Ceramic Powder Feeding and Height Correction for Uniform Patterned Slabs
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Solution Overview
Problem
Existing methods for manufacturing ceramic articles with natural stone or wood-like patterns face issues such as thickness unevenness in the ceramic powder layer, leading to abnormal tension states and uneven density, which compromises the aesthetic appearance and can cause damage during firing, and are limited in the number and direction of veins/streaks that can be produced.
Innovation Solution
A system and method involving a compaction device with a conveyor assembly and a feeding assembly that includes digital feeding devices and a computerized control unit to precisely distribute different types of ceramic powder materials, creating a defined pattern with chromatic effects, and a discharge assembly to ensure even thickness and pattern continuity, using detection and correction units to maintain uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional feeding devices are used to feed ceramic powder material onto the conveyor assembly, then the production process can be maintained, but thickness unevenness occurs in the ceramic powder layer
Solution Approach 1:
The patent replaces conventional mechanical feeding devices with a digital feeding device that uses a conveyor belt with controlled movement. The conveyor belt transports ceramic powder material through a defined path with precise control over speed and position, eliminating the thickness unevenness caused by mechanical feeding mechanisms while maintaining production capability.
Solution Approach 2:
The patent implements a control system that monitors the movement of the conveyor belt and adjusts it to maintain consistent thickness of the ceramic powder layer. The control unit receives information about the conveyor's position and speed, and makes real-time adjustments to ensure uniform feeding, thereby achieving precise thickness control.
2Manufacturing precision
If the width and longitudinal development of veins/streaks increase, then the aesthetic appearance improves, but thickness unevenness increases
Solution Approach 1:
The patent uses a dynamically controllable conveyor belt system that can adjust its speed and position along the defined path. This dynamic control allows the system to accommodate various vein/streak widths and longitudinal developments while maintaining consistent powder layer thickness, enabling both aesthetic flexibility and precision.
Solution Approach 2:
The patent changes the parameters of the conveyor belt movement (speed, position, acceleration) to optimize the feeding process for different vein/streak designs. By adjusting these parameters, the system can produce patterns of varying width and length while maintaining uniform thickness, resolving the contradiction between design flexibility and manufacturing precision.
3Manufacturing precision
If digital feeding devices with computerized control are used, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The patent designs the conveyor assembly to perform multiple functions: transporting ceramic powder material, controlling feeding speed, positioning material accurately, and integrating with the control unit. This multi-functional design consolidates several operations into a single system, improving pattern reproduction accuracy while limiting the increase in overall device complexity.
Data Source
AI summary
System for manufacturing ceramic articles, in particular ceramic slabs or tiles, comprising: a compaction device; a conveyor assembly to transport powder material along a given path from an input station to an output station; a digital feeding assembly to feed powder material to the conveyor assembly at the input station so as to generate a layer of powder material, with feeding devices each comprising a plurality of distribution elements along its transverse output mouth, as well as corresponding actuators; a detection unit to detect the height or thickness of the powder material; and a height correction unit, located upstream of the detection unit and of the compaction device, operable to modify the height or thickness of the layer of powder material crosswise to said moving direction, depending on the data detected by said detection unit, so as to make it more uniform.