Description:FIELD OF DISCLOSURE
[0001] The present disclosure generally relates to the field of mechanical press technology, more specifically, relates to conical earthenware forming hybrid mechanical press apparatus and method thereof.
BACKGROUND OF THE DISCLOSURE
[0002] The present disclosure is providing a highly efficient and manual method for forming conical earthenware with a significantly higher depth compared to traditional techniques. The integration of a screw jack and a hydraulic jack is enabling precise control over the shaping process, ensuring uniformity and consistency in the final product. The manual operation of the apparatus is eliminating the dependency on electricity, making the invention suitable for rural and remote areas where access to power is limited.
[0003] The present disclosure is promoting a more hygienic and controlled process for conical earthenware production by minimizing direct contact with clay. The structured mechanical approach is reducing the risk of contamination and improving workplace safety for potters. The apparatus is enabling the use of materials with low plasticity, such as unsaturated clay-water mixtures, thereby expanding the range of raw materials that are viable for high-quality earthenware production.
[0004] The present disclosure is enhancing employment opportunities for traditional potters by providing an easy-to-operate and cost-effective solution that is increasing production rates without requiring extensive training. The hybrid mechanical press apparatus is allowing artisans to maintain the aesthetic and structural integrity of conical earthenware while significantly improving productivity and reducing labour-intensive processes.
[0005] The existing inventions for forming conical earthenware, such as manually operated potter’s wheels and electric-powered shaping devices, are requiring a high level of skill and experience to achieve uniform and high-depth earthenware production. The manual potter’s wheel is relying entirely on the expertise of the potter, leading to inconsistencies in shape, thickness, and structural integrity. The electric potter’s wheel is improving speed but is failing to produce conical earthenware with significant depth, limiting its application for large and deep clay products.
[0006] The existing hydraulic and pneumatic press systems are struggling to produce high-depth conical earthenware due to their inability to provide controlled and gradual deformation of the clay material. These systems are exerting sudden pressure, causing defects such as cracks and uneven thickness in the final product. Additionally, the requirement for a stable power supply in these systems is making them unsuitable for remote and rural areas, where electricity access is inconsistent or unavailable.
[0007] The conventional earthenware production methods are exposing workers to unhygienic conditions due to direct contact with clay, water, and other materials during shaping. Prolonged exposure to moisture and impurities is increasing the risk of skin infections, respiratory issues, and other health hazards. Additionally, the drying process in manual methods is taking an extended period due to excessive water content in the clay mixture, leading to longer production cycles and reduced efficiency.
[0008] Thus, in light of the above-stated discussion, there exists a need for a conical earthenware forming hybrid mechanical press apparatus and method thereof.
SUMMARY OF THE DISCLOSURE
[0009] The following is a summary description of illustrative embodiments of the invention. It is provided as a preface to assist those skilled in the art to more rapidly assimilate the detailed design discussion which ensues and is not intended in any way to limit the scope of the claims which are appended hereto in order to particularly point out the invention.
[0010] According to illustrative embodiments, the present disclosure focuses on a conical earthenware forming hybrid mechanical press apparatus and method thereof which overcomes the above-mentioned disadvantages or provide the users with a useful or commercial choice.
[0011] An objective of the present disclosure is to facilitate the production of conical earthenware with significant depth while maintaining uniform thickness and structural integrity.
[0012] Another objective of the present disclosure is to enable a manual yet highly efficient pressing mechanism that is eliminating the need for electric power, making it suitable for remote and rural areas.
[0013] Another objective of the present disclosure is to integrate a hybrid pressing mechanism that is combining a screw jack for initial deformation and a hydraulic jack for final shaping, ensuring precise formation of earthenware.
[0014] Another objective of the present disclosure is to reduce the dependency on skilled labour by providing a structured mechanical process that is allowing less experienced individuals to operate the machine efficiently.
[0015] Another objective of the present disclosure is to minimize the use of excess water in the clay mixture, thereby accelerating the drying process and improving the overall production rate.
[0016] Another objective of the present disclosure is to enhance hygiene and safety for potters by eliminating direct hand contact with clay during the shaping process, reducing health risks.
[0017] Another objective of the present disclosure is to offer a cost-effective solution for producing high-depth conical earthenware without relying on expensive automated machinery.
[0018] Another objective of the present disclosure is to ensure that the mechanical press apparatus is maintaining consistent pressure distribution during the forming process, preventing defects such as cracks and uneven thickness.
[0019] Yet another objective of the present disclosure is to provide a durable and easy-to-maintain machine that is offering long-term usability with minimal operational costs.
[0020] Yet another objective of the present disclosure is to promote employment opportunities in pottery and ceramic production by introducing a machine that is increasing productivity while preserving traditional craftsmanship.
[0021] In light of the above, in one aspect of the present disclosure, an apparatus for producing high-depth conical earthenware is disclosed herein. The apparatus comprises a machine frame, being manufactured from cast iron material except dies and being configured to provide structural stability and support all operational components during the earthenware production process. The apparatus includes a plurality of side frames, being made from iron strips and welded together, and being integrated within the machine frame and being configured to support an upper mould support and a lower mould support. The apparatus also includes the upper mould support, being positioned at the top of the plurality of side frames and being configured to house a screw rod assembly and facilitate vertical motion of an upper die. The apparatus also includes the lower mould support, being positioned at the bottom of the plurality of side frames and being configured to support a base plate and a hydraulic jack assembly for controlled vertical movement of a lower die. The apparatus also includes the screw rod assembly, being connected to a rotating lever and being configured to impart a perpendicular upward and downward motion to the upper die. The apparatus also includes the rotating lever, being manually operated and being configured to exert rotational downward pressure on the upper die before hydraulic pressing. The apparatus also includes the hydraulic jack assembly, being positioned at the bottom portion of the apparatus and being configured to provide vertical movement to the lower mould support by applying pressure. The apparatus also includes a clamp mechanism, including a plurality of nut-clamps and being configured to secure the lower die firmly in place and restrict its movement during the forming process. The apparatus also includes a two-way pressing mechanism, including the screw rod assembly and the hydraulic jack assembly operating sequentially, and being configured to perform an initial deformation process through rotational pressure and a final shaping process through hydraulic pressure within permitted tolerances. The apparatus also includes a dual-action pressing mechanism, comprising a rotational pressing assembly and a hydraulic pressing assembly, and being configured to sequentially apply rotational deformation followed by hydraulic pressure. The apparatus also includes the rotational pressing assembly, being integrated within the screw rod assembly and being configured to exert controlled rotational force on the upper die for initial shaping. The apparatus also includes the hydraulic pressing assembly, being positioned within the hydraulic jack assembly and being configured to exert downward pressure to complete the shaping process. The apparatus also includes the specialized surface texture, being applied to the interior of upper die and the lower die and being configured to provide enhanced grip and prevent slippage of low-plasticity clay material during shaping. The apparatus also includes the controlled pressing force unit, being integrated with the hydraulic jack assembly and being configured to apply an optimized pressure profile for uniform shaping without causing defects in low-plasticity materials. The apparatus also includes a spring-loaded locking pin mechanism, being positioned within the lower mould support and being configured to engage and disengage the clamp mechanism upon operator input.
[0022] In one embodiment, the machine frame is reinforced with additional support ribs, the support ribs being integrated within the machine frame and being configured to enhance the structural rigidity of the apparatus during operation.
[0023] In one embodiment, the plurality of side frames includes lateral bracing members, the lateral bracing members being secured between the plurality of side frames and being configured to provide additional structural stability to the upper mould support and the lower mould support.
[0024] In one embodiment, the upper mould support includes an adjustable guiding rail system, the adjustable guiding rail system being connected to the screw rod assembly and being configured to maintain the alignment of the upper die during vertical motion.
