Method and system for managing the production of molded polyurethane products

Abstract

The present disclosure relates to methods and systems for managing the production of molded polymer or polyurethane products. In various embodiments, multiple autonomous mobile platforms (AMPs) are interchangeably engaged with a mold-carrying trolley to provide a self-propelled trolley. Each self-propelled trolley is propelled through a production station and a curing station to complete a production cycle. Between production cycles, the trolley can be transferred to non-production tasks, such as mold changes, without delaying subsequent or other trolleys. During the curing process, the AMP can be detached from the trolley and redeployed to other trolleys.

Description

Technical Field

[0001] The present disclosure generally relates to methods and systems for managing the production of molded polymer products, such as, but not limited to, polyurethane ("PU") products produced by a reaction injection molding process. Background Art

[0002] PU products such as engine hoods and car seats are usually produced in manufacturing plants using a reaction injection molding process. Existing manufacturing plants usually include a long fixed turntable system, where the molds are individually fixedly mounted on interconnected dollies that move around the turntable at a constant speed. This leads to several inefficiencies, including but not limited to the need for a large manufacturing space to accommodate the turntable system with a fixed minimum length; high initial investment to set up a manufacturing plant with no guarantee of bulk orders; lack of flexibility in changing molds or switching to new molds, resulting in production interruptions during mold changes or mold switching; and lack of flexibility in expanding production due to the fixed turntable length.

[0003] Existing molded product production systems include:

[0004] U.S. Patent No. 8,535,582B2, entitled "Method for wirelessly controlling the formation of molded articles",

[0005] German patent application publication number DE102011001516 A1, entitled "Arrangement for producing a transport pallet from recycled plastics, with a conveying device for automatically conveying the molds from a casting station through a cooling zone to a molding station and for returning the molds to the casting station", and

[0006] U.S. Patent No. 6,438,780B1, entitled "Machining Blank Assembly". Summary of the invention

[0007] According to one aspect of the present disclosure, there is provided a method for managing the production of a molded polyurethane product, comprising:

[0008] Move the first autonomous mobile platform (AMP) to the first vehicle that has completed curing;

[0009] engaging the first AMP with the first cart to assemble a first self-propelled cart, wherein the first cart includes a first mold carrier supporting a first mold;

[0010] moving a first self-propelled trolley to a first production station;

[0011] advancing a first self-propelled trolley through at least a first production station;

[0012] moving a first self-propelled trolley to an unoccupied first curing station;

[0013] detaching the first AMP from the first dolly to disassemble the first self-propelled dolly; and

[0014] The contents of the first mold are cured.

[0015] In some embodiments of the first aspect, after detaching the first AMP from the first dolly to disassemble the first self-propelled dolly, the method further comprises:

[0016] Move the first AMP to the second vehicle where curing has been completed;

[0017] engaging the first AMP with a second dolly to assemble a second self-propelled dolly, wherein the second dolly includes a second mold carrier supporting a second mold;

[0018] moving a second self-propelled trolley to the first production station;

[0019] advancing a second self-propelled dolly through at least the first production station;

[0020] moving the second self-propelled trolley to a vacant curing station serving as the first or second curing station;

[0021] detaching the first AMP from the second dolly to remove the second self-propelled dolly; and

[0022] The contents of the second mold are cured.

[0023] In some embodiments of the first aspect, before moving the first self-propelled trolley to the first production station, the method further comprises:

[0024] moving the first self-propelled trolley to a non-production station; and

[0025] At the non-production station, the first mold is replaced, or the first mold carrier is replaced together with the first mold, or the first mold is maintained.

[0026] In some embodiments of the first aspect, the method further comprises:

[0027] Move the second AMP to the third vehicle where curing has been completed;

[0028] engaging the second AMP with a third dolly to assemble a third self-propelled dolly, wherein the third dolly includes a third mold carrier supporting a third mold;

[0029] When the first self-propelled trolley is moved to a non-production station, or when the first mold is replaced, or the first mold carrier is replaced together with the first mold, or maintenance is performed on the first mold, the third self-propelled trolley is moved to the first production station and the third self-propelled trolley is propelled through at least the first production station; and

[0030] moving the third self-propelled trolley to a vacant curing station serving as the first, second or third curing station;

[0031] detaching the second AMP from the third dolly to remove the third self-propelled dolly; and

[0032] The contents of the third mold are cured.

[0033] According to a second aspect of the present disclosure, there is provided a system for managing the production of molded polyurethane products, the system comprising:

[0034] a plurality of carriages, wherein each carriage includes a mold carrier supporting a mold;

[0035] a plurality of AMPs configured to move between at least a plurality of curing stations including a first curing station and a plurality of non-curing stations including a first production station, and further configured to interchangeably engage with any of the carts; and

[0036] A control system is configured to be communicatively coupled to the trolley and the AMP, and is further configured to generate and transmit control signals to the AMP to:

[0037] Move the first autonomous mobile platform (AMP) to the first vehicle that has completed curing;

[0038] Joining the first AMP with the first vehicle to assemble a first self-propelled vehicle;

[0039] moving a first self-propelled trolley to a first production station;

[0040] advancing a first self-propelled trolley through at least a first production station;

[0041] moving the first self-propelled dolly to the vacant first curing station; and

[0042] Disconnecting the first AMP from the first vehicle to disassemble the first self-propelled vehicle,

[0043] The first curing station is configured as follows:

[0044] The contents of the mold of the first vehicle are cured.

