SANITARY WARE PRODUCTION
卫 生 瓷 生 产
1. PRECRUSHING OF RAW MATERIALS 原 料 初 碎
Hard materials (硬质料) like feldspar长石，quartz (石英)，may be precrushed (初碎)，in order to reduce (减少) the grinding (研磨) time during preparation (制备). The hard materials are charged (装) to an impact crusher (锤击破碎机), for reducing (缩小) the grain size (粒度). A vibrating sieve (振动筛) separates oversized (过大的) grain, which is returned (返回) to the crusher (破碎机).
The crushed (破碎过的) materials are stored in silos (料仓). Zircon sand (锆英砂) has to be ground (研磨) in a ball mill (球磨机) to a maximum (最大) size of 100 micron (微米) and is then ground in a vibro-energy-mill (振动磨) to the final sizes.
1、原 料 初 碎
为了缩短原料制备过程的研磨时间，诸如长石，石英之类的硬质原料可先进行初碎。将这些硬质料放进锤击破碎机内缩小其粒度。较大的颗粒由振动筛分离出去，返回破碎机。 破碎过的原料储存在料仓内。锆英砂应在球磨机内研磨，使最大粒度不超过100微米，然后再放入振动磨内研磨到所需要的粒度。
2. BODY PREPARATION
坯 料 制 备
According to （按照）the composition （配方）, the raw materials are taken out of the boxes by a shovel loader（装载机）, weighed（称重）on a platform scale （台秤）and dumped（倾倒）into a box feeder （加料箱）. The amount loaded into the box feeder is recorded by the shovel loader driver.
As soon as a batch（批料）is collected in the box feeder, a ball mill （球磨机）can be charged （加料）. The materials leaving the box feeder pass a clay（粘土） slicer （切碎机）in order to cut chunks（大块）of clay to smaller size for easy dissolving（细碎）of the clay in the ball mill. By means of（通过）conveyor belts（输送带）the raw materials are transported into the ball mills.
After adding the right amount of water via a water meter, they are formed to a fine slip （细浆）. Grinding time will be approx 10 to 16 hours, depending on the materials. This slip is emptied via a course screen （粗目筛）into a propeller blunger tank（螺旋桨搅拌池）. From there the slip is pumped to the mixing blunger（混合搅拌机）. The scrap （废料） and broken pieces are put in a high speed blunger（高速搅拌机）. Water is added to get the right literweight （升重） and
dissolved （溶解）. This slip will be pumped over a screen to a storage tank. From there the scrap slip （回浆）is added to the mixing blunger.
The ready prepared slip is pumped over a screen into slip storage containers（泥浆罐）.
2、坯 料 制 备
按照配方，用装载机将原料从料仓内取出，经台秤称重，倒入加料箱。装入加料箱内的数量由装载机驾驶员负责记录。
当一批料装入加料器之后，先通过粘土切碎机将粘土块破碎到较小程度，以便粘土在球磨机中细碎。原料通过传送带送到球磨机。
通过水表控制加入适量的水，形成泥浆。研磨时间视原料情况大约需要10到16小时。然后通过粗目筛将泥浆倒进螺旋搅拌池。从搅拌池用泵将泥浆打进混合搅拌机，其余的废料和碎块放入高速搅拌机。加入适量的水溶解后，用泵通过筛子将泥浆打到储浆池，回浆从这里放进混合搅拌机。
制好的泥浆，用泵通过筛打到泥浆罐。
3. GLAZE PREPARATION
釉 料 制 备
Glaze（釉） raw materials（原料） are weighed（称重） on a platform scale（台秤） and loaded in containers（桶） whereby a complete batch of the required formula（配方） is compiled（混合）. The loaded containers are lifted to a working platform（工作台） above the ball mill.
The glaze raw materials along with the correct amount of water added are ground（研磨） for approx. 20 to 30 hours. The ground glaze slip is discharged（倒出） from the mills into agitator tanks（搅拌池） for storage（储存）.
The glaze slip is emptied（倒） by gravity（重力） from the tanks via（经过） vibrating sieve（振动筛） into container carts（小车） in which it is transformed to the glazing cabin（喷釉间）, after the adjustment to the right properties——liter-weight（升重）, viscosity（粘度）, with a mixer.
3、釉 料 制 备
将坯釉原料用台秤称重，装入桶内，按配方所需的配料在桶内混合。然后，将桶提升到球磨机上的工作台。
将釉料加入适量的水研磨大约20 至30小时，磨好的釉料从球磨机倒进搅拌池储存。 釉浆经搅拌机调到适当的程度，利用重力由料桶经过振动筛倒进料桶车，然后运到喷釉间。
4.CASTING 注 浆
To minimize production costs and utilize floor space effectively it is proposed to use battery casting machines（立式浇注，组合浇注） for the majority of the production requirements. Simple water closets（坐便器）, all wash basins（洗面器）, tanks（水箱）， lids（水箱盖） and pedestals
（支柱） will be produced on these machines. The balance（其它） of the plant output of more complex（复杂的） water closets will be produced on manual casting benches（人工注浆台）.