[0025] In one embodiment, the lower mould support includes a base plate with a cushioning layer, the cushioning layer being positioned between the base plate and the lower die and being configured to mitigate impact forces during pressing.
[0026] In one embodiment, the rotating lever is connected to a gear assembly, the gear assembly being coupled to the screw rod assembly and being configured to provide controlled rotational force to the upper die.
[0027] In one embodiment, the clamp mechanism includes a quick-release locking mechanism, the quick-release locking mechanism being positioned within the plurality of nut-clamps and being configured to engage and disengage the lower die without requiring manual loosening.
[0028] In one embodiment, the controlled pressing force unit is integrated with a pressure feedback sensor, the pressure feedback sensor being connected to the hydraulic pressing assembly and being configured to monitor and adjust the applied force based on material resistance.
[0029] In one embodiment, the spring-loaded locking pin mechanism includes an actuator mechanism, the actuator mechanism being positioned within the lower mould support and being configured to automatically engage and disengage the clamp mechanism based on operator input.
[0030] In light of the above, in one aspect of the present disclosure, a method for producing high-depth conical earthenware is disclosed herein. The method comprising positioning a lower die onto a lower mould support. The method includes placing a clay material onto the lower die. The method also includes operating a rotating lever connected to a screw rod assembly. The method also includes engaging a two-way pressing mechanism to perform an initial shaping through rotational pressing and a final shaping through hydraulic pressing. The method also includes activating a hydraulic pressing assembly integrated with the hydraulic jack assembly to exert downward hydraulic pressure onto the lower mould support. The method also includes securing the lower die using a clamp mechanism. The method also includes applying a controlled pressing force through a controlled pressing force unit. The method also includes enhancing the shaping precision using a specialized surface texture. The method also includes engaging a spring-loaded locking pin mechanism being positioned within the lower mould support. The method also includes releasing the formed conical earthenware by disengaging the clamp mechanism. The method also includes removing the formed high-depth conical earthenware from the die assembly.
[0031] These and other advantages will be apparent from the present application of the embodiments described herein.
[0032] The preceding is a simplified summary to provide an understanding of some embodiments of the present invention. This summary is neither an extensive nor exhaustive overview of the present invention and its various embodiments. The summary presents selected concepts of the embodiments of the present invention in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other embodiments of the present invention are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.
[0033] These elements, together with the other aspects of the present disclosure and various features are pointed out with particularity in the claims annexed hereto and form a part of the present disclosure. For a better understanding of the present disclosure, its operating advantages, and the specified object attained by its uses, reference should be made to the accompanying drawings and descriptive matter in which there are illustrated exemplary embodiments of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] To describe the technical solutions in the embodiments of the present disclosure or in the prior art more clearly, the following briefly describes the accompanying drawings required for describing the embodiments or the prior art. Apparently, the accompanying drawings in the following description merely show some embodiments of the present disclosure, and a person of ordinary skill in the art can derive other implementations from these accompanying drawings without creative efforts. All of the embodiments or the implementations shall fall within the protection scope of the present disclosure.
[0035] The advantages and features of the present disclosure will become better understood with reference to the following detailed description taken in conjunction with the accompanying drawing, in which:
[0036] FIG. 1 illustrates a block diagram of a conical earthenware forming hybrid mechanical press apparatus and method thereof, in accordance with an exemplary embodiment of the present disclosure;
[0037] FIG. 2 illustrates a flowchart of the apparatus for producing high-depth conical earthenware, in accordance with an exemplary embodiment of the present disclosure;
[0038] FIG. 3 illustrates a flowchart of the method for producing high-depth conical earthenware, in accordance with an exemplary embodiment of the present disclosure;
[0039] FIG. 4A and 4B illustrates a perspective view of the conical earthenware forming hybrid mechanical press apparatus and method thereof, in accordance with an exemplary embodiment of the present disclosure;
[0040] FIG. 5 illustrates a side view of the conical earthenware forming hybrid mechanical press apparatus and method thereof, in accordance with an exemplary embodiment of the present disclosure;
[0041] Like reference, numerals refer to like parts throughout the description of several views of the drawing.
[0042] The conical earthenware forming hybrid mechanical press apparatus and method thereof is illustrated in the accompanying drawings, which like reference letters indicate corresponding parts in the various figures. It should be noted that the accompanying figure is intended to present illustrations of exemplary embodiments of the present disclosure. This figure is not intended to limit the scope of the present disclosure. It should also be noted that the accompanying figure is not necessarily drawn to scale.
DETAILED DESCRIPTION OF THE DISCLOSURE
[0043] The following is a detailed description of embodiments of the disclosure depicted in the accompanying drawings. The embodiments are in such detail as to communicate the disclosure. However, the amount of detail offered is not intended to limit the anticipated variations of embodiments; on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the present disclosure.
[0044] In the following description, numerous specific details are set forth in order to provide a thorough understanding of the embodiments of the present disclosure. It may be apparent to one skilled in the art that embodiments of the present disclosure may be practiced without some of these specific details.
[0045] Various terms as used herein are shown below. To the extent a term is used, it should be given the broadest definition persons in the pertinent art have given that term as reflected in printed publications and issued patents at the time of filing.
[0046] The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
[0047] The terms “having”, “comprising”, “including”, and variations thereof signify the presence of a component.
[0048] Referring now to FIG. 1 to FIG. 5 to describe various exemplary embodiments of the present disclosure. FIG. 1 illustrates a perspective view of a conical earthenware forming hybrid mechanical press apparatus and method thereof 100, in accordance with an exemplary embodiment of the present disclosure.
[0049] The apparatus 100 may include a machine frame 102, being manufactured from cast iron material except dies and being configured to provide structural stability and support all operational components during the earthenware production process, a plurality of side frames 104, being made from iron strips and welded together, and being integrated within the machine frame 102 and being configured to support an upper mould support 106 and a lower mould support 108, the upper mould support 106, being positioned at the top of the plurality of side frames 104 and being configured to house a screw rod assembly 110 and facilitate vertical motion of an upper die 112, the lower mould support 108, being positioned at the bottom of the plurality of side frames 104 and being configured to support a base plate 114 and a hydraulic jack assembly 116 for controlled vertical movement of a lower die 118, the screw rod assembly 110, being connected to a rotating lever 120 and being configured to impart a perpendicular upward and downward motion to the upper die 112, the rotating lever 120, being manually operated and being configured to exert rotational downward pressure on the upper die 112 before hydraulic pressing, the hydraulic jack assembly 116, being positioned at the bottom portion of the apparatus 100 and being configured to provide vertical movement to the lower mould support 108 by applying pressure, a clamp mechanism 122, including a plurality of nut-clamps and being configured to secure the lower die 118 firmly in place and restrict its movement during the forming process, a two-way pressing mechanism 124, including the screw rod assembly 110 and the hydraulic jack assembly 116 operating sequentially, and being configured to perform an initial deformation process through rotational pressure and a final shaping process through hydraulic pressure within permitted tolerances, a dual-action pressing mechanism 126, comprising a rotational pressing assembly 128 and a hydraulic pressing assembly 130, and being configured to sequentially apply rotational deformation followed by hydraulic pressure, the rotational pressing assembly 128, being integrated within the screw rod assembly 110 and being configured to exert controlled rotational force on the upper die 112 for initial shaping, the hydraulic pressing assembly 130, being positioned within the hydraulic jack assembly 116 and being configured to exert downward pressure to complete the shaping process, the specialized surface texture 132, being applied to the interior of upper die 112 and the lower die 118 and being configured to provide enhanced grip and prevent slippage of low-plasticity clay material during shaping, the controlled pressing force unit 134, being integrated with the hydraulic jack assembly 116 and being configured to apply an optimized pressure profile for uniform shaping without causing defects in low-plasticity materials, a spring-loaded locking pin mechanism 136, being positioned within the lower mould support 108 and being configured to engage and disengage the clamp mechanism 122 upon operator input.
