CN109851398B - Intelligent jet printing process for ceramic large plate - Google Patents
Intelligent jet printing process for ceramic large plate Download PDFInfo
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- CN109851398B CN109851398B CN201910147045.4A CN201910147045A CN109851398B CN 109851398 B CN109851398 B CN 109851398B CN 201910147045 A CN201910147045 A CN 201910147045A CN 109851398 B CN109851398 B CN 109851398B
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Abstract
The invention relates to an intelligent jet printing process of a ceramic large plate, which adopts the ink jet printing technology of a serial ink jet printer, realizes the intelligent ink jet production of the ceramic large plate by the layout distribution of preset design of each channel and an intelligent jet printing system with an automatic compensation robot, reduces the manpower and the field of a glaze spraying workshop compared with the production of the prior art, simplifies the production facility, reduces the potential safety hazard, has no glaze spraying on the production field, furthest reduces the equipment loss and the waste water generation caused by a humid environment, obviously improves the production efficiency and the production quality, and more conforms to the modern green automatic intelligent manufacturing direction.
Description
Technical Field
The invention relates to the field of ceramic large plates, in particular to an intelligent jet printing process of a ceramic large plate.
Background
"No big board, not big brand", can see the current ceramic big board (brick) fashion trend. In recent years, no one example of large ceramic plates (bricks) and their molding equipment has become the most attractive product, not only at the blobnia CERSAIE exhibition in italy, but also at the related technical seminars of the ceramic industries at home and abroad, and even in the publicity of large ceramic equipment and manufacturing enterprises. According to the standard specification of GB/T23266-2009, a ceramic large plate (brick) refers to a ceramic tile product with the thickness of not more than 6 mm and the surface area of not less than 1.62 m 2. Compared with stone materials, the ceramic large plate (brick) has many advantages, such as uniform texture, high strength, isotropy, low water absorption, stain resistance, easy cleaning and the like. In decoration, with the maturity of ceramic production technology and inkjet technology, the decoration effect of ceramic large plates (bricks) has revolutionary progress, becomes rich and colorful, exquisite and fine, has stable pattern and color, is suitable for the design expression of large-area and integral effect, and is deeply favored by consumers. At present, but ceramic large plate (brick) manufacturing equipment suppression thickness 3 ~ 30 mm are not equal, have embodied bigger advantage on thickness 3.5 ~ 6 mm especially: the energy consumption is low, the resource utilization rate is high, and compared with a ceramic large plate with the common thickness (the thickness is 10-12 mm), the raw material can be saved by 60%, the energy consumption is reduced by 50%, and the carbon emission is reduced by over 84%. According to different application places, the thin plate and the thick plate are different in different seasons, and all the purposes are determined by actual requirements of markets and application places. In the international ceramic tile market, ceramic large panels (tiles) have become a hot spot in the high-end market. With the continuous breakthrough of the technical difficulties of large-plate production, transportation, paving, installation and the like, the application field of the ceramic large plate (brick) is more and more extensive, the ceramic large plate (brick) is not limited to municipal engineering any more, the application range of the ceramic large plate (brick) is also expanded to the fields of curtain walls, subways, screens, counters, artistic decoration and the like, and the ceramic large plate (brick) becomes a novel decorative building material which is widely applied.
In the prior art, for example, CN104591786A, CN105367131A, for manufacturing ceramic sheet products with inkjet patterns, a process of spraying and/or spraying ground coat (also called cover coat) on the surface of a ground blank layer to play a role of priming and whitening and form a blank coat bonding layer, then spraying color patterns on the ground coat, and then spraying and/or spraying transparent protective glaze on the color pattern layer is generally adopted, because the glaze sprayed and/or sprayed with the ground coat contains more than 25-35% of water, a ball glaze workshop is specially configured for preparation and field operation, which brings complexity to the manufacturing process for environmental protection of a production line and transportation and use of the glaze, so the process of spraying and/or spraying glaze with water operation in the former and later stages needs to be improved and promoted. However, for ceramic large plates, the preparation of the ink-jet layer directly affects the surface color development and the final aesthetic effect of the ceramic large plate.
The above is only for the purpose of assisting understanding of the technical aspects of the present invention, and does not represent an admission that the above is prior art.
