EP3517267B1 - Procede et systeme pour regler la quantite d'email applique sur des carreaux ou des dalles ceramiques - Google Patents

Procede et systeme pour regler la quantite d'email applique sur des carreaux ou des dalles ceramiques Download PDF

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Publication number
EP3517267B1
EP3517267B1 EP19153852.9A EP19153852A EP3517267B1 EP 3517267 B1 EP3517267 B1 EP 3517267B1 EP 19153852 A EP19153852 A EP 19153852A EP 3517267 B1 EP3517267 B1 EP 3517267B1
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EP
European Patent Office
Prior art keywords
pattern
brightness
enamel
slabs
spray
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EP19153852.9A
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German (de)
English (en)
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EP3517267A1 (fr
Inventor
Paolo Malavasi
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Air Power Group SpA
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Air Power Group SpA
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
    • B05B12/08—Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means
    • B05B12/082—Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means responsive to a condition of the discharged jet or spray, e.g. to jet shape, spray pattern or droplet size
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B13/00—Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00
    • B05B13/02—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work
    • B05B13/04—Means for supporting work; Arrangement or mounting of spray heads; Adaptation or arrangement of means for feeding work the spray heads being moved during spraying operation
    • B05B13/0463—Installation or apparatus for applying liquid or other fluent material to moving work of indefinite length
    • B05B13/0468—Installation or apparatus for applying liquid or other fluent material to moving work of indefinite length with reciprocating or oscillating spray heads
    • B05B13/0473—Installation or apparatus for applying liquid or other fluent material to moving work of indefinite length with reciprocating or oscillating spray heads with spray heads reciprocating along a straight line
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/001—Applying decorations on shaped articles, e.g. by painting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • B28B11/044—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers with glaze or engobe or enamel or varnish
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • B28B11/048—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers by spraying or projecting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
    • B28B17/0063—Control arrangements
    • B28B17/0081—Process control

