Abstract: An in situ inspection system and method to inspect a honeycomb body (122) skin in a skinning system. The inspection system includes a line illuminator (148) to generate a line illumination on the skin (136) perpendicular to an axial direction (112) of the honeycomb body travel, and a detector (152) to detect the line illumination scattered from the skin (136) and generate a signal based on the detected line illumination. A controller (184) is configured to receive the signal generated by the detector (152), compare the received signal to a previously stored defect free signal in real-time, and control at least one skinning process parameter based on the comparison. The method includes in situ inspecting the skin (136) and controlling at least one skinning process parameter based on the inspection. In the method, the in situ inspection includes illuminating a line of the skin (136) perpendicular to the axial direction (112) and detecting the illuminated line scattered from the skin (136).

Abstract: A system for delivering and applying a flowable mixture to an article (311-313) is disclosed. The system includes a mixture delivery system (200) and a skinning system (300). The mixture delivery system (200) includes a mixer (220) configured to mix a dry material and a fluid to produce the flowable mixture, and a pump (235) configured to pump the flowable mixture to a delivery line. The skinning system (300) receives the flowable mixture from the mixture delivery system (200) through the delivery line. The skinning system (300) includes a skinning pipe (310) configured to apply the flowable mixture to the article (311-313) and a manifold (305) that supports the skinning pipe (310). The skinning system (300) also includes an article feeding mechanism (315) configured to push the article (311-313) into the skinning pipe (310). The skinning system (300) includes a transfer system (320) configured to hold the article (311-313) and move the article (311-313) out of the skinning pipe (310).

Abstract: A control system for an axial skinning apparatus (100), including: •a force to cause a ceramic honeycomb part (110) to pass through the skinning apparatus (100); •a force that urges flowable cement on to the ceramic honeycomb part (110); •a sensor to detect the force on the cement; •a sensor to detect the force on the ceramic part; and •a controller (300) which receives: •a signal from the sensor on the flowable cement, •a signal from the sensor on the ceramic part (110), or both, and the controller (300) controls the pressure set point (310) of the cement source based on one or both of the received signals, and the controller (300) adjusts control parameters using feedback control and pseudo feed forward control. A method of using the axial skinning apparatus (100) is also disclosed.

Abstract: A process for operating an axial skinning apparatus for continuous manufacture of skinned ceramic honeycomb parts, including: determining the physical process parameters of the apparatus including: the rheology of the flowable skin cement; the geometry of the part to be skinned; and the geometry of the annulus gap of the skinning chamber; and calculating a plurality of dimensionless pressure gradient values (Lambda (?)) according to the formula (1): ? = ( ? ? ? P ) ? R 2 ? m ? ? L ? ( R V ) n ( 1 ) where ?P, P, R, V, L, and m and n are as defined herein; plotting a plurality of manifold pressures versus a plurality of part velocities; and selecting at least one operating window based on the skin quality of a plurality of preliminarily skinned parts.

Abstract: A system for delivering and applying a flowable mixture to an article (311-313) is disclosed. The system includes a mixture delivery system (200) and a skinning system (300). The mixture delivery system (200) includes a mixer (220) configured to mix a dry material and a fluid to produce the flowable mixture, and a pump (235) configured to pump the flowable mixture to a delivery line. The skinning system (300) receives the flowable mixture from the mixture delivery system (200) through the delivery line. The skinning system (300) includes a skinning pipe (310) configured to apply the flowable mixture to the article (311-313) and a manifold (305) that supports the skinning pipe (310). The skinning system (300) also includes an article feeding mechanism (315) configured to push the article (311-313) into the skinning pipe (310). The skinning system (300) includes a transfer system (320) configured to hold the article (311-313) and move the article (311-313) out of the skinning pipe (310).

Abstract: An in situ inspection system and method to inspect a honeycomb body (122) skin in a skinning system. The inspection system includes a line illuminator (148) to generate a line illumination on the skin (136) perpendicular to an axial direction (112) of the honeycomb body travel, and a detector (152) to detect the line illumination scattered from the skin (136) and generate a signal based on the detected line illumination. A controller (184) is configured to receive the signal generated by the detector (152), compare the received signal to a previously stored defect free signal in real-time, and control at least one skinning process parameter based on the comparison. The method includes in situ inspecting the skin (136) and controlling at least one skinning process parameter based on the inspection. In the method, the in situ inspection includes illuminating a line of the skin (136) perpendicular to the axial direction (112) and detecting the illuminated line scattered from the skin (136).

Abstract: Methods of reducing transient temperature variations in a microwave drying process for drying partially dried ceramic logs are disclosed. The methods include sending the logs through an output microwave dryer having multiple applicators, each applicator being capable of generating an adjustable amount of microwave power. A transient drying model is employed based on microwave-drying process parameters to determine a predicted log exit temperature at the output end of the output microwave dryer. The exit temperature of each log is measured. The transient drying model, which is used to control the amount of microwave power applied, is adjusted based on a difference between the predicted and measured log exit temperatures.

Abstract: A control system for an axial skinning apparatus (100), including: •a force to cause a ceramic honeycomb part (110) to pass through the skinning apparatus (100); •a force that urges flowable cement on to the ceramic honeycomb part (110); •a sensor to detect the force on the cement; •a sensor to detect the force on the ceramic part; and•a controller (300) which receives: •a signal from the sensor on the flowable cement, •a signal from the sensor on the ceramic part (110), or both, and the controller (300) controls the pressure set point (310) of the cement source based on one or both of the received signals, and the controller (300) adjusts control parameters using feedback control and pseudo feed forward control. A method of using the axial skinning apparatus (100) is also disclosed.

