Abstract. This research paper focuses on the issues of enhancing technological reliability and reducing energy consumption while shaping ceramic bricks. It proves that these aims can be effectively achieved by using automatic coordinated control of actuating auger vacuum extruder systems. The paper also assesses the extent of energy consumption reductions when the extruder is equipped with an automatic control system.
Problem specificationReduction of energy consumption while producing ceramic bricks of certain required strength is one of the main mandatory requirements to their manufacture [1]. Paper [2] proves that the quality and durability of bricks depend to a great extent on technologies of shaping raw materials. This technological process is quite energy-consuming. Generating capacity of this process can rise up to 250-250 kW and above. The extruder is usually controlled with the help of fairly simple algorithms. This significantly limits the ability not only to select optimal power saving modes, but also to ensure stable quality indicators of bricks formation. This paper aims to introduce effective methods and devices focused both on improving this technological process and reducing energy consumption by the installation drivers.
MethodologyThe authors introduce a mathematical model of the extrusion process considering it to be a nonstationary object with distributed parameters. This model is based on the previous study of factors influencing the technology of bricks shaping as an intermediate stage of production of ceramic bricks and creating the basis for its structure and, consequently, strength [2][3][4]. As one of the main components of the vector of output coordinates the authors adopted shear rate J J of clay mixture in pressure head [4,5]. This is done due to the fact that value J J determines stability of geometric shapes, homogeneity of the internal