The casting shop（注浆车间） will be divided into separate rows of battery casting machines and manual benches. Slip（泥浆） will be supplied to each set of machines（注浆机） or benches（注浆台） by a separate pipe work（管道） ring main（环管） fed by one of a series of high pressure pumps（高压泵）. The pipe work will be configured（布置） to allow slip to be taken from any ark（泥浆池） and delivered to any of the casting ring mains.
On the battery casting machines the high pressure slip（高压泥浆） supply is distributed to the multiple（各个） moulds through pipe work and control valves（控制阀） ensuring even（均等） mould filling（注浆）. After casting the waste slip（余浆） is drained（排除） from the machines into underground storage arks（储浆池）and subsequently（随后） pumped to the slip house（泥浆房） for reuse. The machines are supplied with mould drying（模型干燥） which ensures the moulds are conditioned（准备） sufficiently for the anticipated（预期的） double daily casting（每天两次注浆） operation. After casting the pieces（坯子） are placed onto holders（托架） carried on motorized roller conveyors（辊式输送机） adjacent to（靠近） each machine. The casting pieces are then moved down to the end of the conveyor where they are fettled（修坯） and holes punched（打孔） prior to be placed onto the adjacent（附近的） overhead power and free conveyor carrier（架空电动输送机）.
On the manual casting benches slip is supplied through an overhead manifold（管道） to a central position of each of the benches where the moulds are filled through a flexible pipe（软管） and casting nozzle gun（注浆喷嘴）. After casting the waste slip is again collected in storage arks and pumped to the slip house for reuse. Mould drying is provided for mould conditioning between casts. After casting the pieces are placed onto gravity roller conveyor（重力辊式输送机） adjacent to casting benches before being fettled, punched and placed onto the power and free conveyor system.
4、注 浆
为了减少生产成本和有效地利用地面空间，建议大部分生产需要使用立式浇注设备。简单的坐便器，所有的洗面器、水箱、水箱盖、支柱都用这些设备生产。
成型车间设置数排立式浇注设备及人工注浆台。泥浆通过独立管道，用高压泵送到注浆机或注浆台。所设计的管道能从任何泥浆池抽出泥浆并送到任何泥浆管道。
在立浇线上，高压注浆会通过管道及控制阀门分配到各个模型，以确保注浆均匀。注浆后的余浆排除机外，送到地下储浆池，然后用泵打到泥浆房重新使用。设备配有模型干燥系统，确保模型得到充分干燥，保证每天两次注浆使用。浇注完成后的坯件放到浇注机旁的电动辊式输送机的托架上。然后，注件送到输送机末端进行修坯、打孔，接着送到旁边的电动架空输送机。
至于人工注浆，泥浆经架空管道送到每个浇注台的中心位置，利用软管和注浆喷嘴注模，注浆后的余浆也储存在储浆池，用泵打到泥浆房以备再用。注模之间有模型干燥系统来干燥模型。浇注完成的坯件放到注浆台旁的重力辊式输送机上，然后经修坯、打孔，放到架空输送系统上面。
5. DRYING 干 燥
After green fettling（生坯休整） all casting pieces（注件） from battery and manual casting are placed on to a two deck carrier（双层输送托架） on the overhead power free conveyor system at their respective positions. From the loading position the full carriers are automatically
conveyed to the entrance of one of the rapid tunnel driers（快速隧道式干燥器）. A flag control system（信号控制系统） automatically directs each type of ware to its respective dryer. A
recirculation loop（循环封闭系统） is included to store loaded carriers（满载的托架） in the event of（防止万一） there being no dryer entrance slot（入口位置） available（可用）.
Each dryer has an individual variable speed drive（变速驱动器） which allows cycle time（时间周期） to be adjusted within a range of 3-8 hours to suit the ultimate（最大极限） drying characteristics（特性） of the ware. The conveyor drive（输送驱动器） is provided with a reversing facility（换向装置） which maintains linear speed（线性速度） through the dryer ensuring even（均匀） drying.
Drying of the ware is carried out（完成） in the rapid tunnel dryers（快速隧道干燥器）. The ware on carriers passes through 4 dryer stages（干燥阶段）. In stage 1 moisture content（含水量） is reduced from 18 to 12% by increasing temperature to 35-50 deg. C and controlling relative
humidity（相对湿度） to 55-60%. Air is circulated（循环） through a series of multi directional nozzles（多向喷嘴） around the ware and is exhausted（排气） and/or recirculated dependent on（依照） its humidity content（含湿量） through an under carrier duct（输送管道） and fan system（风机系统）
In drying stage 2 moisture content of the ware is reduces from 12 to 6% by increasing temperature from 50-80 deg. C and circulating large volumes of air through a similar
nozzle/duct/fan system. In final drying stage 3 the moisture content of the ware is reduced down to 1% by increasing temperature to 90 deg. C and circulating maximum air volumes with air movement and turbulence（湍动） throughout the zone.
