Ceramic Pre-cursor Rheology Control via Feedback Injection
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Solution Overview
Problem
The manufacturing of ceramic honeycomb bodies faces challenges with excessive periods of low production yields during die pressure stabilization and variable water content in the batch, leading to defects and instability in extrusion processes.
Innovation Solution
An extrusion system with a liquid injector, sensor, and controller for real-time rheology control, adjusting liquid flow based on detected characteristics such as liquid content, stiffness, and pressure to maintain optimal batch conditions, ensuring consistent extrusion and reducing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If liquid is added to the ceramic pre-cursor batch to control rheology, then extrusion stability and production yield are improved, but batch composition variability and process complexity increase
Solution Approach 1:
The system employs a closed-loop feedback control mechanism where a sensor continuously monitors rheology characteristics (such as liquid content, stiffness, or wall drag) of the ceramic pre-cursor batch. The controller receives this real-time data, compares it to predetermined rheology values, and automatically adjusts liquid flow through the liquid regulator and injector to maintain optimal rheology, thereby improving extrusion stability and production yield while managing batch composition variability
Solution Approach 2:
The patent replaces manual or mechanical rheology adjustment methods with an automated control system that uses sensing and electronic control. Instead of relying on mechanical mixing adjustments or manual liquid addition, the system uses a sensor-controller-actuator loop to dynamically regulate liquid addition based on real-time rheology measurements, reducing process complexity through automation
2Reliability
If liquid flow is increased to maintain rheology during start-up, then extrusion stability improves, but liquid content variability and defect risk increase
Solution Approach 1:
The system dynamically adjusts liquid flow rates based on real-time rheology measurements rather than using fixed flow rates. During start-up conditions, the controller increases liquid flow to maintain extrusion stability, then transitions to lower flow rates as the process stabilizes. This dynamic adjustment ensures extrusion reliability while preventing liquid content variability and associated defects through continuous monitoring and adaptation
Solution Approach 2:
The control system is configured with predetermined rheology values for different operating conditions, including higher liquid content targets for start-up conditions and lower targets for steady-state conditions. This preliminary programming allows the system to proactively adjust liquid flow before rheology deviations occur, maintaining extrusion stability during transitions while preventing defects during steady operation
3Manufacturing precision
If real-time rheology monitoring is implemented, then batch quality control improves, but system complexity and measurement requirements increase
Solution Approach 1:
The system implements real-time rheology monitoring using a sensor that continuously measures batch characteristics such as liquid content, stiffness, or wall drag. The controller receives this feedback signal and automatically adjusts liquid flow to maintain rheology within target ranges, significantly improving batch quality control. The feedback loop integrates seamlessly with the existing extrusion system, managing complexity through automated control rather than manual intervention
Solution Approach 2:
The controller serves multiple functions: it receives rheology measurements from the sensor, compares readings to predetermined values for different operating conditions, calculates appropriate liquid flow adjustments, and actuates the liquid regulator. This multi-functionality consolidates control logic into a single device, improving batch quality control while minimizing system complexity through functional integration
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 stabilizes extrusion processes, reduces defects, and efficiently achieves steady-state pressure, improving production efficiency and product uniformity by dynamically adjusting liquid content and rheology characteristics.
Implementation Method 1
apparatus and methods of ceramic pre-cursor batch rheology control
Implementation Method 2
a sensor configured to detect a rheology characteristic of the ceramic pre-cursor batch
Implementation Method 3
a discharge port configured to extrude a ceramic pre-cursor extrudate out of the extruder barrel
Data Source
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AI summary
A system (100) and method to control rheology of ceramic pre-cursor batch during extrusion is described herein. An extrusion system (100) comprises an extruder (122) with an input port (144) configured to feed ceramic pre-cursor batch into a first section (120) of an extruder barrel and a discharge port configured to extrude a ceramic pre-cursor extrudate (172) out of the extruder barrel downstream of the input port (144). A liquid injector (210) is configured to inject liquid into the ceramic pre-cursor batch. A sensor (106) is configured to detect a rheology characteristic of the ceramic pre-cursor batch. A controller (108) is configured (i) to receive the rheology characteristic from the sensor (106), (ii) compare the rheology characteristic to a predetermined rheology value of the ceramic pre-cursor batch, and (iii) generate a command based on the comparison. A liquid regulator (110) is configured to receive the command and adjust liquid flow to the liquid injector (210) based on the command.