Curtain Coater Hopper Segmentation for Glaze Uniformity
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Solution Overview
Problem
Existing curtain coater head designs face difficulties in easily accessing the hopper for washing, restoring the calibrated outlet slot accurately after washing, and ensuring precise and backlash-free movements during opening and closing, which affects the uniformity and quality of the glaze application on ceramic tiles or slabs.
Innovation Solution
A curtain coater head device with a hopper composed of two parts, where one part is stationary and the other is movable, driven by a screw and nut mechanism with a recirculating ball system, allowing precise horizontal movement to maintain the calibrated outlet slot and facilitate easy washing, and equipped with centring and zeroing means to ensure accurate alignment and real-time measurement of movements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the hopper is made up of two hinged parts for easy opening and washing, then the ease of operation is improved, but the manufacturing precision deteriorates because it is difficult to restore the correct closed position and calibrated outlet slot
Solution Approach 1:
The hopper is divided into two separate parts (first part and second part) that can be moved independently. The second part can be opened horizontally away from the first part for easy access and washing, then returned to the operating position. This segmentation allows the hopper to be both easily openable and capable of precise closing.
Solution Approach 2:
The traditional hinged mechanical connection is replaced with a drive means system (screw and nut mechanism with recirculating ball system) that enables precise positioning. This mechanical substitution eliminates the clearance and positioning errors inherent in hinged systems, allowing the second part to be accurately returned to its correct position relative to the first part.
2Ease of operation
If a hinged connection is used for the two hopper parts, then the ease of opening is improved, but the device complexity increases due to the need for precise positioning mechanisms
Solution Approach 1:
The hopper is segmented into movable and stationary parts that can be independently positioned. The second part is made movable horizontally while the first part remains stationary, simplifying the overall mechanism by eliminating complex hinged connections and multiple moving components.
Solution Approach 2:
Complex hinged positioning mechanisms are replaced with a drive means system using screw and nut mechanisms with recirculating ball systems. This substitution provides precise positioning with minimal complexity, eliminating the need for multiple adjustment mechanisms and clearance compensation devices.
3Ease of operation
If the hopper parts are opened for washing, then the ease of operation is improved, but the loss of time increases due to the difficulty of restoring correct positioning
Solution Approach 1:
The hopper is divided into two parts where the second part can be independently opened horizontally for washing access. After washing, the drive means system quickly and accurately returns the second part to its correct position, minimizing the time lost during the washing cycle.
Solution Approach 2:
The positioning restoration process is accelerated by using a drive means system with screw and nut mechanisms and recirculating ball systems. This mechanical system provides rapid, precise positioning without the time-consuming adjustments required by traditional hinged systems, significantly reducing the time to restore operating conditions after washing.
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
The device allows for easy and precise opening and closing of the hopper, ensuring stable positions and optimal cooperation with washing means, restoring the calibrated outlet slot accurately and enhancing the uniformity of glaze application on ceramic tiles or slabs.
Implementation Method 1
drive means, associated with said second movable part of the hopper and intended to move the same second movable part in a horizontal, rectilinear direction
Implementation Method 2
screw and nut mechanism with a recirculating ball system
Implementation Method 3
screw and nut mechanism with a recirculating ball system
Implementation Method 4
drive means, associated with said second movable part of the hopper and intended to move the same second movable part
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
The device (1) allows the opening of the hopper (20) of a curtain coater head (2) capable of dispensing, from a calibrated outlet slot (21), a curtain of ceramic glaze (S) onto ceramic tiles or slabs (4) in transit therebelow. The hopper (20) consists of two parts, the first of which is stationary (20F) whereas the second is movable (20M), the latter being connected to drive means (10) capable of imparting rectilinear horizontal movements thereto. The drive means (10) are of screw (100) and nut-screw (101) type, with a recirculating ball screw, and are driven by an electric motor (102) with encoder (103). When the second movable part (20M) is brought closer to the first stationary part (20F), so that the aforementioned calibrated exit slot (21) is adjusted, an operating position (W) of said hopper (20) is defined. When the two parts (20F, 20M) are pushed apart, an open position (A) of the hopper (20) is configured, which allows the hopper to be washed with cleaning fluid under pressure.