Finally in stage 4 of the dryer the ware is cooled by introducing controlled quantities of ambient air（内部空气） to a temperature suitable for the following（连续的） fettling and glazing operations（修坯和施釉操作）. Each stage of the cycle can be adjusted for drying time,
temperature and humidity to obtain the ultimate drying conditions（干燥状态） for each specific piece.
The dried（已干的） ware carrier is picked up on exit from the dryer by the power and free conveyor circulating track（电动架空传送循环轨道） and delivered to the fettling station（修坯台） position where the ware is unloaded by hand, a recirculation loop（循环封闭系统） is included in the section to store loaded carriers not able to be unloaded.
After unloading the empty carriers are circulated back to the battery and manual casting（组合和手工浇注车间） department for loading newly cast ware.
5、干 燥
修坯之后，所有的立浇及手工注件按其相应位置放在架空电动输送系统的双层托架上。从装载处满载的托架自动输送到其中的一个快速隧道式干燥器的入口。信号控制系统会自动指示各种坯件到达相应的干燥器。在干燥器没有入口可供使用的情况下，设有循环封闭系统来储存满载的托架。
每个干燥器都有一个独立的变速驱动器，能在周期3-8小时范围内调节，以适应坯体的干燥特性。传送输送器带有换向装置，保持干燥器的线性速度，确保均匀干燥。
坯体的干燥在快速隧道式干燥器内进行。托架上的坯体经过4个干燥阶段。第一阶段，将温度提高到35-50度C，并将相对湿度控制在55-60%，水分含量从18%降到12%。空气通过多向喷嘴在坯体周围循环，并按含湿量通过下层管道及风机系统排出和/或再循环。
第二干燥阶段，温度由50度C升到80度C，并通过同样的喷嘴/管道/风机系统使大量的空气循环，水分含量由12%降到6%。在最后的第三干燥阶段，温度上升到90度C，大量的空气在干燥器内湍动，坯体的含水量降到1%。
最后，在第四阶段，利用控制室内空气参数来冷却坯件，使其温度适合于连续的修坯及施釉操作。每一周期的干燥时间、温度及湿度皆可调节以达到每件产品的最佳干燥状态。已干坯体的托架，由电动架空循环轨道托到干燥器出口，并送到修坯处，用手工卸下来。在此处设有一套循环封闭系统用于储存未能卸载的托架。
卸载后,空架被送回立浇及人工注浆车间装载新的坯体。
6. FETTLING AND SPRAY GLAZING
修 坯 和 喷 釉
After drying, the ware is transported by power and free conveyor to the fettling area. Prior to glazing（施釉） and firing（烧成）, inspection is necessary to ensure that the ware is well finished and free from cracks and pinholes（没有裂纹和针孔）.
Twelve fettling booths（修坯室） each constructed to the standard B.C.R.A（英国陶瓷研究协会）. design with air supply fan and air extraction（抽吸） system will be arranged in close proximity（靠近） to each other where individual sanitary ware（卫生洁具） pieces are inspected, dry fettled（干燥修坯）, de-dusted（除尘） and sponged（用海绵擦） smooth.
The fettled product is placed onto one of eighty worktables（工作台） fitted to a variable speed（变速） floor mounted closed loop conveyor（封闭式环形输送机） which transports the ware through manual and electrostatic glaze spaying booths（静电喷釉橱）.
The conveyor first passes through an open front manual spray glazing booth（人工喷釉橱）where areas of the ware which the automatic equipment cannot coat（喷涂） are manually glaze coated. The conveyor then proceeds to（到达） the totally enclosed electrostatic spray glazing booth where the worktable are rotated（旋转） while two stations（组） of ten spray guns（喷枪） reciprocate（相互交替） within the enclosure（在里面）, projecting atomized（雾化） spray eletrostatically charged towards the clay ware（坯件） on the conveyor. The use of high voltage（高压） electrostatic application together with reciprocators（交替装置） allow glaze patterns to be blended（掺和） together giving a consistent（一致） and even（均匀） surface coating. The spray glazing booths incorporate（带有） a glaze recovering system（回收系统） to facilitate the reclamation（回收） of a high proportion of any oversprayed material.
When glazed the product is manually removed from the worktable and loaded onto kiln cars（窑车）. The worktable is then automatically cleaned and dried before arriving at the loading station ready to receive fettled ware（修好的坯件）.