Disclosure of Invention
The technical problem solved by the invention is that: the formula of the components of the ceramic large plate blank is optimized, the serial ceramic ink-jet printing technology is adopted, the intelligent ink-jet printing production of the ceramic large plate is realized through the layout distribution of the preset design of each channel and the intelligent ink-jet printing system with the automatic compensation robot, compared with the production of the prior art, the labor, the field and the operation of a glaze spraying workshop are reduced, the production facility is simplified, the potential safety hazard is reduced, glaze spraying is not carried out on the production field, the equipment loss and the waste water generation caused by the humid environment are reduced to the maximum extent, the production efficiency and the production quality are obviously improved, and the method is more suitable for the modern green automatic intelligent manufacturing direction.
The technical scheme adopted by the invention is as follows:
an intelligent spray printing process for a ceramic large plate comprises the following process steps:
firstly, preparing a blank: putting raw material components of the green body into a ball mill, uniformly mixing to obtain slurry, sieving the slurry, ageing, removing impurities, performing spray drying to obtain powder, performing compression molding on the powder, and drying in a drying kiln to obtain a green body layer;
secondly, 7 ink-jet printers are installed on a ceramic production line in series, wherein the distance between the first ink-jet printer and each ink-jet printer is 6m, the distance between the first ink-jet printer and each ink-jet printer is 1 or 2 effective channels, the distance between the second ink-jet printer and each ink-jet printer is 2 effective channels, the distance between the third ink-jet printer and each ink-jet printer is 2 effective channels, the distance between the fourth ink-jet printer and each ink-jet printer is 1 effective channel, the distance between the fifth ink-jet printer and each ink-jet printer is 3 effective channels, the fifth ink-jet printer is 1 effective channel, the sixth ink-jet printer is 1 effective channel, the seventh effective channel, and the seventh effective channel;
the assembly of the ceramic production line facilities and the glaze line facilities is completed;
further, digital jet printing
a. And carrying out ink-jet printing on the dried blank to form a ground coat layer, wherein the ceramic ink is a ceramic ink material which has the performance suitable for an ink-jet pipeline and has the suspension characteristic, the mass fraction of the solid content in the ceramic ink material is 42%, and the mass fraction of Si: the mass ratio of Al is 3.2, the total mass fraction of Si and Al is less than 15%, the mass fraction of Zr is not more than 1%, and the mass fraction of Ce is not more than 2%;
b. printing a required pattern on the ground coat layer by ink jet to form a pattern layer;
c. mixing and compounding the ceramic adhesive and the surface glaze according to the weight ratio of 1:4 to obtain an adhesive glaze, and then spraying the adhesive glaze cloth on the pattern layer to form an adhesive glaze layer;
d. uniformly spreading the whitening dry particles on the adhesive glaze layer to obtain a dry particle layer;
e. spraying a ceramic adhesive on the dry particle layer to obtain a surface adhesive layer;
further, high-temperature firing: and (3) placing the blank subjected to the spraying treatment at the temperature of 1225-1240 ℃ for high-temperature sintering for 180min, cooling to room temperature, and polishing and waxing to obtain a ceramic large plate finished product.
Preferably, the 7 inkjet printers are specifically configured to: ceramic ink which presents a bright white glaze layer after being sintered is filled in a channel of a first ink-jet printer; each channel of the second ink-jet printer is filled with white ink and blue ink respectively; the channel of the third ink-jet printer is filled with brown and yellow ink respectively; the channel of the fourth ink-jet printer is respectively filled with ink comprising black, orange and dark green; the channels of the fifth ink-jet printer are respectively filled with ink containing bloody red; a channel of a sixth ink-jet printer is respectively filled with functional ceramic ink or ceramic ink with metal color; and ceramic ink with 2 channels including glue with the function of protecting glaze after sintering is respectively filled into the channels of the seventh ink-jet printer.
Preferably, the formula system of the ceramic large slab body is as follows: 64% of silicon dioxide, 25% of aluminum oxide, 3.8% of potassium oxide, 2.6% of sodium oxide, 0.6% of calcium oxide, 1.2% of magnesium oxide and 1% of ferric oxide. Loss on ignition is 1.8%.
Preferably, the dry particle layer is formed by uniformly paving whitening dry particles, and the silicon-aluminum content ratio of the whitening dry particles is SiO 2: al2O3 ═ 2.95 to 3.4.