[0050] The machine frame 102 is reinforced with additional support ribs, the support ribs being integrated within the machine frame 102 and being configured to enhance the structural rigidity of the apparatus 100 during operation.
[0051] The plurality of side frames 104 includes lateral bracing members, the lateral bracing members being secured between the plurality of side frames 104 and being configured to provide additional structural stability to the upper mould support 106 and the lower mould support 108.
[0052] The upper mould support 106 includes an adjustable guiding rail system, the adjustable guiding rail system being connected to the screw rod assembly 110 and being configured to maintain the alignment of the upper die 112 during vertical motion.
[0053] The lower mould support 108 includes a base plate 114 with a cushioning layer, the cushioning layer being positioned between the base plate 114 and the lower die 118 and being configured to mitigate impact forces during pressing.
[0054] The rotating lever 120 is connected to a gear assembly, the gear assembly being coupled to the screw rod assembly 110 and being configured to provide controlled rotational force to the upper die 112.
[0055] The clamp mechanism 122 includes a quick-release locking mechanism, the quick-release locking mechanism being positioned within the plurality of nut-clamps and being configured to engage and disengage the lower die 118 without requiring manual loosening.
[0056] The controlled pressing force unit 134 is integrated with a pressure feedback sensor, the pressure feedback sensor being connected to the hydraulic pressing assembly 130 and being configured to monitor and adjust the applied force based on material resistance.
[0057] The spring-loaded locking pin mechanism 136 includes an actuator mechanism, the actuator mechanism being positioned within the lower mould support 108 and being configured to automatically engage and disengage the clamp mechanism 122 based on operator input.
[0058] The method 100 includes positioning a lower die 118 onto a lower mould support 108, placing a clay material onto the lower die 118, operating a rotating lever 120 connected to a screw rod assembly 110, engaging a two-way pressing mechanism 124 to perform an initial shaping through rotational pressing and a final shaping through hydraulic pressing, activating a hydraulic pressing assembly 130 integrated with the hydraulic jack assembly 116 to exert downward hydraulic pressure onto the lower mould support 108, securing the lower die 118 using a clamp mechanism 122, applying a controlled pressing force through a controlled pressing force unit 134, enhancing the shaping precision using a specialized surface texture 132, engaging a spring-loaded locking pin mechanism 136 being positioned within the lower mould support 108, releasing the formed conical earthenware by disengaging the clamp mechanism 122, removing the formed high-depth conical earthenware from the die assembly 124.
[0059] In one embodiment, the apparatus 100 includes an integrated alignment guide positioned within the upper mould support 106, the alignment guide being configured to ensure precise vertical movement of the upper die 112 along the screw rod assembly 110. This alignment guide enhances accuracy during the initial rotational pressing stage and reduces lateral displacement of the clay material, resulting in a more uniform final product. The alignment guide works in conjunction with the adjustable guiding rail system to maintain consistent die positioning throughout the pressing process.
[0060] In one embodiment, the lower die 118 is embedded with an airflow venting system, the airflow venting system being configured to release trapped air during the shaping process, thereby preventing defects such as air pockets or cracks in the formed earthenware. The airflow venting system operates in synchronization with the specialized surface texture 132, ensuring that low-plasticity clay material adheres properly to the die surface without deformation. The integration of this system significantly improves the overall structural integrity of the conical earthenware.
[0061] In one embodiment, the apparatus 100 comprises an automated material detection sensor positioned above the lower die 118, the automated material detection sensor being configured to analyze the thickness and moisture content of the clay material before pressing. The sensor communicates with the controlled pressing force unit 134 to dynamically adjust the applied pressure based on real-time material properties. This intelligent feedback mechanism optimizes the pressing force and prevents excessive pressure that may lead to material breakage. The sensor also ensures consistency across multiple production cycles, improving repeatability and reducing waste.
[0062] In one embodiment, the rotating lever 120 is integrated with a mechanical force multiplier, the mechanical force multiplier being configured to enhance the applied rotational pressure during the initial pressing stage. This integration allows the operator to exert greater force with minimal manual effort, improving the efficiency of the shaping process. The force multiplier interacts with the gear assembly connected to the screw rod assembly 110, providing a more controlled and uniform rotational pressing force. Additionally, this configuration ensures that the clay material undergoes even pre-compaction before hydraulic pressing is applied.
[0063] In one embodiment, the hydraulic jack assembly 116 is embedded with a thermal regulation unit, the thermal regulation unit being configured to maintain an optimal temperature for the pressing operation. The thermal regulation unit prevents fluctuations in the hydraulic fluid viscosity, ensuring a consistent pressure application during shaping. This integration enhances the reliability of the hydraulic pressing assembly 130, especially when working with clay materials that exhibit variable compressibility based on temperature conditions. The thermal regulation unit also prevents excessive heat buildup, reducing wear and tear on the hydraulic system components.
[0064] The machine frame 102 is manufactured from cast iron material except for the dies and provides the necessary structural stability to support all operational components during the earthenware production process. The machine frame 102 ensures that the apparatus 100 remains rigid and stable under mechanical stresses encountered during the pressing operations. The machine frame 102 incorporates a reinforced structure with additional support ribs, which distribute the load evenly and prevent deformation during extended use. The machine frame 102 integrates with all other components, forming a cohesive structure that enhances durability and operational efficiency.
[0065] The plurality of side frames 104 is made from iron strips that are welded together and integrated within the machine frame 102. The plurality of side frames 104 provides essential support for the upper mould support 106 and the lower mould support 108, ensuring their stability during the pressing process. The plurality of side frames 104 is designed with lateral bracing members secured between the individual side frames to provide additional reinforcement. The plurality of side frames 104 withstands forces exerted by the upper die 112 and lower die 118 during pressing, ensuring that the alignment of the mould supports remains accurate.
[0066] The upper mould support 106 is positioned at the top of the plurality of side frames 104 and is configured to house the screw rod assembly 110, facilitating the vertical motion of the upper die 112. The upper mould support 106 includes an adjustable guiding rail system that connects to the screw rod assembly 110, ensuring that the upper die 112 remains aligned throughout its movement. The upper mould support 106 is designed to withstand repeated mechanical stresses while maintaining precision in the positioning of the upper die 112. The upper mould support 106 enhances the efficiency of the pressing process by ensuring smooth operation and minimal misalignment.
[0067] The lower mould support 108 is positioned at the bottom of the plurality of side frames 104 and supports the base plate 114 and the hydraulic jack assembly 116. The lower mould support 108 is designed to accommodate the vertical movement of the lower die 118, ensuring controlled shaping of the conical earthenware. The lower mould support 108 includes a base plate 114 with a cushioning layer positioned between the base plate 114 and the lower die 118, mitigating impact forces during pressing. The lower mould support 108 also incorporates a spring-loaded locking pin mechanism 136 that engages and disengages the clamp mechanism 122 upon operator input.
[0068] The screw rod assembly 110 is connected to a rotating lever 120 and is configured to impart a perpendicular upward and downward motion to the upper die 112. The screw rod assembly 110 integrates with the upper mould support 106 to ensure precise control of the upper die 112 movement. The screw rod assembly 110 is equipped with a gear assembly connected to the rotating lever 120, allowing controlled rotational force to be applied to the upper die 112. The screw rod assembly 110 is a critical component in the initial shaping phase, providing mechanical force before hydraulic pressing.
[0069] The upper die 112 is positioned within the upper mould support 106 and moves vertically under the influence of the screw rod assembly 110. The upper die 112 has a specialized surface texture 132 applied to its interior, which enhances grip and prevents slippage of low-plasticity clay material during shaping. The upper die 112 operates in conjunction with the lower die 118 to shape the clay material into high-depth conical earthenware. The upper die 112 is designed to exert uniform pressure, ensuring that the material maintains its structural integrity throughout the pressing process.