[0045] In some embodiments of the second aspect, the curing station includes a second curing station, the dolly includes a second dolly, and wherein after the first AMP is detached from the first dolly to disassemble the first self-propelled dolly, the control system is further configured to:

[0046] Move the first AMP to the second vehicle where curing has been completed;

[0047] Joining the first AMP with the second trolley to assemble a second self-propelled trolley;

[0048] moving a second self-propelled trolley to the first production station;

[0049] advancing a second self-propelled dolly through at least the first production station;

[0050] moving the second self-propelled dolly to one of the vacant curing stations being the first or second curing station; and

[0051] Disconnect the first AMP from the second trolley to disassemble the second self-propelled trolley,

[0052] wherein the identified one of the curing stations as the first or second curing station is configured as:

[0053] The contents of the mold of the second vehicle are cured.

[0054] In some embodiments of the second aspect, the non-curing station comprises a non-production station, and wherein, before the first self-propelled trolley is moved to the first production station, the control system is further configured to:

[0055] moving the first self-propelled trolley to a non-production station; and

[0056] The non-production stations are configured as:

[0057] The mold is replaced on the first self-propelled trolley, or the mold carrier is replaced together with the mold, or the mold is maintained.

[0058] In some embodiments of the second aspect, the curing station comprises a third curing station, the AMP comprises a second AMP, the trolley comprises a third trolley, and wherein the control system is further configured to:

[0059] Move the second AMP to the third vehicle where curing has been completed;

[0060] Joining the second AMP with the third trolley to assemble a third self-propelled trolley;

[0061] When the first self-propelled trolley is moved to a non-production station or when a mold is replaced, or a mold carrier is replaced together with the mold, or maintenance is performed on the mold, a third self-propelled trolley is moved to the first production station, and the third self-propelled trolley is pushed through at least the first production station;

[0062] moving the third self-propelled dolly to one of the vacant curing stations that is the first, second or third curing station; and

[0063] Disconnect the second AMP from the third trolley to dismantle the third self-propelled trolley,

[0064] wherein the identified one of the curing stations as the first, second or third curing station is configured as:

[0065] The contents of the mold of the third car are cured. BRIEF DESCRIPTION OF THE DRAWINGS

[0066] Figure 1A A dolly according to some embodiments is shown;

[0067] Figure 1B A mold carrier supporting the mold is shown;

[0068] Figure 1C A dolly is shown with mounting points to allow the mold carrier to be connected to the movable frame of the dolly;

[0069] Figure 2A The AMP is shown in a disengaged position;

[0070] Figure 2B The dolly is shown in a disengaged position and having a complementary opening or socket for receiving the piston of the AMP;

[0071] Figure 2C The AMP and dolly are shown both in an engaged position (without the mold and mold carrier);

[0072] Figure 2D AMP and dolly (with mold and mold carrier) are shown both in an engaged position;

[0073] Figure 3A is an overall schematic diagram of a production workshop layout according to some embodiments;

[0074] Figure 3B yes Figure 3A A plan view of the plant and showing the production management routes adopted by the AMP which can move between curing and non-curing stations.

[0075] Figure 4 A flow chart describing a method for managing the production of a molded polyurethane product according to some embodiments is shown;

[0076] Figure 5A A mold changing station is shown; and

[0077] Figure 5B Shown is a guide rail arranged at a production station. DETAILED DESCRIPTION

[0078] In the following description, many specific details are set forth in order to provide a thorough understanding of various illustrative embodiments of the present invention. However, those skilled in the art will appreciate that embodiments of the present invention may be implemented without some or all of these specific details. In other cases, well-known process operations are not described in detail to avoid unnecessary confusion of relevant aspects of the described embodiments. In the accompanying drawings, the same reference numerals refer to the same or similar functions or features in several views.

[0079] Embodiments described in the context of one of the method or apparatus are analogously applicable to the other method or apparatus. Similarly, embodiments described in the context of the method are equally valid for the apparatus, and vice versa.

[0080] Features described in the context of an embodiment may be correspondingly applicable to the same or similar features in other embodiments. Features described in the context of an embodiment may be correspondingly applicable to other embodiments, even if not explicitly described in these other embodiments. In addition, additions and / or combinations and / or substitutions described for features in the context of an embodiment may be correspondingly applicable to the same or similar features in other embodiments.

[0081] Throughout this specification, including the claims, the articles "a", "an", and "the" used with respect to features or elements include reference to one or more of the features or elements. Throughout this specification, including the claims, the terms "comprise", "comprises", "comprised", "comprising", "include", "includes", "including", or "having" will be interpreted as specifying the presence of the features, integers, steps, or components, but not excluding the presence of one or more other features, integers, steps, or components. Designations such as "first", "second", and "third" are used only as labels and are not intended to impose numerical requirements on their objects, nor are they interpreted in a manner that imposes any relative position or chronological order between limits or total numbers of their objects. The term "and / or" includes any and all combinations of one or more of the associated listed items. In addition, the term "coupled" and related terms are used in an operational sense and are not necessarily limited to direct physical connections or couplings. Thus, for example, two devices can be coupled directly, or through one or more intermediate devices. In some examples, devices may be appropriately coupled so that information or signals can be transferred between them without sharing any physical connection with each other. For example, two devices may be communicatively coupled via a wired or wireless connection. Based on this disclosure, one of ordinary skill in the art will understand the various ways in which coupling exists based on the foregoing definitions. The term "mold" includes reference to "mould", and related terms apply accordingly.

