Slit Coating Head Hopper Washing With Integrated Spray Cleaning
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Solution Overview
Problem
Existing glazing heads in the ceramic industry require manual cleaning units separate from the production line, which are inefficient and disrupt production, and lack automatic, compact, and reliable cleaning solutions integrated into the production line.
Innovation Solution
A washing apparatus integrated into the production line, comprising a hopper with two parts, lifting means for vertical movement, a cleaning unit with spraying means, and moving means for longitudinal positioning, allowing automatic and efficient cleaning of the hopper without disrupting production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate manual cleaning unit is used, then the hopper can be cleaned, but production is disrupted and efficiency decreases
Solution Approach 1:
The cleaning unit is integrated into the production line as an inherent component rather than a separate manual device. The cleaning unit moves along the production line and performs cleaning operations automatically, combining the cleaning function with the production system to eliminate production disruptions.
Solution Approach 2:
The system enables automatic cleaning operations where the cleaning unit is positioned and operated automatically along the production line. The hopper can be cleaned without manual intervention disrupting production, as the cleaning process is automated and coordinated with production cycles.
2Productivity
If the cleaning unit is integrated into the production line, then productivity is maintained, but the device complexity increases
Solution Approach 1:
The cleaning unit is designed as a multi-functional device that can service multiple hoppers along the production line. It combines lifting mechanisms, spraying systems, and movement capabilities in a single integrated unit that performs both cleaning and positioning functions, reducing the need for separate dedicated components for each hopper.
Solution Approach 2:
The cleaning unit incorporates movable and adjustable components including lifting means for vertical movement, spraying means for cleaning, and moving means for longitudinal positioning. These dynamic elements allow the cleaning unit to adapt to different positions and configurations along the production line, managing complexity through flexibility rather than fixed rigid structures.
3Ease of operation
If the hopper is made of two parts for cleaning access, then cleaning is facilitated, but the device complexity increases
Solution Approach 1:
The hopper is divided into two separate parts: a fixed part and a movable part that can be displaced relative to each other. This segmentation allows the movable part to be opened for cleaning access while maintaining the structural integrity and functionality of the fixed part during operation.
Solution Approach 2:
The movable part of the hopper is designed to be displaceable along the direction of the outlet slot, allowing it to move between a closed position for glazing operation and an open position for cleaning access. This dynamic capability enables easy cleaning without permanent structural modifications.
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 automatic, compact, and reliable cleaning of the glazing head hopper, ensuring consistent glazing quality without production interruptions, aligning with Industry 4.0 requirements.
Implementation Method 1
lifting means, connected to the afore-mentioned glazing head and aimed at vertically moving the glazing head between at least two characteristic positions
Implementation Method 2
spraying means, provided in the afore-mentioned cleaning unit to dispense cleaning fluid under pressure inside the afore-mentioned hopper
Implementation Method 3
moving means, connected to the afore-mentioned cleaning unit, aimed at moving the latter in a longitudinal direction with respect to the afore-mentioned straight conveying line
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The apparatus (1) is aimed at washing a glazing head (2) which, when at work, applies liquid ceramic glaze on ceramic tiles or slabs. The glazing head (2) comprises a hopper (20) composed of two parts (20F, 20M), movable one with respect to the other between an operative close position (W) and an inoperative open position (A), suitable for internal washing. The apparatus (1) comprises: lifting means (11), aimed at vertically moving the glazing head (2) between a lowered operating position (B), and a raised maintenance position (H), in which the hopper (20) is placed in its open position (A); a cleaning unit (12), provided with spraying means (120), capable of dispensing detergent fluid under pressure into the afore-mentioned hopper (20). The cleaning unit (12) is provided with moving means (13), aimed at moving horizontally the cleaning unit between a rest position (N), in which the afore-mentioned cleaning unit (12) is spaced from the afore-mentioned glazing head (2), and a washing position (L) in which it is positioned below the afore-mentioned glazing head (2), which has been previously brought to its raised maintenance position (H): in this way the spraying means (120) are centred with respect to the hopper (20), and it is possible to dispense the detergent liquid that hits and washes the internal walls of the latter.