[0070] The base plate 114 is supported by the lower mould support 108 and provides a stable platform for the lower die 118. The base plate 114 includes a cushioning layer that reduces impact forces and enhances the durability of the lower die 118. The base plate 114 absorbs mechanical vibrations, ensuring that the forming process remains smooth and consistent. The base plate 114 is essential in preventing damage to the lower die 118, contributing to the longevity of the apparatus 100.
[0071] The hydraulic jack assembly 116 is positioned at the bottom portion of the apparatus 100 and provides vertical movement to the lower mould support 108 by applying pressure. The hydraulic jack assembly 116 operates in conjunction with the screw rod assembly 110 as part of the two-way pressing mechanism 124. The hydraulic jack assembly 116 includes a hydraulic pressing assembly 130 that exerts downward pressure to complete the shaping process. The hydraulic jack assembly 116 is integrated with a controlled pressing force unit 134, which applies an optimized pressure profile for uniform shaping without causing defects in low-plasticity materials.
[0072] The lower die 118 is supported by the lower mould support 108 and operates in conjunction with the upper die 112 to shape the clay material. The lower die 118 includes a specialized surface texture 132 that enhances grip and prevents slippage of the clay material during forming. The lower die 118 is secured in place using the clamp mechanism 122, which restricts movement during the pressing process. The lower die 118 plays a crucial role in ensuring that the final earthenware product maintains its desired shape and dimensions with high precision.
[0073] The rotating lever 120 is manually operated and directly connected to the screw rod assembly 110. The rotating lever 120 is configured to exert a controlled downward rotational pressure onto the upper die 112 before the application of hydraulic force. The rotation of the rotating lever 120 translates into a perpendicular downward motion of the screw rod assembly 110, ensuring that the initial deformation of the clay material is achieved through mechanical force before hydraulic pressing begins. The rotating lever 120 enhances operator control over the pressing process, allowing for an even and gradual application of force, which is essential for maintaining the structural integrity of the clay material during shaping. The rotating lever 120 also enables the operator to adjust the pressure manually, preventing sudden impacts that could compromise the uniformity of the formed earthenware.
[0074] The clamp mechanism 122 consists of a plurality of nut-clamps that secure the lower die 118 in place, preventing any unintended movement during the pressing process. The clamp mechanism 122 is configured to firmly lock the lower die 118 onto the lower mould support 108, ensuring that the die remains fixed when subjected to both rotational and hydraulic forces. The clamp mechanism 122 plays a crucial role in stabilizing the shaping process by eliminating any positional shifts that might lead to defects in the final earthenware product. The engagement and disengagement of the clamp mechanism 122 are controlled by the operator, ensuring ease of operation while maintaining a high level of precision. The secure locking of the lower die 118 prevents misalignment and allows for consistent shaping of high-depth conical earthenware.
[0075] The two-way pressing mechanism 124 integrates the screw rod assembly 110 and the hydraulic jack assembly 116 to perform a sequential pressing operation. The two-way pressing mechanism 124 first applies rotational pressure through the screw rod assembly 110, which initiates the deformation of the clay material, followed by hydraulic pressure through the hydraulic jack assembly 116 to finalize the shaping process. The controlled sequence of the two-way pressing mechanism 124 ensures that the shaping process is both gradual and uniform, reducing the likelihood of defects caused by abrupt pressure application. The two-way pressing mechanism 124 allows for greater control over the shaping process by distributing the pressing force in a structured manner, accommodating materials with varying plasticity and ensuring that the formed earthenware retains its structural integrity.
[0076] The dual-action pressing mechanism 126 combines a rotational pressing assembly 128 and a hydraulic pressing assembly 130, operating in a synchronized manner to produce high-depth conical earthenware. The dual-action pressing mechanism 126 enhances the efficiency of the forming process by first exerting rotational deformation through the rotational pressing assembly 128 and then applying hydraulic force through the hydraulic pressing assembly 130. The sequential nature of the dual-action pressing mechanism 126 allows for a gradual transition from initial shaping to final compaction, optimizing the pressure distribution to prevent structural weaknesses in the formed product. The integration of both mechanical and hydraulic forces within the dual-action pressing mechanism 126 ensures high precision in shaping while accommodating the requirements of different clay compositions.
[0077] The rotational pressing assembly 128 is integrated within the screw rod assembly 110 and is responsible for applying controlled rotational force to the upper die 112. The rotational pressing assembly 128 ensures that the clay material undergoes an initial deformation process before the application of hydraulic pressure, thereby improving the overall efficiency of the shaping process. The rotational pressing assembly 128 operates by exerting a circular motion onto the clay, gradually compressing and shaping it to the desired form. The controlled nature of the rotational pressing assembly 128 allows for uniform force distribution, preventing localized stress points that might lead to material failure.
[0078] The hydraulic pressing assembly 130 is positioned within the hydraulic jack assembly 116 and is responsible for exerting downward hydraulic pressure to complete the shaping process. The hydraulic pressing assembly 130 ensures that the final compaction of the clay material is achieved with a controlled and optimized pressure profile. The hydraulic pressing assembly 130 provides a consistent and even force distribution, eliminating the risk of uneven thickness in the formed earthenware. The integration of the hydraulic pressing assembly 130 within the overall pressing mechanism enhances the precision and reliability of the forming process, ensuring that the final product meets the required structural and aesthetic standards.
[0079] The specialized surface texture 132 is applied to the interior surfaces of the upper die 112 and the lower die 118 to enhance grip and prevent slippage of low-plasticity clay material during shaping. The specialized surface texture 132 ensures that the clay remains in position throughout the pressing process, reducing material displacement and improving the accuracy of the formed earthenware. The specialized surface texture 132 also enhances the adhesion between the clay and the dies, allowing for more efficient force transfer and minimizing defects caused by material shifting. The application of the specialized surface texture 132 contributes to the overall consistency and quality of the final product.
[0080] The controlled pressing force unit 134 is integrated with the hydraulic jack assembly 116 and is responsible for applying an optimized pressure profile during the shaping process. The controlled pressing force unit 134 ensures that the applied force remains within the required tolerances, preventing excessive pressure that might cause defects in low-plasticity materials. The controlled pressing force unit 134 regulates the hydraulic pressure to ensure uniform shaping, accommodating variations in material composition and preventing inconsistencies in the final product. The integration of the controlled pressing force unit 134 enhances the precision and repeatability of the forming process, contributing to the overall efficiency of the apparatus.
[0081] The spring-loaded locking pin mechanism 136 is positioned within the lower mould support 108 and is designed to engage and disengage the clamp mechanism 122 upon operator input. The spring-loaded locking pin mechanism 136 provides a secure locking mechanism for the lower die 118, ensuring that it remains firmly in place during pressing operations. The spring-loaded locking pin mechanism 136 enhances the ease of operation by allowing for quick engagement and release of the clamp mechanism 122, streamlining the forming process and reducing downtime between operations. The incorporation of the spring-loaded locking pin mechanism 136 improves the overall usability and efficiency of the apparatus by enabling precise and reliable die locking.
[0082] FIG. 2 illustrates a flowchart of the apparatus for producing high-depth conical earthenware, in accordance with an exemplary embodiment of the present disclosure.
[0083] At 202, the machine frame and side frames provide structural support. The lower mould support and upper mould support are positioned within the frame.
[0084] At 204, the lower die is placed onto the base plate of the lower mould support. The clamp mechanism, secured by nut-clamps, firmly locks the lower die in place. The spring-loaded locking pin mechanism is engaged.
[0085] At 206, low-plasticity clay material is loaded into the lower die. The specialized surface texture inside the dies ensures grip.
[0086] At 208, the upper die is positioned within the upper mould support, connected to the screw rod assembly.