Definitions

  • the present invention relates to the technical field of the ceramic industry, with particular reference to the decoration process of ceramic tiles and/or slabs to give their visible surface the desired chromatic and/or graphic treatment.
  • the ceramic tiles or slabs are moved at a constant forward speed by a conveyor, so as to enter, pass through an array of spray nozzles arranged along the same station in succession and finally exit.
  • Each nozzle which usually sprays the same colour as the others, is carried by a carriage, operated by a translator moving in a direction crosswise to the forward direction, with to-and-fro movements.
  • the enamel is then applied by combining the two movements, the tile advancement movement and the transversal movement of the nozzles.
  • the spray nozzles for this application are equipped with a head having a calibrated hole, which delivers the spray enamel with a fan-shaped jet.
  • the nozzle head is usually made of tungsten carbide, to give better properties of resistance to abrasion action exerted by the enamel ceramic, which, as known, incorporates suspended glass particles that can quickly erode even the hardest materials.
  • a nozzle of this type has an average operating time of about six hours, after which it must be replaced.
  • the abrasive action of the enamel on the calibrated hole of the nozzle causes progressive wear, increasing its diameter. This causes an increase in the flow rate of the product passing through the calibrated hole, and changes the distribution of the product in the pattern.
  • the width of the pattern remains substantially unchanged, but a greater quantity of product is conveyed to the central part of the pattern itself compared to the peripheral part, making its distribution uneven. Therefore, a higher density of the product can be seen in the central part of the pattern which visibly modifies its brightness characteristics.
  • ceramic tiles or slabs produced from when the nozzles are new to when they are to be replaced undergo a progressive increase in the layer of enamel deposited thereon, so the weight of the latter, per unit of surface area of the tile or slab, increases cporrespondingly.
  • a further drawback is that, as already mentioned, the distribution of the product across the pattern is not homogeneous, but tends to increase in the central part of the same. This leads to an accumulation of enamel on the portions of the slab covered by the central part of the pattern, which is greater than the portions covered at both sides. These differences are visible on the finished product as unacceptable differences in colour, in particular for high quality products, such as, generally, for or large-format ceramic slabs or tiles.
  • each nozzle present is homogeneous, but in practice it can be verified that over the estimated duration of six hours a nozzle can wear out more and another one wears less, thus creating unevenness in the application of the enamel, which can generate product waste.
  • EP 3 238 900 discloses a method for application of decorating products on ceramic objects, and a multiaxial applicator device for carrying out said method.
  • the aforesaid method comprises steps for controlling the application of decorating products by moving a series of applicators mounted on respective carriages independently of each other; the movements of each carriage is controlled by a control unit depending on the current position of the ceramic objects to be decorated.
  • the current position of the ceramic objects is defined by sensors located along the path of the objects.
  • This application protects an auxiliary applicator device associated with a station for decorating ceramic tiles or slabs, which provides for a plurality of transversely mobile applicators, equipped with spray nozzles.
  • the spray nozzle in failure is stopped immediately and its action is replaced by an additional nozzle, which until then has not been operational.
  • the decoration station does not have to be stopped and the production of waste ceramic slabs or tiles is considerably limited.
  • JP 2006 266718 A discloses a system for monitoring the state of spray ejection and capable of accurately determining whether the state of spray ejection is satisfactory or not.
  • the object of this invention is to propose a method and a device for controlling, in real time and downstream of the applicators, the quantity of enamel applied by each individual applicator on ceramic tiles or slabs in a decoration station, so as to intervene promptly with suitable actions when anomalies occur, and before such anomalies give rise to the production of wastes.
  • a further object of the invention is to further improve the homogeneity of enamel application on the different surface areas of the slab or tile, and thus to minimize the percentage of waste.
  • Another object of the invention is to keep the weight of enamel deposited per unit area of tiles or slabs as constant as possible, both to avoid those with defective glazing and to limit the consumption of enamel.
  • Another object of the invention is to provide a method that can be implemented in a simple way and with a device easy to implement, with a reliable operation and such that it can be installed even in existing decoration stations, without major changes.
  • reference 1 indicates as a whole a device that implements the method of the present invention for controlling the quantity of enamel.
  • a decoration station 2 for decorating ceramic tiles or slabs 3, intended for the application of ceramic enamel on the latter.
  • the decoration station 2 is driven and controlled by processing equipment 11, according to substantially known techniques.
  • the ceramic tiles or slabs 3 are moved forward by a conveyor 4, so as to enter the station, to move in succession under one or more applicators equipped with respective spray nozzles 5, arranged in the same station 2, and finally to exit.
  • the conveyor 4 is powered with the possibility of controlling the forward speed by suitably interfacing it with the aforementioned processing equipment 11.
  • the figures show a decoration station 2, in which there is preferably a set of applicators with spray nozzles 5 arranged in series, with each of them carried by a carriage 6, driven by a reciprocating movement by a shifter (not shown in detail) along a guide 7 extending transversally to conveyor 4.
  • the applicators are supplied by a pump P, of generally known type, for which pressure and/or flow rate can be controlled.
  • the method according to the invention essentially involves the execution of a sequence of operations on the spraying pattern V generated by each spray nozzle 5, and possible activation of compensation operations, consisting in the variation of at least one operating parameter of the decoration station 2, according to what will be better detailed here below.
  • the method involves the periodic acquisition of an image of the spraying pattern V during normal decoration operations; advantageously, the method involves the acquisition of an image at each operating cycle of the back-and-forth run made by the spraying nozzle 5.