[0082] According to one aspect of the present disclosure, as shown in FIG. Figure 1A , 1B , 1C, 2A, 2B, 2C, at least one system for managing the production of molded polymer or polyurethane products is provided. The system generally includes: a plurality of dollies 100; a plurality of autonomous mobile platforms (AMPs) 200; and a control system configured to communicate with the dollies 100 and the AMPs 200, and also configured to generate control signals and transmit control signals to the AMPs 200. In particular, the AMPs 200 can be interchangeably engaged with the dollies 100 carrying the molds to transport the dollies 100 from one station to another, thereby completing a production cycle and / or transferring the dollies 100 before a subsequent production cycle. The system may also include a plurality of stations, including a curing station 32 and a non-curing station.

[0083] The dolly 100 is mounted with a mold carrier 110 and a mold 120 and can be transported between stations as needed. Figure 1AA trolley 100 according to some embodiments is shown. The trolley 100 includes a movable frame 102, such as a frame supported by wheels, which is drivable, such as by a driving vehicle. The trolley 100 also includes a mold carrier 110 supported by the movable frame 102 and a mold 120 supported by the mold carrier 110. Figure 1B A mold carrier 110 is shown supporting a mold 120, which may include an upper mold 122 and a lower mold 124. The mold 120 can be moved between an open and closed position. In the open position, the finished product can be removed from the mold 120; in the closed position, the mold 120 is configured to promote the solidification of the liquid polyurethane or liquid foam contained therein. The liquid polyurethane or liquid foam can be poured into the mold 120 in the open or closed position. It should be understood that other actions or steps not described herein can be performed on the mold 120 in the open or closed position. The mold 120 can be releasably mounted to the mold carrier 110, for example, by one or more screws, bolts, or other connecting mechanisms; similarly, the mold carrier 110 can be releasably mounted to the movable frame 102, for example, by one or more screws, bolts, or other connecting mechanisms. Therefore, mold replacement or switching can be performed by replacing an existing mold with a replacement mold for the same or different product without removing the mold carrier 110 from the movable frame 102; or by replacing the existing mold carrier with the mold with a replacement mold carrier with a replacement mold. Figure 1C The dolly 100 is shown with mounting points 104 (e.g., flanges and openings) to allow the mold carrier 110 to be removably mounted or connected to the movable frame 102. It should be understood that in some other embodiments, the mold carrier can be fixedly connected to the movable frame, such as being integrally formed with the movable frame, and the mold can be releasably mounted to the mold carrier.

[0084] An autonomous mobile platform (AMP) 200, such as an unmanned ground vehicle and a mobile robot, is configured to navigate or move in an omnidirectional manner at least between stations. The AMP's operating routes between stations may not be fixed during operation and may be determined by a control system. In some embodiments, magnetic tracks may be provided on the ground to define possible routes and guide the AMPs, particularly their magnetic wheels, as they move along the routes determined by the control system, while in some other embodiments, no magnetic tracks or other fixed tracks or rails may be provided.

[0085] The AMP 200 is interchangeably engageable with the dolly 100 and is also configured to transport the dolly 100 together with the mold carrier 110 and the mold 120 . Figure 2AAn AMP 200 is shown that includes an AMP body 202, a wheel rotatably coupled to the AMP body 202, a movable piston 204 disposed on the AMP body 202, and one or more motors (not shown) housed in the AMP body 202. The piston 204 may be operated by one or more electric, pneumatic, or hydraulic actuators. Figure 2B The dolly 100 is shown having a complementary opening 104 or socket for receiving a piston 204 of an AMP. Figure 2A and 2B AMP200 and trolley 100 are shown in a disengaged position, respectively, where they are not coupled and are separately actuatable or transportable.To achieve the engaged position, AMP200 is appropriately positioned, such as at or below trolley 100, after which piston 204 is pushed in and engaged with complementary opening 104 or socket. Figure 2C AMP 200 and dolly 100 are both shown in an engaged position (mold carrier and mold not shown). In the engaged position, AMP 200 and coupled dolly 100 are temporarily assembled so that moving or driving AMP 200 simultaneously moves or transports dolly 100. The assembled combination of AMP 200 and coupled dolly 100, in the engaged position, may alternatively be referred to as a self-propelled dolly 300 (see Figure 2D ). To disassemble the self-propelled trolley 300, the piston 204 is withdrawn from the complementary opening 104 or socket, so that the AMP 200 is disengaged from the trolley 100, that is, in the disengaged position. In the disengaged position, the AMP 200 can be considered idle; in the engaged position, the AMP 200 can be considered occupied. It should be understood that the AMP 200 can be engaged and disengaged with the trolley 100 using other mechanisms, such as fasteners, bolts and socket combinations, and magnetic locks.

[0086] The control system is configured to manage the deployment of AMPs and carts according to the production plan. It can also manage other aspects of production, such as the flow of each station, data collection, utilities required for each station, etc. The control system is communicatively coupled to the carts, AMPs, stations, etc., and is configured to generate signals, send signals to them, and receive signals from them. The control system includes at least one computer processor, which is communicatively coupled to at least one memory, the memory storing computer executable instructions for execution by the processor, and a transmission and reception unit for transmitting signals, such as control signals to AMPs, carts and / or stations and receiving signals from AMPs, carts and / or stations, such as data signals.

[0087] The stations or workstations, including the curing station 32 and the non-curing stations, provide various production and / or maintenance steps performed to produce the molded PU products.