Further, the ceramic adhesive comprises 1.6% of sodium carboxymethyl cellulose, 1-5% of an active agent, 1-3% of an anti-settling agent and 8% of glycerin in percentage by weight, and the chemical components of the ceramic adhesive comprise 20-40% of Na2O and 40-60% of loss on ignition in percentage by weight.
Preferably, the intelligent jet printing process further comprises a ceramic jet printing robot system, and the robot system comprises a six-degree-of-freedom industrial robot.
Further, the robot system specifically comprises a spray gun, full intelligent control equipment, a Kinect vision system, a material conveyor and a gantry robot.
Furthermore, the full intelligent control equipment comprises a mechanism for compensating the robot, and the transmission routes of all joints of the six-freedom-degree industrial robot are split by adopting a compensation method, and the transmission routes of all joints are independently analyzed; performing corner calculation to obtain an induced corner, and further solving a relational expression of an output corner and an input corner; performing superposition operation on the output rotation angles, and obtaining the relationship between the corrected three joint rotation angles and the input rotation angle; and converting the obtained result by a transmission ratio to obtain a mapping relation between the corrected joint rotation angle and the input rotation angle of the servo motor, obtaining a specific motion compensation scheme according to the mapping relation, and converting the motion compensation scheme into an executable instruction file to be input into the robot to be executed.
The invention has the beneficial effects that: the ceramic inkjet printing technology is adopted, intelligent inkjet production of large ceramic boards is realized through layout distribution of preset design of all channels and an intelligent inkjet printing system with an automatic compensation robot, compared with production of the prior art, manpower and places of a glaze spraying workshop are reduced, production facilities are simplified, potential safety hazards are reduced, glaze spraying is not carried out on a production site, equipment loss and waste water generation caused by a humid environment are reduced to the maximum extent, production efficiency and production quality are remarkably improved, and the ceramic inkjet printing technology is more suitable for the modern green automatic intelligent manufacturing direction.
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FIG. 1 is a process flow diagram of the present invention.
Detailed Description
The present invention is specifically described below with reference to examples in order to facilitate understanding of the present invention by those skilled in the art. It should be particularly noted that the examples are given solely for the purpose of illustration and are not to be construed as limitations on the scope of the invention, as non-essential improvements and modifications to the invention may occur to those skilled in the art, which fall within the scope of the invention as defined by the appended claims. Meanwhile, the raw materials mentioned below are not specified in detail and are all commercial products; the process steps or preparation methods not mentioned in detail are all process steps or preparation methods known to the person skilled in the art.
[ example 1 ]
An intelligent spray printing process for a ceramic large plate comprises the following process steps:
firstly, preparing a blank: putting raw material components of the green body into a ball mill, uniformly mixing to obtain slurry, sieving the slurry, ageing, removing impurities, performing spray drying to obtain powder, performing compression molding on the powder, and drying in a drying kiln to obtain a green body layer;
secondly, 7 ink-jet printers are installed on a ceramic production line in series, wherein the distance between the first ink-jet printer and each ink-jet printer is 6m, the distance between the first ink-jet printer and each ink-jet printer is 1 or 2 effective channels, the distance between the second ink-jet printer and each ink-jet printer is 2 effective channels, the distance between the third ink-jet printer and each ink-jet printer is 2 effective channels, the distance between the fourth ink-jet printer and each ink-jet printer is 1 effective channel, the distance between the fifth ink-jet printer and each ink-jet printer is 3 effective channels, the fifth ink-jet printer is 1 effective channel, the sixth ink-jet printer is 1 effective channel, the seventh effective channel, and the seventh effective channel;
the assembly of the ceramic production line facilities and the glaze line facilities is completed;
further, digital jet printing
a. And carrying out ink-jet printing on the dried blank to form a ground coat layer, wherein the ceramic ink is a ceramic ink material which has the performance suitable for an ink-jet pipeline and has the suspension characteristic, the mass fraction of the solid content in the ceramic ink material is 42%, and the mass fraction of Si: the mass ratio of Al is 3.2, the total mass fraction of Si and Al is less than 15%, the mass fraction of Zr is not more than 1%, and the mass fraction of Ce is not more than 2%;
b. printing a required pattern on the ground coat layer by ink jet to form a pattern layer;
c. mixing and compounding the ceramic adhesive and the surface glaze according to the weight ratio of 1:4 to obtain an adhesive glaze, and then spraying the adhesive glaze cloth on the pattern layer to form an adhesive glaze layer;
d. uniformly spreading the whitening dry particles on the adhesive glaze layer to obtain a dry particle layer;
e. spraying a ceramic adhesive on the dry particle layer to obtain a surface adhesive layer;
further, high-temperature firing: and (3) placing the blank subjected to the spraying treatment at the temperature of 1225-1240 ℃ for high-temperature sintering for 180min, cooling to room temperature, and polishing and waxing to obtain a ceramic large plate finished product.