Abstract: An in situ inspection system and method to inspect a honeycomb body skin in a skinning system. The inspection system includes a line illuminator to generate a line illumination on the skin perpendicular to an axial direction of the honeycomb body travel, and a detector to detect the line illumination scattered from the skin and generate a signal based on the detected line illumination. A controller is configured to receive the signal generated by the detector, compare the received signal to a previously stored defect free signal in real-time, and control at least one skinning process parameter based on the comparison. The method includes in situ inspecting the skin and controlling at least one skinning process parameter based on the inspection. In the method, the in situ inspection includes illuminating a line of the skin perpendicular to the axial direction and detecting the illuminated line scattered from the skin.

Abstract: An in situ inspection system and method to inspect a honeycomb body skin in a skinning system. The inspection system includes a line illuminator to generate a line illumination on the skin perpendicular to an axial direction of the honeycomb body travel, and a detector to detect the line illumination scattered from the skin and generate a signal based on the detected line illumination. A controller is configured to receive the signal generated by the detector, compare the received signal to a previously stored defect free signal in real-time, and control at least one skinning process parameter based on the comparison. The method includes in situ inspecting the skin and controlling at least one skinning process parameter based on the inspection. In the method, the in situ inspection includes illuminating a line of the skin perpendicular to the axial direction and detecting the illuminated line scattered from the skin.

Abstract: A process for operating an axial skinning apparatus for continuous manufacture of skinned ceramic honeycomb parts, including: determining the physical process parameters of the apparatus including: the rheology of the flowable skin cement; the geometry of the part to be skinned; and the geometry of the annulus gap of the skinning chamber; and calculating a plurality of dimensionless pressure gradient values (Lambda (?)) according to the formula (1): ? = ( ? ? ? P ) ? R 2 ? m ? ? L ? ( R V ) n ( 1 ) where ?P, P, R, V, L, and m and n are as defined herein; plotting a plurality of manifold pressures versus a plurality of part velocities; and selecting at least one operating window based on the skin quality of a plurality of preliminarily skinned parts.

Abstract: Methods of reducing transient temperature variations in a microwave drying process for drying partially dried ceramic logs are disclosed. The methods include sending the logs through an output microwave dryer having multiple applicators, each applicator being capable of generating an adjustable amount of microwave power. A transient drying model is employed based on microwave-drying process parameters to determine a predicted log exit temperature at the output end of the output microwave dryer. The exit temperature of each log is measured. The transient drying model, which is used to control the amount of microwave power applied, is adjusted based on a difference between the predicted and measured log exit temperatures.

Abstract: A fuzzy logic-based system and method for controlling the drying of material by a microwave applicator. The system includes power output controller that controls applicator output power; material sensor that detects amount of material in the applicator; and fuzzy logic controller that receives a signal from the material sensor indicating the current amount of material in the applicator and adjusts the microwave output power based on the current amount of material in accordance with fuzzy logic rules by sending a control signal to the power output controller. A membership function divides the expected range for the amount of material into multiple regions, each region having precomputed regional output settings. The regional output settings of the regions that include the current amount of material are used to compute the control signal.

Abstract: Methods and apparatus for microwave drying of green cellular ceramic bodies (logs) using feedback and feed forward control are disclosed. The methods include measuring an amount of dissipated microwave power and measuring temperatures of the logs and inputting this information into a drying model. The drying model accounts for at least a heat capacitance, a water content and a mass of the logs, and relates changes in the dissipated microwave power to changes in the log temperature. The changes in microwave power generated by the adjustable microwave source are thus based on the calculated dissipated power changes.

Abstract: Methods and apparatus for drying ceramic green bodies include providing one or more ceramic green bodies in a microwave heating chamber operatively connected to a microwave source and a PLC. The total mass of the ceramic green bodies present in the microwave heating chamber is determined. Microwave energy is generated with the microwave source and transmitted from the microwave source to the microwave heating chamber. A transmitted power of the microwave energy transmitted from the microwave source to the microwave heating chamber is measured with power sensors. The reflected power of reflected microwave energy reflected back from the microwave heating chamber is also measured. The power of the microwave energy transmitted from the microwave source to the microwave heating chamber is adjusted based on the total mass of ceramic green bodies present in the microwave heating chamber, the measured transmitted power and the measured reflected power.

Abstract: A fuzzy logic-based system and method for controlling the drying of material by a microwave applicator. The system includes power output controller that controls applicator output power; material sensor that detects amount of material in the applicator; and fuzzy logic controller that receives a signal from the material sensor indicating the current amount of material in the applicator and adjusts the microwave output power based on the current amount of material in accordance with fuzzy logic rules by sending a control signal to the power output controller. A membership function divides the expected range for the amount of material into multiple regions, each region having precomputed regional output settings. The regional output settings of the regions that include the current amount of material are used to compute the control signal.

Abstract: Methods and apparatus for drying ceramic green bodies include providing one or more ceramic green bodies in a microwave heating chamber operatively connected to a microwave source and a PLC. The total mass of the ceramic green bodies present in the microwave heating chamber is determined. Microwave energy is generated with the microwave source and transmitted from the microwave source to the microwave heating chamber. A transmitted power of the microwave energy transmitted from the microwave source to the microwave heating chamber is measured with power sensors. The reflected power of reflected microwave energy reflected back from the microwave heating chamber is also measured. The power of the microwave energy transmitted from the microwave source to the microwave heating chamber is adjusted based on the total mass of ceramic green bodies present in the microwave heating chamber, the measured transmitted power and the measured reflected power.