[0088] Non-curing stations may include production stations and non-production stations. In the present disclosure, production stations generally include workstations that process molds and process raw materials in a predetermined order before curing. Production stations 34 may include (i) mold opening and finished product removal stations 34a, (ii) mold cleaning stations 34b, (iii) auxiliary material insertion and / or insert insertion stations 34c (optional), (iv) liquid polyurethane or foam material distribution and mold closing stations 34d. At least some production stations may provide utilities, such as compressed air, hydraulics and / or electricity to facilitate production steps. Non-production stations generally include workstations where molds, mold carriers, trolleys and / or AMPs are replaced and / or maintained on a specific basis, such as after a predetermined number of production cycles. Non-production stations 36 may include mold replacement or maintenance stations. Non-curing stations may be manned, such as operated by a person with or without machine intervention, or unmanned, such as operated by a machine without human intervention. It should be understood that reference to non-curing stations includes reference to their operators, whether human or machine. The processing steps to be performed at each non-curing station will be described in the following paragraphs.

[0089] The curing station 32 allows the contents of the mold, such as liquid polyurethane or liquid foam material, to be cured according to the required curing time. The curing station 32 can provide a heating unit and utilities, such as compressed air, hydraulic pressure and / or electricity, to promote curing. The heating unit can be operated by a hot water supply, wherein the hot water supply can be heated by solar energy, or operated by electricity or electric induction. The curing station 32 can be operated by a person, such as operated by a person with or without machine intervention, or unmanned, such as operated by a machine without human intervention. It should be understood that mentioning the curing station includes mentioning its operator, whether it is a person or a machine. When there is no trolley placed in the curing station 32 or when the curing process is not carried out, the curing station can be considered to be idle or vacant. On the contrary, when the trolley is placed in the curing station 32 or when the curing process occurs, the curing station can be considered to be occupied.

[0090] The production cycle for the mold and / or mold carrier includes advancing through certain production stations and then through a curing station in a predetermined sequence. The cycle is typically iterative until it is determined that a non-production task is necessary, in which case the next production cycle is paused to perform the non-production task, after which the next production cycle is resumed or started.

[0091] Figure 3Ais an overall schematic diagram of a production workshop layout according to some embodiments. The layout includes a plurality of production stations 34a, 34b, 34c, 34d, which are configured to perform sequential processing steps on the mold, a plurality of curing stations 32, which are configured to cure the contents of the mold after the mold is transferred from the four production stations 34a, 34b, 34c, 34d, and at least one mold replacement station 36, which is configured to perform mold replacement or maintenance. It should be understood that in some other embodiments, the number of production stations can be more than four or less than four, depending on the product and the necessary production steps. Figure 3B yes Figure 3A and shows possible production management routes of AMP200 between curing station 32 and non-curing station (see box arrows). Figure 3B , the AMP points to one of the curing stations 32 (see dashed arrow 1). The AMP 200 approaches the dolly 100 at the identified curing station 32 and engages with the dolly 100. The AMP 200 transports the dolly 100 to circulate through the first, second, third and / or fourth production stations 34a, 34b, 34c, 34d (see dashed arrow 2). At each of these stations, the AMP 200 pauses the dolly 100 for a corresponding predetermined period of time or until it receives an instruction to move to the next station (see dashed arrows 3, 4, 5). After the AMP 200 pushes the dolly 100 through the production stations 34a, 34b, 34c, 34d, the AMP 200 transports the dolly 100 to an empty curing station for curing (see dashed arrow 6). In the above route, before AMP200 transports the cart 100 from the curing station to circulate through the first, second, third and / or fourth production stations 34a, 34b, 34c, 34d, AMP200 can, if necessary, transfer the cart 100 to a non-production station 36 to perform mold replacement or maintenance or other non-production steps before guiding the cart to the first production station 34a (i.e., the dotted arrow 2 turns to the dotted arrow 7 and then returns to the route of the dotted arrow 2).

[0092] According to one aspect of the present disclosure, according to some embodiments, referring to the flowchart Figure 4 At least one method for managing the production of molded polymer or polyurethane products is provided and described.

[0093] In block 402, the method includes determining whether any cart placed at an occupied curing station has completed curing. This may be performed by a control system that may receive signals from the curing stations regarding the status of the curing process at each curing station.

[0094] In box 404, if one of the carts can be located at an occupied curing station and is identified as having completed curing, the method includes directing an unoccupied AMP to move to the identified curing station and engage with the identified cart to assemble into a self-propelled cart. This can be performed by a control system that transmits a signal with instructions to the AMP. Specifically, the AMP is moved to the identified cart at the curing station, appropriately positioned at / below the cart and engaged with the cart by activating the piston of the AMP and pushing the piston into the complementary opening of the cart. Once engaged, the AMP and the cart are assembled into a self-propelled cart. The AMP is now occupied.

[0095] In block 406, the method includes determining whether a transfer of the self-propelled trolley is required before the next production cycle. In particular, the method can determine whether a non-production step is required for the self-propelled trolley, such as a mold change or maintenance. This can be performed by the control system based on data (e.g., mold condition, number of production cycles). If a transfer is not required, such as a mold change or maintenance, block 406 proceeds to block 408.

[0096] In block 408, the self-propelled trolley moves from the curing station to the first production station to start the next production cycle. This can be performed by a control system that can transmit a signal with instructions to the AMP.

[0097] In block 410, the self-propelled dolly is propelled through the first and any subsequent production stations, as described in the following paragraphs.

[0098] The self-propelled trolley is moved to a first production station, such as a finished product removal station. More specifically, the self-propelled trolley is appropriately positioned at the station; if necessary, the self-propelled trolley is connected to public facilities; the mold carrier and / or the mold is opened; the finished product is removed from the mold; if necessary, the self-propelled trolley is disconnected from the public facilities.

[0099] Thereafter, the self-propelled trolley is pushed or moved to a second production station, such as a mold cleaning station. More specifically, the self-propelled trolley is appropriately positioned at the station; the mold without a finished product is now processed, such as cleaned, to prepare for injection molding.

