Online mold replacement system and method

Abstract

The invention relates to the technical field of mold replacement, in particular to an online mold replacement system and method. The system comprises a movable die changing device which is laterally arranged and moves in parallel along a production line, a synchronous control unit, a movable die changing device integration butt joint mechanism and a die taking and placing mechanism, and an off-line die processing station, a transfer trolley and a safety grating are further matched. The synchronous control unit obtains real-time information of the carrying tool and controls the movable die changing device to move synchronously with the synchronous control unit, releasable connection is established through the docking mechanism, and the die taking and placing mechanism completes die transfer. The method comprises the steps of synchronous movement, connection establishment and mold transfer, and supports a double-vehicle cooperation and one-way mold change mode. According to the automatic die changing device, automatic die changing without line stopping is achieved, product scrapping caused by line stopping is avoided, the production efficiency and the yield are improved, operation is safe and accurate, and the automatic die changing device is suitable for various production scenes.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of mold replacement, in particular to an online mold replacement system and method. BACKGROUND

[0002] In the production field such as automotive seat foaming, a mode of sequentially casting and forming multiple molds on a continuously running production line is usually adopted. Due to product model replacement or mold regular cleaning and maintenance, the molds on the production line must be replaced. At present, the common mold replacement mode mainly relies on manual operation. Specifically, when mold replacement is needed, the whole production line must be stopped. The operator then uses a heavy-duty forklift or other equipment to unload the mold to be replaced from the production line trolley and install the prepared new mold in place.

[0003] However, this traditional manual stop-line mold replacement mode has obvious defects. First, the forced interruption of the production line directly leads to the loss of production time, reducing the overall equipment utilization and production efficiency. More importantly, in the casting area, the sudden stop of the production line will cause the products in the molding process to be scrapped, seriously affecting the product yield. Secondly, the rhythm and accuracy of mold replacement operations completely depend on the experience and proficiency of the operator, making it difficult to achieve fast, accurate and repeatable standardized operations, restricting the upgrading of the production line to flexibility and intelligence.

[0004] Therefore, the industry urgently needs a mold replacement scheme that can realize non-stop line and automatic operation to ensure the stability and economy of continuous production. SUMMARY

[0005] To solve one or more of the above problems, the present application provides an online mold replacement system, comprising: A mobile mold replacement device is arranged on the side of the production line and can move in a direction parallel to the production line; A synchronization control unit is communicatively connected with the production line control system to obtain real-time position and speed information of the carrying tool in the production line, and the synchronization control unit is configured to control the mobile mold replacement device and the carrying tool to move synchronously; The mobile mold replacement device is provided with a docking mechanism and a mold taking and placing mechanism; The docking mechanism is configured to form a releasable connection with the carrying tool during synchronous movement; The mold taking and placing mechanism is configured to transfer the mold between the mobile mold replacement device and the carrying tool when the docking mechanism is connected with the carrying tool.

[0006] According to the online mold replacement system provided by the application, at least two mobile mold replacement devices are provided, and the synchronous control unit is configured to control the at least two mobile mold replacement devices to perform any one of the following operation modes: The two mobile mold replacement devices cooperate to respectively perform the operations of taking down the mold from the production line and putting the mold into the production line; Any one of the mobile mold replacement devices puts the mold into the idle carrier vehicle of the production line; Any one of the mobile mold replacement devices takes down the mold from the carrier vehicle of the production line.

[0007] According to the online mold replacement system provided by the application, a preparation position sensor, a waiting position sensor and a synchronous position sensor corresponding to the carrier vehicle position are arranged along the movement path of the mobile mold replacement device; The synchronous control unit is connected with the preparation position sensor, the waiting position sensor and the synchronous position sensor respectively, so as to control the action stage of the mobile mold replacement device according to the signals of the sensors.

[0008] According to the online mold replacement system provided by the application, the synchronous control unit is configured to: When the mobile mold replacement device moves to the waiting position according to the signal of the waiting position sensor, the mobile mold replacement device is controlled to accelerate to synchronize with the carrier vehicle according to the obtained carrier vehicle information.

[0009] According to the online mold replacement system provided by the application, the mobile mold replacement device comprises a chassis; the bottom of the chassis is provided with a roller for moving along the running track on the side of the production line; and the chassis is provided with a sliding groove.

[0010] According to the online mold replacement system provided by the application, the docking mechanism is provided with a guide rail strip at the bottom, and the guide rail strip cooperates with the sliding groove on the chassis, so that the docking mechanism can slide relative to the chassis in a direction perpendicular to the production line.

[0011] According to the online mold replacement system provided by the application, the docking mechanism is provided with a docking block at both ends, and the docking block is used to engage with the corresponding structure on the carrier vehicle to form the releasable connection.

[0012] According to the online mold replacement system provided by the application, the docking mechanism further comprises a front pushing cylinder; the cylinder body of the front pushing cylinder is connected to the chassis, and the piston rod of the front pushing cylinder is connected to the docking mechanism, so as to drive the docking mechanism to slide relative to the chassis in a direction perpendicular to the production line.

[0013] According to the online mold replacement system provided by the application, the docking mechanism is provided with a docking sensor, which is used to detect the establishment state of the releasable connection.

[0014] According to the online mold replacement system provided by the present application, the mold taking and placing mechanism comprises: a fork assembly for inserting into a bearing structure at the bottom of the mold; a translation device connected to the fork assembly for driving the fork assembly to move along a direction perpendicular to the production line to realize the pushing in or pulling out of the mold; a jacking device connected to the fork assembly for driving the fork assembly to lift and lower to realize the picking up or releasing of the mold.

[0015] According to the online mold replacement system provided by the present application, an offline mold processing station is arranged on the side of the production line, and a transfer trolley is arranged for carrying the mold, and the transfer trolley can transfer the mold between the offline mold processing station and the production line.

[0016] According to the online mold replacement system provided by the present application, a safety grating is arranged in the interaction area between the mobile mold changing device and the production line.

[0017] The present application also provides an online mold replacement method, comprising the steps of: controlling at least one mobile mold changing device to move synchronously with a carrier on the production line; during the synchronous movement, establishing a releasable connection between the mobile mold changing device and the carrier; in the connected state, transferring the mold between the mobile mold changing device and the carrier.

[0018] According to the online mold replacement method provided by the present application, at least two mold changing trolleys are controlled to work cooperatively to replace the mold, comprising the steps of: controlling a first mold changing trolley to carry a mold to be replaced and move to a waiting position; controlling a second mold changing trolley to move synchronously with the carrier carrying the mold to be replaced, connect and transfer the mold to be replaced; controlling the second mold changing trolley to be disconnected from the carrier; controlling the first mold changing trolley to move synchronously with the carrier, connect and transfer the mold to be replaced to the carrier.

