X-ray Density Measurement for Compacted Powder Products
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Solution Overview
Problem
Existing methods for measuring and controlling the density of compacted powder products in ceramic tile production, such as mercury immersion and X-ray absorption techniques, are either destructive, laborious, operator-dependent, and prone to fluctuations, leading to inconsistent product quality and productivity issues, especially in continuous compacting lines.
Innovation Solution
A method and apparatus using an X-ray beam to detect density by compensating output intensity with a reference parameter, generating a control signal to adjust the powder deposition and compacting process, ensuring uniform density across products and batches, and employing a control unit to normalize measurements and account for X-ray beam fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mercury immersion weighing system is used to measure density, then measurement precision is improved (±0.1%), but the process becomes destructive and laborious requiring operator skill
Solution Approach 1:
The patent replaces the mechanical mercury immersion weighing system with an X-ray absorption measurement system. The X-ray beam passes through the compacted powder product and the absorption signal is processed to determine density, eliminating the need for manual sample preparation, mercury handling, and operator skill while achieving comparable or superior measurement precision.
2Measurement precision
If mercury immersion method is used for density measurement, then precision is improved, but productivity decreases due to discontinuous measurement process
Solution Approach 1:
The X-ray measurement system is integrated into the continuous compacting line, allowing density measurements to be performed continuously on the compacted powder product as it moves through the production line. This eliminates the discontinuous nature of the mercury immersion method where samples must be removed, measured, and the production line stopped or slowed.
3Productivity
If X-ray beam is used to measure density, then non-destructive continuous measurement is achieved, but X-ray beam intensity fluctuations affect measurement accuracy
Solution Approach 1:
The patent employs a feedback mechanism where the reference detector continuously monitors the X-ray beam intensity and provides real-time correction signals to the measurement system. The absorption signal from the compacted powder product is compensated based on the reference beam intensity, automatically correcting for fluctuations and maintaining measurement accuracy throughout continuous operation.
Solution Approach 2:
The reference detector acts as an intermediary element that measures the X-ray beam intensity before it interacts with the compacted powder product. By measuring the reference beam and using it to compensate the absorption signal, the system isolates the measurement from beam intensity fluctuations, ensuring accurate density determination.
4Shape
If thickness control system with position transducers is used, then product thickness is kept constant, but density uniformity especially in transverse direction is not improved
Solution Approach 1:
The patent replaces the mechanical thickness control system with X-ray absorption measurement to directly measure and control density. The X-ray beam passes through the compacted powder product and the absorption signal provides direct information about density distribution, including in the transverse direction, allowing for comprehensive density uniformity control rather than just thickness control.
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 enables continuous, non-destructive, and precise measurement of density, maintaining uniformity within individual products and entire production batches, improving productivity and reducing operator variability and X-ray beam fluctuations' impact.
Implementation Method 1
a product can be tested using an X-ray beam which is partially absorbed by the product itself. The X-ray beam emerges from the underside surface in the form of an output beam and is received by a detector.
Implementation Method 2
Processing the X-ray absorption signal and taking into account the thickness measured provides an information item correlated with the density of the material, by applying the Lambert Beer law.
Data Source
AI summary
An apparatus for forming compacted powder products. The apparatus includes a powder supply system and a compacting station. An emitter emits an input X-ray beam having a predetermined emission intensity. An output detector detects an output parameter representing an output intensity of the X-ray beam which passes through the powders. A reference detector detects a reference parameter representing the effective intensity of the X-ray beam generated. A control unit is programmed to compensate the output parameter by means of the reference parameter and to generate a control signal representing the density detected and to control the powder supply system by means of the control signal.