JP6975442B2 - Fired product manufacturing method - Google Patents

Description

The present invention relates to a technique for producing a fired product such as ceramics.

Conventionally, as a method for manufacturing fired products such as ceramics, a split formwork and an outer frame that prevents deformation of the split formwork are integrated with fasteners, and a ceramic fabric material such as clay is pressed against the inner surface of the integrated split formwork. There is a method for manufacturing a ceramic dough molded body to be molded (see, for example, Reference 1).

Japanese Unexamined Patent Publication No. 2016-150543

However, the above-mentioned conventional method for manufacturing a ceramic dough molded product is a method of manufacturing using a mold for manufacturing ceramics, and the quality of the dough is such that the dough such as ceramic material before firing is kept at a predetermined hardness. It did not improve the manufacturing process, including control.

The present invention has been made in view of these problems, and an object of the present invention is to provide a method for producing a calcined product capable of producing a calcined product having a predetermined quality.

The present invention has been made to solve at least a part of the above-mentioned problems, and can be realized as the following application examples. It should be noted that the reference numerals and supplementary explanations in parentheses in this column indicate the correspondence with the embodiments described later in order to help the understanding of the present invention, and do not limit the present invention in any way. ..

[Application example 1]
In the method for producing a baked product according to the present invention, in the kneading step of kneading the raw material of the fired product, the hardness of the raw material at the time of kneading is measured by a hardness measuring means, and the measured hardness is a value within a predetermined range. If this is the case, the gist is to perform the next step.

According to such a method for producing a fired product, a fired product having a predetermined quality can be produced. The reason will be described below.
In the method for producing a fired product, first, the raw material is generally kneaded (in the production of ceramics and the like, it is called "earth kneading". Hereinafter, the kneading of the raw material is also referred to as "earth kneading").

Conventionally, clay kneading is performed by a skilled worker, and the worker has an appropriate hardness by using a simple measuring tool (for example, a hardness tester such as NGK-01 manufactured by NGK Insulators, Ltd.) and the feeling of the hand. Was decided. Therefore, the hardness may vary depending on the worker, and the quality of the fired product obtained in the final step of the manufacturing method may not be a predetermined value.

On the other hand, in the method of the present invention, the soil-kneaded raw material (hereinafter, also referred to as “yes soil”) is measured by a hardness measuring means, and when the measured hardness is within a predetermined range, the next step is performed. If the measured hardness is not within the predetermined range, for example, the soil is kneaded again.

By doing so, since the yesterday having a hardness in a predetermined range is obtained at the stage of kneading the soil, a calcined product having a predetermined quality is finally obtained, and the raw material is not wasted. ..

[Application example 2]
In the method for producing a baked product according to Application Example 1, after the kneading step and the storage step of storing for a predetermined time as the next step, the hardness of the raw material stored by the hardness measuring means is measured and the measurement is performed. The gist is to perform the next step when the hardness is within a predetermined range.

Normally, after the kneading process, the raw material after kneading (soil-kneaded yes soil) is stored for a predetermined period of time and put into a so-called laid state. Then, the hardness of the raw material (yes soil) becomes higher than the hardness immediately after kneading the soil.

Therefore, after the kneading step and the storage step of storing for a predetermined time as the next step, the hardness of the raw material stored by the hardness measuring means is measured, and when the measured hardness is within a predetermined range, the next step is performed. When the step is performed, if the hardness is within a predetermined range at this point, the raw material can be sent to the next step to finally obtain a fired product of a predetermined quality.

On the contrary, when the hardness of the raw material is not within a predetermined range, it can be sent to the kneading step again to eliminate the waste of the raw material.

It is a process drawing which shows the manufacturing process of a fired product (porcelain). It is a figure which shows the schematic structure of the earth kneading apparatus. It is sectional drawing which shows the schematic structure of the earth kneading part of the earth kneading apparatus. It is a figure which shows the schematic structure of the molding apparatus.

Hereinafter, embodiments to which the present invention has been applied will be described with reference to the drawings. The embodiments of the present invention are not limited to the following embodiments, and various embodiments may be adopted as long as they belong to the technical scope of the present invention.

[Ceramic manufacturing process]
The manufacturing process of the fired product will be described with reference to FIG. FIG. 1 is a process diagram showing a manufacturing process of a fired product. In this embodiment, ceramics will be used as the fired product.

