Ceramic Tile Kiln Cooling Rate Adjustment for Dimensional Accuracy
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Solution Overview
Problem
Ceramic tile manufacturing faces challenges with dimensional and shape deformations due to high sintering temperatures, which are difficult to correct without manual intervention and result in scrap material.
Innovation Solution
A method for manufacturing ceramic tiles that involves measuring shape and dimension parameters after firing and adjusting firing parameters, particularly the cooling rate, to improve the manufacturing process efficacy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual intervention is used to correct deformations by adjusting process parameters, then dimensional and shape deformations can be corrected, but the process becomes time-consuming and generates scrap material
Solution Approach 1:
The patent applies preliminary action by measuring the deformation of fired tiles and adjusting pressing conditions before the next production batch. This feedback loop allows corrections to be made in advance, preventing defective tiles from being produced rather than detecting and correcting them after production, thereby reducing scrap material and improving productivity while maintaining high dimensional accuracy
Solution Approach 2:
The patent implements feedback by measuring the deformation of fired tiles and using this information to adjust pressing conditions for subsequent batches. This closed-loop control system continuously optimizes the manufacturing process, enabling high precision dimensional accuracy while improving productivity through automated adjustment rather than manual intervention
2Manufacturing precision
If multiple parameters are adjusted simultaneously to correct deformations, then comprehensive correction can be achieved, but the interaction between parameters complicates the adjustment process
Solution Approach 1:
The patent applies segmentation by isolating and adjusting only the pressing conditions parameter while keeping other firing parameters constant. This focused approach divides the complex multi-parameter adjustment problem into manageable segments, allowing precise correction of shape deformations without the complexity of coordinating multiple interacting parameters simultaneously
Solution Approach 2:
The patent implements local quality by applying specific pressing conditions adjustments to address particular deformation issues while maintaining other process parameters at their optimal fixed values. This targeted adjustment strategy improves shape consistency by focusing control efforts on the specific parameter that most directly influences the observed deformations, thereby reducing overall system complexity
3Ease of operation
If measurement is delayed until the operator can handle the sample, then safety can be ensured, but the measurement no longer precisely reflects the real deformation of the product
Solution Approach 1:
The patent replaces manual mechanical measurement with an automated optical or laser-based measurement system that can measure tile deformations immediately after firing without requiring operator contact. This substitution maintains operator safety by eliminating the need for handlers to touch hot tiles while simultaneously improving measurement precision by capturing deformation data at the exact moment of production, eliminating delays that would allow cooling-induced dimensional changes
Solution Approach 2:
The patent implements self-service by designing a measurement system that automatically measures and records tile deformations immediately after they exit the kiln, without requiring operator intervention. This automated system ensures both operator safety by avoiding contact with hot tiles and measurement precision by capturing data before cooling occurs, with the system performing the measurement function independently and continuously
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 method allows for precise correction of deformations, reducing scrap material and improving the consistency of ceramic tiles by optimizing the cooling rate during the firing process.
Implementation Method 1
During firing said powders are sintered to consolidate the ceramic material and reduce the residual porosity thereof
Implementation Method 2
said adjustable firing parameter comprises the cooling rate
Data Source
AI summary
A method for manufacturing a ceramic tile and an equipment for manufacturing a ceramic tile. A method for manufacturing ceramic tiles (3) that comprises the steps of providing a green tile (2) formed by a mixture of ceramic raw materials, firing said green tile (2) in a kiln (1) to obtain a ceramic tile (3), said kiln (1) being configured to fire the green tile (2) according to a firing cycle defined by one or more firing parameter (HR, MFT, UICR, UIICR, UIIICR, LICR, LIICR, LIIICR), characterized int that it comprises the steps of measuring a shape and/or dimension parameter of the obtained ceramic tile (3), and the step of adjusting the firing parameter on the basis of said measurement, preferably while one parameter is adjustable the remaining parameters are be kept constant.