CN113511880B - Process system for manufacturing ceramic products by adopting clay material of volcanic rock - Google Patents
Process system for manufacturing ceramic products by adopting clay material of volcanic rock Download PDFInfo
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- C04B33/00—Clay-wares
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- C04B33/00—Clay-wares
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- C04B33/00—Clay-wares
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- C04B33/00—Clay-wares
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- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
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Abstract
The invention provides a clay material adopting volcanic rock, which comprises a mixture consisting of an initial clay material, a viscosity reducer, an active agent, a separant and a mixing agent; the viscosity reducer is used for mixing the initial pug, the active agent is used for enhancing the activity of the initial pug, the isolating agent is used for isolating bubbles, and the mixing agent is used for enhancing the mixing effect of the initial pug. According to the invention, for example, the good-quality volcanic clay in the Zhongdao and the matching of the manufacturing process can be selected, so that the prepared ceramic product has the advantages of light weight, convenience in carrying and strong plasticity in the preparation process; meanwhile, the initial mud, the viscosity reducer, the active agent, the separant and the mixing agent are mixed with one another, so that the volcanic mud is modified, the use performance of the ceramic product is effectively improved, the ceramic product has the advantages of high hardness, wear resistance, heat dispersion and grabbing hand feeling, and the best use effect is guaranteed.
Description
Technical Field
The invention relates to the technical field of ceramic product manufacturing, in particular to a clay material adopting volcanic rock and a process system for manufacturing ceramic products by using the clay material.
Background
The porcelain is an article which is composed of porcelain stone, kaolin, quartz stone, mullite and the like, and is coated with vitreous glaze or colored drawing on the surface. The invention of the porcelain is a great contribution of the Chinese nation to the world civilization, and the porcelain (China) is the same as the Chinese (China) in English. But volcanic rock has incomparable effect compared with common materials.
For example, CN111732424A prior art discloses a low expansion ceramic blank and a preparation method of ceramic, the expansion coefficient of the existing ceramic for containing or boiling water is mostly about α (800-20 ℃) =3.5 × 10-6/DEG C, the thermal shock resistance of the existing ceramic for containing or boiling water is not cracked after water quenching at 250-20 ℃, the existing ceramic cannot be used for heating water or cooking food by high-power electric appliances, the application range of volcanic ceramic is blocked, and the requirements of ceramic cookers matched with electric appliances are further increased along with the upgrading of consumption quality of people, so that a volcanic ceramic product with wider application range is urgently required to be developed. The high-performance volcanic ceramic product requires that the volcanic ceramic product has a very low thermal expansion coefficient so as to meet the requirement on the rapid cooling and thermal shock resistance of the volcanic ceramic product. A large number of searches show that the existing prior art such as KR101654364B1, EP2482996B1 and US08721396B1, natural volcanic products have more than thirty trace elements beneficial to human health, but the treatment process is complex, the volcanic is used as a raw material, and the prepared volcanic ceramic ware product has tiny air holes which cannot be seen by naked eyes and has the characteristics of ventilation and no leakage. However, the existing ceramic tile products still have the defect of poor weather resistance, are easy to age and crack and limit the service life of the ceramic tiles.
The invention is made in order to solve the problems of easy bubble generation, low plasticity, low strength, heavy quality and the like in the field.
Disclosure of Invention
The invention aims to provide a clay material adopting volcanic rock and a process for manufacturing a ceramic product by using the clay material aiming at the defects of the prior clay material and the manufacturing process thereof.
In order to overcome the defects of the prior art, the invention adopts the following technical scheme:
a clay material adopting volcanic rocks comprises an initial clay material, a viscosity reducer, an active agent, a separant and a mixing agent, wherein the initial clay material, the viscosity reducer, the active agent, the separant and the mixing agent are mixed with each other to form a mixture; the viscosity reducer is used for mixing the initial pug and reducing the viscosity of the initial pug; the active agent is used for enhancing the activity of the initial pug; the release agent is used for releasing bubbles; the mixing agent is used for enhancing the mixing effect of the initial pug.
Optionally, the initial mud material comprises 160-2000 parts of finished slurry water with volcanic rock solid concentration of 10% -70%; 100-900 parts of clay; 10-20 parts of a binder; 30-90 parts of silicone oil; 2-10 parts of octyl phenol polyoxyethylene ether; 1-7 parts of Tween-60 and 23-50 parts of unsaturated fatty acid.
Optionally, the viscosity reducer comprises 3-30% by weight of at least one of methyl tosylate, dimethyl sulfate and dimethyl carbonate.
Optionally, the active agent comprises one or more of 20-50% saturated fatty acid, 12-20% organosilicon compound, 2-5% high molecular organic substance, and 12-32% sodium stearate.
Optionally, the sequestering agent comprises at least 95% calcium phosphate comprising α -tricalcium phosphate, β -tricalcium phosphate, octacalcium phosphate, alkali or alkaline earth modified tricalcium phosphate, calcium pyrophosphate, B-carbon apatite, calcium deficient hydroxyapatite, or mixtures thereof.
Optionally, the mixing agent comprises one or more of limestone, calcite, diopside, wollastonite, dolomite, talc and industrial waste residue.
Optionally, the separant comprises 35-60 parts of 32-100 mesh quartz particles; 40-65 parts of 100-140 mesh calcined Al2O3 or quartz particles; 0.5-2 parts of peach gum or sodium carboxymethyl cellulose CMC, and the peach gum or the sodium carboxymethyl cellulose is dissolved by using a solvent with the weight ratio of 6-20 times, and a proper amount of solvent is added to be prepared into a thin paste.
A process system for manufacturing ceramic products by using volcanic clay comprises the steps of processing initial clay by production equipment, and mixing each initial clay, a viscosity reducer, an active agent, a separant and a mixing agent to form finished slurry;
adding soda ash accounting for 0.4-0.5% of the mass of the dry base materials to dilute the slurry, dissolving the soda ash by hot water at the temperature of 80-85 ℃, adding the hot water until the soda ash is completely dissolved, then discharging the slurry after ball milling and mixing for 10min, and standing and ageing the slurry for 3-5 h for later use;
the slurry is fully pulped and sieved by a 60-mesh sieve for use, a ceramic blank body is formed by adopting the traditional slip casting process, and the ceramic blank body is dried;
drying, sintering in roller kiln at 1200-1300 deg.c for 3-5 hr to obtain the ceramic product.