[0019] The above one or more technical solutions provided by the present application at least have the following beneficial effects: The core advantage of the online mold changing system and method presented in this application lies in its automated mold changing capability without shutting down the production line, fundamentally solving the problems of low production efficiency and product scrap caused by traditional manual mold changing during line downtime. Through real-time communication between the synchronous control unit and the production line control system, the mobile mold changing device can precisely follow the speed and position of the transport vehicle. Combined with a releasable docking mechanism, a stable working environment is formed, allowing mold transfer to be completed while the production line continues to run. This avoids the scrapping of semi-finished products caused by interruptions in the casting process, significantly improving the product yield. Simultaneously, the cooperation between the off-line mold processing station and the transfer vehicle allows pre-processing operations such as mold cleaning and repair to be carried out in parallel with on-line mold changing, without occupying main line production time. This greatly shortens the single mold changing cycle and effectively improves the overall operating efficiency and equipment utilization rate of the production line.

[0020] This technical solution boasts a high degree of automation and operational flexibility, significantly reducing reliance on manual labor and labor intensity. The synchronous control unit coordinates multiple independently operating mold-changing vehicles, supporting various operation modes such as dual-vehicle collaborative mold changing and single-vehicle unidirectional mold changing. It can flexibly adapt to different production scenarios, including replacing old and new molds, replacing molds under no-load conditions, and disassembling faulty molds. Utilizing multiple detection components, including preparation and waiting position sensors, the system can accurately control the timing and positioning of each action stage. The mold pick-and-place mechanism, through the coordinated action of the forklift assembly, translation device, and lifting device, achieves smooth mold transfer, reducing collisions and wear, protecting mold precision and lifespan, and avoiding positioning deviations and safety hazards caused by manual forklift operation. This makes mold-changing operations more standardized and repeatable.

[0021] Furthermore, the system ensures operational safety and long-term reliable operation through comprehensive safety protection design and stable structural coordination. Safety light curtains installed in the interaction area between the mobile mold-changing device and the production line form a blind-spot-free protective light curtain. If personnel or foreign objects accidentally enter, an emergency stop is triggered, preventing collisions and crushing accidents. Anti-fall chains and other structures in the off-line mold processing station further enhance the safety of manual mold pre-processing. Precise signal interaction and motion coordination between components form a complete operational closed loop. The synchronous control unit provides real-time monitoring and rapid response to abnormal states, ensuring the stability of system operation. At the same time, this solution does not require large-scale modifications to existing production lines, is adaptable to various production scenarios requiring frequent mold changes, such as automotive seat foaming, and has strong versatility, providing reliable support for the flexible and intelligent upgrading of production lines. Attached Figure Description

[0022] To more clearly illustrate the technical solutions in this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0023] Figure 1 This is a schematic diagram of the structure of an online mold changing system provided in some embodiments of this application; Figure 2 This is a partial structural schematic diagram of an online mold changing system provided in some embodiments of this application; Figure 3 This is a schematic diagram of the structure of the mobile mold changing device of the online mold changing system provided in some embodiments of this application; Figure 4 This is a schematic diagram of the base portion of the mobile mold changing device of the online mold changing system provided in some embodiments of this application; Figure 5 This is a top view of the mobile mold changing device of the online mold changing system provided in some embodiments of this application; Figure 6 It is along Figure 5 The sectional view obtained by section line AA in the diagram; Figure 7 This is a schematic diagram of the docking mechanism of the mobile mold changing device of the online mold changing system provided in some embodiments of this application; Figure 8 This is a schematic diagram of the docking mechanism of the mobile mold changing device of the online mold changing system provided in some embodiments of this application from another angle; Figure 9 This is a schematic diagram of the mold loading and unloading mechanism of an online mold changing system provided in some embodiments of this application; Figure 10 This is a schematic diagram of one state in the operation of the online mold changing system provided in some embodiments of this application; Figure 11 This is another schematic diagram of the online mold changing system provided in some embodiments of this application during operation; Figure 12 This is yet another schematic diagram of the online mold changing system provided in some embodiments of this application during operation; Figure 13 This is another schematic diagram of the online mold changing system provided in some embodiments of this application during operation.

[0024] Figure label: 1. Movable mold changing device; 10. Chassis; 100. Front push cylinder; 101. Roller; 102. Sliding groove; 103. Front push cylinder seat connection part; 11. Docking mechanism; 111. Guide rail; 112. Front push cylinder seat connection; 113. Docking block; 114. Docking sensor; 115. Moving bar; 116. Translation rack; 12. Mold picking and placing mechanism; 121. Fork assembly; 122. Translation device; 1221. Moving groove; 1222. Translation motor; 1223. Translation gear; 123. Lifting device; 1231. Linkage mechanism; 1232. Lifting cylinder; 124. Front position sensor; 125. Rear position sensor; 13. First mold changing machine; 14. Second mold changing machine; 2. Production line; 21. Vehicle; 3. Run the track; 31. Prepare the position sensor; 32. Wait for the position sensor; 33. Synchronize the position sensor; 4. Off-line mold processing station; 5. Transfer vehicle; 6. Safety light curtain. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this application clearer, the technical solutions of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0026] The terms "first" and "second" in the specification and claims of this application may explicitly or implicitly include one or more of the features. In the description of this application, unless otherwise stated, "multiple" means two or more. Furthermore, "and / or" in the specification and claims indicates at least one of the connected objects, and the character " / " generally indicates that the preceding and following objects are in an "or" relationship.

[0027] In the description of this application, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential", etc., indicating the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this application.

[0028] In the description of this application, it should be noted that, unless otherwise expressly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection between two components. Those skilled in the art can understand the specific meaning of the above terms in this application based on the specific circumstances.

[0029] The following is combined with Figures 1 to 13 This application describes an online mold changing system. This system is suitable for production scenarios requiring frequent mold changes, especially for mold replacement needs in automotive seat foam production lines. Its overall structural design enables efficient collaboration with production line 2, avoiding interference with main line production.

[0030] The online mold changing system includes a mobile mold changing device 1 and a synchronous control unit. Specifically: See Figure 1 and Figure 2 The mobile mold changing device 1 is set on the side of the production line 2. The side of the production line 2 is covered with a running track 3. The mobile mold changing device 1 slides with the running track 3, and its movement direction is parallel to the running direction of the production line 2. This layout will not occupy the core working space of the production line 2, and the movement accuracy of the mobile mold changing device 1 can be ensured by the guiding effect of the running track 3, laying a structural foundation for the subsequent precise cooperation with the transport vehicle 21 in the production line 2.

