专利摘要:
Device and method of monitoring ceramics by measuring their impedance. The invention relates to a novel device that monitors the hardening state of ceramic (1) during its casting process in a porous mold (2) through the measurement of the electrical impedance of both the mold (2) and the ceramic (one). For this, the disclosed device comprises in its preferred embodiment: a first impedance sensor (3) adapted to measure the impedance of the ceramic (1); a second impedance sensor (5) adapted to measure the impedance of the porous mold (2); an electronic assembly (7) configured to generate, process and transmit the impedance measurements obtained by said first and second impedance sensor (3, 5). Likewise, another object of the invention relates to a method of monitoring the impedance in real time during the casting process of ceramic (1) in mold (2) comprising the use of the device disclosed by the present invention. (Machine-translation by Google Translate, not legally binding)
公开号:ES2719934A1
申请号:ES201830046
申请日:2018-01-16
公开日:2019-07-16
发明作者:Nebra Roberto Casas;Gimeno Angel Asensio;Bascuas Teresa Blanco;Marin Rubén Blasco;Marco Alvaro Marco;José María Berges;Redondo César Macias
申请人:Universidad de Zaragoza;
IPC主号:
专利说明:

[0001]
[0002] CERAMIC MONITORING DEVICE AND METHOD BY MEASURING YOUR IMPEDANCE
[0003]
[0004] FIELD OF THE INVENTION
[0005]
[0006] The present invention is framed within the technical field corresponding to the ceramic forming sector. More specifically, the invention relates, although without limitation, to a device capable of controlling and monitoring the hardening processes of ceramics, and more advantageously, the slides and / or porcelain casting processes, by measuring the variation of the electrical impedance.
[0007]
[0008] In this document, the term "ceramic" will be used generically to designate, interchangeably, materials such as aqueous ceramic suspension, cast ceramic, slip or porcelain, suitable for application in the device disclosed by the present invention.
[0009]
[0010] BACKGROUND OF THE INVENTION
[0011]
[0012] At present, one of the most widespread processes for the conformation of ceramic sanitary pieces with complex shapes is based on the filling of closed and porous molds, usually of plaster or resins, with slippers and / or porcelains. The aforementioned conformation process is based on the following stages:
[0013] a) Preparation of the mold of porous materials.
[0014] b) Preparation of the ceramic in the form of an aqueous ceramic suspension.
[0015] b) Filling the mold with ceramics.
[0016] c) Beginning of the solidification of the ceramic, formation of the wall and increase of the thickness of said wall by adsorption of the water of the aqueous ceramic suspension in the porous mold.
[0017] d) Once a certain wall thickness has been reached, of the order of millimeters (and preferably between 5 and 15 mm), the excess ceramic is removed from the inside of the mold through emptying channels arranged in said mold.
[0018] e) Hardening of the piece and opening of the mold once it reaches sufficient hardness and mechanical strength.
[0019] This forming process is called the ceramic casting process. Once said process is finished, the piece is subjected to subsequent hardening and finishing treatments, such as drying, cooking or painting, among others.
[0020]
[0021] The said solidification process, dominated by water absorption phenomena of the aqueous ceramic suspension in the porous mold, is affected by physical-chemical parameters, among which are:
[0022] - Parameters related to the adsorption capacity of the mold: size, shape and number of pores of the mold, particles in them, pH, preparation and old age of the mold, temperature and humidity thereof, thickness, design, etc.
[0023] - Parameters related to ceramics: granulometric distribution, density, viscosity, thixotropy, temperature and storage time, etc.
[0024] - Parameters related to other aspects such as: the design and geometry of the piece, the times and pressures during the filling of the mold, emptying, hardening and evacuation.
[0025]
[0026] The stages of wall formation and hardening generate considerable contractions while the ceramic is inside the mold, the latter limiting its movement. This contraction generates tensions in the ceramics that can produce cracks or deformations that will not become visible until the demoulding of the ceramic piece or in subsequent processes, aggressive with the microstructure of the material to be formed, such as drying or cooking. On the other hand, another additional problem that can occur during the ceramic casting process is related to the lack of hardness, which frequently generates deformations in the solidified piece of ceramic, once it is demoulded. These problems are directly associated with the solidification process, in which the decisions of when to empty and unmold the ceramic piece are determined based on human criteria, hardly quantifiable and related to the problems mentioned. These problems are the main causes of scrapping and reprocessing of shaped ceramic pieces.