Optionally, the production equipment includes a stirring device, a detection device, an induction device, a ball milling device, a processing device and a processor, and the processor is respectively in control connection with the stirring device, the detection device, the induction device, the ball milling device and the processing device.
The beneficial effects obtained by the invention are as follows:
1. by adopting the cooperation of the clay material and the manufacturing process, the prepared ceramic product has the advantages of light weight, convenience in carrying and high plasticity in the preparation process;
2. the initial pug, the viscosity reducer, the active agent, the separant and the mixing agent are mixed with one another, and volcanic rock is modified, so that the service performance of the ceramic product is effectively improved, and the ceramic product has the advantages of high hardness, wear resistance, heat dispersion and optimal grabbing hand feeling;
3. the detection device is used for detecting the stirring degree of the mixture, the stirring device and the detection device are matched with each other, and the stirring speed and the stirring time of the stirring device are adjusted based on the detection effect of the detection device;
4. the ball milling device is used for grinding volcanic rocks or dry materials and is used for ensuring that the mixture is in the same granularity range;
5. by adopting the matching of the detection device and the induction device, the mixing effect of the mixture can be accurately controlled, and the quality of the ceramic product is effectively improved;
6. each sensing piece is matched with the flat laying component for use, so that the thickness of the coating layer can be increased, and the parameters of the coating layer are further improved and collected;
7. the ball milling cavity is locked through the locking component, so that the position of the ball milling cavity is effectively prevented from being limited, and the ball milling mechanism is more stable and reliable in the process of grinding raw materials such as limestone;
8. the induction pieces are arranged on one side, facing the transparent plate, of the sweeping piece, and the mixing effect of the mixture is detected in the process of sweeping the mixture flat.
Drawings
The invention will be further understood from the following description in conjunction with the accompanying drawings. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the embodiments. Like reference numerals designate corresponding parts throughout the different views.
FIG. 1 is a schematic flow chart of the process for making the ceramic product according to the present invention.
Fig. 2 is a schematic structural diagram of the ball milling device.
Fig. 3 is a schematic side view of the ball milling apparatus.
Fig. 4 is a schematic structural view of the sampling member.
Fig. 5 is a schematic structural diagram of the detection mechanism.
FIG. 6 is a schematic view of the lay-flat member.
FIG. 7 is a partially detailed schematic view of the lay-flat member.
Fig. 8 is a schematic structural view of the detection probe and the transparent plate.
Fig. 9 is a schematic structural view of the mixing device.
Fig. 10 isbase:Sub>A schematic cross-sectional view taken atbase:Sub>A-base:Sub>A in fig. 9.
Fig. 11 is a schematic view of the construction of the stirring rod and the mixing mechanism.
The reference numbers indicate: 1-a support member; 2-erecting a rod; 3-a locking member; 4-a movable rod; 5-a confinement ring; 6-ball milling chamber; 7-adjusting the base; 8-posture detection; 9-sampling spoon; 10-limit stop; 11-a sampling channel; 12-a lifting rod; 13-a wiper; 14-a support bar; 15-lifting the rod; 16-a support seat; 17-a sweeping drive mechanism; 18-a connecting rod; 19-a storage chamber; 20-a storage recess; 21-detection area; 22-a lifting drive mechanism; 23-a mixing chamber; 24-a stirring rod; 25-a mixing mechanism; 26-mixing the materials; 27-a transparent plate; 28-distance sensor; 29-a sensing member; 30-a detection probe; 31-a storage chamber; 32-cleaning a plate; 33-cleaning the driving mechanism; 34-a storage chamber; 35-a hinged lever; 36-a sensor strip; 37-a clearing bar; 38-flat lay member.
Detailed Description
In order to make the objects and advantages of the present invention more apparent, the present invention will be further described in detail with reference to the following embodiments; it should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. Other systems, methods, and/or features of the present embodiments will become apparent to those skilled in the art upon review of the following detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the present invention. Additional features of the disclosed embodiments are described in, and will be apparent from, the detailed description that follows.
The same or similar reference numerals in the drawings of the embodiments of the present invention correspond to the same or similar components; in the description of the present invention, it should be understood that if there is an orientation or positional relationship indicated by the terms "upper" and "lower" and "left" and "right" etc., it is only for convenience of description and simplification of the description based on the orientation or positional relationship shown in the drawings, but it is not indicated or implied that the device or assembly referred to must have a specific orientation.