[0031] The synchronization control unit is the core control component for non-stop mold changing. It establishes a stable communication connection with the control system of production line 2, enabling it to acquire the position and speed information of the transport vehicle 21 within production line 2 in real time. In a specific example, the encoder line of the main line is electrically connected to the synchronization control unit, accurately transmitting the real-time operating data of the transport vehicle 21 to the synchronization control unit. Based on this data, the synchronization control unit sends control commands to the mobile mold changing device 1, driving the drive components of the mobile mold changing device 1 to adjust its own moving speed and position, ultimately achieving synchronized movement with the transport vehicle 21. This synchronization control mechanism ensures that the mobile mold changing device 1 and the transport vehicle 21 remain relatively stationary during the mold changing process, fundamentally avoiding mold transfer deviations caused by relative motion. It also provides key technical support for non-stop mold changing, effectively solving the technical pain point of traditional mold changing methods requiring line stoppage.

[0032] See Figures 3 to 9 The mobile mold changing device 1 includes a chassis 10, a docking mechanism 11, and a mold picking and placing mechanism 12, which cooperate with each other to complete the mold transfer operation.

[0033] The chassis 10 of the mobile mold-changing device 1 is the basic load-bearing and motion support component of the entire device, and its structural design directly determines the stability and accuracy of the device's movement. Rollers 101 are mounted on the bottom of the chassis 10. The grooves of the rollers 101 precisely match the surface of the running track 3, forming a low-friction sliding fit. This allows the chassis 10 to move smoothly along the running track 3, providing a reliable motion basis for switching the device between the preparation position, waiting position, and mold-changing operation position. Two parallel sliding grooves 102 are machined on the upper surface of the chassis 10. The cross-sectional shape of the sliding grooves 102 matches the guide rails 111 provided on the docking mechanism 11, providing guiding constraints for the lateral movement of the docking mechanism 11 and preventing deviation or jamming during movement. Meanwhile, the chassis 10 is also equipped with a front push cylinder seat connection part 103. This connection part adopts a bolt fixing structure. The cylinder seat of the front push cylinder 100 is integrally connected to it through fasteners. The piston rod of the front push cylinder 100 is rigidly connected to the crossbeam of the docking mechanism 11. Through the extension and retraction of the front push cylinder 100, the docking mechanism 11 can be precisely driven to move linearly relative to the chassis 10 along the sliding groove 102, providing power support for subsequent docking with the transport vehicle 21.

[0034] See Figure 6 , Figure 7 and Figure 8 The docking mechanism 11 adopts a frame structure design, combining structural strength and movement flexibility. Its bottom surface is integrally formed with a long strip guide rail 111, which forms a clearance fit with the sliding groove 102 of the chassis 10. This ensures smooth relative sliding and restricts accidental movement of the docking mechanism 11 through the two sides of the guide rail 111, improving the stability of the docking process. A crossbeam is transversely arranged in the middle of the docking mechanism 11, with a pre-reserved connecting part 112 for the front-push cylinder seat. This connecting part is hinged to the piston rod of the front-push cylinder 100 via a pin, converting the axial thrust of the cylinder into the lateral movement force of the docking mechanism 11, ensuring efficient and stable power transmission.

[0035] The docking mechanism 11 has symmetrical docking blocks 113 at both ends. The middle part of the docking block 113 has an arc-shaped concave structure, which forms a complementary locking structure with the protruding docking part on the carrier 21. This design can increase the contact area of ​​the docking surface, improve the structural stability after connection, and avoid loosening of the connection due to vibration or uneven force during mold transfer.

[0036] A docking sensor 114 is installed on the inner side of the docking block 113. The sensor adopts the contact detection principle. When the docking mechanism 11 moves towards the carrier 21 under the drive of the push cylinder 100, and the docking block 113 and the docking part of the carrier 21 are fully engaged and fitted, the docking sensor 114 is triggered and sends a docking signal to the synchronization control unit. This provides a precise timing trigger for the start of the mold pick-and-place mechanism 12, ensuring that subsequent operations are only performed after the connection is stable.

[0037] After the mold transfer is completed, the synchronous control unit issues a disengagement command. The forward cylinder 100 reverses and extends to drive the docking mechanism 11 to retract along the sliding groove 102. The docking sensor 114 detects the disengagement state and feeds back a signal. At this time, the mobile mold changing device 1 can move independently along the running track 3 to the next working position. The entire docking and disengagement process is precise and responsive, ensuring the continuity of mold changing operations.

[0038] See Figure 3 and Figure 9 The mold picking and placing mechanism 12 is the core functional component for performing mold transfer. Through the coordinated action of the fork assembly 121, the translation device 122 and the lifting device 123, it realizes the smooth transfer of the mold between the mobile mold changing device 1 and the transport vehicle 21.

[0039] The translation device 122 is responsible for adjusting the lateral position of the mold picking and placing. It has a moving groove 1221 machined on its bottom. The moving groove 1221 and the moving strip 115 on the upper surface of the docking mechanism 11 form a sliding fit. The length of the moving strip 115 covers the maximum stroke required for mold picking and placing, providing full-process guidance for translation operation and ensuring that the movement trajectory of the fork assembly 121 is accurate and controllable. Meanwhile, the translation device 122 is equipped with a translation motor 1222 and a translation gear 1223. A translation rack 116 is fixed on the upper surface of the docking mechanism 11. The output shaft of the translation motor 1222 and the translation gear 1223 are connected by a key to achieve synchronous rotation. The translation gear 1223 and the translation rack 116 mesh and drive each other. This gear and rack transmission method has the advantages of constant transmission ratio and strong load-bearing capacity. It can convert the rotational motion of the translation motor 1222 into the linear motion of the mold picking and placing mechanism 12. By controlling the forward and reverse rotation and speed of the translation motor 1222, the moving direction and speed of the fork assembly 121 can be precisely adjusted to meet the picking and placing requirements of molds of different specifications.

[0040] The structure of the fork assembly 121 is customized according to the load-bearing structure at the bottom of the mold. The spacing, thickness and length of its fork legs are precisely matched with the load-bearing holes or support beams at the bottom of the mold. It can be smoothly inserted into the load-bearing structure to form multi-point support, avoiding deformation or falling off of the mold due to concentrated force during the transfer process, and providing a reliable load-bearing foundation for the mold.