[0100] Thereafter, the self-propelled trolley is propelled or moved to a third production station, such as an auxiliary material and / or insert insertion station. More specifically, the self-propelled trolley is appropriately positioned at this station; if necessary, a release agent is dispensed into the treated mold; if necessary, an insert is provided in the treated mold. This station or step is optional and therefore not required if the production cycle does not require auxiliary materials or inserts.

[0101] Thereafter, the self-propelled cart is pushed or moved to a fourth production station, such as a liquid polyurethane or foam dispensing station. More specifically, the self-propelled cart is appropriately positioned at the station; if necessary, the self-propelled cart is connected to utilities; the mold carrier and / or mold are closed; the liquid polyurethane or liquid foam is injected into the mold through the mixing head and the injection opening by moving the mixing head of the dispensing robot to the injection opening of the mold, and the mixing head is removed from the injection opening to transfer the liquid polyurethane or liquid foam to the mold; thereafter, if necessary, the self-propelled cart is disconnected from the utilities. The mold in the self-propelled cart is now ready for curing. Although closed mold casting is described above, it should be understood that in some embodiments, open mold casting can be performed. More specifically, after the self-propelled trolley is properly positioned at the liquid polyurethane or foam dispensing station and the self-propelled trolley is connected to utilities if necessary, the mold carrier and / or mold is opened or kept open from the previous station; the liquid polyurethane or liquid foam is injected into the mold through the mixing head and the injection opening by moving the mixing head of the dispensing robot to a position above the open mold, and the mixing head is removed from the open mold, and the liquid polyurethane or liquid foam is transferred to the open mold; the mold is actuated to close; thereafter, if necessary, the self-propelled trolley is disconnected from the utilities.

[0102] In box 410, moving the self-propelled trolley to the first, second, third and / or fourth production station of each production station can be instructed by the control system, which can send a signal with instructions to the AMP. The pausing of the trolley at each production station can be instructed by the control system, which can receive signals from sensors of the corresponding station, determine whether the trolley has completed processing at each corresponding production station based on these sensor signals, and thereby generate a signal with instructions to the AMP to continue pausing at the station or moving to the next station. Also in box 410, the connection of the trolley to the utilities and the execution of production steps, such as removing the finished product, cleaning the mold, inserting the insert, transferring the liquid polyurethane or liquid foam to the mold, can be performed by the corresponding production station or its operator at the location of the trolley. In the first to fourth production stations, the AMP can remain engaged with the trolley.

[0103] In block 412, the method includes determining whether any curing stations are unoccupied. This may be performed by a control system that may receive signals from the curing stations regarding the occupancy status of each curing station.

[0104] In block 414, if it is determined that one of the curing stations is not occupied, the self-propelled trolley is directed to the identified curing station. More specifically, the self-propelled trolley is moved to the unoccupied curing station and positioned appropriately. This can be performed by a control system that can transmit a signal with instructions to the AMP. In addition, the trolley can be connected to a heating unit and / or utility.

[0105] In block 416, after the self-propelled dolly is properly positioned at the curing station, the AMP is disconnected from the dolly to detach the self-propelled dolly so that the AMP is now unoccupied. This may be performed by a control system that may transmit a signal with instructions to the AMP.

[0106] In block 418, the contents of the mold of the trolley are cured at a curing station, where heat is supplied to the mold contents so that a chemical reaction occurs to cause hardening and / or stabilization of the mold contents. This can be performed by a corresponding curing station. Curing conditions, such as temperature, pressure, curing time, can be controlled by a control system.

[0107] Before curing is performed, for example before or after the AMP is disconnected from the cart, the cart can be connected to the heating unit in blocks 414 or 416. After curing is performed, for example, the cart can be disconnected from the heating unit. This can be performed by the corresponding curing station.

[0108] In block 420, curing of the cart is completed at the curing station. After curing is completed, the method returns to block 402 and the cart repeats the process sequence comprising blocks 402 to 420. In the repeated process sequence, a different AMP or the same AMP that propelled the cart through blocks 406 to 416 in the previous cycle may be directed to engage the cart, depending on the AMPs available at the start of the repeated process sequence.

[0109] It should be understood that after box 416, after the AMP is disengaged from the cart at the curing station, the unoccupied AMP can now be redeployed to another cart that has completed curing. This can be performed by the control system, which can determine the need for the AMP by another cart and transmit a signal with instructions to the AMP.

[0110] In the foregoing description, box 406 proceeds directly to box 408 because the transfer is determined not to be required. However, if it is determined in box 406 that a transfer is required, box 406 proceeds to box 407, where the self-propelled trolley is moved to a non-production station to replace a mold, for example, if the existing mold is not suitable for use or if a different mold design is required to produce a different PU product, or for maintenance of the mold or other parts of the trolley, or for other purposes. When the self-propelled trolley is transferred before its next production cycle, other self-propelled trolleys that have completed curing can then proceed from box 404 to box 406 and then to box 408, that is, bypassing the transferred trolley to start their next production cycle without being affected or delayed by the transfer.

[0111] If the self-propelled trolley is transferred to a non-production station to change the mold (see Figure 5A), the mold carrier and / or mold may be unloaded from the self-propelled cart; a replacement mold carrier and / or mold may be installed; and the finished product may be removed from the unloaded mold carrier and / or mold. This may be performed by the corresponding non-production station. In block 408, the self-propelled cart along with its replacement mold carrier and mold is moved to the production station for the next production cycle through blocks 410 to 420. This may be performed by a control system that transmits a signal with instructions to the AMP.