As shown in FIG. 1, in the ceramic manufacturing process, first, in the process of S100, soil kneading is performed (earth kneading process). The soil kneading is a step of mixing kaolin, wood-brush clay, frog-meal clay, keiseki, and the like using the clay kneading device 10 described later to obtain yes soil which is a raw material for pottery. The yes soil obtained in the clay kneading process has a cylindrical shape (yes clay pillar 5).

Further, the soil kneading device 10 is provided with a hardness sensor 15 and measures the hardness of the soil that has been extruded from the soil kneading portion 11 of the soil kneading device 10 and cut by the cutter 13.
In the subsequent step of S105, the sorting unit 14 of the soil kneading device 10 determines whether or not the hardness of the yes soil column 5 obtained by soil kneading in the soil kneading step is within a predetermined range. Then, when the hardness is within the predetermined range (S105: Yes), the process is shifted to S110, and when the hardness is not within the predetermined range (S105: No), the yes soil is returned to the soil kneading process of S100. It will be used again as a raw material for soil kneading.

In the step of S110, the yesterday earth pillar 5 obtained in the step of S100 and having a hardness within a predetermined range is stored, and after a predetermined period of time elapses, the yesterday earth pillar 5 is supplied to the molding apparatus 30 described later and is supplied to the molding apparatus 30. The hardness sensor 33 provided measures the hardness of the soil mass 7 (storage step).

In the subsequent step of S115, it is determined whether or not the hardness of the yes soil mass 7 measured in the storage step of S110 is within a predetermined range. Then, when the hardness is within the predetermined range (S115: Yes), the step is shifted to the molding step of S120, and when the hardness is not within the predetermined range (S115: No), the yes soil mass 7 is kneaded with the soil of S100. Return to the process and use it again as a raw material for clay kneading.

In the step of S120, the solidified soil mass 7 is molded into a molded body 8 having a desired shape by the molding portion 34 of the molding apparatus 30 described later. After molding, the molded body 8 is dried in the primary drying chamber 35. After the primary drying, the weight of the molded body 8 is measured by the weight sensor 36 (primary molding step).

In the step of S125, it is determined whether or not the weight of the molded product 8 acquired in S120 is within the predetermined value, and if the weight is within the predetermined value (S125: Yes), the process is shifted to S130 and the weight is increased. If is not within the predetermined value (S125: No), the molded body 8 is returned to the soil kneading step of S100 and used again as a raw material for soil kneading.

In the step of S130, the molded body 8 is dried in the secondary drying chamber 37 of the molding apparatus 30 (secondary molding step), and in the subsequent step of S135, the shape measuring sensor (camera) 42 provided in the molding apparatus 30 is used. An image of the molded body 8 is acquired, image processing is performed on the acquired image, and the shape of the molded body 8 is converted into data.

In the step of S135, it is determined from the image data acquired in S130 whether or not the molded body 8 has a predetermined shape, and if it has a predetermined shape (S135: Yes), the process is shifted to S140 and the predetermined shape is obtained. If not (S135: No), the molded body 8 is returned to the soil kneading step of S100 and used again as a raw material for soil kneading.

In the step of S140, the molded body 8 that has completed the step of S135 is unglazed (unglazed step), and in the subsequent step of S145, printing is performed on the surface of the unglazed molded body 8 (printing step).
In the subsequent step of S150, the molded body 8 after printing in the printing step is painted (painting step), and in the subsequent step of S155, the molded body 8 painted in the painting step is brushed. Apply the glaze by painting or pickling (glazing process).

In the subsequent step of S160, the molded body 8 coated with the glazed material is fired in the glazing step (baking step), and in the subsequent step of S165, the fired product (not shown) after the firing step is visually inspected for cracks or distortions. Inspect by etc. (inspection process).

[Explanation of soil kneading device]
Next, the soil kneading device 10 will be described with reference to FIG. FIG. 2 is a diagram showing a schematic configuration of the soil kneading device 10.
As shown in FIG. 2, the earth kneading device 10 includes an earth kneading unit 11, a transport unit 12, a cutter 13, a sorting unit 14, a hardness sensor 15, and an operation unit 16.