[0087] At 210, the rotating lever is manually operated, applying rotational downward pressure to the upper die. The rotational pressing assembly within the screw rod assembly performs initial deformation of the clay.
[0088] At 212, the hydraulic jack assembly applies controlled hydraulic pressure to the lower mould support, moving the lower die upward. The hydraulic pressing assembly completes the final shaping of the earthenware. The controlled pressing force unit ensures uniform pressure.
[0089] At 214, the two-way pressing mechanism utilizes the sequential rotational and hydraulic pressing to form the high-depth conical shape.
[0090] At 216, the hydraulic jack assembly retracts, lowering the lower die. The screw rod assembly retracts, lifting the upper die.
[0091] At 218, the clamp mechanism is disengaged using the spring-loaded locking pin mechanism. The formed high-depth conical earthenware is removed from the lower die.
[0092] FIG. 3 illustrates a flowchart of the method for producing high-depth conical earthenware, in accordance with an exemplary embodiment of the present disclosure.
[0093] At 302, positioning a lower die onto a lower mould support.
[0094] At 304, placing a clay material onto the lower die.
[0095] At 306, operating a rotating lever connected to a screw rod assembly.
[0096] At 308, engaging a two-way pressing mechanism to perform an initial shaping through rotational pressing and a final shaping through hydraulic pressing.
[0097] At 310, activating a hydraulic pressing assembly integrated with the hydraulic jack assembly to exert downward hydraulic pressure onto the lower mould support.
[0098] At 312, securing the lower die using a clamp mechanism.
[0099] At 314, applying a controlled pressing force through a controlled pressing force unit.
[0100] At 316, enhancing the shaping precision using a specialized surface texture.
[0101] At 318, engaging a spring-loaded locking pin mechanism being positioned within the lower mould support.
[0102] At 320, releasing the formed conical earthenware by disengaging the clamp mechanism.
[0103] At 322, removing the formed high-depth conical earthenware from the die assembly.
[0104] FIG. 4A illustrates a perspective view of the conical earthenware forming hybrid mechanical press apparatus and method thereof, in accordance with an exemplary embodiment of the present disclosure.
[0105] At 402, the screw rod 402 rotates continuously around its central axis, facilitating vertical displacement of the upper aluminium die 406. The rotational force exerted by the screw rod 402 initiates the primary compression of the clay material, ensuring an even and controlled deformation. The screw rod 402 maintains stability throughout the pressing process, preventing abrupt pressure variations that could affect the structural integrity of the formed greenware. The precise threading of the screw rod 402 enables smooth and gradual movement, reducing frictional losses during operation. The screw rod 402 remains securely fastened to the rotating lever, which allows the operator to manually apply controlled force. The mechanical advantage provided by the screw rod 402 enhances the efficiency of the forming process, ensuring the clay material undergoes uniform compression. The screw rod 402 continues to play a pivotal role in transferring applied torque into a downward pressing motion, creating the foundational shape of the earthenware. The controlled descent of the screw rod 402 ensures the gradual deformation of the material while maintaining its aesthetic properties.
[0106] At 404, the green ware separator 404 continuously serves as a critical interface between the formed clay structure and the aluminium die 406, preventing unwanted adhesion. The green ware separator 404 ensures that the newly shaped greenware can be easily detached from the aluminium die 406 without causing surface imperfections. The material composition of the green ware separator 404 is optimized to provide non-stick properties, thereby reducing the likelihood of defects during the removal process. The green ware separator 404 continuously maintains a uniform layer between the die and the clay, preventing any inconsistencies in the moulded structure. The green ware separator 404 ensures that even after prolonged use, the production efficiency remains intact without compromising product quality. The design of the green ware separator 404 facilitates quick detachment of the greenware, significantly reducing production cycle times. The green ware separator 404 continuously functions to enhance operational smoothness, minimizing the risk of distortion or breakage when extracting freshly moulded greenware. The green ware separator 404 provides a seamless transition between the shaping and removal stages, ensuring the final product retains its intended form.
[0107] At 406, the aluminium die 406 continuously plays a fundamental role in shaping the clay into a high-depth conical earthenware structure. The aluminium die 406 applies uniform pressure across the entire surface of the clay, ensuring that the final product maintains precise dimensional accuracy. The aluminium die 406 remains resistant to deformation, allowing for repeated usage without compromising the consistency of production. The aluminium die 406 is designed with a specialized surface texture that enhances grip while preventing slippage of the clay material. The aluminium die 406 continuously facilitates efficient compaction, reducing air gaps and ensuring a smooth finish on the final product. The aluminium die 406 maintains its alignment with the screw rod 402, ensuring that the applied force remains evenly distributed throughout the forming process. The aluminium die 406 undergoes minimal wear and tear due to its high-strength construction, enabling prolonged operational efficiency. The aluminium die 406 continuously ensures that the clay maintains its shape during both the initial rotational pressing phase and the final hydraulic pressing phase. The aluminium die 406 enhances the precision of the moulding process, ensuring that the high-depth conical structure is consistently replicated.
[0108] At 408, the hydraulic jack 408 continuously applies controlled downward force to finalize the shaping of the greenware. The hydraulic jack 408 ensures deep deformation of the clay material while maintaining the necessary structural integrity of the product. The hydraulic jack 408 provides a smooth and controlled pressing action, eliminating abrupt force variations that could result in defects. The hydraulic jack 408 enhances the overall efficiency of the process by allowing precise pressure adjustments based on the material properties of the clay. The hydraulic jack 408 seamlessly integrates with the lower mould support, ensuring uniform force distribution across the entire die assembly. The hydraulic jack 408 continuously reinforces the shaping process, ensuring that the greenware achieves the desired depth without structural inconsistencies. The hydraulic jack 408 remains a key component in achieving uniform compression, allowing for the production of high-depth conical earthenware with repeatable accuracy. The hydraulic jack 408 sustains optimal performance across multiple production cycles, ensuring long-term reliability and efficiency. The hydraulic jack 408 ensures that the clay is subjected to controlled and gradual force, minimizing the risk of cracks or material defects.
[0109] At 410, the blue colour base frame 410 continuously provides structural integrity to the entire apparatus, ensuring stability during high-pressure operations. The blue colour base frame 410 withstands mechanical stress generated during both the rotational and hydraulic pressing stages, preventing any form of structural distortion. The blue colour base frame 410 is designed from high-strength cast iron, ensuring that all connected components remain securely in place throughout the operation. The blue colour base frame 410 supports the alignment of the upper and lower mould assemblies, preventing unwanted shifts that could affect the uniformity of the final product. The blue colour base frame 410 maintains a rigid foundation, minimizing vibration during the pressing process and enhancing precision. The blue colour base frame 410 continuously absorbs impact forces, reducing the overall strain on other operational components. The blue colour base frame 410 integrates seamlessly with the hydraulic system, allowing for controlled force distribution throughout the pressing mechanism. The blue colour base frame 410 ensures that the apparatus remains durable and resistant to long-term wear, supporting multiple production cycles without compromise. The blue colour base frame 410 continuously reinforces the overall stability of the system, ensuring smooth operation and consistent performance.
[0110] At 412, the green ware remover stand 412 continuously facilitates the safe extraction of formed greenware from the aluminium die 406. The green ware remover stand 412 ensures that the freshly moulded conical earthenware is detached without causing deformation or damage to its structural integrity. The green ware remover stand 412 provides a stable support system, allowing operators to handle the delicate greenware without excessive manual force. The green ware remover stand 412 minimizes the risk of accidental breakage, ensuring that each formed product retains its intended design. The green ware remover stand 412 continuously aids in the post-moulding process by streamlining the removal stage, reducing production time. The green ware remover stand 412 remains positioned in alignment with the die assembly, allowing for seamless extraction of the moulded earthenware. The green ware remover stand 412 ensures that even under high-frequency operation, the removal process remains efficient and controlled. The green ware remover stand 412 continuously enhances workflow efficiency, allowing for the rapid transition from one production cycle to the next. The green ware remover stand 412 ensures that the final product is handled with care, maintaining its quality from the moulding stage to the drying stage.
