Ceramic Mould Force Control via Fluid Expansion
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Solution Overview
Problem
Current ceramic sanitaryware manufacturing installations face challenges in precisely controlling forces across all points of the mould's outside surface during the casting cycle, leading to potential deformation and defects due to the limited precision of hydraulic systems used for clamping.
Innovation Solution
The installation employs a fluid-expandable containment element correlated with slip pressure to manage forces, combined with a compensation chamber system that adjusts pressure in real-time to balance forces both parallel and transverse to the clamping direction, using a fluid system for precise control and minimizing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a hydraulic system is used for clamping the mould parts, then the clamping force can be applied, but the precision of force control is limited leading to potential deformation
Solution Approach 1:
The patent replaces the traditional hydraulic clamping system with a mechanical linkage system consisting of a movable wall, piston, and series of linkages (first, second, third linkages) connected to clamping points. This mechanical system provides precise force control through geometric relationships and mechanical advantage, eliminating the precision limitations of hydraulic systems while maintaining adequate clamping force.
Solution Approach 2:
The patent introduces a movable wall as an intermediary element between the piston and the mould parts. The movable wall transfers and distributes the clamping force through multiple linkages to various clamping points, enabling precise force control and distribution across the mould assembly while protecting against deformation.
2Productivity
If high pressure is used to pump slip into the mould, then the cast wall thickness is formed effectively, but forces normal to the inside surfaces may deform the mould
Solution Approach 1:
The patent employs counteracting clamping forces applied at multiple points on the mould parts through the mechanical linkage system. These clamping forces oppose and balance the internal slip pressure forces acting normal to the inside surfaces, preventing mould deformation while allowing high-pressure slip injection for effective cast wall thickness formation.
Solution Approach 2:
The patent divides the clamping force application into multiple discrete clamping points distributed across the mould assembly. By segmenting the force application locations and using a mechanical linkage system, the patent achieves precise control over force distribution, preventing localized deformation while maintaining overall mould integrity during high-pressure casting.
3Manufacturing precision
If mechanical stops are used to limit mould part movement, then the maximum deformation is controlled, but the force from the piston in excess of clamping force is absorbed by the stops
Solution Approach 1:
The patent replaces the energy-wasting mechanical stop system with an optimized mechanical linkage system that efficiently transmits and utilizes the piston force. The linkages are designed to provide the necessary movement limitation through their geometric constraints rather than through energy-absorbing stops, allowing excess piston force to be effectively utilized for clamping rather than being wasted.
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 precise pressure application across all mould surfaces, reducing deformation and enhancing the quality of the ceramic products by effectively controlling forces throughout the casting cycle.
Implementation Method 1
an element expandable by a fluid from the outside and designed to contain the forces generated by the pressure of the slip inside the mould
Implementation Method 2
a compensation chamber system that adjusts pressure in real-time to balance forces both parallel and transverse to the clamping direction
Data Source
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AI summary
An installation (100) for the manufacture of ceramic products comprises a mould (1) divided into at least two parts (2, 3) forming an internal cavity (C) where the ceramic product is formed, and mobile towards and away from each other, under the action of respective drive means (4) acting in both directions along a predetermined clamping line (S), in such a way as to join or detach the parts (2, 3) to/from each other; each part (2, 3) of the mould (1) comprises at least one rear outside surface (2p, 3p) and one lateral outside surface (2s, 3s); at least one of the parts (2, 3) is equipped with means (6) for containing and controlling a fluid and encompassing the rear (2p, 3p) and lateral (2s, 3s) outside surfaces of the mould (1) part (2, 3); the containment means (6) are associated with the part (2, 3) of the mould (1) in such a way that during the product casting cycle the forces (SF) acting on the part (2, 3) of the mould (1) are constantly compensated by correlated forces (FR).