The clay kneading portion 11 is a portion where clay or the like as a raw material is kneaded and extruded to form a columnar yesterday clay pillar 5. The soil kneading section 11 is provided with a soil filling port 11a and a soil filling port 11b, and clay or the like, which is a raw material, is introduced from the soil filling port 11b to the inside of the soil kneading section 11 via the soil mixing port 11a. It is designed to be put into. The structure of the soil kneading portion 11 will be described later.

The transport section 12 is a section for transporting the yesterday soil formed by the soil kneading section 11 to the sorting section 14. The transport path 12 is provided with a cutter 13, which is pushed out from the soil kneading portion 11 to cut the yesterday soil transported on the transport path 12 to a predetermined length, and a columnar yesterday is used. The earth pillar 5 is used.

The sorting unit 14 is a portion that sorts the yes soil pillar 5 cut to a predetermined size into a non-defective product and a defective product based on the hardness. In the sorting unit 14, the hardness of the yes soil column 5 is measured by the hardness sensor 15. The hardness sensor 15 is a pressure sensor, and measures the value of pressure when the probe of the pressure sensor is moved by a predetermined distance.

The operation unit 16 converts the pressure measured by the pressure sensor 15 of the sorting unit 14 into hardness, and if the converted hardness is within a predetermined range, the operation unit 16 determines that the yes soil column 5 is a non-defective product, and the hardness is predetermined. If it is not within the range, it is judged as a defective product and sorted based on the judgment result (in FIG. 2, if it is a good product, it is carried out to the "OK" side, and if it is a defective product, it is carried out to the "NG" side).

Further, the operation unit 16 is provided with a lamp buzzer 16a, and the lamp and the buzzer notify the determination result of a non-defective product / a defective product based on the hardness of the yes soil pillar 5. For example, if the yes soil pillar 5 is a non-defective product, the green lamp is turned on and the buzzer is not activated, while if it is a defective product, the red lamp is turned on and the buzzer is activated.

Further, the operation unit 16 has a data logger function, records the measurement result of the hardness of the yes soil pillar 5, performs statistical processing on non-defective products and defective products, and determines the cause of defective products. It can be verified.

[Explanation of the soil training section]
Next, the soil kneading section 11 will be described with reference to FIG. FIG. 3 is a cross-sectional view showing a schematic configuration of a soil kneading portion of a soil kneading device.

As shown in FIG. 3, the clay kneading portion 11 includes a first drum 20, a first motor 21, a first screw 22, a perforated plate 23, a second drum 24, a second motor 25, a second screw 26, and a nozzle 27. I have.

A first motor 21 is attached to the outside of the first drum 20, and a first screw 22 is attached to the inside. The first screw 22 is rotated by the rotation of the rotation shaft of the first motor 21.
Further, the first drum 20 is provided with a soil input port 11b, and the soil charged from the soil input port 11b is kneaded by the first screw 22 rotated by the first motor 21, and a plurality of pieces are kneaded. It is extruded to the second drum 24 through the perforated plate 23 provided with the holes.

A second motor 25 is attached to the outside of the second drum 24, and a second screw 26 is attached to the inside. The second screw 26 is rotated by the rotation of the rotation shaft of the second motor 25.
The soil extruded from the first drum 20 is further kneaded in the second drum 24 by the second screw 26 rotated by the second motor 25, and is extruded to the transport portion 12 as the soil pillar 5 via the nozzle 27. Is done.

[Explanation of molding equipment]
Next, the molding apparatus 30 will be described with reference to FIG. FIG. 4 is a diagram showing a schematic configuration of the molding apparatus 30.

As shown in FIG. 4, the molding apparatus 30 includes a soil supply unit 31, a cutter 32, a hardness sensor 33, a molding unit 34, a primary drying chamber 35, a weight sensor 36, a secondary drying chamber 37, and a first transport unit 38. It includes a finishing 40, a product sorting unit 41, a shape measuring sensor 42, a mounting table 43, a second transport unit 44, a hardness / weight measuring unit 50, and a shape measuring unit 60.

The yes soil supply unit 31 is a device on which the yes soil pillar 5 generated by the earth kneading device 10 is placed and conveyed toward the first transfer unit 38.
The cutter 32 is provided in the soil supply unit 31, and the soil pillar 5 conveyed by the soil supply unit 31 is cut to a predetermined length to generate a soil mass 7.