[0112] If the self-propelled trolley is transferred to a non-production station for maintenance, the mold carrier and / or the mold can be unloaded from the self-propelled trolley; the finished product can be taken out from the unloaded mold carrier and / or the mold. This can be performed by the corresponding non-production station. Thereafter, the self-propelled trolley can be moved to another place for maintenance. This can be performed by the control system transmitting a signal with instructions to the AMP.

[0113] Reference below Figure 3B To describe Figure 4 An illustrative example of method 400, Figure 3B A schematic route of an AMP is shown. In the first cycle of method 400, the first trolley is determined to have completed curing at an occupied curing station (box 402, first cycle). The first AMP is moved to the first trolley and engaged with it to be assembled into a first self-propelled trolley (box 404, first cycle). If it is determined that the first self-propelled trolley does not need to be transferred (box 406, first cycle), the first self-propelled trolley is moved to the production station to start a new production cycle (box 408, first cycle). The first self-propelled trolley is pushed through the first, second, third and / or fourth production stations until the mold of the first self-propelled trolley is ready for curing (box 410, first cycle). The curing station is determined to be vacant (box 412, first cycle). The first self-propelled trolley is moved to an identified vacant curing station (box 414, first cycle), where the first AMP is disengaged from the first trolley, thereby disassembling the first self-propelled trolley (box 416, first cycle). The first AMP is now unoccupied and can be redeployed, for example, moved to a second cart that has completed curing at another occupied curing station, joined thereto to assemble into a second self-propelled cart, and the second self-propelled cart is propelled through blocks 408 to 414 in a separate cycle of method 400, i.e., separate from the aforementioned first cycle. On the other hand, continuing the aforementioned first cycle, the first cart completes curing (blocks 418 and 420, the first cycle), thereby completing the first cycle of method 400.

[0114] Thereafter, the second cycle of method 400 begins, wherein the first vehicle is determined to have completed curing at the occupied curing station (block 402, second cycle). An available AMP is moved to the first vehicle and engaged with it to assemble into a self-propelled vehicle (block 404, second cycle). This available AMP may be the first AMP deployed in the first cycle, or may be the second, third, or subsequent AMP available at the time. The second cycle of method 400 continues accordingly, and the third, fourth, and subsequent cycles of method 400 are then executed.

[0115] If it is determined that the first self-propelled trolley needs to be transferred (box 406, first cycle), the first self-propelled trolley is moved to a non-production station for mold replacement or maintenance (box 407, first cycle). After the necessary mold replacement or maintenance, the first self-propelled trolley is ready to start the next production cycle, so the first self-propelled trolley is moved to the production station to start the next production cycle (box 408, first cycle). In the above transfer, after the first self-propelled trolley leaves the curing station or during the transfer of the first self-propelled trolley (box 407, first cycle), other trolleys at the occupied curing station, such as the third trolley, may now have completed curing. The second AMP is moved to the third trolley and engaged with it to be assembled into a third self-propelled trolley. The third self-propelled trolley is moved to a non-curing station to start the next production cycle. In other words, even if the third or other carts may complete curing later than the first cart, if the first cart is diverted, the third or other carts can bypass the first cart when starting the next production cycle, and do not have to wait for the next production cycle to start from the first cart before they can start their next production cycle.

[0116] It should be understood that in some of the foregoing embodiments, the guide rail 38 may be disposed at the first, second, third and / or fourth production station (see Figure 5B ). The guide rail 38 may carry some, for example two, wheels of a trolley that is propelled through a production station to improve the alignment of the trolley therewith. Thus, as the self-propelled trolley moves through a production station, i.e., as the AMP drives the trolley, one side of the trolley moves along the guide rail. In some other embodiments, no guide rail is provided at the production stations 34a, 34b, 34c, 34d, in which case sensors may be provided at the production stations to determine the alignment of the trolley relative to the relevant production station. The alignment information may be transmitted to a control system, which determines whether the current alignment is acceptable, and if the current alignment is not acceptable, the control system transmits a signal with instructions to the AMP of the self-propelled trolley to improve the alignment.

[0117] It should be understood that in some of the foregoing embodiments, the curing station may be disposed in a heated tunnel or enclosure. Within the heated tunnel or enclosure, one or more designated areas may be provided as curing stations. The designated areas may be discrete areas or continuous areas arranged adjacent to each other. The interior of the heated tunnel or enclosure may be provided at a curing temperature, so that a trolley placed therein may not need to be connected to utilities, such as electricity, or to a heating unit to facilitate curing.

[0118] It should be understood that in some other embodiments, each trolley or mold carrier may include a heating unit configured to provide heat to the contents of the mold. Thus, the curing station can be arranged as one or more designated areas on a production floor or layout where the trolleys can be parked during curing. The heating units can be operated by a power source supported by the trolley or a battery of the AMP or by a utility (e.g., electricity provided at the curing station). The designated areas can be discrete areas or continuous areas arranged adjacent to each other.

[0119] Throughout this specification, including the claims, although reference is made to a first and a second AMP; a first, second, and third trolley; a first, second, third, and fourth production station; and a first, second, and third curing station, it should be understood that the above references are for ease of description and do not limit the number of the various components. In various embodiments, the number of AMPs may be two or more; the number of trolleys may be two, three, or more; the number of production stations may be one or more; the number of curing stations may be two or more; and the number of non-production stations may be one or more.

[0120] Embodiments of the present disclosure provide advantages including but not limited to the following.

[0121] (i) Comparison with a fixed line carousel system, where the mold moves along the line at a constant speed:

[0122] a. Unlike fixed production line carousel systems that require a fixed minimum length, embodiments of the present disclosure require less installation space.