[0111] FIG. 4B illustrates a perspective view of the components of the conical earthenware forming hybrid mechanical press apparatus and method thereof, in accordance with an exemplary embodiment of the present disclosure.
[0112] At 104, the plurality of side frames 104 is manufactured from robust iron strips that undergo a welding process to form a rigid structure. These side frames 104 play a crucial role in maintaining the overall stability and alignment of the machine during the earthenware production process. The plurality of side frames 104 supports both the upper mould support 106 and the lower mould support 108, ensuring that the entire assembly remains structurally sound during operation. By providing lateral support, the plurality of side frames 104 prevents any misalignment or deformation caused by the forces exerted during pressing. Additionally, the plurality of side frames 104 integrates lateral bracing members, which reinforce the framework and distribute the applied pressure evenly across the entire structure. The rigid construction of the plurality of side frames 104 ensures that external vibrations and operational stresses do not compromise the precision of the forming process. By serving as a foundational support structure, the plurality of side frames 104 enhances the efficiency of the pressing mechanism and contributes to the machine's durability and longevity.
[0113] At 106, the upper mould support 106 is positioned at the top of the plurality of side frames 104, acting as a critical structural component that houses the screw rod assembly 110. The upper mould support 106 facilitates the controlled vertical motion of the upper die 112, ensuring that the applied pressure is evenly distributed during the forming process. By integrating an adjustable guiding rail system, the upper mould support 106 maintains the precise alignment of the upper die 112, preventing any deviation from the intended path. The upper mould support 106 provides a stable mounting platform for the screw rod assembly 110, allowing for smooth rotational movement and consistent downward force application. The design of the upper mould support 106 incorporates high-strength materials, ensuring that the repeated forces exerted during the shaping process do not compromise its structural integrity. The upper mould support 106 also serves as an anchor point for additional components such as the rotating lever 120, enabling manual operation with minimal resistance. By maintaining proper alignment and stability, the upper mould support 106 significantly enhances the accuracy and repeatability of the conical earthenware formation process.
[0114] At 108, the lower mould support 108 is positioned at the base of the plurality of side frames 104, providing a stable foundation for the forming process. The lower mould support 108 houses the base plate 114, which serves as the primary contact surface for the lower die 118. By integrating a hydraulic jack assembly 116, the lower mould support 108 enables controlled vertical movement of the lower die 118, ensuring that the shaping process occurs within the specified tolerances. The lower mould support 108 incorporates a cushioning layer beneath the base plate 114 to mitigate impact forces during pressing, preventing damage to both the machine and the formed earthenware. The lower mould support 108 also features a robust mounting system for the clamp mechanism 122, which securely holds the lower die 118 in place throughout the shaping process. By ensuring that the lower mould support 108 remains structurally stable under high-pressure conditions, the design facilitates efficient and defect-free production of high-depth conical earthenware. The precision alignment of the lower mould support 108 ensures that the applied force is evenly distributed, contributing to the machine's overall reliability and performance.
[0115] At 110, the screw rod assembly 110 is an integral component that enables the initial deformation of the clay material before hydraulic pressing. The screw rod assembly 110 is connected to the rotating lever 120, which imparts rotational force to the system, generating a controlled downward motion. By utilizing a precisely machined thread mechanism, the screw rod assembly 110 ensures smooth and consistent movement, allowing the upper die 112 to exert uniform pressure on the clay. The screw rod assembly 110 is housed within the upper mould support 106, maintaining its alignment throughout the operation. The connection between the screw rod assembly 110 and the upper die 112 is facilitated through a connector plate, eliminating any unwanted play and ensuring that the movement remains strictly vertical. The screw rod assembly 110 is designed to operate with minimal friction, enhancing the efficiency of the pressing process. By providing an initial shaping force before hydraulic compression, the screw rod assembly 110 plays a crucial role in achieving the desired form and depth of the conical earthenware.
[0116] At 112, the upper die 112 is a precisely engineered component responsible for shaping the clay material into its final form. The upper die 112 is securely mounted to the screw rod assembly 110, ensuring controlled vertical motion during the pressing process. The upper die 112 features a specialized surface texture 132 that enhances grip and prevents slippage of the low-plasticity clay material during forming. The design of the upper die 112 allows for uniform pressure distribution, ensuring that the final product maintains consistent thickness and structural integrity. The upper die 112 is constructed from high-strength materials, ensuring durability and resistance to deformation under high-pressure conditions. By working in conjunction with the lower die 118, the upper die 112 contributes to the efficient and repeatable production of high-depth conical earthenware. The upper die 112 undergoes a precision manufacturing process to ensure that its surface remains free from defects that could affect the final product's quality.
[0117] At 114, the base plate 114 is a critical support component positioned within the lower mould support 108, providing a stable foundation for the lower die 118. The base plate 114 is designed to withstand the high pressures exerted during the shaping process, ensuring that the lower die 118 remains firmly in place. A cushioning layer is incorporated into the base plate 114 to absorb impact forces and prevent damage to both the die and the formed earthenware. The base plate 114 is secured using a clamp mechanism 122, which restricts any unwanted movement during the forming process. The structural integrity of the base plate 114 ensures that the applied forces are evenly distributed, minimizing the risk of defects in the final product. By maintaining a stable and vibration-free platform, the base plate 114 enhances the overall efficiency and reliability of the pressing operation.
[0118] At 116, the hydraulic jack assembly 116 is positioned at the bottom portion of the apparatus 100, playing a vital role in providing controlled vertical movement to the lower mould support 108. The hydraulic jack assembly 116 operates by applying pressurized fluid to generate a consistent upward force, enabling precise shaping of the clay material. The hydraulic jack assembly 116 works in conjunction with the screw rod assembly 110, forming a two-way pressing mechanism 124 that ensures both initial and final shaping processes occur within the desired tolerances. The hydraulic jack assembly 116 integrates a controlled pressing force unit 134, which optimizes the pressure profile to prevent defects in the formed earthenware. By allowing for smooth and gradual movement, the hydraulic jack assembly 116 enhances the overall accuracy and quality of the shaping process.
[0119] At 118, the lower die 118 is a crucial forming component that works in tandem with the upper die 112 to shape the clay material. The lower die 118 is securely positioned on the base plate 114 within the lower mould support 108, ensuring precise alignment throughout the pressing process. The lower die 118 incorporates a specialized surface texture 132 that prevents slippage and ensures proper material distribution. By working with the clamp mechanism 122, the lower die 118 remains firmly in place during both the initial rotational pressing and final hydraulic compression. The lower die 118 is manufactured from high-strength materials, ensuring resistance to wear and deformation over repeated cycles.
[0120] At 120, the rotating lever 120 is a manually operated component that connects to the screw rod assembly 110, allowing for controlled application of rotational pressure. The rotating lever 120 initiates the first stage of pressing, ensuring that the clay material undergoes an initial deformation before hydraulic compression. The design of the rotating lever 120 enables smooth and efficient operation with minimal effort, allowing for precise control over the shaping process. The rotating lever 120 ensures that the pressure applied to the upper die 112 remains consistent, contributing to the overall quality of the final product.
[0121] FIG. 5 illustrates a side view of the conical earthenware forming hybrid mechanical press apparatus and method thereof, in accordance with an exemplary embodiment of the present disclosure.