  • V pattern is created (see figure 3 ) with homogeneous product distribution characteristics and with product density per unit of surface area as predefined by the operational characteristics of pump P, and in particular by its operation pressure and its overall flow rate.
  • At least one brightness value is detected for each of these acquisitions at one or more selected spots in the V pattern; these values are compared with predetermined reference values.
  • the product is dispensed into the V pattern with progressive density variations in different areas of the same pattern.
  • a higher density is found in the central part of the pattern V, and a corresponding lower density in the peripheral areas.
  • These variations correspond to detectable variations in the brightness characteristics in different areas of the pattern V, which are usually related to an increase of brightness in areas with higher density.
  • areas with higher product density may be darker than those with lower density.
  • the indirect quantification of the enamel density delivered by the corresponding spray nozzle 5 is obtained, from which the weight of enamel deposited per unit of surface on the underlying tile or ceramic slab 3 can be calculated.
  • This first threshold value is generally obtained empirically from experimental evaluations of the relationship between the variations in the density of supply in the different areas of the pattern V - and therefore in the luminosity of the same - and the effect that this has on the variations in the weight of the product deposited and on its distribution over the tile or slab 3.
  • a preferred embodiment of the method involves acquiring the brightness parameters of the spray pattern V when a spray nozze 5 is new ( Fig. 3 ), and using the same parameters as predetermined reference values with which to make the above comparison later.
  • the detection of the brightness in the pattern V is carried out, preferably but not necessarily, near the portion of the latter closest to the relative spray nozzle 5 in one or more spots, not highlighted in the figures as they are not significant for the understanding of the invention.
  • the comparison can be made, according to an initial embodiment of the method, on the basis of a calculation of the average of the differences between the values of brightness detected compared to the default values for these spots, to determine the activation, or not, of the action, or actions, for compensation.
  • the compensation action is triggered on the basis of exceeding, even at one of the aforementioned spots, the threshold value set for the latter.
  • the above compensation action may include an appropriate correction, normally in increase, of the flow rate of the above mentioned pump P, intended to feed the sprayer nozzle(s) 5 while keeping the pressure constant; alternatively, or in combination, the compensation action consists in the correction, also usually in increase, of the forward speed of conveyor 4.
  • the method provides for the stop of the applicator, with suspension of the enamel supply by the relative spray nozzle 5 and the replacement of the latter, as a necessary compensation action.
  • the method involves stopping for maintenance, or replacing, the spray nozzles 5 in their respective positions so as to be clear of the side of the ceramic tiles or slabs 3, in transit within the station 2, thus avoiding possible damage to the same (see Fig. 2 ).
  • the proposed method in practice, is based on the expected progressive wear of the spray nozzles 5, mentioned in the introduction and which determines a lack of homogeneity in the distribution of the enamel in the pattern V generated, and in particular a greater accumulation in the central part thereof.
  • the application parameters of the ceramic enamel and also the state of wear of the nozzles 5 are controlled in progress.
  • the device 1 mentioned above for the implementation of the method described above, comprises a plurality of 10 video-cameras, at a rate of at least one for each of these spray nozzles 5.
  • the video-cameras 10 are located inside the decoration station 2, next to conveyor 4, and are suitable for taking real time images of the corresponding spraying patterns V generated by the 5 spraying nozzles, preferably for each of the back-and-forth operating cycles performed by the latter, in order to measure the brightness parameters.
  • the above mentioned electronic processing equipment 11 are interfaced to the video-cameras 10, and consist of a dedicated computer, or include the same computer used to control the station 2, for the acquisition of the images being taken. These images are appropriately processed according to predetermined calculation algorithms, to quantify the enamel density delivered by the relative spray nozzle 5 and determine, consequently, the weight of the same enamel deposited, per unit area, on the ceramic tiles or slabs 3.
  • the computer 11 is conveniently interfaced, according to known techniques, to the transport drive and/or the control of pump P.
  • the decoration station 2 is equipped with lighting elements 12 that make the respective spray pattern V visible to each of these video-cameras 10 in the best possible way.
  • the lighting elements 10 are so arranged that said spraying patterns V are illuminated on the front side, with respect to the video-cameras 10, so that the brightness parameters are obtained due to light reflection.
  • the lighting elements 12 are so arranged that said spraying patterns V are illuminated from the back side, with respect to the video-cameras 10, so that the brightness parameters are obtained due to light transmission.
  • a device 1 includes advantageously an additional spray nozzle 50, associated with a corresponding trolley 6 and controlled by a corresponding video-camera 10S.
  • the additional spray nozzle 50 is kept inoperative when all other spray nozzles 5 are operating properly ( Fig. 1 ).
  • ceramic tiles or slabs 3 can continue to pass through and be enamelled regularly, without the risk of any damage.
  • Preferred compensation actions according to the invention advantageously include adjusting the transport speed 4, adjusting the delivery parameters of pump P, and/or replacing the nozzle 5 which is no longer within the acceptable operating range.
  • the production of ceramic tiles or slabs obtained during the working life of a set of spray nozzles has a weight of enamel deposited per unit of surface almost constant and corresponding to optimal values.
  • the proposed method can be implemented in a simple and effective way and with a device easy to implement, with a reliable operation and such that it can be installed even in existing decoration stations, without substantial changes.
  • a further benefit, in order to avoid defective tiles or slabs, at the same time stopping the production as little as possible, is given by the additional nozzle, which allows the stopped nozzle to be replaced or its correct functioning to be restored, while keeping the decoration station in regular operation.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Structural Engineering (AREA)
  • Automation & Control Theory (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
  • Spray Control Apparatus (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
  • Finishing Walls (AREA)