[0123] b. Embodiments of the present disclosure require a lower initial investment to set up, unlike fixed line carousel systems which require a higher initial investment due to their minimum length.

[0124] c. The embodiments of the present disclosure provide greater flexibility in expanding production capacity because curing stations and production stations can be added to the production floor without having to rebuild the production layout or destroy existing stations. This is different from fixed production line carousel systems that do not allow expansion due to their fixed length.

[0125] d. In the embodiments of the present disclosure, changing the mold does not interrupt production because the cart that needs mold change or maintenance is moved, thereby minimizing or eliminating waiting time. In a fixed line carousel system, changing the mold will interrupt production because the fixed line carousel system must be stopped to allow mold change or maintenance.

[0126] e. In embodiments of the present disclosure, different curing times can be accommodated, thereby minimizing waiting time. This allows two or more product types to be produced in a production layout. In a fixed line turntable system, since the line runs at a constant speed, it is not possible to accommodate different curing times.

[0127] (ii) Interchangeable engagement or connection of the AMP with the cart allows for efficient deployment of the AMP. For example, when a self-propelled cart is positioned at a curing station to begin curing, its AMP can be detached from the cart and redeployed on another cart.

[0128] (iii) The mold or the mold carrier with the mold is detachable from the trolley to make mold replacement and maintenance easier.

[0129] (iv) The ability to navigate the AMP between stations is not limited to a fixed sequence defined by a turntable or conveyor belt and the arrangement of non-production stations separate from production stations allows certain carts that require non-production tasks to be diverted from the production queue. This allows other carts to bypass the carts going to non-production tasks and continue with the next production cycle without waiting for the completion of the non-production tasks.

[0130] Other embodiments will be apparent to those skilled in the art through consideration of the specification and practice of the present disclosure. In addition, certain terms have been used for the purpose of describing clearly, rather than limiting the disclosed embodiments. The above embodiments and features should be considered as exemplary.

Claims

1. A method of managing the production of molded polyurethane products by moving a plurality of autonomous mobile platforms (AMPs) between at least a plurality of curing stations and a plurality of non-curing stations and interchangeably engaging the AMPs with any of a plurality of dollies, the method comprising: Move the first AMP to the first car where curing has been completed; engaging the first AMP with the first cart to assemble a first self-propelled cart, wherein the first cart includes a first mold carrier supporting a first mold; moving the first self-propelled trolley to a first production station; advancing the first self-propelled dolly through at least the first production station; moving the first self-propelled trolley to an unoccupied first curing station; detaching the first AMP from the first trolley to disassemble the first self-propelled trolley; curing the contents of the first mold; moving the usable AMP to the first cart after curing the contents of the first mold; as well as engaging the available AMP with the first cart to assemble the first self-propelled cart, wherein the AMP comprises the first AMP and the available AMP different from the first AMP, wherein the curing station comprises the first curing station, wherein the non-curing station comprises the first production station, and wherein the trolley comprises the first trolley.

2. The method according to claim 1, wherein: After detaching the first AMP from the first cart to disassemble the first self-propelled cart, the method further includes: Moving the first AMP to a second vehicle where curing has been completed; engaging the first AMP with the second cart to assemble a second self-propelled cart, wherein the second cart includes a second mold carrier supporting a second mold; moving the second self-propelled trolley to the first production station; advancing the second self-propelled dolly through at least the first production station; moving the second self-propelled trolley to an empty curing station serving as the first curing station or the second curing station; detaching the first AMP from the second cart to disassemble the second self-propelled cart; and curing the contents of the second mold, Wherein the trolley comprises the second trolley, wherein the curing station comprises the second curing station.

3. The method according to any one of claims 1 or 2, wherein: Prior to moving the first self-propelled trolley to the first production station, the method further comprises: moving the first self-propelled trolley to a non-production station; At the non-production station, replacing the first mold, or replacing the first mold carrier together with the first mold, or maintaining the first mold; Moving the second AMP to a third vehicle that has completed curing later than the first vehicle; engaging the second AMP with the third cart to assemble a third self-propelled cart, wherein the third cart includes a third mold carrier supporting a third mold; When the first self-propelled trolley is moved to the non-production station, or when the first mold is replaced, or the first mold carrier is replaced together with the first mold, or the first mold is maintained, the third self-propelled trolley is moved to the first production station and pushed through at least the first production station; and moving the third self-propelled trolley to an empty curing station; detaching the second AMP from the third trolley to disassemble the third self-propelled trolley; and curing the contents of the third mold, Wherein the AMP comprises the second AMP, wherein the non-curing station comprises the non-production station, and wherein the trolley comprises the third trolley.

4. The method according to any one of claims 1 to 2, wherein: Propelling the first self-propelled trolley through at least the first production station comprises: removing a finished product from the first mold at a first production station; processing said first mold without said finished product at a second production station; and In the fourth production station, liquid polyurethane or liquid foam is dispensed into the treated first mold.

5. The method according to claim 4, wherein: Propelling the first self-propelled trolley through at least the first production station comprises: before removing the finished product from the first mold, positioning at least a portion of the plurality of wheels of the first cart in a guide rail; Prior to processing the first mold, moving the first self-propelled trolley to the second production station comprises moving the first trolley along the guide rail; and Prior to dispensing the liquid polyurethane or liquid foam to the treated first mold, moving the first self-propelled cart to the fourth production station includes moving the first cart along the guide rail.