[0122] At 502, the screw rod Sq. thread continuously rotates around its axis, facilitating the controlled upward and downward motion necessary for shaping the conical earthenware. The screw rod Sq. thread remains integral to the machine’s pressing mechanism by converting the rotational motion applied through the rotating lever into linear displacement. The fine threading of the screw rod Sq. thread provides a gradual and precise movement, ensuring a uniform distribution of force during the initial deformation stage. The screw rod Sq. thread consistently regulates the initial compression, allowing for a slow and controlled pressing process before hydraulic pressure takes over. The material composition of the screw rod Sq. thread ensures durability, preventing wear and tear even under continuous mechanical stress. The precision of the screw rod Sq. thread ensures that the upper die remains in perfect alignment with the lower die throughout the entire pressing process. The smooth operation of the screw rod Sq. thread directly influences the overall quality and consistency of the final earthenware product.
[0123] At 504, the upper mould support firmly holds the upper die and ensures its alignment during the pressing process. The upper mould support remains positioned at the topmost section of the apparatus, effectively distributing the pressure exerted by the screw rod assembly. The rigid structure of the upper mould support minimizes any flexing or misalignment, ensuring that the upper die consistently applies uniform pressure. The upper mould support prevents unnecessary lateral movement of the upper die, ensuring the formation of a symmetrical and precise conical shape. The strength of the upper mould support allows it to withstand the repeated forces applied by the screw rod Sq. thread and hydraulic jack without deformation. The seamless integration of the upper mould support with the upper frame contributes to the overall stability and operational efficiency of the apparatus. The upper mould support ensures that the force applied during pressing remains concentrated, preventing any inconsistencies in the earthenware shape.
[0124] At 506, the upper frame encloses and reinforces the structural integrity of the entire apparatus. The upper frame accommodates the upper mould support and the screw rod assembly while providing additional rigidity. The robust nature of the upper frame allows it to withstand repeated mechanical stresses without deformation, maintaining the precision of the pressing operation. The upper frame effectively supports the weight of all the upper components, ensuring the even distribution of mechanical forces throughout the apparatus. The upper frame also acts as a structural barrier, protecting the internal components from external vibrations or impacts that could affect the precision of the pressing process. The design of the upper frame contributes to the ease of maintenance and operational longevity of the machine. The rigid and well-engineered upper frame ensures that the pressing force is transmitted directly through the moulds without unnecessary flexing or deviation.
[0125] At 508, the side frame provides lateral support to the apparatus, preventing any unwanted shifts during the pressing process. The welded iron strips forming the side frame enhance the machine's stability, allowing the force exerted by the screw rod and hydraulic jack to remain directed along the vertical axis. The precise fabrication of the side frame ensures accurate alignment of all moving components. The robust construction of the side frame helps maintain the correct positioning of the upper and lower moulds, ensuring a consistent and even application of force during the pressing process. The side frame absorbs any minor vibrations or external disturbances, ensuring that the apparatus operates smoothly under varying conditions. The side frame also plays a critical role in maintaining the long-term durability of the machine by reducing strain on the pressing mechanism. The well-engineered structure of the side frame ensures that the pressing force remains effectively contained within the working area of the apparatus.
[0126] At 510, the lower mould support holds the lower die in position while accommodating the pressing forces exerted from both the screw rod and hydraulic jack. The lower mould support, constructed from thick cast iron, prevents any flexing or shifting of the lower die. The lower mould support also integrates the clamp mechanism, which secures the lower die firmly in place, preventing any misalignment during the pressing process. The lower mould support ensures that the applied pressure is evenly distributed, allowing the earthenware to be shaped with high precision and consistency. The stability of the lower mould support plays a crucial role in maintaining the structural integrity of the conical earthenware throughout the pressing cycle. The lower mould support also facilitates easy removal of the finished product, ensuring a smooth and efficient workflow. The integration of the lower mould support with the hydraulic system enhances the machine’s ability to produce high-depth earthenware without compromising on accuracy or quality.
[0127] At 512, the hydraulic jack continuously generates vertical motion for the lower mould support, applying the required pressure for the final shaping of the conical earthenware. The hydraulic jack ensures a smooth and controlled pressing force, allowing the clay material to conform precisely to the mould’s shape. The integration of the hydraulic jack within the apparatus enables the production of deep earthenware structures without requiring an external power source. The hydraulic jack provides a uniform pressing force that eliminates air pockets and imperfections, ensuring a flawless final product. The ability of the hydraulic jack to deliver consistent pressure across multiple cycles enhances the overall efficiency of the machine. The durable construction of the hydraulic jack ensures that it withstands repeated use without performance degradation. The hydraulic jack plays a critical role in the final pressing stage, ensuring that the earthenware achieves the desired depth and structural integrity.
[0128] At 514, the lower frame remains responsible for supporting the hydraulic jack and the entire lower assembly of the apparatus. The lower frame provides a stable foundation, ensuring the force applied during the pressing process remains evenly distributed. The strength and durability of the lower frame contribute to the machine’s ability to maintain high precision across multiple production cycles. The lower frame absorbs the force exerted by the hydraulic jack, preventing any excess stress from affecting the structural integrity of the apparatus. The lower frame also enhances the safety and reliability of the machine by maintaining a fixed and stable base for all pressing operations. The robust construction of the lower frame minimizes wear and tear, extending the operational lifespan of the apparatus. The lower frame ensures that all forces remain properly channelled through the pressing mechanism, maintaining uniformity in the produced earthenware. The lower frame plays a crucial role in maintaining overall machine balance, preventing vibrations or misalignment that could affect production quality.
[0129] The best mode of operation of the apparatus for producing high-depth conical earthenware begins with the preparation and positioning of the lower die 118 onto the lower mould support 108. The lower mould support 108, which is reinforced by the plurality of side frames 104, ensures a stable foundation for the shaping process. The operator carefully secures the lower die 118 using the clamp mechanism 122, which consists of a plurality of nut-clamps that prevent unwanted movement during the pressing operation. Once the lower die 118 is firmly locked into place, the clay material is placed onto the surface of the lower die 118, ensuring proper alignment to achieve uniform shaping.
[0130] Following the placement of the clay material, the upper die 112, which is housed within the upper mould support 106, is aligned with the lower die 118. The upper die 112 is connected to the screw rod assembly 110, which is responsible for facilitating vertical motion. The upper mould support 106, being positioned at the top of the plurality of side frames 104, provides the necessary structural stability to ensure precise movement of the upper die 112. The operator manually engages the rotating lever 120, which is directly connected to the screw rod assembly 110. By rotating the rotating lever 120, the operator applies a controlled rotational downward pressure onto the upper die 112, initiating the initial deformation of the clay material. The rotational force exerted through the rotating lever 120 is transferred to the screw rod assembly 110, which ensures that the upper die 112 moves in a perpendicular downward direction.
[0131] Once the initial deformation has been achieved, the two-way pressing mechanism 124 comes into action. The two-way pressing mechanism 124 consists of the rotational pressing assembly 128, which is integrated within the screw rod assembly 110, and the hydraulic pressing assembly 130, which is positioned within the hydraulic jack assembly 116. The rotational pressing assembly 128 continues applying controlled rotational force to the upper die 112, further shaping the clay material and ensuring that it conforms to the contours of the lower die 118. This stage of the process allows for a gradual transition in the shaping process, ensuring that the clay material retains its integrity without experiencing sudden stress or deformation.
[0132] Following the completion of the initial shaping, the hydraulic jack assembly 116 is activated to initiate the final shaping process. The hydraulic pressing assembly 130, being a part of the hydraulic jack assembly 116, exerts a precise downward hydraulic force on the lower mould support 108, which in turn presses the clay material between the upper die 112 and the lower die 118. The hydraulic pressing assembly 130 ensures that the applied pressure is distributed evenly across the clay material, minimizing the risk of inconsistencies and defects. The controlled pressing force unit 134, which is integrated within the hydraulic jack assembly 116, optimizes the pressure profile to accommodate the properties of low-plasticity materials, ensuring uniform shaping without causing cracks or deformities.
