Concept Generation for Semi-Automated Clay Roof Tile Making Machine

Objective

Develop a semi-automated machine for producing high-quality clay roof tiles, balancing automation for
efficiency with manual intervention for cost-effectiveness and flexibility. The machine should be suitable
for small to medium-scale operations, using clay, soil, or mud as raw materials, and incorporate
ergonomic design, low maintenance, and energy efficiency.

Key Requirements

• Input Materials: Clay, soil, or mud, with water for mixing.

• Output: Flat, arched, or profiled clay roof tiles (customizable molds).

• Semi-Automation: Automate repetitive tasks (e.g., extrusion, cutting, pressing) while retaining manual
oversight for quality control and mold changes.

• Production Capacity: 1,000–3,000 tiles per 8-hour shift.

• Energy Efficiency: Low power consumption, suitable for regions with limited electricity.

• Maintenance: Simple design with accessible parts for easy repairs.

• Cost: Affordable for small businesses, with modular upgrades for scalability.

• Ergonomics: Minimize operator fatigue through intuitive controls and reduced physical effort.

Concept 1: Modular Extrusion and Press System

Description

A compact, modular machine with three core units: a clay preparation module, an extrusion and cutting
module, and a hydraulic press module. Operators manually load raw clay and water into the preparation
module, while the system automates mixing, extrusion, cutting, and pressing. A conveyor moves tiles to
a drying rack, where operators stack them manually.

Features

• Clay Preparation: Motorized mixer with adjustable water injection to achieve optimal clay consistency.
Manual loading of raw materials.

• Extrusion: High-pressure extruder with interchangeable molds for flat, arched, or profiled tiles.
Pneumatic cutting system slices extruded clay into precise lengths.

• Hydraulic Press: Semi-automatic press (10–20 tons) shapes tiles with customizable molds, activated via
foot pedal for operator control.
• Conveyor System: Belt conveyor transports cut tiles to the press and then to a drying rack.

• Control Panel: PLC-based interface for adjusting extrusion speed, cutting frequency, and press force.
Manual override for troubleshooting.

• Energy Efficiency: Low-power motors (5–10 kW total) with variable speed drives to reduce energy use
during idle periods.

• Safety: Emergency stop buttons, guarded moving parts, and ergonomic height for loading/unloading.

Workflow

• Operator loads clay and water into the mixer.

• Mixed clay is fed into the extruder, forming a continuous ribbon.

• Pneumatic cutter slices the ribbon into tile-sized pieces.

• Conveyor moves pieces to the hydraulic press, where the operator aligns them and activates the press.

• Pressed tiles are conveyed to a drying rack, where the operator stacks them for air drying or kiln firing.

Advantages

• Modular design allows upgrades (e.g., automated stacking) as budget permits.

• Interchangeable molds support diverse tile designs.

• Low power consumption suits off-grid or low-electricity environments.

• Operator involvement ensures quality control at critical stages.

Challenges

• Manual stacking may slow production for higher volumes.

• Requires skilled operators for mold changes and maintenance.

Concept 2: Roller-Based Forming Machine

Description

A roller-based system that combines clay preparation, forming, and cutting in a single continuous
process. The machine uses a series of high-speed rollers to crush and mix clay, followed by a forming
roller with engraved molds to shape tiles. A semi-automatic cutter trims tiles, and operators handle
stacking and drying.

Features
• Clay Processing: Dual rollers crush raw clay, followed by a mixing chamber with water injection.
Manual clay loading.

• Forming Rollers: Engraved rollers shape clay into tiles as it passes through. Rollers are interchangeable
for different tile profiles.

• Cutting System: Electronic cutter with variable speed, triggered by a sensor to ensure consistent tile
lengths.

• Stacking Station: Tiles exit onto a platform where operators manually stack them onto drying racks.

• Control System: Simple interface to adjust roller speed, water flow, and cutting frequency.

• Portability: Compact design with wheels for mobility within a workshop.

• Maintenance: Rollers and cutters use durable materials (e.g., tungsten carbide) to minimize wear.

Workflow

• Operator loads clay into the hopper.

• Rollers crush and mix clay with water, forming a uniform sheet.

• Forming rollers shape the clay sheet into tiles.

• Sensor-triggered cutter trims tiles to size.

• Operators collect tiles from the exit platform and stack them for drying.

Advantages

• Continuous process reduces bottlenecks.

• Compact footprint suits small workshops.

• Fewer moving parts simplify maintenance.

• Roller-based forming is energy-efficient compared to hydraulic presses.

Challenges

• Engraved rollers are expensive to customize for new tile designs.

• Manual stacking limits scalability for high-volume production.

Concept 3: Hybrid Manual-Automatic Tile Press

Description
A hybrid machine focused on a manual clay preparation stage and an automated pressing and cutting
stage. Operators prepare clay using a separate mixer, then feed it into a semi-automatic press that
extrudes, cuts, and presses tiles. The system is designed for simplicity and low cost, ideal for small-scale
producers.

Features

• Clay Input: Manual feeding of pre-mixed clay into a hopper.

• Extrusion and Cutting: Low-pressure extruder forms a clay ribbon, cut by a pneumatic blade with
adjustable length settings.

• Pressing Station: Hydraulic press (5–10 tons) with quick-change molds, operated via a hand lever or
foot pedal.

• Output Tray: Tiles exit onto a tray for manual collection and stacking.

• Energy Efficiency: Minimal power use (3–5 kW) for extrusion and pressing.

• Durability: Steel frame with corrosion-resistant coating for outdoor use.

• Ergonomics: Adjustable tray height and lever controls to reduce operator strain.

Workflow

• Operator mixes clay externally and loads it into the hopper.

• Extruder forms a clay ribbon, which is cut into tile-sized pieces.

• Operator places cut pieces into the press mold and activates the press.

• Pressed tiles are ejected onto the tray, where the operator collects and stacks them.

Advantages

• Low cost due to simplified design and minimal automation.

• Small footprint fits in constrained spaces.

• Easy to operate with minimal training.

• Flexible for small-batch production with varied tile designs.

Challenges

• Manual clay preparation and stacking are labor-intensive.

• Lower production capacity compared to fully automated systems.

Feature

Concept 1: Modular Extrusion

Concept 2: Roller-Based

Concept 3: Hybrid Press

Automation Level

Medium (automated extrusion, cutting, pressing)

Medium (automated forming, cutting)

Low (automated pressing, cutting)

Production Capacity

2,000–3,000 tiles/shift

1,500–2,500 tiles/shift

1,000–1,500 tiles/shift

Power Consumption

5–10 kW

4–8 kW

3–5 kW

Cost

Moderate

Moderate

Low

Maintenance

Moderate (modular parts)

Low (fewer parts)

Low (simple design)

High (interchangeable molds)

Medium (roller changes)

High (quick mold swaps)

Ergonomics

High (conveyor, foot pedal)

Medium (manual stacking)

Medium (lever controls)

Recommended Concept

Concept 1: Modular Extrusion and Press System is recommended for its balance of automation,
flexibility, and scalability. It automates repetitive tasks (extrusion, cutting, pressing) to boost efficiency
while allowing manual oversight for quality control. The modular design supports future upgrades, such
as automated stacking or increased capacity, making it suitable for small to medium-scale producers. Its
energy efficiency and ergonomic features align with the needs of cost-conscious operations in diverse
settings.

Next Steps

• Develop a prototype of Concept 1, focusing on the extrusion and press modules.

• Test with local clay sources to ensure compatibility and tile quality.

• Conduct user trials to refine ergonomics and control interface.

• Estimate production costs and finalize pricing for small-business markets.