[0041] The lifting device 123 adopts a combined structure of a linkage mechanism 1231 and a lifting cylinder 1232. The linkage mechanism 1231 is composed of multiple rigid connecting rods hinged together. One end of the linkage mechanism 1231 is hinged to the bottom of the fork assembly 121, and the other end is connected to the cylinder body of the lifting cylinder 1232. The piston rod of the lifting cylinder 1232 is fixed on the frame of the translation device 122. This structural design can convert the axial extension force of the lifting cylinder 1232 into the vertical lifting motion of the fork assembly 121. Furthermore, the force transmission characteristics of the linkage mechanism 1231 make the lifting process more stable, preventing the mold from tilting or shaking.

[0042] To ensure precise coordination and stroke control of each action, the mold pick-and-place mechanism 12 is also equipped with a front position sensor 124, a rear position sensor 125, a cylinder extension position magnetic switch, and a lifting cylinder retraction magnetic switch. These detection elements are all electrically connected to the synchronization control unit to form a closed-loop control circuit. The front position sensor 124 is used to detect the position of the fork assembly 121 when it moves forward to the mold pick-and-place position, and its setting position corresponds to the position of the fork assembly 121 when it moves forward to the mold pick-and-place position. The rear position sensor 125 is used to confirm the position of the fork assembly 121 when it moves backward to the reset position, and its setting position corresponds to the position of the fork assembly 121 when it moves backward to the reset position. The cylinder extension position magnetic switch and the lifting cylinder retraction magnetic switch are used to detect the maximum extension and maximum retraction of the cylinder, and their setting positions are also opposite to the detection target positions. Through the signal feedback from these detection elements, the synchronous control unit can monitor the translation stroke and lifting height of the forklift assembly 121 in real time, and accurately control the start and stop timing of the translation motor 1222 and the lifting cylinder 1232 to avoid mold collision or equipment damage due to overtravel. This ensures that the entire mold transfer process is accurate, orderly and safe, providing key guarantees for the stability and reliability of non-stop mold changing operations.

[0043] Since the mobile mold changing device 1 and the transport vehicle 21 remain relatively stationary after docking, the working environment of the mold picking and placing mechanism 12 is more stable, providing favorable conditions for precise operation. In actual operation, if it is necessary to pick up the mold from the transport vehicle 21, the translation device 122 will drive the fork assembly 121 to move forward. After the current positioning sensor 124 detects that the fork assembly 121 is precisely inserted into the bearing structure at the bottom of the mold and triggers, the front and rear moving motors stop running. Then, the lifting device 123 starts, the lifting cylinder extends and drives the fork assembly 121 to lift through the linkage mechanism, and smoothly removes the mold from the transport vehicle 21. At this time, the cylinder extension positioning magnetic switch is triggered, and the lifting positioning signal is fed back to the synchronous control unit. After receiving the signal, the synchronous control unit sends a reverse operation command to the front and rear moving motors, driving the fork assembly 121 and the mold to move backward. When the rear positioning sensor 125 detects that the mold has been transferred to the preset bearing area of ​​the mobile mold changing device 1 and triggers, the front and rear moving motors stop. Then, the lifting cylinder begins to retract, and drives the fork assembly 121 to descend through the linkage mechanism until the lifting cylinder retraction magnetic switch is triggered, feeding back the reset positioning signal, and completing the transfer of the mold to the mobile mold changing device 1.

[0044] If a mold needs to be placed on the transport vehicle 21, the reverse process is followed: the translation device 122 drives the forklift assembly 121 carrying the mold to move forward, and the front-end position sensor 124 is triggered, stopping the front and rear movement motors to ensure that the mold is accurately aligned with the preset installation position on the transport vehicle 21; the lifting device 123 drives the forklift assembly 121 to descend, placing the mold smoothly on the transport vehicle 21, at which point the lifting cylinder retracts and the magnetic switch is triggered; subsequently, the front and rear movement motors rotate in reverse, driving the forklift assembly 121 to move backward and reset, and the rear position sensor 125 is triggered, stopping the motor. This structural design, through the coordinated operation of the forklift assembly 121, the translation device 122, and the lifting device 123, combined with the precise detection of the front and rear position sensors and various magnetic switches, can strictly control the stroke and timing of each action, reduce collisions and wear during mold transfer, effectively protect the mold's precision and service life, and improve the efficiency and reliability of mold transfer, further ensuring the continuous operation of the production line 2.

[0045] The above-mentioned components are connected and coordinated to form a complete work process. The synchronous control unit establishes an electrical connection with the control system of production line 2, the drive component of the mobile mold changing device 1, the docking mechanism 11, and the mold picking and placing mechanism 12 to realize command transmission and action coordination. The mobile mold changing device 1 forms a spatial coordination with production line 2 through the running track 3. The docking mechanism 11 and the mold picking and placing mechanism 12 operate in an orderly manner under the control of the synchronous control unit. The three work together so that the entire mold changing process does not require stopping the operation of production line 2, which effectively improves production efficiency, reduces the risk of product scrap due to line stoppage, and also improves the automation level and operational safety of mold changing.

[0046] In some embodiments, see Figure 1 and Figure 2 The mobile mold changing device 1 includes at least two independently controllable mold changing carriages, namely a first mold changing carriage 13 and a second mold changing carriage 14. The mechanical structure of the two mold changing carriages is consistent with the basic configuration of the mobile mold changing device 1, and both integrate a docking mechanism 11, a mold picking and placing mechanism 12, and an independent drive module. Both are slidably engaged with the running track 3 and can move independently in a direction parallel to the production line 2. The first mold changing carriage 13 and the second mold changing carriage 14 are both connected to a synchronous control unit. The synchronous control unit can send independent control commands to a single mold changing carriage or both mold changing carriages according to production needs, so as to achieve precise control of their respective actions. This independent control feature enables the system to flexibly adapt to different mold changing scenarios, improving the overall flexibility and adaptability of the operation.

[0047] The synchronous control unit, through preset control logic, can drive at least two mold-changing vehicles to perform various operation modes adapted to production needs. In a specific example, when production line 2 needs to quickly replace old molds with new ones, the synchronous control unit will activate the collaborative operation mode of the two mold-changing vehicles. At this time, the first mold-changing vehicle 13, carrying the pre-processed molds from outside the production line, moves to the preset waiting position under the command of the synchronous control unit; the second mold-changing vehicle 14, under the control of the synchronous control unit, moves synchronously with the transport vehicle 21 carrying the old mold to be replaced. After establishing a stable connection through the docking mechanism 11, the mold picking and placing mechanism 12 completes the picking and transfer of the old mold. After the second mold-changing vehicle 14 is disengaged from the transport vehicle 21, the synchronous control unit immediately drives the first mold-changing vehicle 13 to move synchronously with the transport vehicle 21 and complete the docking, placing the pre-processed mold smoothly on the transport vehicle 21, completing the entire replacement process of old and new molds. This dual-vehicle cooperative operation mode can achieve seamless connection between the replacement of old and new molds, significantly shortening the overall time of a single mold replacement, and further ensuring the continuous operation efficiency of production line 2.