The first embodiment is as follows: a clay material adopting volcanic rock comprises an initial clay material, a viscosity reducer, an active agent, a separant and a mixing agent, wherein the initial clay material, the viscosity reducer, the active agent, the separant and the mixing agent are mixed with each other to form a mixture; the viscosity reducer is used for mixing the initial pug and reducing the viscosity of the initial pug; the active agent is used for enhancing the activity of the initial pug; the release agent is used for releasing bubbles; the mixing agent is used for enhancing the mixing effect of the initial pug; the initial mud material is volcanic mud material;
further, the initial mud comprises 160-2000 parts of finished slurry water with volcanic rock solid concentration of 10% -70%; 100-900 parts of clay; 10-20 parts of a binder; 30-90 parts of silicone oil; 2-10 parts of octyl phenol polyoxyethylene ether; 1-7 parts of Tween-60 and 23-50 parts of unsaturated fatty acid; in this embodiment, volcanic rock may be preferred to \28064;, volcanic rock in the continental island;
further, the viscosity reducer comprises 3-30% by weight of at least one of methyl tosylate, dimethyl sulfate and dimethyl carbonate;
further, the active agent comprises one or more of 20-50% of saturated fatty acid, 12-20% of organic silicon compound, 2-5% of high molecular organic matter and 12-32% of sodium stearate;
further, the sequestering agent comprises at least 95% calcium phosphate comprising α -tricalcium phosphate, β -tricalcium phosphate, octacalcium phosphate, alkali metal-modified or alkaline earth metal-modified tricalcium phosphate, calcium pyrophosphate, a carbon apatite B, a calcium deficient hydroxyapatite, or a mixture thereof;
further, the mixing agent comprises one or more of limestone, calcite, diopside, wollastonite, dolomite, talc and industrial waste residues;
further, the separant comprises 35-60 parts of 32-100 mesh quartz particles; 40-65 parts of 100-140 mesh calcined Al2O3 or quartz particles; 0.5-2 parts of peach gum or sodium carboxymethyl cellulose CMC, dissolving the peach gum or the sodium carboxymethyl cellulose by using a solvent with the weight ratio of 6-20 times, and adding a proper amount of solvent to be prepared into a thin paste;
a process system for manufacturing ceramic products by using volcanic clay comprises the steps of processing initial clay by production equipment, and mixing each initial clay, a viscosity reducer, an active agent, a separant and a mixing agent to form finished slurry;
adding soda ash accounting for 0.4-0.5% of the mass of the dry base materials to dilute the slurry, dissolving the soda ash by hot water at the temperature of 80-85 ℃, adding the hot water until the soda ash is completely dissolved, then discharging the slurry after ball milling and mixing for 10min, and standing and ageing the slurry for 3-5 h for later use;
the slurry is fully pulped and is used after being screened by a 60-mesh sieve, a ceramic blank body is formed by adopting the traditional slip casting process, and the ceramic blank body is dried; in other embodiments, screening with 20-120 meshes can be used for preparing different ceramic products, in this embodiment, only 60 meshes are taken as an example, and other meshes can be produced according to 60 meshes;
drying, sintering in a roller kiln by using oxidizing flame at 1200-1300 ℃ for 3-5 hours to obtain a ceramic product;
furthermore, the production equipment comprises a stirring device, a detection device, an induction device, a ball milling device, a processing device and a processor, wherein the processor is respectively in control connection with the stirring device, the detection device, the induction device, the ball milling device and the processing device.
Example two: this embodiment is to be understood as embracing at least all the features of any one of the preceding embodiments and further modifications thereto; providing a clay material adopting volcanic rock, which comprises an initial clay material, a viscosity reducer, an active agent, a separant and a mixing agent, wherein the initial clay material, the viscosity reducer, the active agent, the separant and the mixing agent are mixed with each other to form a mixture; the viscosity reducer is used for mixing the initial pug and reducing the viscosity of the initial pug; the active agent is used for enhancing the activity of the initial pug; the release agent is used for releasing bubbles; the mixing agent is used for enhancing the mixing effect of the initial pug;
the initial mud material comprises 160-2000 parts of finished slurry water with the volcanic rock solid concentration of 10% -70%; 100-900 parts of clay; 10-20 parts of a binder; 30-90 parts of silicone oil; 2-10 parts of octyl phenol polyoxyethylene ether; 1-7 parts of Tween-60 and 23-50 parts of unsaturated fatty acid; the viscosity reducer comprises 3-30 wt% of at least one of methyl tosylate, dimethyl sulfate and dimethyl carbonate; the volcanic rock can be preferably selected from 28064volcanic rock in the continental island; the active agent comprises one or more of 20-50% of saturated fatty acid, 12-20% of organic silicon compound, 2-5% of high molecular organic matter and 12-32% of sodium stearate; the sequestering agent comprises at least 95% calcium phosphate comprising α -tricalcium phosphate, β -tricalcium phosphate, octacalcium phosphate, alkali or alkaline earth modified tricalcium phosphate, calcium pyrophosphate, a type B carbon apatite, a calcium deficient hydroxyapatite, or a mixture thereof; the mixing agent comprises one or more of limestone, calcite, diopside, wollastonite, dolomite, talc and industrial waste residues; the separant comprises 35-60 parts of 32-100 mesh quartz particles; 40-65 parts of 100-140-mesh calcined Al2O3 or quartz particles; 0.5-2 parts of peach gum or sodium carboxymethyl cellulose CMC, dissolving the peach gum or the sodium carboxymethyl cellulose by using a solvent with the weight ratio of 6-20 times, and adding a proper amount of solvent to be prepared into a thin paste;
three different formulations were used as comparative controls in this example below:
comparative example 1: s1: stirring initial pug (160-2000 parts of finished slurry with volcanic rock solid concentration of 10-70%, 100-900 parts of clay, 10-20 parts of binder, 30-90 parts of silicone oil, 2-10 parts of octylphenol polyoxyethylene ether, 23-50 parts of Tween-601-7 parts and unsaturated fatty acid) in a homogenizing stirrer at constant temperature of 50 ℃; wherein the proportion of each component is as follows: 200 parts, 120 parts, 11 parts, 32 parts, 3.5 parts and 26 parts; the volcanic rock can be preferably selected from 28064volcanic rock in the continental island;
s2: fully stirring viscosity reducers (methyl tosylate, dimethyl sulfate and dimethyl carbonate with the weight of 3-30%) in a homogenizing mixer, then adding the viscosity reducers into the step S1), and stirring and dissolving; wherein the proportion of each component is as follows: 12%, 3.9% and 5.6%;