Claims (13)

  1. Procédé pour régler la quantité d'émail applique sur des carreaux ou des dalles céramiques dans une station de décoration (2), lesdits carreaux ou dalles en céramique (3) étant déplacés par un convoyeur (4), de sorte qu'ils entrent dans ladite station, passent successivement par au moins un dispositif d'application équipé d'une buse de pulvérisation (5) disposé dans la même station (2) et sortent finalement de ladite station, ledit procédé étant caractérisé en ce qu'il comprend les étapes opérationnelles suivantes :
    - l'acquisition périodique d'au moins une image du modèle de pulvérisation (V) généré par la au moins une buse de pulvérisation (5) susmentionnée;
    - la détection d'au moins une valeur de luminosité dans ledit modèle (V) pour chacune desdites acquisitions, et la comparaison de la valeur détectée avec des valeurs de référence prédéterminées, la différence entre la valeur de luminosité détectée et lesdites valeurs de référence identifiant une variation correspondante de la densité d'un produit émis par ladite buse (5) et, de manière correspondante, du poids du produit par unité de surface appliqué par ladite buse (5) sur lesdits carreaux ou dalles en céramique (3);
    - l'activation d'au moins une action de compensation de l'effet de ladite variation de densité sur le poids du produit déposé sur chaque unité de surface lorsqu'une première valeur seuil prédéterminée est dépassée, ladite action de compensation comprenant la variation d'au moins un paramètre de fonctionnement de ladite station de décoration (2).
  2. Procédé selon la revendication 1, caractérisé en ce que: ladite détection d'au moins une valeur de luminosité dans ledit modèle (V) est effectuée à proximité d'une portion de ce dernier la plus proche possible de la buse de pulvérisation (5) précitée.
  3. Procédé selon la revendication 1, caractérisé en ce que: ladite détection de luminosité dans ledit modèle (V) est effectuée en différents points de celui-ci et en ce que ladite action de compensation est activée sur la base d'un calcul de la moyenne des différences entre les valeurs de luminosité détectées par rapport à des valeurs prédéterminées pour lesdits points.
  4. Procédé selon la revendication 1, caractérisé en ce que: ladite détection de luminosité dans ledit modèle (V) est effectuée en différents points de celui-ci et en ce que ladite action de compensation est activée sur la base d'un dépassement de ladite première valeur seuil, même en un seul desdits points.
  5. Procédé selon la revendication 1 ou 2 ou 3 ou 4, caractérisé en ce que: ladite action de compensation consiste en la correction du débit d'une pompe (P) destinée à alimenter ladite au moins une buse de pulvérisation (5).
  6. Procédé selon la revendication 1 ou 2 ou 3 ou 4, caractérisé en ce que ladite action de compensation consiste à corriger la vitesse d'avancement dudit convoyeur (4).
  7. Procédé selon la revendication 1 ou 2 ou 3 ou 4, caractérisé en ce que ladite action de compensation implique l'arrêt d'un dit dispositif d'application lorsqu'une deuxième valeur de seuil prédéterminée, supérieure à la première valeur de seuil, est dépassée pour ce dispositif d'application, y compris la suspension de l'alimentation en émail par la buse de pulvérisation correspondante (5), ainsi que lorsque cette dernière est remplacée.
  8. Procédé selon la revendication 1 ou 2 ou 3 ou 4, caractérisé en ce que ladite action de compensation implique l'arrêt de tous les dispositifs d'application susmentionnés et le remplacement complet des buses de pulvérisation relatives (5) lorsqu'une une deuxième valeur seuil prédéterminée, supérieure à la première, est dépassée.
  9. Procédé selon la revendication 1, caractérisé en ce qu' il comprend l'acquisition des paramètres de luminosité du modèle de pulvérisation (V) lorsque ladite au moins une buse de pulvérisation (5) est nouvelle, et l'utilisation des mêmes paramètres pour définir lesdites valeurs de référence prédéterminées avec lesquelles la comparaison susmentionnée doit ensuite être effectuée.