[0048] When the transport vehicle 21 of production line 2 is idle and only needs to be replenished to meet production demands, the synchronization control unit will select the single mold-changing vehicle operation mode. At this time, the synchronization control unit can, according to system status instructions, select either the first mold-changing vehicle 13 or the second mold-changing vehicle 14 to perform the mold placement operation. This mold-changing vehicle carries the prepared mold and moves it to the waiting position. When the idle transport vehicle 21 reaches the preset synchronization position, the mold-changing vehicle and the transport vehicle 21 synchronously dock and complete the mold placement, then detach and return to the initial position. This single-vehicle mold placement mode does not require the cooperation of another mold-changing vehicle, making the operation process simpler, enabling rapid response to the mold replenishment needs of production line 2, and improving the load utilization rate of production line 2.

[0049] When a mold on the production line needs to be disassembled and recycled separately due to a malfunction or reaching its maintenance cycle, and there is no need to immediately replace it with a new mold, the synchronous control unit can also activate the single mold-changing vehicle operation mode. Under the control of the synchronous control unit, the selected mold-changing vehicle moves synchronously and docks with the transport vehicle 21 carrying the mold to be disassembled. The mold to be disassembled is removed from the transport vehicle 21 by the mold pick-and-place mechanism 12, and then detached from the transport vehicle 21, and the mold is transferred to the off-line mold-changing station for further processing. The transport vehicle 21 continues to run along the production line 2. This single-vehicle mold-removal mode can flexibly handle the need for individual mold disassembly without affecting other operations on the production line 2, and without occupying the operating resources of another mold-changing vehicle, making the system more adaptable and flexible in scenarios such as mold maintenance and fault handling.

[0050] In some embodiments, to achieve precise control of each action stage of the mobile mold changing device 1 and ensure efficient coordination between the mold changing process and the operating rhythm of the production line 2, a preparation position sensor 31, a waiting position sensor 32, and a synchronization position sensor 33 are rationally arranged along the moving path of the mobile mold changing device 1. These sensors are key components for system positioning and detection, and their installation positions are precisely planned to capture the position status of the mobile mold changing device 1 and the transport vehicle 21 in real time, providing reliable signal input to the synchronization control unit.

[0051] The ready position sensor 31 is installed in the initial standby area of ​​the mobile mold changing device 1. This area is the standby position before the mold changing operation begins and the reset position after the operation is completed. The ready position sensor 31 is electrically connected to the synchronization control unit. Its core function is to detect in real time whether the mobile mold changing device 1 is in the preset ready position. When the mobile mold changing device 1 completes the reset or initial standby, the ready position sensor 31 will trigger a corresponding signal and transmit it to the synchronization control unit. The synchronization control unit will then determine whether the mobile mold changing device 1 is ready to receive new mold changing commands, avoiding action conflicts caused by starting the operation when the device is not ready, and ensuring the stability of the system during the startup phase. In a specific example, the ready position sensor 31 can be a proximity switch, whose sensing end is adapted to the sensing block at the bottom of the mobile mold changing device 1. When the mobile mold changing device 1 accurately stops at the ready position, the sensing block aligns with the proximity switch, and the sensor immediately outputs a position signal, providing rapid response and accurate positioning.

[0052] The waiting position sensor 32 is located in the area where the mobile mold changing device 1 is ready to dock with the transport vehicle 21. It is a key node for the mobile mold changing device 1 to wait for the transport vehicle 21 to arrive. The waiting position sensor 32 is also electrically connected to the synchronization control unit. When the mobile mold changing device 1 moves to this area carrying a mold or without a load, the waiting position sensor 32 sends a position confirmation signal to the synchronization control unit. After receiving the signal, the synchronization control unit will further link with the control system of the production line 2 to monitor the running status of the transport vehicle 21 in real time, ensuring that the mobile mold changing device 1 is ready at this position until the transport vehicle 21 arrives at the preset docking area, then initiates the synchronous acceleration action and completes the docking. In a specific example, two waiting position sensors 32 can be set, respectively located at the waiting positions of the first mold changing vehicle 13 and the second mold changing vehicle 14.

[0053] The synchronous position sensor 33 is installed in a position corresponding to the mold-changing operation position of the transport vehicle 21, typically located on the side of the production line 2. Its detection range covers the critical position where the transport vehicle 21 moves to the mold-changing area. The synchronous position sensor 33 maintains a stable signal connection with the synchronous control unit. Its core function is to accurately capture the state of the transport vehicle 21 reaching the preset mold-changing position. When the transport vehicle 21 reaches this position, the synchronous position sensor 33 immediately sends a trigger signal to the synchronous control unit. After receiving this signal, the synchronous control unit, combined with the previously acquired speed information of the transport vehicle 21, issues a synchronous acceleration command to the mobile mold-changing device 1, driving the mobile mold-changing device 1 to quickly adjust its own speed until it achieves speed and position synchronization with the transport vehicle 21, creating stable conditions for the subsequent connection of the docking mechanism 11 and the operation of the mold pick-and-place mechanism 12. In a specific example, two synchronous position sensors 33 can be set, respectively located in the line corresponding to the waiting positions of the first mold-changing vehicle 13 and the second mold-changing vehicle 14, thereby detecting whether the position of the transport vehicle 21 has reached the docking position. Furthermore, it can employ photoelectric sensors, with its transmitter and receiver arranged on both sides of the production line 2. When the transport vehicle 21 passes by and blocks the light, the sensor outputs a trigger signal. This signal has low transmission delay, which can ensure the timeliness of synchronous control.

[0054] The synchronization control unit, as the core of signal processing and command issuance, establishes bidirectional signal connections with the ready position sensor 31, the waiting position sensor 32, and the synchronization position sensor 33. It not only receives position detection signals from each sensor in real time but also identifies and processes these signals, issuing corresponding action commands to the mobile mold-changing device 1 according to preset control logic. Through this collaborative operation between the sensors and the control unit, the actions of the mobile mold-changing device 1 are clearly divided into three core stages: preparation and standby, waiting for docking, and synchronous operation. The switching between each stage is based on precise sensor signals, avoiding errors that may be caused by manual intervention. This ensures that every step of the mold-changing operation is carried out in an orderly and precise manner, effectively improving the automation level and operational reliability of the entire system, while providing crucial timing control guarantees for non-stop mold changing.