s3: slowly adding an active agent into the mixture obtained in the step S1) and the step S2) under stirring, (20-50% of saturated fatty acid, 12-20% of organic silicon compound, 2-5% of high molecular organic matter and 12-32% of sodium stearate), and carrying out vacuum homogeneous mixing for 5 minutes; wherein the proportion of each component is as follows: 22%,13.5%,3.5%,18%; the polymer organic material includes: animal feathers;
s4: starting cooling water under slow stirring, adding 95% calcium phosphate, and stirring thoroughly;
s5: adding the mixture powder, and fully and uniformly stirring;
s6; adding soda ash 0.4-0.5% of the dry base material by mass for diluting the slurry, dissolving the soda ash by hot water at 80-85 ℃, adding the hot water until the soda ash is completely dissolved, then discharging the slurry after ball milling and mixing for 10min, standing and ageing the slurry for 3-5 h for later use
S7: sampling and detecting the mixing degree of the finished slurry;
s8: the slurry is fully pulped and is used after being screened by a 60-mesh sieve, a ceramic blank body is formed by adopting the traditional slip casting process, and the ceramic blank body is dried;
s9: the finished product is tested to be qualified and dried, and then the finished product is put into a roller kiln, and is sintered in the roller kiln by adopting oxidizing flame at the sintering temperature of 1200-1300 ℃ for 3-5 hours to obtain a ceramic product;
comparative example 2: s1: stirring initial pug (160-2000 parts of finished slurry with volcanic rock solid concentration of 10-70%, 100-900 parts of clay, 10-20 parts of binder, 30-90 parts of silicone oil, 2-10 parts of octylphenol polyoxyethylene ether, 23-50 parts of Tween-601-7 parts and unsaturated fatty acid) in a homogenizing stirrer at constant temperature of 50 ℃; wherein the proportion of each component is as follows: 320 parts, 150 parts, 15 parts, 50 parts, 5.5 parts and 36 parts; the volcanic rock can be preferably selected from 28064volcanic rock in the continental island;
s2: fully stirring viscosity reducers (methyl tosylate, dimethyl sulfate and dimethyl carbonate with the weight of 3-30%) in a homogenizing mixer, then adding the viscosity reducers into the step S1), and stirring and dissolving; wherein the proportion of each component is as follows: 16%, 8.9%,3.9%;
s3: slowly adding an active agent into the mixture obtained in the step S1) and the step S2) under stirring, (20-50% of saturated fatty acid, 12-20% of organic silicon compound, 2-5% of high molecular organic matter and 12-32% of sodium stearate), and carrying out vacuum homogeneous mixing for 5 minutes; wherein the proportion of each component is as follows: 26%,15%,4.2%,22%;
s4: starting cooling water under slow stirring, adding 95% calcium phosphate, and stirring thoroughly;
s5: adding the mixture powder, and fully and uniformly stirring;
s6: adding soda ash accounting for 0.4-0.5% of the mass of the dry base materials to dilute the slurry, dissolving the soda ash by hot water at the temperature of 80-85 ℃, adding the hot water until the soda ash is completely dissolved, then discharging the slurry after ball milling and mixing for 10min, and standing and ageing the slurry for 3-5 h for later use;
s7: sampling and detecting the mixing degree of the finished slurry;
s8: the slurry is fully pulped and is used after being screened by a 60-mesh sieve, a ceramic blank body is formed by adopting the traditional slip casting process, and the ceramic blank body is dried;
s9: the finished product is tested to be qualified and dried, and then the finished product is put into a roller kiln, and is sintered in the roller kiln by adopting oxidizing flame at the sintering temperature of 1200-1300 ℃ for 3-5 hours to obtain a ceramic product;
comparative example 3: s1: stirring initial pug (160-2000 parts of finished slurry with 10-70% of volcanic rock solid concentration, 100-900 parts of clay, 10-20 parts of binder, 30-90 parts of silicone oil, 2-10 parts of octylphenol polyoxyethylene ether, 23-50 parts of Tween-601-7 parts and unsaturated fatty acid) in a homogenizing stirrer at constant temperature of 50 ℃; wherein the proportion of each component is as follows: 350 parts, 300 parts, 16 parts, 60 parts, 8.5 parts and 43 parts; the volcanic rock can be preferably selected from 28064volcanic rock in the continental island;
s2: fully stirring viscosity reducers (methyl tosylate, dimethyl sulfate and dimethyl carbonate with the weight of 3-30%) in a homogenizing mixer, then adding the viscosity reducers into the step S1), and stirring and dissolving; wherein the proportion of each component is as follows: 26%, 7.65%,6.43%;
s3: slowly adding an active agent into the mixture obtained in the step S1) and the step S2) under stirring, (20-50% of saturated fatty acid, 12-20% of organic silicon compound, 2-5% of high molecular organic matter and 12-32% of sodium stearate), and carrying out vacuum homogeneous mixing for 5 minutes; wherein the proportion of each component is as follows: 46%,19%,4.7%,29%;
s4: starting cooling water under slow stirring, adding 95% calcium phosphate, and stirring thoroughly;
s5: adding the mixture powder, and fully and uniformly stirring;
s6: adding sodium carbonate with the mass of 0.4-0.5% of the dry base material to dilute the slurry, dissolving the sodium carbonate by hot water with the temperature of 80-85 ℃ until the sodium carbonate is completely dissolved, then discharging the slurry after ball milling and mixing for 10min, standing and ageing the slurry for 3-5 h for later use
S7: sampling and detecting the mixing degree of the finished slurry;
s8: the slurry is fully pulped and is used after being screened by a 60-mesh sieve, a ceramic blank body is formed by adopting the traditional slip casting process, and the ceramic blank body is dried;
s9: the finished product is tested to be qualified and dried, and then the finished product is put into a roller kiln, and is sintered in the roller kiln by adopting oxidizing flame at the sintering temperature of 1200-1300 ℃ for 3-5 hours to obtain a ceramic product;
the following are the results of trial use to evaluate the use of the ceramic products manufactured in examples 1, 2 and 3; selecting 100 consumers as trial objects by adopting a blind test investigation and grading method, dividing the trial objects into two groups at random, and respectively using the products prepared in the comparative examples 1, 2 and 3 for daily use, wherein the service time is two months; the using effects of the ingredients are divided into 5 points: 5 is the highest score, which represents good and very satisfactory; 4, the division is better; 3 is acceptable; not good for less than 3 points, unacceptable; the average score of each item is as follows;
the results are shown in Table 1:
TABLE 1 examination of the comprehensive results
In addition, compared with the ceramic products sold in the market, volunteers (18-66 years old, 200 persons) were selected, and the prepared ceramic products were used in daily life of the volunteers for one month, as shown in table 2:
table 2:
volunteers generally feel hot water at the same temperature, the cooling effect is obvious, and the grabbing touch feeling is good; the ceramic has no special reaction in daily use and high hardness; after one month of continuous use, the ceramic surface has a layer of film, and the ceramic surface has the self-cleaning effect of the surface.
