Checking Over or Under Spray of Glaze on Ceramic Sanitaryware

Is this an:

• High production run
• automated systems

If you're looking for an automated systems. You can try contacted these Cognex

There are other vision systems that are used for high volume sorters for fruits and vegetables. this may also help. I don't have the contacts right now.

We are doing a 165k piecees per month, so about 6k per day. Not that fast.

the other thing would be the costs of these 'defects' to determine the plan of action to ensure return on investment.

With all of the lighting options available, determine which one will allow you to see the flaws and install it.

In the meantime, I'd also be determining what's causing the flaws in the first place, and eliminating them. Why isn't your glaze consistent?

From nozzles that block, impurities coming thru, positioning of the pieces on the carousel, we have checks and balances in place, but it still happens unfortunatly.

This may get more involved here.

it still happens because of the complexities of possibilities? or because checks and balanced not fully followed through.

If its the complexities, we would need more details.

Nozzles that block wouldn't that cause a increase in the fluid pressure in the pump system. Which a pressure transducer and controller could give an alarm to.

Impurities. Why are they not being filtered out?

Fixtures on the carousel for positioning. Also optical devices to check their position.

That sounds like the agenda for action. Please report back on the outcome of those actions as it may be helpful to other readers.

Two thoughts:

1. Add a small amount of UV fluorescent ink to your glaze. Then when you shine a UV light on the glaze the ink might help show if there is over- or under-coverage.

2. Instead of scrapping the pieces with improper glaze, sell them as 'seconds' on a site like ebay.

A blast from the past.

Used this when clear coating PWB assemblies, pre-surface mount days for space flight.

It helped us find uncoated areas.

CALCOFLUOR WHITE RW SINGLE - ChemicalBook

How are the pieces held during the glaze application?

Can the pieces be rotated during the application?

Does "different color paths" mean more than one color?

Why can't a robot do it?

My thoughts, exactly! Why didn't anybody ask that sooner.

If humans are applying the glaze, your answer should be obvious.

In a former life I sprayed CLEAR coatings on through hole PWB assemblies. And, later had to teach others how to do it.

So, I'll assume the unspoken that humans are the problem. Then robotics is the solution. Robotic paint application is a thing of beauty to watch.

Robots don't get sick, miss work on Fridays and Mondays (or any other day), they never have periods, bad hair days, flat tires, sick kids, psycho girlfriends (or boyfriends) vacations, they never ask for a raise or want your job.

No further communication from this member until adequate process information is provided by the person with the problem.

<In stand-by mode>

You must have missed the first post and a few after that about ROI, also with the lack of information to determine ROI.

No, didn't miss 'em.

They are just irrelevant.

Really? You either missed it or sloppy, automation would be relevant to robotics. from the first post.

If the problem only happens on certain occasion, I would look back and double check what changes made that took place on such occasion and correct!

If the problem is hurting your profit margin, you can consider using some electronics in your production line instead of just relying on your eyes using fluorescent lighting!

A simple combination of photocells in combination with constant, focused light source is a common tool used by tile manufacturers.... where the output signals of strategically placed photocells are used along the production line. Used for either QA function and to control either the paint sprayers / paint mixer mechanisms.

You may need to consult / hire an instrumentation engineer!

Sell the blems as "art" for a premium price.

Is it possible to post a video on this discussion, i believe it will be helpful if all can see the process as we are using Robots.

You can sign up for drop box for free and post a link there