[0027]
[0028] To address the technical problem outlined above, the scientific publication entitled "Real-time monitoring of cake thickness during slip casting" published in the "Journal of Materials Science", volume 28, 1993, pages 5679-5683, describes a method of monitoring to measure in real time the one-dimensional growth of the thickness of the cake during the ceramic casting processes in porous mold. Through a single ultrasonic sensor placed inside the cast ceramic, said Measurement of cake thickness growth according to vertical direction in a flat porous mold. However, this system does not allow to take into account the effects of the physical parameters of the mold, which also affect the solidification process of the ceramics, and on the other, it focuses solely on quantifying the thickness of solidified ceramics over time.
[0029]
[0030] On the other hand, in the Slovenian patent application with publication number SI 21150 A a device and method for monitoring the solidification of aqueous ceramic suspensions inside closed molds is disclosed, through impedance measurements of said aqueous suspension. However, said patent application is applied to solidification processes called "direct coagulation" processes based on the coagulation of an aqueous ceramic solution by the addition of chemical agents, rather than based on physical adsorption phenomena. Therefore, said solidification process requires a non-porous mold, differing substantially from the technical problem posed by the present invention.
[0031]
[0032] Finally, for its part, Chinese patent CN 104165907 B refers to a method of monitoring the solidification process of concrete from the measurement of piezoelectric impedance. In said document the need for a mold is not disclosed and therefore the variation of the mold parameters that are relevant in ceramic casting processes for the technical problem posed by the present invention are not taken into account.
[0033]
[0034] For this purpose, the present invention thus proposes an electrical impedance monitoring device designed, but not limited to, the process of casting and shaping the ceramics with complex geometries in porous and closed molds, whose technical implementation allows to overcome the problems detailed above.
[0035]
[0036] BRIEF DESCRIPTION OF THE INVENTION
[0037]
[0038] An object of the present invention relates, but not limited to, a device for monitoring the impedance of a ceramic, during a casting process in a porous mold, suitable for molds of variable geometry and for casting processes of slippers and / or porcelain in mold.
[0039]
[0040] Advantageously, said device comprises at least:
[0041] - a first electrical impedance sensor, adapted for contact with the cast ceramic and configured to obtain impedance measurements of said cast ceramic;
[0042] - a second electrical impedance sensor, arranged in a housing in the mold and adapted to obtain measurements of the impedance of said mold;
[0043] - an electronic set configured to generate, process and transmit the impedance measurements obtained by the first and second sensors, and comprising:
[0044] i) a control module adapted to inject current into the first and second sensors to obtain impedance measurements;
[0045] ii) a computer module adapted for processing impedance measurements;
[0046] iii) a data transmission module configured to transmit the data resulting from the computing and control modules to one or more data reception means.
[0047]
[0048] This achieves a device capable of controlling in real time the solidification of the ceramics during the process of casting in a closed porous mold, and which, in addition, allows to predict and optimize the decision making regarding the emptying and demolding of the ceramics in the mold , through the control of the state of both the ceramic and said mold.
[0049]
[0050] In a preferred embodiment of the invention, the device additionally comprises one or more auxiliary sensors, both for the ceramic and for the mold, adapted to measure auxiliary variables such as the temperature and ambient humidity, temperature, viscosity and density of the cast ceramic, thixotropy, filling and emptying pressure of the cast ceramic, mold temperature, mold pore condition and mold moisture, number of mold castings, etc. This achieves a wide variety of relevant data for the process, resulting in better predictions and optimization of decision making regarding the emptying and demolding of ceramics in the mold.
[0051]
[0052] In a preferred embodiment of the invention, the device comprises a manual input module of the auxiliary variables of temperature and humidity, temperature and density of the cast ceramic, thixotropy, viscosity of the cast ceramic, filling and emptying pressure of the ceramic casting, mold temperature, humidity and condition of the mold pores, number of mold castings. This achieves an alternative to have a variety of data relevant to the process without the constructive and operational complexity of having a large number of sensors simultaneously.