Example three: this embodiment should be understood to include at least all of the features of any of the foregoing embodiments and further modifications thereon; providing a process system for manufacturing ceramic products by using the clay material of volcanic rock, wherein the process comprises the steps of treating the initial clay material through production equipment, and mixing each initial clay material, a viscosity reducer, an active agent, a separant and a mixing agent to form a finished product slurry; adding soda ash accounting for 0.4-0.5% of the mass of the dry base materials to dilute the slurry, dissolving the soda ash by hot water at the temperature of 80-85 ℃, adding the hot water until the soda ash is completely dissolved, then discharging the slurry after ball milling and mixing for 10min, and standing and ageing the slurry for 3-5 h for later use; the slurry is fully pulped and sieved by a 60-mesh sieve for use, a ceramic blank body is formed by adopting the traditional slip casting process, and the ceramic blank body is dried; drying, sintering in a roller kiln by using oxidizing flame at 1200-1300 ℃ for 3-5 hours to obtain a ceramic product;
the production equipment comprises a stirring device, a detection device, an induction device, a ball milling device, a processing device and a processor, wherein the processor is respectively in control connection with the stirring device, the detection device, the induction device, the ball milling device and the processing device; the stirring device is used for mixing the initial pug, the viscosity reducer, the active agent, the separant and the mixing agent to form a mixed material and stirring; the detection device is used for detecting the stirring degree of the mixture, meanwhile, the stirring device is matched with the detection device, and the stirring speed and the stirring time of the stirring device are adjusted based on the detection effect of the detection device; the ball milling device is used for grinding volcanic rocks or dry materials and is used for ensuring that the mixture is in the same granularity range; the processing device collects the data of the detection device and the ball milling and stores the processing data in the processing process; the processor is respectively in control connection with the stirring device, the detection device, the induction device, the ball milling device and the processing device, and is used for uniformly regulating and controlling all the devices under the centralized control of the processor, so that the high efficiency and the reliability of ceramic product processing are improved;
the stirring device comprises a stirring cavity, a stirring mechanism and a mixing mechanism, wherein the stirring mechanism and the mixing mechanism are both arranged in the stirring cavity and are used for stirring and mixing the mixture added into the stirring cavity; the mixing mechanism is used for stirring the material pieces stirred by the stirring mechanism in an auxiliary manner, so that the material can be stirred in a stirring area of the stirring mechanism; the stirring mechanism comprises a speed detection module, a stirring rod and a stirring driving mechanism, one end of the stirring rod extends into the stirring cavity, the other end of the stirring rod is in driving connection with the stirring driving mechanism, and the speed detection module is used for detecting the stirring speed of the stirring rod; in addition, the stirring rod is arranged to be a telescopic structure and is used for stirring different positions of the stirring cavity; the stirring mechanism further comprises a telescopic driving mechanism which is constructed to be in driving connection with the stirring rod so that the stirring rod is driven to extend or shorten;
the mixing mechanism comprises a rotating rod, a poking disc and a mixing driving mechanism, the poking disc is arranged at one end of the rotating rod, the other end of the rotating rod is in driving connection with the mixing driving mechanism, and the mixing mechanisms are arranged at two sides of the stirring mechanism and used for detecting the positions of the two sides of the stirring mechanism so as to ensure that materials in the stirring cavity can be fully mixed;
the detection device comprises a detection mechanism and a sampling mechanism, and the sampling mechanism and the detection mechanism are used for detecting the stirring degree of the mixture in the mixing cavity; the detection mechanism comprises a detection plate, a detection module and a cleaning component, wherein the detection plate is provided with a storage cavity for the detection module to accommodate, and is also provided with a transparent plate for sealing the storage cavity; the detection module is arranged in the storage cavity and extends out towards one side of the transparent plate; the detection module comprises a plurality of detection probes and a steering component, each detection probe is arranged on the steering component, and the detection angle is adjusted under the rotation operation of the steering component; the sampling mechanism comprises a sampling component and a cleaning component, and is used for sampling the mixture and transporting the mixture to the detection area of the detection mechanism through the sampling component; the cleaning component is used for cleaning the detection area; the cleaning component comprises a cleaning plate, a cleaning rod and a cleaning driving mechanism, the cleaning plate is arranged at one end of the cleaning rod, and the other end of the cleaning rod is in driving connection with the cleaning driving mechanism; the cleaning component is arranged on one side of the cleaning plate and is hidden in the storage cavity in a non-use state; the cleaning rod is arranged in a telescopic mode, and the cleaning driving mechanism is arranged in a hydraulic driving structure;
the sampling component comprises a sampling channel, a sampling spoon, a lifting rod and a lifting driving mechanism, wherein the sampling spoon is arranged at one end of the lifting rod to form a sampling part, and the sampling part is nested with the sampling channel and moves in the sampling channel under the action of the lifting driving mechanism; the end part of the other end of the lifting rod is in driving connection with the lifting driving mechanism; the sampling spoon is matched with the sampling channel; one end of the sampling channel is communicated with the stirring cavity, the other end of the sampling channel is arranged above the detection plate, a storage groove for storing the mixture is arranged at the tail end of the sampling channel, and the groove direction of the storage groove is parallel to the groove direction of the storage cavity, so that the mixture conveyed by the sampling spoon can be gathered on the detection plate; the detection mechanism further comprises a flat laying component, and the flat laying component is used for carrying out flat laying on the mixed material; during the process of flatly laying the mixture through the flatly laying component, the mixture can be detected in the detection area under the flatly laying operation of the flatly laying component; meanwhile, the flat laying component can adjust the flat laying thickness according to the process requirement; in addition, limit stops are arranged on the periphery of the sampling spoon and the sampling channel and used for cleaning the residual materials of the mixture in the sampling channel; the lifting driving mechanism is in a hydraulic driving type;
