Quartz Container Forming with Dynamic Angle and Rotation Control
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Solution Overview
Problem
The existing manufacturing process of quartz containers faces challenges with raw materials sliding down to the central position of the mold bottom, leading to a low molding rate and reduced efficiency.
Innovation Solution
A method involving a mold with a top cylinder and mold bottom, where raw materials are formed into first and second green bodies at different included angles and rotational speeds to prevent sliding, using a molding piece to create a complete container green body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If raw materials are poured into an inclined and rotating mold using conventional electric arc method, then the molding process can be completed, but the raw materials easily slide down to the center position of the bottom resulting in incomplete container green body formation
Solution Approach 1:
The mold is designed to dynamically adjust its inclination angle during the molding process. The mold starts at an initial inclination angle to facilitate material distribution, then transitions to a second inclination angle to prevent material sliding and ensure complete green body formation. This dynamic adjustment resolves the contradiction between achieving complete molding and maintaining high productivity.
Solution Approach 2:
The invention changes the inclination angle parameter of the mold during the molding process. By adjusting the inclination angle from a first angle to a second angle, the system optimizes material distribution and prevents sliding, thereby improving both the completeness of the green body and the overall molding rate.
2Productivity
If the mold rotates at high speed to improve molding rate, then productivity increases, but the raw materials slide down more easily to the center position reducing manufacturing precision
Solution Approach 1:
The system dynamically adjusts both the rotation speed and inclination angle of the mold. By coordinating the change in inclination angle with the rotation speed, the invention maintains optimal material distribution even at higher rotation speeds, thereby achieving both high productivity and high manufacturing precision.
Solution Approach 2:
The mold is pre-positioned at a specific inclination angle before material pouring, and then adjusted to a second angle during the molding process. This preliminary and sequential adjustment ensures that materials are properly distributed before centrifugal forces from high-speed rotation can cause sliding, thus maintaining precision while achieving high productivity.
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 the molding rate and manufacturing efficiency of quartz containers by preventing material slippage and ensuring a stable formation process.
Implementation Method 1
forming the raw material into a first green body on an inner wall of the top cylinder through the molding piece in a case where a first included angle is formed between an axis of the mold and a horizontal plane and the mold rotates around the axis at a first rotational speed
Implementation Method 2
the raw materials easily slide down to a center position of the bottom under the action of gravity
Data Source
AI summary
A quartz container manufacturing method and a forming apparatus, relating to the solar photovoltaic technical field, and providing a mold comprising a top cylinder and a mold bottom; during formation of a container blank, when the mold forms a first included angle with a horizontal plane and the mold is rotated at a first rotation speed, the source material forms a first blank on the inner wall of the top cylinder; when the mold forms a second included angle with the horizontal plane and the mold is rotated at a second rotation speed, the source material forms a second blank on the inner wall of the mold bottom; a quartz container is manufactured from a container blank composed of the first blank and the second blank.