6. The method according to claim 4, wherein: Propelling the first self-propelled trolley through at least the first production station comprises: Before dispensing the liquid polyurethane or liquid foam into the treated first mold, an insert or auxiliary material is inserted into the treated first mold at a third production station.

7. The method according to claim 4, wherein: Propelling the first self-propelled trolley through at least the first production station comprises: connecting the first trolley to utilities at the first production station before removing the finished product from the first mold; connecting the first cart to utilities at the second production station prior to processing the first mold; and Prior to dispensing the liquid polyurethane or liquid foam into the treated first mold, the first cart is connected to utilities of the fourth production station.

8. The method according to any one of claims 1 to 2, wherein: After moving the first self-propelled dolly to the identified vacant curing station or after detaching the first AMP from the first dolly to remove the first self-propelled dolly, connecting the first dolly to a heating unit.

9. The method according to any one of claims 1 to 2, wherein: The curing station is located in a heated tunnel or enclosure, or in a designated area of ​​the production hall.

10. A system for managing the production of molded polyurethane products, the system comprising: a plurality of carriages, wherein each carriage includes a mold carrier supporting a mold; a plurality of autonomous mobile platforms (AMPs) configured to move between at least a plurality of curing stations including a first curing station and a plurality of non-curing stations including a first production station, and further configured to interchangeably engage with any of said dollies; as well as a control system configured to be communicatively coupled to the trolley and the AMP and further configured to generate and transmit control signals to the AMP, thereby: Move the first AMP to the first car where curing has been completed; Joining the first AMP with the first cart to assemble a first self-propelled cart; moving the first self-propelled trolley to a first production station; advancing the first self-propelled dolly through at least the first production station; moving the first self-propelled trolley to the vacant first curing station; as well as detaching the first AMP from the first trolley to disassemble the first self-propelled trolley, The first curing station is configured as follows: curing the contents of the mold of the first vehicle; The control system is configured as follows: moving the usable AMP to the first cart after curing the contents of the mold of the first cart; as well as engaging the available AMP with the first cart to assemble the first self-propelled cart, The AMP includes the first AMP and the available AMP different from the first AMP, and the cart includes the first cart.

11. The system according to claim 10, wherein: The curing station comprises a second curing station, wherein the trolley comprises a second trolley, and wherein after the first AMP is detached from the first trolley to disassemble the first self-propelled trolley, the control system is further configured to: Moving the first AMP to the second vehicle on which curing has been completed; Joining the first AMP with the second cart to assemble a second self-propelled cart; moving the second self-propelled trolley to the first production station; advancing the second self-propelled dolly through at least the first production station; moving the second self-propelled trolley to one of the curing stations that is vacant as the first curing station or the second curing station; as well as detaching the first AMP from the second trolley to disassemble the second self-propelled trolley, wherein the identified one of the curing stations as the first curing station or the second curing station is configured as: The contents of the mold of the second vehicle are cured.

12. A system according to claim 10 or claim 11, wherein: The non-curing station comprises a non-production station, wherein, before the first self-propelled trolley is moved to the first production station, the control system is further configured to: moving the first self-propelled trolley to the non-production station; The non-production station is configured as follows: Replace the mold on the first self-propelled trolley, or replace the mold carrier together with the mold, or maintain the mold; wherein the AMP comprises a second AMP, wherein the trolley comprises a third trolley, and wherein the control system is further configured to: Moving the second AMP to the third vehicle that has completed curing later than the first vehicle; Joining the second AMP with the third trolley to assemble a third self-propelled trolley; When the first self-propelled trolley is moved to the non-production station or when the mold is replaced, or the mold carrier is replaced together with the mold, or maintenance is performed on the mold, the third self-propelled trolley is moved to the first production station and the third self-propelled trolley is pushed through at least the first production station; moving the third self-propelled trolley to an unoccupied one of the curing stations; and detaching the second AMP from the third trolley to disassemble the third self-propelled trolley, wherein the identified one of the curing stations is configured to: The contents of the mold of the third vehicle are solidified.

13. The system according to any one of claims 10 to 11, wherein: The non-curing station includes a second production station and a fourth production station, and wherein The first production station is configured to remove a finished product from the mold; The second production station is configured to process the mold without the finished product; and The fourth production station is configured to transfer liquid polyurethane or liquid foam into the treated mold.

14. The system according to claim 13, wherein: The control system is also configured to: before removing the finished product from the mold, positioning at least a portion of the plurality of wheels of the first cart in a guide rail; Before processing the mold, moving the first self-propelled trolley to the second production station and moving the first trolley along the guide rail; as well as Before the liquid polyurethane or the liquid foam is transferred to the treated mold, the first self-propelled trolley is moved to the fourth production station and the first trolley is moved along the guide rail.

15. The system of claim 13, wherein: The non-curing station includes a third production station, which is configured to: Before transferring the liquid polyurethane or liquid foam into the treated mold, an insert or auxiliary material is inserted into the treated mold.

16. The system of claim 13, wherein: The first production station is configured to connect the first cart to a utility at the first production station before the finished product is removed from the mold; The second production station is configured to connect the first cart to utilities at the second production station prior to processing the mold; and The fourth production station is configured to connect the first cart to utilities at the fourth production station before the liquid polyurethane or liquid foam is transferred to the treated mold.

17. The system according to any one of claims 10 to 11, wherein: The first curing station is configured as: After moving the first self-propelled cart to the identified vacant curing station, or after the first AMP is detached from the first cart to remove the first self-propelled cart, the first cart is connected to a heating unit.

18. The system according to any one of claims 10 to 11, wherein: The curing station is located in a heated tunnel or enclosure, or in a designated area of ​​the production hall.

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