the flat laying component comprises a sweeping part, a supporting rod and a sweeping driving mechanism, one end of the supporting rod is connected with the sweeping part, the other end of the supporting rod is connected with the sweeping driving mechanism in a driving mode to form a sweeping part, and the sweeping driving mechanism drives the sweeping part to draw a circular arc in the detection area to be shifted, so that accurate coating in the detection area is achieved; the flat laying component further comprises a supporting seat, a lifting rod, a height detection piece and a height driving mechanism, wherein one end of the lifting rod is connected with the bottom of the supporting seat, the other end of the lifting rod is in driving connection with the height driving mechanism to form a lifting part, and the height detection piece is used for detecting the lifting height of the lifting rod; the flat laying component also comprises a connecting rod, and two ends of the connecting rod are connected with the sweeping driving mechanism and the sweeping part body, so that the sweeping driving mechanism can drive the sweeping part to sweep; the lifting rod preferably adopts a telescopic structure and acts in a hydraulic driving mode, and in addition, the height driving mechanism is set to be a hydraulic driving structure; the height driving mechanism, the height detection piece and the supporting seat form closed-loop control, when the height detection piece detects that the supporting seat rises to a set position, a stop instruction is sent, and after the processor receives the stop instruction, the lifting rod is driven by the height driving mechanism in a controlled mode, so that the lifting height of the supporting seat is accurately controlled; the flat laying component further comprises a storage cavity, the storage cavity is used for placing the sweeping part and the lifting part, and the sweeping part and the lifting part are hidden in the storage cavity in a non-use state; in addition, the lifting height of the lifting rod can be adjusted according to the actual working condition and the screening mesh number; the screening mesh number is 60 meshes as in the embodiment; if the number of the meshes is larger, the corresponding height of the lifting rod is adjusted; the detection probe includes, but is not limited to, the following listed ones: detecting components such as a camera, a detection camera and a vision sensor for acquiring image data; the flat laying component further comprises an induction strip, the induction strip is arranged on the sweeping rod and used for detecting the pressure of the sweeping rod contacting with the mixed material, if the induction strip cannot detect the pressure of the mixed material on the sweeping rod, the signal is transmitted through the processor, and the induction mechanism or the detection mechanism collects data based on the regulation and control of the processor; meanwhile, the acquisition or processing time of the processing device can be accurately controlled; when the induction bar detects that the pressure value of the mixture is within a set threshold range, the sweeping piece is defaulted to be in contact with the mixture;
the sensing device comprises a plurality of sensing pieces, a distance sensor and a reset module, and the reset module senses the thickness of the coating layer by the sensing pieces on the basis of the control operation of the processor; the distance sensor is used for detecting the distance between the sweeping piece and the transparent plate and is matched with the flat component for use, so that the thickness of the coating layer can be increased; meanwhile, each induction piece is arranged on one side, facing the transparent plate, of the sweeping piece, and the mixing effect of the mixture is detected in the process of sweeping the mixture flat; if the mixing effect is not good, the stirring device is controlled to adjust the stirring parameters, so that the mixture is mixed again or continuously.
Example four: the embodiment provides a process system for manufacturing a ceramic product by using the clay material of volcanic rock, which can be at least used in the first embodiment to the second embodiment, wherein the process system comprises the steps of treating the initial clay material through production equipment, and mixing the initial clay material, a viscosity reducer, an active agent, a separant and a mixing agent to form a finished product slurry; adding soda ash accounting for 0.4-0.5% of the mass of the dry base materials to dilute the slurry, dissolving the soda ash in hot water at the temperature of 80-85 ℃, wherein the adding amount of the hot water is that the soda ash is completely dissolved, discharging the slurry after ball milling and mixing for 10min, and standing and ageing the slurry for 3-5 h for later use; the slurry is fully pulped and is used after being screened by a 60-mesh sieve, a ceramic blank body is formed by adopting the traditional slip casting process, and the ceramic blank body is dried; drying, sintering in a roller kiln by using oxidizing flame at 1200-1300 ℃ for 3-5 hours to obtain a ceramic product;
the production equipment comprises a stirring device, a detection device, an induction device, a ball milling device, a processing device and a processor, wherein the processor is respectively in control connection with the stirring device, the detection device, the induction device, the ball milling device and the processing device; the stirring device is used for mixing the initial pug, the viscosity reducer, the active agent, the separant and the mixing agent to form a mixed material and stirring; the detection device is used for detecting the stirring degree of the mixture, meanwhile, the stirring device is matched with the detection device, and the stirring speed and the stirring time of the stirring device are adjusted based on the detection effect of the detection device; the ball milling device is used for grinding the volcanic rock produced in the Zhou island and is used for ensuring that the mixture is in the same granularity range; the processing device collects the data of the detection device and the ball milling and stores the processing data in the processing process; the processor is respectively in control connection with the stirring device, the detection device, the induction device, the ball milling device and the processing device, and is used for uniformly regulating and controlling all the devices under the centralized control of the processor, so that the high efficiency and the reliability of ceramic product processing are improved;
the detection device comprises a detection mechanism and a sampling mechanism, and the sampling mechanism and the detection mechanism are used for detecting the stirring degree of the mixture in the mixing cavity; the detection mechanism comprises a detection plate, a detection module and a cleaning component, the detection plate is provided with a storage cavity for the detection module to accommodate, and the detection plate is also provided with a transparent plate for sealing the storage cavity; the detection module is arranged in the storage cavity and extends out towards one side of the transparent plate; the detection module comprises a plurality of detection probes and a steering component, and each detection probe is arranged on the steering component and realizes the adjustment of a detection angle under the rotation operation of the steering component; the sampling mechanism comprises a sampling component and a cleaning component, and is used for sampling the mixture and transporting the mixture to the detection area of the detection mechanism through the sampling component; the cleaning component is used for cleaning the detection area; the cleaning component comprises a cleaning plate, a cleaning rod and a cleaning driving mechanism, the cleaning plate is arranged at one end of the cleaning rod, and the other end of the cleaning rod is in driving connection with the cleaning driving mechanism; the cleaning component is arranged on one side of the cleaning plate and is hidden in the storage cavity in a non-use state; the cleaning rod is arranged in a telescopic mode, and the cleaning driving mechanism is arranged in a hydraulic driving structure;