[0055] In some embodiments, the synchronization control unit is designed with precise motion coordination control logic. Its core purpose is to ensure that the mobile mold changing device 1 can achieve precise speed and position synchronization with the transport vehicle 21 at the appropriate time, laying a stable foundation for subsequent mold transfer operations. The synchronization control unit maintains continuous signal interaction with the waiting position sensor 32, receiving position detection data fed back by the sensor in real time. When the waiting position sensor 32 detects that the mobile mold changing device 1 has accurately moved to the preset waiting position, it sends a clear arrival signal to the synchronization control unit. The synchronization control unit confirms that the mobile mold changing device 1 is in the pre-dock ready state by recognizing and judging the signal.

[0056] Meanwhile, the synchronization control unit continuously acquires real-time operating information of the transport vehicle 21 through a communication connection established with the control system of production line 2. This information includes, but is not limited to, key data such as the current moving speed, location, and trajectory of the transport vehicle 21. After confirming that the mobile mold changing device 1 has reached the waiting position, the synchronization control unit immediately analyzes and processes the acquired information about the transport vehicle 21, and formulates a targeted acceleration control strategy based on the current state of the mobile mold changing device 1 itself.

[0057] Subsequently, the synchronization control unit sends precise acceleration commands to the drive module of the mobile mold-changing device 1. The drive module adjusts its output power according to the commands, driving the mobile mold-changing device 1 to accelerate smoothly along the running track 3. During acceleration, the synchronization control unit continuously compares the speed and position data of the mobile mold-changing device 1 and the carrier 21, dynamically fine-tuning the acceleration parameters to ensure that the speed of the mobile mold-changing device 1 can steadily increase and gradually approach the speed of the carrier 21, ultimately achieving synchronous movement between the two.

[0058] In some embodiments, see Figure 1 and Figure 2To enable parallel operation of mold pretreatment and in-line mold changing, and to avoid the operation of mold cleaning and repair occupying the running time of production line 2, the online mold changing system provided in this application also includes an off-line mold processing station 4 set on the side of production line 2 and a transfer vehicle 5 for carrying molds. The two work together to form an off-line pretreatment and transfer unit for molds, forming a highly efficient collaboration with the in-line mold changing components, further improving the overall operating efficiency of the system.

[0059] The off-line mold processing station 4 is fixedly located in the side area of ​​production line 2. Its location is designed to facilitate mold processing operations by operators and allow the transfer vehicle 5 to quickly hand over molds without affecting the normal operation of production line 2. The off-line mold processing station 4 has functions such as mold fixing, top cover opening, and safety protection, and can provide a stable and safe working environment for pre-processing operations such as mold cleaning and repair.

[0060] The transfer cart 5 is a movable mold-carrying component. Its structural design is adapted to the mold's external dimensions and load-bearing requirements, providing stable support and fixing the mold to prevent displacement or collision during transfer. The transfer cart 5's movement path covers the mold-changing area on the side of the off-line mold processing station 4 and production line 2, allowing for flexible movement between the two to facilitate mold transfer and handover. A positioning and mating structure is provided between the transfer cart 5 and the off-line mold processing station 4. When the transfer cart 5 moves to the side of the off-line mold processing station 4, it can quickly and accurately achieve positioning through the positioning structure, facilitating operators to place pre-processed molds on the transfer cart 5 or remove molds to be processed from it. Simultaneously, the transfer cart 5 also has a positioning and mating relationship with the mobile mold-changing device 1. When the transfer cart 5 carries the mold to the mold-changing area, it can accurately stop at a position accessible to the mobile mold-changing device 1, ensuring that the mobile mold-changing device 1 can smoothly complete the mold loading and unloading operations.

[0061] The setup of the off-line mold processing station 4 and the transfer vehicle 5 allows for independent off-line pre-processing operations such as mold cleaning and repair, without occupying the core operating time of production line 2. This enables parallel processing of off-line pre-processing and on-line mold changing. The transfer vehicle 5, as the mold transfer carrier, ensures safe and efficient transfer of molds between the pre-processing station and production line 2 through its stable load-bearing capacity and flexible mobility, preventing damage during transfer. This off-line pre-processing and transfer design not only reduces the risk of production line 2 downtime but also allows for more meticulous and thorough mold pre-processing operations, ensuring mold accuracy and improving the molding quality of subsequent products. It also reduces safety risks for operators working on the production line, making the overall mold changing process layout more rational.

[0062] In some embodiments, see Figure 1 and Figure 2To further ensure the safe operation of mold changing and prevent accidents caused by personnel or foreign objects accidentally entering dangerous areas, a safety light curtain 6 is specially installed in the interaction area between the mobile mold changing device 1 and the production line 2. This interaction area is the core operating area for mold transfer between the mobile mold changing device 1 and the production line 2. During the operation, the driving action of the mobile mold changing device 1 and the lifting and translation of the mold are all completed in this area. The installation of the safety light curtain 6 can form a comprehensive safety protection barrier, filling the safety protection gap in this area.

[0063] The safety light curtain 6 employs an infrared sensing protection structure, typically comprising two corresponding components: a transmitter and a receiver. These are symmetrically installed on both sides of the interaction area, with precisely planned installation heights to ensure that the infrared light emitted by the transmitter forms a comprehensive, blind-spot-free protective light curtain, completely covering the entire working path of the mold transfer and the movement range of the moving mold-changing device 1. The safety light curtain 6 establishes a stable electrical connection with the system's control unit, forming a safety interlock control logic. Its operating status is monitored by the control unit in real time, and it can also feed back detected signals to the control unit in real time, enabling rapid response.

[0064] During normal mold-changing operations, the transmitter of safety light curtain 6 continuously emits infrared light, which is received in real time by the receiver, forming a continuous light path. At this time, the system determines that there is no safety hazard in the interaction area, and the control unit allows the mobile mold-changing device 1 and the transport vehicle of production line 3 to perform mold transfer actions according to the preset process. When an operator accidentally enters the interaction area, or when tools, foreign objects, etc., accidentally enter the protection range, they will block the infrared light of safety light curtain 6, causing the light path to be interrupted. Safety light curtain 6 will immediately send a trigger signal to the control unit. After receiving the signal, the control unit will issue an emergency stop command in a very short time, simultaneously terminating all actions of the mobile mold-changing device 1, including translation, docking, mold picking and placing, etc., and controlling the transport vehicle of production line 3 to stop running to avoid collisions and squeezing between moving equipment or molds and personnel or foreign objects, thus fundamentally preventing the occurrence of safety accidents.