[0053]
[0054] In a preferred embodiment of the invention, the first and second sensors for measuring the impedance of the mold and the ceramic are integrated into a monolithic body and self-installable in the mold itself. This minimizes the number of housings needed in the mold for taking measurements, resulting in greater simplicity of the device.
[0055]
[0056] In a preferred embodiment of the invention, the data reception means are configured to use wired or wireless communication protocols.
[0057] Another object of the invention relates to a method of real-time impedance monitoring during cast ceramic casting, suitable for slides and / or porcelain casting processes, comprising the use of a monitoring device for ceramics according to any of the embodiments described herein and performing the following steps:
[0058]
[0059] - the first electrical impedance sensor of the ceramic is placed in contact with it;
[0060] - the second electrical impedance sensor of the mold is placed in its corresponding housing in the mold itself;
[0061] - the cast ceramic is introduced into the mold;
[0062] - the data collection is timed and a current is injected into the first and second impedance sensors of the ceramic and the mold, through the control module;
[0063] - signals are generated by means of the first and second impedance sensors and sent to the electronic assembly, where the control module conditions them for further processing;
[0064] - the signals conditioned by the computing module are processed and the impedance for the casting of the cast ceramic into the mold is determined by means of the computing module;
[0065] - the resulting data is transmitted to the data reception means by means of the transmission module;
[0066] - the previous steps are repeated until the optimum emptying impedance is reached, this being calculated by means of the computing module;
[0067] - once this optimum emptying impedance has been reached, the remaining ceramic of the mold is emptied;
[0068] - the data collection is timed and a current is injected into the first and second impedance sensors of the ceramics and the mold, through the control module;
[0069] - signals are generated by means of the first and second impedance sensors and sent to the electronic assembly, where the control module conditions them for further processing;
[0070] - the signals conditioned by the computing module are processed and the impedance for the demoulding of the cast ceramic in the mold is determined by means of the computing module;
[0071] - the resulting data is transmitted to the data reception means by means of the transmission module;
[0072] - the previous steps are repeated until the optimum demoulding impedance is reached, this being calculated by means of the computing module;
[0073] - once the optimum demolding impedance is reached, the mold is demoulded.
[0074]
[0075] In a preferred embodiment of the invention, the processing of the signals by the computing module is carried out by means of adaptive and / or self-learning algorithms. In said preferred embodiment, initially a plurality of threshold values are set manually to generate the optimal emptying and demoulding signals. After each demoulding process, it is possible to perform one or more quality control stages where the result of the process can be assessed, so that the system can automatically adjust the manually set reference thresholds according to the context and evolution of said process.
[0076]
[0077] In a preferred embodiment of the invention, in addition to being timed and injecting currents to the first and second impedance sensor of the mold and the ceramic by the control module, current is injected and injected into auxiliary sensors by the control module, said auxiliary sensors being adapted to measure auxiliary variables such as the temperature and ambient humidity, temperature and density of the cast ceramic, thixotropy of the cast ceramic, viscosity of the cast ceramic, filling and emptying pressure of the cast ceramic, mold temperature , moisture and condition of the mold pores, and number of mold castings.
[0078]
[0079] In a preferred embodiment of the invention, the data relating to auxiliary variables such as temperature and ambient humidity, temperature and density of the cast ceramic, thixotropy, viscosity of the cast ceramic, filling and emptying pressure of the ceramic casting, mold temperature, humidity and pore condition of the mold, number of mold castings, are introduced to the computing module through a manual data entry module.
[0080]
[0081] Also object of the present invention is a system comprising a plurality of monitoring devices according to any of the previous embodiments for the process of casting ceramic mold, where at least one control module of said devices is a multichannel module configured to connect Multiple pairs of first and second impedance sensors for various molds.
[0082]
[0083] DESCRIPTION OF THE FIGURES
[0084]
[0085] Figure 1 shows a diagram of the device object of the present invention, according to a preferred embodiment of the invention.
[0086]
[0087] NUMERICAL REFERENCES USED IN THE FIGURES
[0088]
[0089] In order to help a better understanding of the technical characteristics of the invention, said Figure 1 is accompanied by a series of numerical references where, for illustrative and non-limiting purposes, the following is represented:
[0090]
[0091]
[0092] DETAILED DESCRIPTION OF THE INVENTION
[0093]
[0094] A preferred embodiment of the present invention will be described below, provided for illustrative but not limiting purposes.