the sampling component comprises a sampling channel, a sampling spoon, a lifting rod and a lifting driving mechanism, wherein the sampling spoon is arranged at one end of the lifting rod to form a sampling part, and the sampling part is nested with the sampling channel and moves in the sampling channel under the action of the lifting driving mechanism; the end part of the other end of the lifting rod is in driving connection with the lifting driving mechanism; the sampling spoon is matched with the sampling channel; one end of the sampling channel is communicated with the stirring cavity, the other end of the sampling channel is arranged above the detection plate, a storage groove for storing the mixture is arranged at the tail end of the sampling channel, and the groove direction of the storage groove is parallel to the groove direction of the storage cavity, so that the mixture conveyed by the sampling spoon can be gathered on the detection plate; the detection mechanism further comprises a flat laying component, and the flat laying component is used for carrying out flat laying on the mixed material; during the process of flatly laying the mixture by the flatly laying component, the mixture can be detected in the detection area under the flatly laying operation of the flatly laying component; meanwhile, the flat laying component can adjust the flat laying thickness according to the process requirement; in addition, limit stops are arranged on the periphery sides of the sampling spoon and the sampling channel and used for cleaning the residual materials of the mixture in the sampling channel; the lifting driving mechanism is in a hydraulic driving type;
the flat laying component comprises a sweeping part, a supporting rod and a sweeping driving mechanism, one end of the supporting rod is connected with the sweeping part, the other end of the supporting rod is connected with the sweeping driving mechanism in a driving mode to form a sweeping part, and the sweeping driving mechanism drives the sweeping part to draw a circular arc in the detection area to be shifted, so that accurate coating in the detection area is achieved; the flat laying component further comprises a supporting seat, a lifting rod, a height detection piece and a height driving mechanism, wherein one end of the lifting rod is connected with the bottom of the supporting seat, the other end of the lifting rod is in driving connection with the height driving mechanism to form a lifting part, and the height detection piece is used for detecting the lifting height of the lifting rod; the flat laying component also comprises a connecting rod, and two ends of the connecting rod are connected with the sweeping driving mechanism and the sweeping part body, so that the sweeping driving mechanism can drive the sweeping part to sweep; the lifting rod preferably adopts a telescopic structure and acts in a hydraulic driving mode, and in addition, the height driving mechanism is set to be a hydraulic driving structure; the height driving mechanism, the height detection piece and the supporting seat form closed-loop control, when the height detection piece detects that the supporting seat is lifted to a set position, a stop instruction is sent, and after the processor receives the stop instruction, the precise control of the lifting height of the supporting seat is realized by controlling the driving of the height driving mechanism on the lifting rod; the flat laying component also comprises a storage cavity, the storage cavity is used for placing the sweeping part and the lifting part, and the sweeping part and the lifting part are hidden in the storage cavity in a non-use state; in addition, the lifting height of the lifting rod can be adjusted according to the actual working condition and the screening mesh number; the screening mesh number is 60 meshes as in the embodiment; if the number of the meshes is larger, the corresponding height of the lifting rod is adjusted; the detection probes include, but are not limited to, the following list of several: detecting components such as a camera, a detection camera and a visual sensor for acquiring image data; the flat laying component further comprises an induction strip, the induction strip is arranged on the sweeping rod and used for detecting the pressure of the sweeping rod contacting with the mixed material, if the induction strip cannot detect the pressure of the mixed material on the sweeping rod, the signal is transmitted through the processor, and the induction mechanism or the detection mechanism collects data based on the regulation and control of the processor; meanwhile, the acquisition or processing time of the processing device can be accurately controlled; when the induction bar detects that the pressure value of the mixed material is within a set threshold range, the sweeping piece is defaulted to be in contact with the mixed material;
collecting the position sensed by the sensing strip
The sensor is transmitted with the processor, and meanwhile, based on the detection of the detection probe and the steering component on the detection position by the processor, image data corresponding to the position of the induction bar is collected, and the collected image information is analyzed; sensing positions of several groups of sensing bars on collected picture data
And the image data is identified by the following formula:
wherein, the first and the second end of the pipe are connected with each other,
and
is the first derivative of the sensor bar in the g and t directions;
is the weight of the corresponding location; by computing outliers of the matrixJudging whether the response value is an abnormal point; if present:
wherein det and trace are determinant and operator of trace moved by the sweeping member, and m is constant between 0.04 and 0.06; when the response value of the abnormal value is larger than the set lowest threshold value and is a local maximum value in the position field, the position is taken as an abnormal value area; if the area with the abnormal value exceeds 1/3 of the area, remixing the mixture; in addition, the data of the sensing strip is acquired based on the data of the sensing piece on the flat coating layer, namely: if the qualified flat coating layer meets the set requirement of detection thickness, acquiring data of qualified areas through the induction bars, and triggering the detection of abnormal values of the qualified areas based on the data acquisition of the qualified areas through the induction bars by means of formulas (1) and (2);
the sensing device comprises a plurality of sensing pieces, a distance sensor and a reset module, and the reset module senses the thickness of the coating layer by the sensing pieces on the basis of the control operation of the processor; the distance sensor is used for detecting the distance between the sweeping piece and the transparent plate and is matched with the flat laying component for use, so that the thickness of the coating layer can be increased; meanwhile, each induction piece is arranged on one side, facing the transparent plate, of the sweeping piece, and the mixing effect of the mixture is detected in the process of sweeping the mixture flat; if the mixing effect is not good, the stirring device is controlled to adjust the stirring parameters, so that the mixture is mixed again or continuously;
assuming that the sensing member detects the thickness value of the flat coating layer as (x, y, z), and taking the data (u, v, w) of the distance sensor in the detection posture, and comprehensively evaluating the data of the flat coating layer according to the following formula;
wherein s belongs to n, and n is the number of acquisition times; namely: the number of tests of the flat layup passed during the flat layup operation of the flat layup member;
meanwhile, the detection mechanism and the induction mechanism also detect the area S (t, u, p) of the flat coating layer, and the area S (t, u, p) is used for calculating the mixing result in unit area, so that the correct and reliable detection of the integrated mixing effect can be ensured; exist of
Wherein, the first and the second end of the pipe are connected with each other,
the area of the flat coating component for flat coating; in addition, the air conditioner is provided with a fan,
the position of the sensor can be determined by the position detected by each sensor; through the matching of the sensing mechanism and the detection mechanism, the data of the mixture can be accurately detected, and the mixing degree of the mixture is adjusted based on the detection result fact, so that the optimal process requirement is met.