[0065] This application also provides an online mold changing method, suitable for production line operations requiring frequent mold changes, especially adaptable to the mold replacement needs of automotive seat foam production lines. Its core is to achieve automated mold changing without interrupting the production line through time-sequential motion coordination, effectively solving the problems of low production efficiency and product scrap caused by line stoppages in traditional mold changing methods. This method uses the motion coordination of the mobile mold changing device and the production line transport vehicle as its core logic. Through the orderly connection of three key links, it constructs an efficient and stable mold changing process, which does not require interruption of production line operation, balancing mold changing accuracy and operational safety.

[0066] The method provided in this application specifically includes the following steps: S1. Control at least one mobile mold changing device to move synchronously with the transport vehicle on the production line; S2. During synchronous movement, a releasable connection is established between the mobile mold-changing device and the transport vehicle; S3. In the connected state, the mold is transferred between the moving mold changing device and the transport vehicle.

[0067] In some embodiments, the synchronous movement of the mobile mold changing device and the carrier in step S1 relies on the real-time communication support between the synchronization control unit and the production line control system. The synchronization control unit continuously receives real-time operating data of the carrier transmitted by the production line control system through a dedicated communication link, including key information such as instantaneous speed, current position and running trajectory. At the same time, combined with the status data fed back by the position detection module on the mobile mold changing device itself, the drive command is dynamically adjusted through a preset control algorithm to ensure that the speed difference and position deviation between the two are controlled within a preset range, thereby achieving high-precision synchronization.

[0068] In some embodiments, before step S1 is executed, the mobile mold changing device will first complete the standby at a preset preparation position. After the preparation position sensor detects that the device is in place and sends a feedback signal, the synchronization control unit will respond to the external mold changing command and drive the mobile mold changing device to move along the running track to the waiting position. After the waiting position sensor confirms that the device has accurately stopped, the synchronization control unit will start the synchronization matching process with the vehicle to avoid synchronization failure caused by the device not being ready or position deviation.

[0069] In some embodiments, the establishment of the releaseable connection in step S2 is subject to the synchronous stabilization signal in step S1 as a prerequisite. Only after the synchronous control unit confirms that the moving mold changing device and the transport vehicle have achieved continuous and stable synchronous movement through comparison of multiple sets of speed and position data will it issue a connection command to the docking mechanism to avoid structural impact caused by starting docking when the synchronization is not stable.

[0070] In some embodiments, the transfer direction of the mold in step S3 can be flexibly switched according to production needs. If the mold to be replaced on the transport vehicle needs to be disassembled to the mobile mold changing device, the transfer process is to insert the fork assembly, lift it, and move it backward. If the prepared mold on the mobile mold changing device needs to be installed on the transport vehicle, the transfer process is to move the fork assembly forward, lift it, and release it. The action logic of the two transfer directions is automatically identified and switched by the synchronous control unit according to the mold changing command.

[0071] In some embodiments, the mold transfer process in step S3 is linked to the connection status in step S2. The synchronization control unit continuously monitors the signal of the docking sensor. If a loose connection or abnormal synchronization status is detected during the transfer process, a pause command will be issued immediately, and the mold pick-and-place mechanism will stop operating. The transfer process will continue after the synchronization status is restored to stability and the connection is relocked, so as to avoid the mold falling or being damaged due to connection failure.

[0072] In some embodiments, after step S3 is completed, the synchronization control unit will first issue a disengagement command to the docking mechanism, drive the docking component to retract, and release the releasable connection between the mobile mold changing device and the carrier. After the docking sensor reports that the disengagement is in place, the mobile mold changing device will be controlled to disengage from the synchronization state and move along the running track to the preset position to avoid structural tension caused by movement when the connection is not disengaged.

[0073] In some embodiments, see Figures 10 to 13 To achieve seamless replacement of old and new molds, further shorten the mold change cycle and ensure the continuous operation of production line 2, the system adopts a mode of collaborative operation of at least two mold change vehicles. This mode, through the unified scheduling of the synchronous control unit, enables the first mold change vehicle 13 and the second mold change vehicle 14 to cooperate in an orderly manner according to the preset time sequence, and complete the entire process of old mold disassembly and new mold installation without interrupting the operation of production line 2.

[0074] For the initial stage of collaborative work, see [link / reference]. Figure 10 The synchronous control unit first issues a mold picking and shifting command to the first mold changing vehicle 13. The first mold changing vehicle 13 accurately picks up the mold to be replaced after pre-processing by the off-line mold processing station 4 through its own mold picking and placing mechanism 12.

[0075] During operation, the translation motor 1222 drives the translation gear 1223 to mesh with the translation rack 116, which in turn moves the fork assembly 121 forward. When the current position sensor 124 is triggered, the motor stops, and the fork assembly 121 is precisely inserted into the support structure at the bottom of the mold. Then, the lifting cylinder 1232 extends and drives the fork assembly 121 to be lifted through the linkage mechanism 1231. When the cylinder extends to the position, the magnetic switch provides feedback signal to ensure that the mold is smoothly removed from the transfer vehicle 5 and is securely supported, thus preventing displacement or collision during the transfer process.

[0076] Then refer to Figure 11 Under the guidance of the synchronization control unit, the first mold changing vehicle 13 and the second mold changing vehicle 14 move along the running track 3 to their respective preset waiting positions. After the waiting position sensor 32 detects that the two vehicles have stopped precisely, it sends a signal of arrival to the synchronization control unit. The first mold changing vehicle 13 and the second mold changing vehicle 14 then enter the standby state and wait for subsequent instructions.

[0077] Meanwhile, the synchronization control unit continuously receives real-time operating data of the transport vehicle 21 transmitted by the production line 2 control system. When the transport vehicle 21 carrying the mold to be replaced is about to arrive at the mold changing area, the synchronization control unit issues a synchronization command to the second mold changing vehicle 14. The second mold changing vehicle 14 starts its drive module and, based on the acquired speed and position information of the transport vehicle 21, smoothly accelerates to a state of complete synchronization with the transport vehicle 21, with both remaining relatively stationary. Subsequently, the docking mechanism 11 of the second mold changing vehicle 14 is activated. The forward-pushing cylinder 100 drives the docking mechanism 11 to move through the cooperation of its bottom guide rail 111 and the sliding groove 102 of the chassis 10, until the docking block 113 at the end precisely engages and locks with the corresponding docking part on the transport vehicle 21. After the docking sensor 114 detects that the two are completely in contact, it sends a connection in place signal back to the synchronization control unit. Immediately afterwards, the mold picking and placing mechanism 12 of the second mold changing vehicle 14 starts to operate. The translation motor 1222 drives the fork assembly 121 to move forward. After the front positioning sensor 124 is triggered, it stops. The fork assembly 121 is inserted into the bottom support structure of the mold to be replaced. The lifting cylinder 1232 extends and lifts the mold, so that the old mold is removed from the support surface of the transport tool 21. The magnetic switch of the cylinder extension position gives feedback signal. Then the translation motor 1222 rotates in reverse, driving the fork assembly 121 and the old mold to move backward. After the rear positioning sensor 125 is triggered, the motor stops. The old mold is smoothly pulled back to the support area of ​​the second mold changing vehicle 14, completing the transfer and removal of the old mold.