6、修 坯 和 喷 釉
干燥完毕后，坯体用电动架空输送系统运到修坯处。在施釉及烧成前，必须检查，以确保坯体完美无缺，没有裂纹和针孔。
十二个修坯室每一个都按“英国陶瓷研究协会”标准设计，并有供气风机和排气风机。每件产品在这里都经过检查、干修、除尘，并用海绵擦平。
修过的产品依次放到落地式变速环形传送机上的八十个工作台上，接着通过人工和静电喷釉橱。
传送机首先通过开放式人工喷釉橱，所有自动设备不能喷到的地方用人工喷釉，然后输送机到达全封闭的静电喷釉橱。橱内有工作台旋转，十个喷枪在里面分成两组相互交叉工作，雾化喷射器通过静电喷向输送机上的坯体。高压静电及相互交叉装置的使用使釉料掺和，从而使釉层均匀一致。喷釉橱设有釉料回收系统来收集大部分溢喷的釉料。
产品施釉后，用手工搬离工作台，放在窑车上。工作台在抵达装坯台前自动清洗、干燥、准备再次接收修好的坯体。
7. FIRING 烧 成
Single firing（一次烧成） of all production from the factory will be carried out in the latest state of the art（现代化的） skate type tunnel kiln（隧道窑）. The kiln incorporates（包括） ultra modern（最先进的） design of refractories（耐火材料）, insulation（保温）, air movement instrumentation and computer control ensuring low energy consumption and high product yield output（产量） with minimum losses. Automatic control of temperature, pressure, combustion（燃烧）, cooling（冷却） and draught（通风） ensure the ultimate firing conditions（最佳烧成条件）.
The kiln incorporates（包括） a fully automatic kiln car（窑车） motion equipment system with kiln pusher（顶车机）, transfer cars（托车）, storage and load/ unload tracks.
For refiring（重烧） of ware that was substandard（次等的） after first firing and has been subsequently repaired（修补）, a direct fired（明焰） intermittent（间歇） shuttle kiln（梭式窑） is provided. This kiln has the capacity to fire 20% of the tunnel kiln(隧道窑) output if necessary.
7、烧 成
所有的产品都在最先进的“SKATE”型隧道窑内一次烧成。该窑拥有设计先进的保温耐火材料、气体流动仪器及计算机控制，确保能耗低，产量高，损失少。温度、压力、燃烧、冷却及排气采用自动控制，保证最佳烧成条件。
窑炉还包括一套全自动窑车运转系统，有顶车机、托车、储存和装卸轨道。
对于一次烧成低于标准的产品，经过修补，可用明焰间歇窑重烧。如果需要，该窑可烧成隧道窑烧后20%的产品。
8. FINAL INSPECTION AND TESTING
最 后 检 验 与 测 试
Fired products（烧成的产品） are manually transferred from the kiln car to the final
inspection benches where every piece of ware is examined for cracks（裂纹）, warping（变形）, glaze appearance（釉面）, pinholes（针孔）, blemishes（斑点） and size.
After inspection the ware is transported by overload monorail（单轨） conveyor to the testing, warehouse, repair, re-spray and re-fire areas.
Ware having small cracks, pinholes or other surface blemishes（瑕疵） will be repaired and stopped with a suitable fired body filler（填料）. Repairs will be carried out in a suitable grinding booth equipped with the necessary air extraction system（排气系统）. Three wet back spray booths（湿式喷釉橱） will be utilized for manual glaze overspraying of repaired ware prior to refiring in the intermittent shuttle kiln. Where necessary the backs of washbasins（脸盆） and the feet of water closets（坐便器） will be ground flat utilizing a pantograph arm grinding machine（缩放研磨机）.
Satisfactory ware（合格产品） and ware having had minor faults（缺陷） removed by polishing（抛光） would be stored in the warehouse for packaging（包装） and dispatched（发货）.
Tests carried out on finished products would include visual inspection（视觉检查）, flushing（冲水） tests, water absorption（吸水性）, chemical resistance, crazing resistance（耐裂性）, resistances to staining and burning.
8、最 后 检 验 与 测 试
烧成的产品由人工从窑车送到最后的检验台。每件产品都要检查其裂纹、变形、釉面、针孔、斑点及尺寸。
检验后的产品由架空单轨输送机送到测试、储存、修补、重新施釉及重烧区域。
有小的裂纹、针孔或其它表面斑点的产品可以用适当的填充料修补，修补过程是在设有必要的排气系统的研磨室内进行的。
三个湿式喷橱用于间歇式梭式窑重烧前修补件的人工喷釉。 必要情况下，洗面器的背面及坐便器底部可用缩放研磨机磨平。 合格的产品或经抛光没有缺陷的产品存在仓库等待包装、发货。
`成品的测试包括视觉检查、冲水测试、吸水性能、化学稳定性、抗裂强度、耐侵蚀及耐氧化性。
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