[ example 2 ]
The difference between this embodiment and embodiment 1 is that the inkjet printer of the above-mentioned jet printing process is specifically configured as follows: ceramic ink which presents a bright white glaze layer after being sintered is filled in a channel of a first ink-jet printer; each channel of the second ink-jet printer is filled with white ink and blue ink respectively; the channel of the third ink-jet printer is filled with brown and yellow ink respectively; the channel of the fourth ink-jet printer is respectively filled with ink comprising black, orange and dark green; the channels of the fifth ink-jet printer are respectively filled with ink containing bloody red; a channel of a sixth ink-jet printer is respectively filled with functional ceramic ink or ceramic ink with metal color; and ceramic ink with 2 channels including glue with the function of protecting glaze after sintering is respectively filled into the channels of the seventh ink-jet printer.
[ example 3 ]
Compared with the examples 1 and 2, the formulation system of the ceramic large slab body in the example 3 is as follows: 64% of silicon dioxide, 25% of aluminum oxide, 3.8% of potassium oxide, 2.6% of sodium oxide, 0.6% of calcium oxide, 1.2% of magnesium oxide and 1% of ferric oxide. Loss on ignition is 1.8%.
The dry particle layer is formed by uniformly paving whitening dry particles, and the silicon-aluminum content ratio of the whitening dry particles is SiO 2: al2O3 ═ 2.95 to 3.4.
Further, the ceramic adhesive comprises 1.6% of sodium carboxymethyl cellulose, 1-5% of an active agent, 1-3% of an anti-settling agent and 8% of glycerin in percentage by weight, and the chemical components of the ceramic adhesive comprise 20-40% of Na2O and 40-60% of loss on ignition in percentage by weight.
[ example 4 ]
Embodiment 4 is an intelligent inkjet printing process and apparatus, which is an apparatus for implementing the intelligent inkjet printing process described in embodiments 1 to 3, and specifically includes a ceramic inkjet printing robot system, where the robot system includes a six-degree-of-freedom industrial robot.
Further, the robot system specifically comprises a spray gun, full intelligent control equipment, a Kinect vision system, a material conveyor and a gantry robot.
Furthermore, the full intelligent control equipment comprises a mechanism for compensating the robot, and the transmission routes of all joints of the six-freedom-degree industrial robot are split by adopting a compensation method, and the transmission routes of all joints are independently analyzed; performing corner calculation to obtain an induced corner, and further solving a relational expression of an output corner and an input corner; performing superposition operation on the output rotation angles, and obtaining the relationship between the corrected three joint rotation angles and the input rotation angle; and converting the obtained result by a transmission ratio to obtain a mapping relation between the corrected joint rotation angle and the input rotation angle of the servo motor, obtaining a specific motion compensation scheme according to the mapping relation, and converting the motion compensation scheme into an executable instruction file to be input into the robot to be executed.
It is to be understood that the invention is not limited to the examples described above, but that modifications and variations may be effected thereto by those of ordinary skill in the art in light of the above teachings, and that all such modifications and variations are intended to be within the scope of the invention as defined in the appended claims.