[0095]
[0096] A main object of the invention relates, as described in the preceding sections, and as represented in Figure 1 of this document, to a ceramic monitoring device (1) cast by measuring its impedance, preferably related to the solidification process during its conformation in a mold (2) which preferably comprises: a closed porous mold (2) inside which an aqueous ceramic suspension (1) is poured, or also called ceramic (1) wash. The porous mold (2) additionally comprises: a first sensor (3) adapted for obtaining electrical impedance measurements of the cast ceramic (1); a housing (4) designed to accommodate a second sensor (5) adapted for obtaining electrical impedance measurements of the porous mold (2); one or more auxiliary sensors (6) whose function is to measure auxiliary variables that affect the solidification process of the ceramic (1) such as: temperature and humidity, temperature, density, thixotropy of the ceramic (1) casting, viscosity of the ceramic (1) casting, filling and emptying pressure of the ceramic (1) casting, mold temperature (2), moisture and pore condition of the mold (2), number of mold casting (2), etc .; an electronic assembly (7) configured to generate, process and transmit the electrical impedance measurements obtained by the first and second sensors (5) of the mold (2) and the ceramics (1) as well as the measurements taken by the auxiliary sensors (6).
[0097]
[0098] Said electronic assembly (7) comprises, in turn, a series of modules such as: a control module (8); a computing module (9); a data transmission module (10); and one or more means of receiving (11) data; whose functionality and interconnection are described below. On the one hand, the control module (8) is connected to both the auxiliary sensors (6) and the first and second (3, 5) electrical impedance sensors of the cast ceramic (1) and the porous mold (2) . Said control module (8) is configured to timing the measurements taken by both auxiliary sensors (6) and said first and second (3, 5) impedance sensors, performing said measurement by injecting current into said sensor set (3, 5, 6). Said control module (8) is configured to transmit said measurements to the computing module (9), which processes the measurements and determines the state of the solidification process of the cast ceramic (1). Finally, the data transmission module (10), On the one hand, it receives the information processed by the computing module (9) and transmits it periodically to one or several data reception means (11) in order to keep the user in charge of supervising the ceramic casting process informed. (1) as well as to speed up and optimize decision-making regarding the emptying of the remaining liquid ceramic (1) in the mold (2) and its demolding. Said data transmission module (10) is configured so that the at least one data receiving means (11) is a mobile device; that is an interface, configured with screen and buttons; that is, an industrial controller configured to receive the data through wireless and / or wired communication protocols and configured to automate the emptying and unmolding of the ceramic (1) casting.
[0099]
[0100] In another preferred embodiment of the invention, the device further comprises a manual input module for the data of the auxiliary variables that would be obtained by the auxiliary sensors. In this way, it is achieved that the user of the device can enter the variables in the device manually and have a variety of data relevant to the process without the constructive and operational complexity of having a large number of sensors simultaneously.
[0101]
[0102] Once the main object of the invention has been described, a second main object of the invention referred to a system comprising several ceramic monitoring devices (1) is then described by measuring its impedance where at least one module of control (8) is a multichannel module configured to connect multiple auxiliary sensors (6) and multiple pairs of first and second impedance sensors (3,5), so that by means of a single multichannel control module (8) the timing of impedance measurements and current injection into the pairs of first and second impedance sensors (3, 5) of various mold assemblies (2) and cast ceramic (1).
