Optical Density Detection for Compacted Ceramic Powder
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Solution Overview
Problem
Current methods for detecting the density of compacted ceramic powder are laborious, require skilled operators, pose health risks due to mercury use, and disrupt continuous production lines, leading to productivity losses and inaccurate density measurements.
Innovation Solution
A detection system and method that uses X-ray absorption and thickness measurements to determine the density of compacted ceramic powder continuously, without creating samples or interrupting production, allowing automated calibration and precise density control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mercury or glycerine immersion measuring devices are used to detect density, then density measurement is possible, but the procedure is laborious and requires skilled operators
Solution Approach 1:
The patent replaces the mechanical immersion measurement system with an optical detection system using a laser beam and photodetector. The laser measures the position of the meniscus formed by mercury or glycerine, and the system calculates density based on optical readings rather than physical immersion and weight measurement. This substitution eliminates the need for skilled operators to perform manual immersion measurements while maintaining measurement accuracy.
2Measurement precision
If mercury immersion measuring devices are used, then density can be determined, but health risks arise due to mercury use
Solution Approach 1:
The patent introduces an optical intermediary (laser beam and photodetector system) that allows measurement of mercury properties without direct human contact with the mercury. The laser measures the meniscus position and the system calculates density, serving as an intermediary between the mercury sample and the operator, thereby eliminating health risks while maintaining measurement capability.
3Measurement precision
If sample production and immersion measurement are performed, then density can be detected, but production continuity is disrupted
Solution Approach 1:
The patent enables continuous density measurement by integrating the optical detection system directly into the production line. The laser and photodetector system continuously monitors the meniscus position of mercury or glycerine as it flows through the measurement chamber, allowing density to be measured without stopping production or creating separate samples, thus maintaining continuous productive action.
4Measurement precision
If manual sample immersion procedure is used, then density measurement is achieved, but time-consuming operations occur
Solution Approach 1:
The patent replaces the time-consuming manual immersion procedure with an automated optical measurement system. The laser continuously tracks the meniscus position and the system automatically calculates density in real-time, eliminating the manual steps of immersing samples, reading scales, and recording data, thereby dramatically reducing measurement time while maintaining accuracy.
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
Enables rapid, reliable, and cost-effective density detection in continuous production, eliminating the need for skilled operators and minimizing production downtime, while ensuring homogeneous density and consistent product quality.
Implementation Method 1
a laser, which measures the position of a meniscus formed by said mercury or glycerine; and a processing unit, which receives a signal from the photodetector and calculates the density of the compacted ceramic powder on the basis of said position
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A detection system (1) and method to detect the density of a layer of compacted ceramic powder (KP); the detection system (1) comprises: a compacting device (8) to compact the ceramic powder (CP) and obtain the layer of compacted ceramic powder (KP); a conveyor assembly (3) to receive and move along a given path (P) the layer of compacted ceramic powder (KP); a measuring device (17) to measure at least a thickness of at least one cross section of said layer of compacted ceramic powder (KP); a weighing device (22) to determine a weight of at least one first portion (PI) of the layer of compacted ceramic powder (KP); a detection device (18) to detect a quantity correlated with the density of the first portion (PI) of the layer of compacted ceramic powder (KP); and a control assembly (23) designed to estimate an actual density of at least one second portion (P2) of the layer of compacted ceramic powder (KP) or of a further layer of compacted ceramic powder (KP) based on data detected by the detection device (18), by the weighing device (22) and by the measuring device (17).