The hardness sensor 33 is a sensor that measures the hardness of the yesterday soil mass 7 generated by cutting with the cutter 32, and is a pressure sensor having the same structure as the hardness sensor 15.
The molding unit 34 is a portion that forms the yes soil mass 7 into a desired shape to form the molded body 8. In the molding unit 34, the ingot 7 is put into a mold, and the ingot 7 is rotated and pressed down by the inner mold (core) to deform the ingot 7 and form the molded body 8.

The primary drying chamber 35 is a so-called drying furnace whose inside is kept at a predetermined temperature, and the molded body 8 molded by the molding unit 34 is transported by the first transport unit 38 and dried at a predetermined temperature.

The weight sensor 36 is a pressure sensor and is provided at the rear end portion of the primary drying chamber 35. The weight of the molded body 8 after the primary drying is measured by the weight applied to the weight sensor (pressure sensor) 36.

The secondary drying chamber 37 is a drying furnace that keeps the inside at a predetermined temperature (higher than the internal temperature of the primary drying chamber), and is determined to have a predetermined weight as a result of weight measurement after the primary drying. The molded product 8 is transported by the second transport unit 44 and dried.

The finish 40 is a portion for finishing the molded product 8 after the secondary drying in the secondary drying chamber 37 into the final form. Specifically, the molded body 8 is placed on a turntable (not shown), and the turntable (that is, the molded body 8) is rotated while deburring the molded body 8 using a sponge and water.

The product sorting unit 41 is a portion that sorts the molded product 8 that has been finished by the finishing 40. The product sorting unit 41 is provided with a shape measurement sensor 42, and if it is determined to pass based on the data acquired by the shape measurement sensor 42, the molded body 8 is sent to the mounting table 43 and fails. If it is determined, the molded body 8 is discarded.

Specifically, the shape measurement sensor 42 is a camera, and the image data of the molded body 8 acquired by the camera is transmitted to the shape measurement unit 60.
The shape measurement unit 60 performs image processing based on the product shape data registered in advance and the image data transmitted from the camera (shape measurement sensor 42), and the image data is within the allowable range for the product shape data. Determine if it exists.

Then, if it is within the permissible range, it is determined to pass, the blue lamp of the lamp buzzer 62 is turned on, and if it is not within the permissible range, it is determined to be unacceptable, and the red lamp of the lamp buzzer 62 is made to emit light. At the same time, the buzzer is activated to notify the user.

The mounting table 43 is a table on which the molded product 8 sorted by the product sorting unit 41 is temporarily placed.
The hardness / weight measuring unit 50 inputs pressure data measured from the pressure sensor 33 of the soil supply unit 31, converts it into hardness, and if the converted hardness is within a predetermined range, the soil mass 7 is a non-defective product. If the hardness is not within the predetermined range, it is determined as a defective product, and based on the determination result, the determination result of the non-defective product / defective product is notified by the lamp buzzer 52.

Further, the hardness / weight measuring unit 50 inputs the pressure data measured from the weight sensor 36, converts it into a weight, and if the converted weight is within a predetermined range, determines that the molded body 8 is a non-defective product. If the hardness is not within a predetermined range, it is determined as a defective product, and the determination result of a non-defective product / defective product is notified by a lamp buzzer 52 based on the determination result.

The notification by the lamp buzzer 52 of the hardness / weight measuring unit 50 is, for example, when the yes soil mass 7 and the molded body 8 are non-defective products, the green lamp is turned on and the buzzer is not activated, while the buzzer is not activated. The red lamp is turned on and the buzzer is activated to notify the user.

Further, the hardness / weight measuring unit 50 has a data logger function, records the measurement results of the hardness and weight of the molded body 8, performs statistical processing on non-defective / defective products, and generates defective products. It is possible to verify the cause of.

The shape measuring unit 60 processes the image data of the molded body 8 acquired by the camera, which is the shape measuring sensor 42 of the product sorting unit 41, and compares it with the image data of the molded body stored in advance, and the shape is predetermined. If it is not within the range of, it is judged as a defective product and sorted based on the judgment result. Since the image processing in the shape measuring unit 60 is a general processing such as binarizing the image data, extracting the edges of the images, and then performing the comparison, the description thereof will be omitted.