[0103]
[0104] A third main object of the invention relates to a method of monitoring the electrical impedance in real time during the casting process of the ceramic (1) in the porous mold (2), which comprises the use of a monitoring device for Ceramics (1) as well as performing the following steps:
[0105] - the first electrical impedance sensor (3) of the ceramic (1) is placed in contact with it;
[0106] - the second electrical impedance sensor (5) of the mold (2) is placed in its corresponding housing (4) in the mold itself (2);
[0107] - the ceramic (1) is introduced into the mold (2);
[0108] - the data collection is timed and a current is injected both to the first and second impedance sensors (3, 5) of the ceramic (1) and mold (2) impedance and to the auxiliary sensors (6), through the control module (8);
[0109] - signals are generated by means of both the first and the second impedance sensor (3.5) and the auxiliary sensors (6) and are sent to the electronic assembly (7), where the control module (8) conditions them for further processed;
[0110] - the signals conditioned by the computing module (9) are processed and the impedance for the emptying of the ceramic (1) cast in the mold (2) is determined, by means of the computing module (9);
[0111] - the resulting data is transmitted through the transmission module (10) to the data reception means (11);
[0112] - the previous steps are repeated until the optimum emptying impedance is reached, this being calculated by means of the computing module (9);
[0113] - once said optimum emptying impedance is reached, the ceramic (1) left over from the mold (2) is emptied;
[0114] - the data collection is timed and a current is injected both to the first and second impedance sensor (3, 5) of the ceramic (1) and of the mold (2) and to the auxiliary sensors (6), through the control module (8);
[0115] - signals are generated by means of both the first and the second impedance sensor (3, 5) and the auxiliary sensors (6) and are sent to the electronic assembly (7), where the control module (8) conditions them for further processed;
[0116] - the signals conditioned by the computing module (9) are processed and the impedance for the demoulding of the ceramic (1) cast in the mold (2) is determined, by means of the computing module (9);
[0117] - the resulting data is transmitted through the transmission module (10) to the data reception means (11);
[0118] - the previous steps are repeated until the optimum demolding impedance is reached, this being calculated by means of the computing module (9);
[0119] - once the optimum demolding impedance is reached, the mold is demoulded (2).
[0120]
[0121] In another preferred embodiment of the invention, the processing of the signals and the determination of the emptying and demolding impedances by the computing module (9) is carried out by means of adaptive and / or self-learning algorithms which, in said preferred embodiment comprises the following steps:
[0122] - threshold values of optimum emptying and demolding impedances are initially entered manually;
[0123] - after the casting and demolding process, a quality control is carried out on the ceramic piece (1);
[0124] - the quality control assessment is introduced in the computing module (9) so that the algorithm recalculates the optimum values of the emptying and demolding impedances for subsequent ceramic casting processes (1).
[0125]
[0126] In this way, the control of the ceramic solidification process (1) in porous mold (2) is achieved by optimizing the decision making regarding the emptying and demolding of the ceramics (1) in the mold (2).
权利要求:
Claims (11)
[1]
1. - Device for monitoring the impedance of a ceramic (1) during a casting process in a porous mold (2), suitable for molds (2) of variable geometry and for casting processes of slippers and / or porcelains in mold (two),
characterized in that it comprises:
- a first electrical impedance sensor (3), adapted for contact with the cast ceramic (1) and configured to obtain impedance measurements of said cast ceramic (1);
- a second electrical impedance sensor (5), arranged in a housing (4) in the mold (2) and adapted to obtain measurements of the impedance of said mold (2);
- an electronic assembly (7) configured to generate, process and transmit the impedance measurements obtained by the first and second sensors (3,5), and comprising:
a control module (8) adapted to inject current into the first and second sensor (3,5) to obtain impedance measurements;
a computing module (9) adapted for processing impedance measurements;
a data transmission module (10) configured to transmit the data resulting from the computing (9) and control modules (8) to one or more data reception means (11).
[2]
2. - Device according to the preceding claim, which additionally comprises one or more auxiliary sensors (6), both for the ceramic (1) and for the mold (2), adapted to measure auxiliary variables of ambient temperature and humidity, temperature and density of the ceramic (1) casting, thixotropy, viscosity of the ceramic (1) casting, filling and emptying pressure of the ceramic (1) casting, mold temperature (2), humidity and condition of the mold pores (2) , and / or number of mold castings (2).
[3]
3. - Device according to any of the preceding claims, comprising a module for manually entering the data of the auxiliary variables of ambient temperature and humidity, temperature and density of the ceramic (1) casting, thixotropy, viscosity of the ceramic (1 ) casting, filling and emptying pressure of the ceramic (1) casting, mold temperature (2), moisture and pore condition of the mold (2), and / or number of mold casting (2).
[4]
4. - Device according to any of the preceding claims, wherein the first and second (3.5) sensor for measuring the impedance of the mold (2) and the ceramic (1) are integrated in a monolithic body and self-installed in the own mold (2).
[5]
5. - Device according to any of the preceding claims, wherein the data reception means (11) are wired or wireless.
