Parallel Ceramic Pressing Segmentation for Cycle Time Reduction
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Solution Overview
Problem
Current ceramic material compacting processes are inefficient due to prolonged pre-compacting and deaerating steps, which increase the total pressing cycle time and energy expenditure, and can result in air bubbles causing damage during unloading and firing, leading to suboptimal slab quality.
Innovation Solution
A device comprising a compactor and a press that perform pre-compacting and deaerating steps in parallel, with the compactor applying a lower load than the press, allowing for simultaneous processing of multiple layers and reducing the thickness of the material before the press applies maximum pressure, thereby shortening the overall cycle time and improving air evacuation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pre-compacting and deaerating steps are performed for sufficiently prolonged time to evacuate air uniformly, then air evacuation quality is improved, but total pressing cycle time increases
Solution Approach 1:
The pressing system is divided into two independent pressing units (first pressing unit and second pressing unit) that operate in parallel. Each unit has its own pressing element and can perform pre-compacting and deaerating steps simultaneously and independently, allowing air evacuation to occur in parallel processes rather than sequentially, thus maintaining high air evacuation quality while reducing total cycle time.
Solution Approach 2:
The first pressing unit performs pre-compacting and deaerating steps as preliminary actions before the second pressing unit applies maximum compacting pressure. This preliminary treatment removes air bubbles and pre-compresses the ceramic material, enabling the subsequent maximum compacting step to be performed more efficiently and in less time.
2Reliability
If pressers are moved away from each other during deaerating step to create passageway for air exit, then air evacuation is improved, but energy expenditure increases due to displacement and return movement
Solution Approach 1:
The pressing system is segmented into two independent units with separate pressing elements. The first pressing unit can maintain its pressing elements in a retracted position or perform deaerating steps while the second pressing unit applies maximum compacting pressure, eliminating the need to fully retract pressing elements and reducing energy expenditure associated with large displacements.
Solution Approach 2:
While the first pressing unit performs deaerating steps, the second pressing unit simultaneously performs maximum compacting. This continuous useful action ensures that pressing operations continue without interruption and that energy is not wasted on retracting and re-advancing pressing elements, as the second unit maintains continuous compacting pressure.
3Device complexity
If a single press performs all compacting steps sequentially, then device complexity is reduced, but productivity decreases due to sequential processing
Solution Approach 1:
The pressing device is segmented into two independent pressing units, each capable of performing the complete pressing cycle (approach, pre-compacting, deaerating, maximum compacting, unloading, return) independently and simultaneously. This segmentation enables parallel processing of multiple ceramic material layers, doubling productivity while maintaining relatively simple individual unit structures.
Solution Approach 2:
Two independent pressing units are merged into a single integrated device that shares common support structures, conveyor systems, and control mechanisms. This merging allows simultaneous operation of multiple pressing elements on different material layers, increasing productivity while avoiding the full complexity of completely separate systems.
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 significantly increases productivity by processing more slabs per unit time, enhances air evacuation during pre-compacting and deaerating, and improves the quality of the final product by reducing air trapped in the ceramic material.
Implementation Method 1
the pressing of the layer of ceramic material takes place directly on the conveyor belt during a stopping step
Implementation Method 2
involves reducing the pressure and moving the two pressers away from each other, for a predefined time, so as to create a passageway that promotes the exit of air still trapped close to the surface areas
Data Source
AI summary
A pressing device for pressing a layer of ceramic material, comprising:a press (10), provided with a lower pad (11), provided with a pressing surface (11a) facing upwards and arranged below the active portion (3) of a first movable belt (2), and an upper pad (12), provided with a pressing surface (12a) facing downwards and arranged above the active portion (3) of the first movable belt (2);a compactor (20), arranged upstream of the press (10), which comprises a lower presser (21), provided with a pressing surface (21a) facing upwards, which is arranged below the active portion (3) of a first movable belt (2), and an upper presser (22), provided with a pressing surface (22a) facing downwards, which is arranged above the active portion (3) of the first movable belt (2).The pressers (21,22) of the compactor (20) can be activated independently of the pads (11,12) of the press (10).