[0133] To further enhance the precision of the shaping process, the specialized surface texture 132, which is applied to the interior of both the upper die 112 and the lower die 118, prevents the clay material from slipping during the pressing operation. The specialized surface texture 132 provides additional grip, allowing the clay material to maintain its position and adhere to the intended shape. The application of this specialized surface texture 132 contributes to achieving a consistent and high-quality final product.
[0134] Throughout the pressing operation, the stability of the lower die 118 is maintained by the clamp mechanism 122, which remains engaged to prevent any movement. Once the shaping process is complete, the spring-loaded locking pin mechanism 136, which is positioned within the lower mould support 108, is engaged by the operator. The spring-loaded locking pin mechanism 136 interacts with the clamp mechanism 122, allowing for the controlled release of the lower die 118. This mechanism ensures that the formed high-depth conical earthenware can be easily removed from the lower die 118 without causing damage to its structure.
[0135] After disengaging the clamp mechanism 122, the operator carefully lifts the formed high-depth conical earthenware from the die assembly. The dual-action pressing mechanism 126, which incorporates both the rotational pressing assembly 128 and the hydraulic pressing assembly 130, ensures that the final product possesses the required depth and shape with a high degree of accuracy. The structural rigidity provided by the machine frame 102, which is manufactured from cast iron material, plays a crucial role in maintaining the stability of all components throughout the operation. The reinforcement of the machine frame 102 with additional support ribs further enhances its ability to withstand the mechanical and hydraulic forces exerted during the pressing process.
[0136] While the invention has been described in connection with what is presently considered to be the most practical and various embodiments, it will be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the scope of the appended claims.
[0137] A person of ordinary skill in the art may be aware that, in combination with the examples described in the embodiments disclosed in this specification, units and algorithm steps may be implemented by electronic hardware, computer software, or a combination thereof.
[0138] The foregoing descriptions of specific embodiments of the present disclosure have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present disclosure to the precise forms disclosed, and many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described to best explain the principles of the present disclosure and its practical application, and to thereby enable others skilled in the art to best utilize the present disclosure and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the scope of the present disclosure.
[0139] In a case that no conflict occurs, the embodiments in the present disclosure and the features in the embodiments may be mutually combined. The foregoing descriptions are merely specific implementations of the present disclosure, but are not intended to limit the protection scope of the present disclosure. Any variation or replacement readily figured out by a person skilled in the art within the technical scope disclosed in the present disclosure shall fall within the protection scope of the present disclosure. Therefore, the protection scope of the present disclosure shall be subject to the protection scope of the claims.
, Claims:I/We Claim:
1. An apparatus for producing high-depth conical earthenware (100), the apparatus (100) comprising:
a machine frame (102), being manufactured from cast iron material except dies and being configured to provide structural stability and support all operational components during the earthenware production process;
a plurality of side frames (104), being made from iron strips and welded together, and being integrated within the machine frame (102) and being configured to support an upper mould support (106) and a lower mould support (108);
the upper mould support (106), being positioned at the top of the plurality of side frames (104) and being configured to house a screw rod assembly (110) and facilitate vertical motion of an upper die (112);
the lower mould support (108), being positioned at the bottom of the plurality of side frames (104) and being configured to support a base plate (114) and a hydraulic jack assembly (116) for controlled vertical movement of a lower die (118);
the screw rod assembly (110), being connected to a rotating lever (120) and being configured to impart a perpendicular upward and downward motion to the upper die (112);
the rotating lever (120), being manually operated and being configured to exert rotational downward pressure on the upper die (112) before hydraulic pressing;
the hydraulic jack assembly (116), being positioned at the bottom portion of the apparatus (100) and being configured to provide vertical movement to the lower mould support (108) by applying pressure;
a clamp mechanism (122), including a plurality of nut-clamps and being configured to secure the lower die (118) firmly in place and restrict its movement during the forming process;
a two-way pressing mechanism (124), including the screw rod assembly (110) and the hydraulic jack assembly (116) operating sequentially, and being configured to perform an initial deformation process through rotational pressure and a final shaping process through hydraulic pressure within permitted tolerances;
a dual-action pressing mechanism (126), comprising a rotational pressing assembly (128) and a hydraulic pressing assembly (130), and being configured to sequentially apply rotational deformation followed by hydraulic pressure;
the rotational pressing assembly (128), being integrated within the screw rod assembly (110) and being configured to exert controlled rotational force on the upper die (112) for initial shaping;
the hydraulic pressing assembly (130), being positioned within the hydraulic jack assembly (116) and being configured to exert downward pressure to complete the shaping process;
the specialized surface texture (132), being applied to the interior of upper die (112) and the lower die (118) and being configured to provide enhanced grip and prevent slippage of low-plasticity clay material during shaping;
the controlled pressing force unit (134), being integrated with the hydraulic jack assembly (116) and being configured to apply an optimized pressure profile for uniform shaping without causing defects in low-plasticity materials;
a spring-loaded locking pin mechanism (136), being positioned within the lower mould support (108) and being configured to engage and disengage the clamp mechanism (122) upon operator input.
2. The apparatus (100) as claimed in claim 1, wherein the machine frame (102) is reinforced with additional support ribs, the support ribs being integrated within the machine frame (102) and being configured to enhance the structural rigidity of the apparatus (100) during operation.
3. The apparatus (100) as claimed in claim 1, wherein the plurality of side frames (104) includes lateral bracing members, the lateral bracing members being secured between the plurality of side frames (104) and being configured to provide additional structural stability to the upper mould support (106) and the lower mould support (108).
4. The apparatus (100) as claimed in claim 1, wherein the upper mould support (106) includes an adjustable guiding rail system, the adjustable guiding rail system being connected to the screw rod assembly (110) and being configured to maintain the alignment of the upper die (112) during vertical motion.
5. The apparatus (100) as claimed in claim 1, wherein the lower mould support (108) includes a base plate (114) with a cushioning layer, the cushioning layer being positioned between the base plate (114) and the lower die (118) and being configured to mitigate impact forces during pressing.
6. The apparatus (100) as claimed in claim 1, wherein the rotating lever (120) is connected to a gear assembly, the gear assembly being coupled to the screw rod assembly (110) and being configured to provide controlled rotational force to the upper die (112).
7. The apparatus (100) as claimed in claim 1, wherein the clamp mechanism (122) includes a quick-release locking mechanism, the quick-release locking mechanism being positioned within the plurality of nut-clamps and being configured to engage and disengage the lower die (118) without requiring manual loosening.
8. The apparatus (100) claimed in claim 1, wherein the controlled pressing force unit (134) is integrated with a pressure feedback sensor, the pressure feedback sensor being connected to the hydraulic pressing assembly (130) and being configured to monitor and adjust the applied force based on material resistance.
9. The apparatus (100) as claimed in claim 1, wherein the spring-loaded locking pin mechanism (136) includes an actuator mechanism, the actuator mechanism being positioned within the lower mould support (108) and being configured to automatically engage and disengage the clamp mechanism (122) based on operator input.
10. A method for producing high-depth conical earthenware (100), the method (100) comprising:
positioning a lower die (118) onto a lower mould support (108);
placing a clay material onto the lower die (118);
operating a rotating lever (120) connected to a screw rod assembly (110);
engaging a two-way pressing mechanism (124) to perform an initial shaping through rotational pressing and a final shaping through hydraulic pressing;
activating a hydraulic pressing assembly (130) integrated with the hydraulic jack assembly (116) to exert downward hydraulic pressure onto the lower mould support (108);
securing the lower die (118) using a clamp mechanism (122);
applying a controlled pressing force through a controlled pressing force unit (134);
enhancing the shaping precision using a specialized surface texture (132);
engaging a spring-loaded locking pin mechanism (136) being positioned within the lower mould support (108);
releasing the formed conical earthenware by disengaging the clamp mechanism (122);
removing the formed high-depth conical earthenware from the die assembly (124).