patent applies preliminary action by measuring the dry dimension of the ceramic dried body before the extrusion process and using this measurement to precisely determine the amount of liquid to add. This advance adjustment ensures that the optimal liquid content is achieved for smooth extrusion while preventing excessive drying shrinkage, as the liquid amount is carefully controlled based on pre-measured dimensional data.
4Stability of the object's composition
If the amount of liquid added is not adjusted properly, then the viscosity remains unstable, but frequent die adjustments and machine stoppages are required
Solution Approach 1:
The patent implements feedback control by continuously measuring the dry dimension of the ceramic dried body and using this information to adjust the liquid addition amount. This feedback mechanism maintains stable viscosity of the forming material, preventing the need for frequent die adjustments and machine stoppages, thereby sustaining high manufacturing efficiency and productivity throughout the extrusion process.
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 ensures high dimensional accuracy of ceramic structures by controlling the dry dimension of the ceramic dried body, reducing the need for die adjustments and machine stoppages, thereby enhancing manufacturing efficiency and productivity.
Implementation Method 1
Viscosity of a forming material largely depends on the amount of liquid, such as water, added during wet-mixing
Implementation Method 2
a forming step of extruding a forming material of which viscosity is adjusted by the kneading step and the liquid adding step into a ceramic formed body
Implementation Method 3
In the drying step in which the ceramic formed body is dried to be transformed into the ceramic dried body, a drying shrinkage occurs by evaporation or transpiration of the liquid contained in the forming material
Implementation Method 4
a drying shrinkage occurs by evaporation or transpiration of the liquid contained in the forming material
Implementation Method 5
a drying shrinkage occurs by evaporation or transpiration of the liquid contained in the forming material. As a result, the size of the ceramic dried body (for example, a honeycomb diameter and a honeycomb length) after drying becomes smaller than that of the ceramic formed body before dried
Implementation Method 6
Moreover, a firing shrinkage may also occur during firing
Data Source
AI summary
A manufacturing method includes a mixing step, a kneading step of kneading a wet mixture, a liquid adding step of further adding a liquid to a kneaded material, a forming step of extruding a forming material of which viscosity is adjusted into a honeycomb formed body, a drying step of drying the honeycomb formed body, and a dimension measuring step of measuring a dry dimension of a honeycomb dried body that has been dried, where in the liquid adding step, the amount of the liquid to be added is adjusted based on the result of measuring the dry dimension of the honeycomb dried body.