Further, the shape measuring unit 60 is provided with a lamp buzzer 62, and the lamp and the buzzer notify the determination result of a non-defective product / a defective product based on the shape of the molded body 8. For example, when the molded body 8 is a non-defective product, the green lamp is turned on and the buzzer is not activated, while when the molded body 8 is a defective product, the red lamp is turned on and the buzzer is activated to notify the notification.

Further, the shape measuring unit 60 has a data logger function, records the measurement result of the shape of the molded body 8, performs statistical processing on non-defective products and defective products, and determines the cause of defective products. It can be verified.

[Characteristics of this technology]
In the above-mentioned fired product manufacturing method, the clay-kneaded raw material (sand pillar 5) was measured by the hardness sensor 15, and when the measured hardness was within a predetermined range, the next step was performed and the measurement was performed. If the hardness is not within the predetermined range, for example, the soil is kneaded again.

Therefore, since the yes soil pillar 5 having a hardness in a predetermined range is obtained at the stage of kneading the soil, a fired product having a predetermined quality is finally obtained, and the raw material is not wasted.

In addition, after the kneading step, the raw material after kneading (soil-kneaded yes soil) is stored for a predetermined period to put it in a so-called laid state. Then, the hardness of the raw material (yes soil) becomes higher than the hardness immediately after kneading the soil.

Therefore, after the kneading step and the storage step of storing for a predetermined time as the next step, the hardness of the raw material (soil column 5) stored by the hardness sensor 33 is measured, and the measured hardness is within the predetermined range. If the next step is performed when the value is high, if the hardness is within a predetermined range at this point, the raw material can be sent to the next step to finally obtain a fired product of a predetermined quality. ..

On the contrary, when the hardness of the raw material (yes soil pillar 5) is not within a predetermined range, the raw material can be sent to the kneading step again to eliminate waste of the raw material.

5 ... Yes soil pillar 7 ... Yes soil mass 8 ... Molded body 10 ... Earth kneading device 11 ... Earth kneading part 11a ... Yes soil introduction path 11b ... Yes soil inlet 12 ... Transport part 13 ... Cutter 14 ... Sorting part 15 ... Hardness sensor 16 ... Operation unit 16a ... Lamp buzzer 20 ... 1st drum 21 ... 1st motor 22 ... 1st screw 23 ... Perforated plate 24 ... 2nd drum 25 ... 2nd motor 26 ... 2nd screw 27 ... Nozzle 30 ... Molding device 31 ... Yes Soil supply unit 32 ... Cutter 33 ... Hardness sensor 34 ... Molding unit 35 ... Primary drying chamber 36 ... Weight sensor 37 ... Secondary drying chamber 38 ... Primary transport unit 40 ... Finishing unit 41 ... Product sorting unit 42 ... Shape measurement Sensor 43 ... Mounting table 44 ... Second transport unit 50 ... Hardness / weight measurement unit 52 ... Lamp / buzzer 60 ... Shape measurement unit 62 ... Lamp / buzzer.

Claims (2)

It is a method for manufacturing fired products.
In the kneading step of kneading the raw material of the fired product, a primary hardness measuring step of measuring the hardness of the raw material at the time of kneading by a hardness measuring means, and a primary hardness measuring step.
A storage step of storing for a predetermined time when the hardness measured in the primary hardness measuring step is within a predetermined range, and a storage step.
After the storage step, a secondary hardness measuring step of measuring the hardness of the stored raw material by the hardness measuring means, and a secondary hardness measuring step.
When the hardness measured in the secondary hardness measuring step is within a predetermined range, the primary molding step of molding the molded product of the fired product with the raw material, and the primary molding step.
A drying step of drying the molded product molded in the primary molding step, and a drying step of drying the molded body.
A weight measuring step for measuring the weight of the molded product dried in the drying step, and a weight measuring step.
A secondary molding step of drying the molded product in a drying chamber when the weight of the molded product measured in the weight measuring step is within a predetermined range.
A method for producing a fired product, which comprises the above. In the method for producing a baked product according to claim 1,
After the secondary molding step, the external shape of the molded product is imaged by an image pickup device, the external shape of the imaged molded product is extracted by image processing, and the extracted external shape is stored in the storage unit in advance. A method for producing a baked product, which comprises performing the next step when the shape is within the range of a predetermined shape as compared with the image data of a predetermined molded product.

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