Multi-Jet Stone Flaming Apparatus with Asymmetric Cooling
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Solution Overview
Problem
Existing surface flaming methods for stone products often result in poor aesthetic quality due to visible patterns and thermal shocks, leading to material deformation and increased energy costs, as they rely on single nozzles and uncontrolled cooling liquids.
Innovation Solution
A multi-tool apparatus combining high-temperature and low-temperature jets, controlled by a microprocessor, which allows for complex movements and simultaneous cooling to emulate manual processing, reducing thermal stress and energy consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single high-temperature flame jet is used for surface flaming, then the flaming process is simple and fast, but visible patterns and grooves are created on the surface degrading aesthetic quality
Solution Approach 1:
The single flame jet is divided into multiple flame jets (at least three) arranged in a specific configuration. Each jet treats a different zone of the surface, and their combined action covers the entire treatment area without creating visible repetitive patterns, thereby maintaining high productivity while improving surface aesthetic quality.
Solution Approach 2:
The flame jets are arranged asymmetrically with different orientations relative to the surface treatment direction. At least one jet is oriented at an angle different from the others, which disrupts the formation of uniform grooves and visible patterns, enhancing surface aesthetic quality while preserving treatment efficiency.
2Productivity
If continuous flame action is applied to the surface, then the flaming process is efficient, but product temperature increases causing ruptures and fractures
Solution Approach 1:
The flame jets operate in a periodic manner with alternating activation and deactivation cycles. This allows the surface to cool between heating pulses, preventing excessive temperature accumulation and thermal shocks that would cause fractures, while maintaining overall flaming efficiency through repeated treatment cycles.
Solution Approach 2:
Cooling jets are positioned to act on the surface before or during the flame treatment to pre-cool the material. This preliminary cooling action prevents the surface from reaching critical temperatures that would cause thermal shocks and fractures, allowing efficient flame treatment without damaging the product.
3Temperature
If cooling liquid is applied to control surface temperature, then overheating is prevented, but uncontrolled cooling contrasts with flame action and causes energy waste
Solution Approach 1:
The system incorporates feedback control where the activation of cooling jets is automatically regulated based on the treatment progress and surface temperature conditions. This ensures cooling is applied only when and where needed, preventing energy waste from uncontrolled cooling while maintaining effective temperature management during flame treatment.
Solution Approach 2:
The cooling liquid application is made dynamic and adaptive rather than continuous and static. The cooling jets are activated and deactivated in response to real-time treatment conditions, optimizing the balance between temperature control and energy consumption by applying cooling only when thermal management is required.
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
The apparatus achieves a high-quality, aesthetically pleasing surface finish with reduced thermal shocks and micro-fractures, similar to manual processing, while optimizing the use of burning and cooling fluids, thus enhancing the cost-effectiveness and safety of the flaming process.
Implementation Method 1
exposing the product surface to local surface heating by the direct action of one or more high-temperature flames
Implementation Method 2
the action of a direct cooling fluid, simultaneous with the flame, to limit the heat load on the slab
Implementation Method 3
The uncontrolled use of cooling liquids in these prior art solutions provides no control over thermal shocks but only prevents overheating of the surface being processed
Data Source
Figure 1
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Figure 3~7
AI summary
A multi-tool apparatus for surface flaming of stone products comprises a support frame (2), a tool holding head (3), means (4) for surface flaming of the product (P), having at least one first jet tool (6) designed to direct a jet (JA) of a high-temperature fluid to the surface (S) being processed, means (5) for locally cooling the product (P) being processed, having at least one second jet tool (7) for directing a low-temperature jet (JB) to the surface (S) being processed. The flaming means (4) comprise at least one series (8) of first jet tools (6, 6', 6'', ...) mounted to said head (3) in a predetermined arrangement for directing respective high-temperature jets (JA, J'A, J''A, ...) to the surface (S) being processed, said at least one second tool (7) being susceptible of directing its respective low-temperature jet (JB) in close proximity to at least one of said high-temperature jets (JA, J'A, J''A, ...).