Ceramic Honeycomb Perpendicularity via Contour Measurement
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Solution Overview
Problem
Conventional manufacturing methods for ceramic honeycomb structures face challenges in achieving sufficient perpendicularity, especially for larger sizes, with the integral forming method resulting in poor perpendicularity yield and the outer periphery coating method being laborious and prone to distortion.
Innovation Solution
A manufacturing method that involves precise contour measurement and fixation of a ceramic honeycomb body using multiple measurement points and fixtures to optimize chuck angles, allowing for accurate finishing and firing without the need for laborious outer periphery coating, ensuring excellent perpendicularity regardless of size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the manufacturing method by integral forming is used, then the manufacturing process is simplified, but the perpendicularity of the honeycomb structure deteriorates
Solution Approach 1:
The invention applies preliminary action by measuring the contour of the dried honeycomb body before the finishing step and determining the optimum chuck angle in advance. This allows the honeycomb body to be positioned correctly before finishing operations, ensuring high perpendicularity while using the simplified integral forming method.
Solution Approach 2:
The invention implements feedback by measuring the actual contour of the dried honeycomb body and using this measurement information to determine the optimum chuck angle for the finishing step. This closed-loop approach ensures that the finishing operation achieves the required perpendicularity based on the actual dimensions of the workpiece.
2Manufacturing precision
If the manufacturing method by outer periphery coating is used, then the perpendicularity of large honeycomb structures is improved, but the manufacturing process becomes laborious and productivity decreases
Solution Approach 1:
The invention determines the optimum chuck angle before the finishing step by measuring the contour of the dried honeycomb body. This preliminary determination eliminates the need for laborious outer periphery coating operations while ensuring high perpendicularity, thereby maintaining productivity.
Solution Approach 2:
The invention replaces the mechanical outer periphery coating process with a measurement and positioning system. By using contour measurement and optimum chuck angle determination, the finishing operation can directly achieve the required perpendicularity without the intermediate coating step, improving productivity.
3Manufacturing precision
If the contour measurement and fixation method is applied, then the perpendicularity is significantly enhanced, but the measurement and setup process becomes more complex
Solution Approach 1:
The invention applies self-service by having the dried honeycomb body itself provide the measurement data for determining the optimum chuck angle. The contour measurement is performed on the actual workpiece, and the resulting information is used to position that same workpiece, eliminating the need for separate master patterns or complex external reference systems.
Solution Approach 2:
The invention changes the parameter of chuck angle based on the measured contour data. By dynamically adjusting the chuck angle parameter according to the actual dimensions of the dried honeycomb body, the system achieves high perpendicularity without requiring complex fixed fixtures or multiple measurement devices.
Data Source
Figure 1
Figure 2A
Figure 2B~2C
AI summary
There is disclosed a manufacturing method of a ceramic honeycomb structure in which it is possible to manufacture a ceramic honeycomb structure having an excellent perpendicularity. A contour of an outer diameter dimension of a dried ceramic honeycomb body 50 is measured in a first measuring portion Q1 and a second measuring portion Q2 of the surface of an outer wall 63 of the dried ceramic honeycomb body 50; a total of absolute values of differences between respective values of four contours C1x, C1y, C2x and C2y measured at a first measurement point P1x and a second measurement point P1y of the first measuring portion Q1 and a third measurement point P2x and a fourth measurement point P2y of the second measuring portion Q2 is obtained; and one end surface 61 and the other end surface 62 of the dried ceramic honeycomb body 50 are subjected to finishing step in a state where four measurement points of the outer wall 63 of the dried ceramic honeycomb body 50, at which the total of the absolute values of the differences between the respective values of the contours is minimum, are supported fixed by a first fixture and a second fixture.