In the above embodiments, the descriptions of the respective embodiments have respective emphasis, and reference may be made to the related descriptions of other embodiments for parts that are not described or illustrated in a certain embodiment. Although the invention has been described above with reference to various embodiments, it should be understood that many changes and modifications may be made without departing from the scope of the invention.
Claims (1)
1. A process system for manufacturing ceramic products by using clay material of volcanic rocks comprises the steps of processing the clay material of volcanic rocks by production equipment to obtain the ceramic products;
the production equipment comprises a stirring device, a detection device, an induction device, a ball milling device, a processing device and a processor, wherein the processor is respectively in control connection with the stirring device, the detection device, the induction device, the ball milling device and the processing device; the stirring device is used for mixing the initial pug, the viscosity reducer, the active agent, the separant and the mixing agent to form a mixture and stirring the mixture; the detection device is used for detecting the stirring degree of the mixture, meanwhile, the stirring device is matched with the detection device, and the stirring speed and the stirring time of the stirring device are adjusted based on the detection effect of the detection device; the ball milling device is used for grinding volcanic rock and is used for ensuring that the mixture is in the same granularity range; the processing device collects the data of the detection device and the ball milling and stores the processing data in the processing process; the processor is respectively in control connection with the stirring device, the detection device, the induction device, the ball milling device and the processing device, and is used for uniformly regulating and controlling all the devices under the centralized control of the processor, so that the high efficiency and the reliability of ceramic product processing are improved;
the detection device comprises a detection mechanism and a sampling mechanism, and the sampling mechanism and the detection mechanism are used for detecting the stirring degree of the mixture in the mixing cavity; the detection mechanism comprises a detection plate, a detection module and a cleaning component, wherein the detection plate is provided with a storage cavity for the detection module to accommodate, and is also provided with a transparent plate for sealing the storage cavity; the detection module is arranged in the storage cavity and extends out towards one side of the transparent plate; the detection module comprises a plurality of detection probes and a steering component, each detection probe is arranged on the steering component, and the detection angle is adjusted under the rotation operation of the steering component; the sampling mechanism comprises a sampling component and a cleaning component, and is used for sampling the mixture and transporting the mixture to a detection area of the detection mechanism through the sampling component; the cleaning component is used for cleaning the detection area; the cleaning component comprises a cleaning plate, a cleaning rod and a cleaning driving mechanism, the cleaning plate is arranged at one end of the cleaning rod, and the other end of the cleaning rod is in driving connection with the cleaning driving mechanism; the cleaning component is arranged on one side of the cleaning plate and is hidden in the storage cavity in a non-use state; the cleaning rod is arranged in a telescopic mode, and the cleaning driving mechanism is arranged in a hydraulic driving structure;
the sampling component comprises a sampling channel, a sampling spoon, a lifting rod and a lifting driving mechanism; the sampling spoon is arranged at one end part of the lifting rod to form a sampling part which is configured to be nested with the sampling channel and move in the sampling channel under the action of the lifting driving mechanism; the end part of the other end of the lifting rod is in driving connection with the lifting driving mechanism; the sampling spoon is matched with the sampling channel; one end of the sampling channel is communicated with the stirring cavity, the other end of the sampling channel is arranged above the detection plate, a storage groove for storing the mixture is formed at the tail end of the sampling channel, and the groove direction of the storage groove is parallel to the groove direction of the storage cavity, so that the mixture conveyed by the sampling spoon can be gathered on the detection plate; the detection mechanism further comprises a flat laying component, and the flat laying component is used for carrying out flat laying on the mixed material; during the process of flatly laying the mixture by the flatly laying component, the mixture can be detected in the detection area under the flatly laying operation of the flatly laying component; meanwhile, the flat laying component can adjust the flat laying thickness according to the process requirement; a limit stop block is arranged on the periphery of the sampling spoon and the sampling channel and used for cleaning the residual materials of the mixture in the sampling channel; the lifting driving mechanism is in a hydraulic driving type;
the flat laying component comprises a sweeping part, a supporting rod and a sweeping driving mechanism, wherein one end of the supporting rod is connected with the sweeping part, and the other end of the supporting rod is in driving connection with the sweeping driving mechanism to form a sweeping part; the flat laying component further comprises a supporting seat, a lifting rod, a height detection piece and a height driving mechanism, wherein one end of the lifting rod is connected with the bottom of the supporting seat, the other end of the lifting rod is in driving connection with the height driving mechanism to form a lifting part, and the height detection piece is used for detecting the lifting height of the lifting rod; the flat laying component also comprises a connecting rod, and two ends of the connecting rod are connected with the sweeping driving mechanism and the sweeping part body, so that the sweeping driving mechanism can drive the sweeping part to sweep; the height driving mechanism, the height detection piece and the supporting seat form closed-loop control, when the height detection piece detects that the supporting seat is lifted to a set position, a stop instruction is sent, and after the processor receives the stop instruction, the precise control of the lifting height of the supporting seat is realized by controlling the driving of the height driving mechanism on the lifting rod; the flat laying component also comprises a storage cavity, the storage cavity is used for placing the sweeping part and the lifting part, and the sweeping part and the lifting part are hidden in the storage cavity in a non-use state;
the flat laying component further comprises an induction strip, the induction strip is arranged on the sweeping part and used for detecting the pressure of the sweeping part contacting with the mixed material, if the induction strip cannot detect the pressure of the mixed material on the sweeping part, signals sensed by the induction strip are transmitted with the processor, and data are acquired by the induction device or the detection mechanism based on the regulation and control of the processor;
the induction device comprises a plurality of induction pieces, a distance sensor and a reset module, and the reset module is used for inducing the induction pieces to the thickness of the coating layer based on the control operation of the processor; the distance sensor is used for detecting the distance between the sweeping piece and the transparent plate and is matched with the flat component for use, so that the thickness of the coating layer can be increased; meanwhile, each induction piece is arranged on one side, facing the transparent plate, of the sweeping piece, and the mixing effect of the mixture is detected in the process of sweeping the mixture flat; if the mixing effect is not good, the stirring device is controlled to adjust the stirring parameters, so that the mixture is mixed again or continuously.
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