Glaze Weight Control Plant for Ceramic Handpieces
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Solution Overview
Problem
Current methods for supplying glazes on ceramic handmade articles require repetitive weighing checks, leading to decreased productivity and waste due to glaze dispersions and losses, particularly from ricochets and filtration systems, increasing production costs.
Innovation Solution
A method and plant that automatically maintain programmed glaze weights by using a PLC-controlled system with a pumping unit, flow rate adjustment, and sensors to account for losses, eliminating the need for downstream weighing apparatuses and optimizing glaze distribution to minimize waste and dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If repetitive weighing checks are performed to ensure glaze weight accuracy, then manufacturing precision is improved, but productivity decreases due to time loss from repeated measurements
Solution Approach 1:
The patent performs weighing operations upstream before the glazing process to establish a baseline weight. This preliminary measurement allows the system to calculate the required glaze application weight in advance, eliminating the need for repetitive downstream weighing checks. The control unit uses this preliminary data combined with programmed glaze characteristics to automatically regulate the glazing process, thus maintaining precision while improving productivity.
Solution Approach 2:
The system implements a feedback mechanism where the control unit continuously monitors the glazing process using upstream weighing data and adjusts the glaze application accordingly. The control unit regulates the pumping unit and flow rate based on the difference between the baseline weight and the desired final weight, ensuring accurate glaze application without requiring repetitive physical checks downstream.
2Productivity
If glaze flow rate is increased to improve productivity, then production speed increases, but glaze waste increases due to ricochets and dispersion
Solution Approach 1:
The patent employs a dynamic control system that continuously adjusts the glaze flow rate based on real-time process conditions. The control unit modulates the pumping unit speed and delivery aperture opening to optimize the balance between productivity and glaze utilization. This dynamic adjustment prevents excessive flow rates that cause ricochets and dispersion while maintaining sufficient speed for productive operation.
Solution Approach 2:
The system changes operational parameters such as pumping speed, flow rate, and delivery aperture opening to optimize glaze application. By programmatically controlling these parameters based on upstream weighing data and glaze characteristics, the system achieves efficient glaze utilization that minimizes waste from ricochets and dispersion while maintaining high productivity.
3Manufacturing precision
If downstream weighing apparatuses are installed to verify glaze weight, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent extracts the weighing function from the downstream verification stage and relocates it to the upstream stage before glazing. By performing the weighing operation upstream, the system eliminates the need for complex downstream weighing apparatuses and repetitive verification mechanisms. The control unit uses this upstream weight data to calculate and control the glaze application, simplifying the overall system structure while maintaining precision.
Solution Approach 2:
The control unit acts as an intermediary that processes upstream weighing data and translates it into precise glaze application control. Rather than installing complex downstream weighing equipment, the system uses the control unit to mediate between the upstream weight measurement and the glazing process, regulating the pumping unit and flow rate to achieve the desired glaze weight without additional physical verification apparatus.
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 enhances productivity by reducing the need for repetitive checks, minimizing glaze waste, and lowering production costs while ensuring consistent glaze application on ceramic handmade articles.
Implementation Method 1
assemble a pumping unit which creates a flow of glazes between a container in which they are prepared and accumulated and the hopper
Implementation Method 2
A vertical continuous veil pf glaze drops onto the upper surface of the transiting tiles on the conveyor plane
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The method for the weight application of glazes on surfaces of ceramic handmade articles (2) comprises the steps of: - setting a plant (1) for the weight application of glazes on a base-weight of glaze to be supplied, loading a base-data set in an electronic control unit (9) of the plant (1), which produces a base-flow rate of glaze to be supplied as a function of the base-data, which comprise a base-density of a reference base-glaze; a base-surface of a reference handmade article (2); a base-weight of glaze to be supplied; - resetting the plant (1) by loading in the electronic control unit (9), in order to produce a pre-established flow rate of said glaze to be supplied, a series of target-data which comprise a density of a target-glaze to be supplied; a target-surface of the target-handmade article (2); the pre-established weight value of glaze to be supplied on the target-surface.