  10. Dispositif pour régler la quantité d'émail applique sur des carreaux ou des dalles céramiques dans une station de décoration (2), ledit dispositif (1) étant adapté pour fonctionner dans une station de décoration (2), ce dernier comprenant un convoyeur (4), au moins un dispositif d'application muni d'une buse de pulvérisation (5) pour pulvériser ledit émail sur lesdits carreaux ou dalles en céramique, ces derniers étant déplacés à travers ledit dispositif d'application par un convoyeur (4), au moins une pompe (5) pour fournir ledit émail à ladite buse de pulvérisation (5), ledit dispositif (1) comprenant:
    - une pluralité de caméras vidéo (10), avec au moins une d'entre elles pour chacune desdites buses de pulvérisation (5), conçues pour prendre, en temps réel, des images concernant le modèle de pulvérisation (V) généré par la buse de pulvérisation relative (5) dans chacun des cycles de fonctionnement de va-et-vient effectués par cette dernière;
    - des moyens de traitement électroniques (11), destinés à acquérir des images numériques prises pendant chaque cycle par chacune desdites caméras vidéo (10) et configurés pour exécuter les procédures suivantes:
    - une procédure pour détecter la luminosité dudit modèle de pulvérisation (V), pour chaque image et dans au moins un point du modèle mentionné (V), et conçue pour traiter chaque image selon des algorithmes de calcul prédéterminés afin de quantifier la densité d'émail délivrée par la buse de pulvérisation relative (5);
    - une procédure de comparaison desdites valeurs de luminosité avec des valeurs de référence, stockées dans ledit moyen de traitement électronique (11), afin d'identifier des seuils d'intervention en fonction des différences détectées entre lesdites valeurs de luminosité et lesdites valeurs de référence;
    - des moyens de contrôle du fonctionnement dudit convoyeur (4) et/ou de ladite pompe (P), conçus pour compenser les variations de densité dudit émail délivré en appliquant des variations correspondantes des paramètres de fonctionnement dudit convoyeur (4) et/ou de ladite pompe (P).
  11. Dispositif selon la revendication 10, caractérisé par la fourniture d'éléments d'éclairage (12) prévus dans ladite station de décoration (2) et capables de rendre visible le modèle de pulvérisation respectif (V) à chacune desdites caméras (10).
  12. Dispositif selon la revendication 11, caractérisé en ce que lesdits éléments d'éclairage (12) sont disposés de telle sorte que lesdits modèles de pulvérisation (V) sont éclairés sur le côté avant, par rapport auxdites caméras (10), de sorte que les paramètres de luminosité mentionnés ci-dessus sont obtenus en raison de la réflexion de la lumière.
  13. Dispositif selon la revendication 11, caractérisé en ce que lesdits éléments d'éclairage (12) sont agencés de telle sorte que lesdits modèles de pulvérisation (V) sont éclairés sur le côté arrière, par rapport auxdites caméras (10), de sorte que les paramètres de luminosité mentionnés ci-dessus sont obtenus en raison de la transmission de la lumière.
EP19153852.9A 2018-01-26 2019-01-26 Procede et systeme pour regler la quantite d'email applique sur des carreaux ou des dalles ceramiques Active EP3517267B1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
IT201800001969A IT201800001969A1 (it) 2018-01-26 2018-01-26 Metodo e dispositivo per il controllo della quantità di smalto applicato su piastrelle o lastre ceramiche

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EP3517267A1 EP3517267A1 (fr) 2019-07-31
EP3517267B1 true EP3517267B1 (fr) 2022-08-03

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ES (1) ES2929177T3 (fr)
IT (1) IT201800001969A1 (fr)

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CN111360987B (zh) * 2020-04-23 2021-08-06 台州正兴阀门有限公司 一种用于加工家用小型浴缸的喷釉设备
CN111391086B (zh) * 2020-06-03 2020-10-30 佛山市东鹏陶瓷发展有限公司 一种可打印精细图案的喷气式干粒打印生产系统

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US7182271B2 (en) * 2004-11-12 2007-02-27 Spraying Systems Co. Apparatus and method for detecting liquid flow from a spray device
JP2006266718A (ja) * 2005-03-22 2006-10-05 Sumitomo Chemical Co Ltd スプレー噴射状態監視システム及びスプレー噴射状態監視プログラム
ITUA20163013A1 (it) * 2016-04-29 2017-10-29 Air Power Group S P A Dispositivo applicatore multiasse di prodotti di decorazione su articoli ceramici e metodo di applicazione di tali prodotti

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IT201800001969A1 (it) 2019-07-26
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