Claims (5)
1. An intelligent spray printing process for a ceramic large plate is characterized by comprising the following process steps:
(1) preparing a blank body:
putting raw material components of the green body into a ball mill, uniformly mixing to obtain slurry, sieving the slurry, ageing, removing impurities, performing spray drying to obtain powder, performing compression molding on the powder, and drying in a drying kiln to obtain a green body layer;
(2) 7 ink-jet printers are installed on a ceramic production line in series, wherein the distance between the first ink-jet printer and each ink-jet printer is 6m, the distance between the first ink-jet printer and each ink-jet printer is 1 or 2 effective channels, the distance between the second ink-jet printer and each ink-jet printer is 6m, the distance between the second ink-jet printer and each ink-jet printer is 2 effective channels, the distance between the third ink-jet printer and each ink-jet printer is 1 effective channel, the distance between the fourth ink-jet printer and each ink-jet printer is 3 effective channels, the third ink-jet printer and the fourth ink-jet printer are 2 effective channels, and the distance between the fifth ink-jet printer and the sixth ink-jet printer is 2 effective channels;
(3) the assembly of the ceramic production line facilities and the glaze line facilities is completed;
(4) digital jet printing:
a. and carrying out ink-jet printing on the dried blank to form a ground coat layer, wherein the ceramic ink is a ceramic ink material which has the performance suitable for an ink-jet pipeline and has the suspension characteristic, the mass fraction of the solid content in the ceramic ink material is 42%, and the mass fraction of Si: the mass ratio of Al is 3.2, the total mass fraction of Si and Al is less than 15%, the mass fraction of Zr is not more than 1%, and the mass fraction of Ce is not more than 2%;
b. printing a required pattern on the ground coat layer by ink jet to form a pattern layer;
c. mixing and compounding the ceramic adhesive and the surface glaze according to the weight ratio of 1:4 to obtain an adhesive glaze, and then spraying the adhesive glaze cloth on the pattern layer to form an adhesive glaze layer;
d. uniformly spreading the whitening dry particles on the adhesive glaze layer to obtain a dry particle layer;
e. spraying a ceramic adhesive on the dry particle layer to obtain a surface adhesive layer;
(5) and (3) high-temperature sintering: sintering the sprayed blank at the temperature of 1225-1240 ℃ for 180min, cooling to room temperature, polishing and waxing to obtain a ceramic large plate finished product;
the intelligent spray printing process further comprises a ceramic spray printing robot system, wherein the robot system comprises a six-degree-of-freedom industrial robot; the robot system specifically comprises a spray gun, full intelligent control equipment, a Kinect vision system, a material conveyor and a portal frame robot;
the full intelligent control equipment comprises a mechanism for compensating the robot, and splits the transmission route of each joint of the six-freedom-degree industrial robot by adopting a compensation method, and independently analyzes the transmission route of each joint; performing corner calculation to obtain an induced corner, and further solving a relational expression of an output corner and an input corner; performing superposition operation on the output rotation angles, and obtaining the relationship between the corrected three joint rotation angles and the input rotation angle; and converting the obtained result by a transmission ratio to obtain a mapping relation between the corrected joint rotation angle and the input rotation angle of the servo motor, obtaining a specific motion compensation scheme according to the mapping relation, and converting the motion compensation scheme into an executable instruction file to be input into the robot to be executed.
2. The intelligent jet printing process of the ceramic large plate according to claim 1, wherein the 7 inkjet printers are specifically configured to: ceramic ink which presents a bright white glaze layer after being sintered is filled in a channel of a first ink-jet printer; each channel of the second ink-jet printer is filled with white ink and blue ink respectively; the channel of the third ink-jet printer is filled with brown and yellow ink respectively; the channel of the fourth ink-jet printer is respectively filled with ink comprising black, orange and dark green; a channel of the fifth ink-jet printer is filled with ink containing bloody red; a channel of a sixth ink-jet printer is filled with functional ceramic ink or ceramic ink with metal color; and ceramic ink with 2 channels including glue with the function of protecting glaze after sintering is respectively filled into the channels of the seventh ink-jet printer.
3. The intelligent jet printing process of the ceramic large plate according to claim 1, characterized in that: the formula system of the ceramic large plate blank body is as follows: 64% of silicon dioxide, 25% of aluminum oxide, 3.8% of potassium oxide, 2.6% of sodium oxide, 0.6% of calcium oxide, 1.2% of magnesium oxide, 1% of ferric oxide and 1.8% of loss on ignition.
4. The intelligent jet printing process of the ceramic large plate according to claim 1, characterized in that: the dry particle layer is formed by uniformly paving whitening dry particles, and the silicon-aluminum content ratio of the whitening dry particles is SiO 2: al2O3 ═ 2.95 to 3.4.
5. The intelligent jet printing process of ceramic large plates according to any one of claims 1 or 2, wherein the ceramic binder comprises 1.6% of sodium carboxymethyl cellulose, 1-5% of an active agent, 1-3% of an anti-settling agent and 8% of glycerin by weight, and the chemical components comprise 20-40% of Na2O and 40-60% of ignition loss by weight.
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