[6]
6. - Device according to any of the preceding claims, wherein at least one data receiving means (11) comprises a mobile device; an interface configured with screen and buttons; or an industrial controller configured to receive the data through wireless and / or wired communication protocols, and configured with means of emptying and automatic demolding of the ceramic (1) casting.
[7]
7. - Method of monitoring the impedance in real time during the process of casting ceramic (1) in mold (2), suitable for casting processes of slippers and / or porcelains in mold (2), which includes the use of a system according to any one of the preceding claims and performing the following steps:
- the first electrical impedance sensor (3) of the ceramic (1) is placed in contact with it;
- the second electrical impedance sensor (5) of the mold (2) is placed in its corresponding housing (4) in the mold itself (2);
- the ceramic (1) is introduced into the mold (2);
- the data collection is timed and a current is injected into the first and second impedance sensor (3.5) of the ceramic (1) and the mold (2), through the control module (8);
- signals are generated by means of the first and second impedance sensor (3,5) and sent to the electronic assembly (7), where the control module (8) conditions them for further processing;
- the signals conditioned by the computing module (9) are processed and the impedance for the emptying of the ceramic (1) cast in the mold (2) is determined, by means of the computing module (9);
- the resulting data is transmitted through the transmission module (10) to the data reception means (11);
- the previous steps are repeated until the optimum emptying impedance is reached, this being calculated by means of the computing module (9);
- once said optimum emptying impedance is reached, the ceramic (1) left over from the mold (2) is emptied;
- the data collection is timed and a current is injected into the first and second impedance sensor (3.5) of the ceramic (1) and the mold (2), through the control module (8);
- signals are generated by means of the first and second impedance sensor (3,5) and sent to the electronic assembly (7), where the control module (8) conditions them for further processing;
- the signals conditioned by the computing module (9) are processed and the impedance for the demoulding of the ceramic (1) cast in the mold (2) is determined, by means of the computing module (9);
- the resulting data is transmitted through the transmission module (10) to the data reception means (11);
- the previous steps are repeated until the optimum demolding impedance is reached, this being calculated by means of the computing module (9);
- once the optimum demolding impedance is reached, the mold is demoulded (2).
[8]
8. - Method according to the preceding claim, wherein the processing of the signals by the computing module (9) is carried out by means of adaptive and / or self-learning algorithms.
[9]
9. - Method according to any one of claims 7-8, wherein in addition to timed and injected currents to the first and second impedance sensor (3.5) of the mold (2) and the ceramic (1) by the module of control (8), the auxiliary sensors (6) are timed and injected by the control module (8), said auxiliary sensors (6) being adapted to measure variables of ambient temperature and humidity, ceramic temperature and density (1) casting, thixotropy of the ceramic (1) casting, viscosity of the ceramic (1) casting, filling and emptying pressure of the ceramic (1) casting, mold temperature (2), humidity and pore state of the mold (2) and / or number of mold castings (2).
[10]
10. - Method according to any of claims 7-9, wherein the data relating to the auxiliary variables of temperature and ambient humidity, temperature and density of the cast ceramic, thixotropy, viscosity of the cast ceramic, filling and emptying pressure of the cast ceramics, mold temperature, humidity and pore condition of the mold and / or number of mold castings, are introduced to the computing module through a manual data entry module.
[11]
11. System comprising a plurality of monitoring devices according to any of claims 1-6 for the ceramic casting process (1) in molds (2), wherein at least one control module (8) of said devices is a multichannel module configured to connect multiple pairs of first and second impedance sensors (3.5) for several molds (2).
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同族专利:
公开号 | 公开日
ES2719934B2|2020-06-08|
引用文献:
公开号 | 申请日 | 公开日 | 申请人 | 专利标题
CN104165907A|2014-08-25|2014-11-26|上海应用技术学院|Monitoring method for solidification process of concrete test blocks on basis of piezoelectric impedance method|
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ES201830046A|ES2719934B2|2018-01-16|2018-01-16|DEVICE AND METHOD OF MONITORING CERAMICS BY MEASURING ITS IMPEDANCE|ES201830046A| ES2719934B2|2018-01-16|2018-01-16|DEVICE AND METHOD OF MONITORING CERAMICS BY MEASURING ITS IMPEDANCE|
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