[0078] After the old mold is transferred, the synchronization control unit issues a disengagement command to the second mold changing vehicle 14. The forward-pushing cylinder 100 drives the docking mechanism 11 to retract, and the docking block 113 disengages from the docking part of the transport tool 21. The docking sensor 114 feeds back a disengagement signal. Afterward, under the control of the synchronization control unit, the second mold changing vehicle 14 disengages from the synchronization state with the transport tool 21 and moves along the running track 3 to the ready position. The transfer vehicle 5 moves to the side of the second mold changing vehicle 14 and is precisely positioned. The mold picking and placing mechanism 12 transfers the old mold to the transfer vehicle 5 in the reverse process, and then the transfer vehicle 5 transfers it to the off-line mold processing station 4 for cleaning, repair or storage. Meanwhile, the transport tool 21 continues to operate normally along the production line 2, reserving sufficient working space and time for the installation of the new mold.

[0079] See Figure 12 and Figure 13When the transport vehicle 21 reaches the preset new mold installation area, the synchronization control unit sends a synchronization command to the first mold-changing vehicle 13, which is in a standby state. The first mold-changing vehicle 13 immediately starts its drive module and adjusts its speed and position according to the real-time operating data of the transport vehicle 21 to quickly achieve synchronized movement with the transport vehicle 21. Subsequently, the docking mechanism 11 of the first mold-changing vehicle 13 is activated, and the forward-pushing cylinder 100 drives the docking block 113 to engage and lock with the transport vehicle 21. After the docking sensor 114 confirms that the connection is stable, the mold loading and unloading mechanism 12 begins to perform the mold loading action. The translation motor 1222 drives the forklift assembly 121 carrying the pre-prepared mold to move forward. The forward positioning sensor 124 triggers and stops the movement, ensuring the mold is precisely aligned with the preset installation position on the transport vehicle 21. The lifting cylinder 1232 slowly retracts, lowering the forklift assembly 121 and the mold. The mold is then smoothly placed on the transport vehicle 21, and the lifting cylinder retraction magnetic switch provides feedback. Subsequently, the translation motor 1222 reverses its rotation, driving the forklift assembly 121 to move backward and reset. The rear positioning sensor 125 triggers and the motor stops. Finally, the docking mechanism 11 of the first mold-changing vehicle 13 disengages, and it returns to its ready position along the running track 3, awaiting the next collaborative operation instruction.

[0080] Throughout the entire collaborative operation, the synchronous control unit serves as the core scheduling hub, coordinating the timing of the actions of the first mold-changing vehicle 13, the second mold-changing vehicle 14, and the transport vehicle 21 in real time. Sensors and magnetic switches provide real-time feedback on position, connection, and operational status, ensuring tight coordination and precise execution of each step. This dual-vehicle collaborative mode achieves seamless integration of old mold disassembly and new mold installation. The mold-changing process runs completely in parallel with the operation of production line 2, significantly reducing the overall time required for a single mold change, effectively improving production efficiency, and avoiding product scrap due to line stoppages for mold changes, further guaranteeing product yield.

[0081] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.

Claims

1. An online mold changing system, characterized in that, include: A movable mold changing device is located on the side of the production line and can move in a direction parallel to the production line. A synchronization control unit is communicatively connected to the production line control system to obtain real-time position and speed information of the transport vehicle within the production line. The synchronization control unit is configured to control the moving mold changing device to move synchronously with the transport vehicle. The mobile mold changing device is equipped with a docking mechanism and a mold picking and placing mechanism; The docking mechanism is configured to form a releasable connection with the vehicle during synchronous movement; The mold loading and unloading mechanism is configured to perform the transfer of the mold between the mobile mold changing device and the transport vehicle when the docking mechanism is connected to the transport vehicle.

2. The system according to claim 1, characterized in that, The system includes at least two mobile mold-changing devices, and the synchronization control unit is configured to control the at least two mobile mold-changing devices to perform any of the following operating modes: Two movable mold changing devices work together to perform the operations of removing molds from the production line and placing molds into the production line, respectively. Any mobile mold changing device places a mold onto an empty transport vehicle on the production line; Any mobile mold-changing device removes the mold from the transport vehicle on the production line.

3. The system according to claim 1, characterized in that, Along the moving path of the mobile mold changing device, there are preparation position sensors, waiting position sensors, and synchronization position sensors corresponding to the position of the transport vehicle; The synchronization control unit is connected to the preparation position sensor, the waiting position sensor, and the synchronization position sensor respectively, so as to control the operation phase of the moving mold changing device according to the sensor signals.

4. The system according to claim 3, characterized in that, The synchronization control unit is configured to: When the signal from the waiting position sensor indicates that the mobile mold-changing device has moved to the waiting position, the device is controlled to accelerate to synchronize with the vehicle based on the acquired vehicle information.

5. The system according to claim 1, characterized in that, The mobile mold changing device includes a chassis; the bottom of the chassis is provided with rollers for moving along the running track on the side of the production line; the chassis is provided with a sliding groove.

6. The system according to claim 5, characterized in that, The bottom of the docking mechanism is provided with a guide rail, which cooperates with the sliding groove on the chassis, so that the docking mechanism can slide relative to the chassis in a direction perpendicular to the production line.

7. The system according to claim 6, characterized in that, The docking mechanism has docking blocks at both ends, which are used to engage with corresponding structures on the vehicle to form the releasable connection.

8. The system according to claim 6, characterized in that, The docking mechanism further includes a forward-pushing cylinder; the cylinder body of the forward-pushing cylinder is connected to the chassis, and its piston rod is connected to the docking mechanism for driving the docking mechanism to slide relative to the chassis in a direction perpendicular to the production line.

9. The system according to claim 1, characterized in that, The docking mechanism is equipped with a docking sensor for detecting the establishment status of the releasable connection.

10. The system according to claim 1, characterized in that, The mold loading and unloading mechanism includes: Forklift assembly, used to insert into the support structure at the bottom of the mold; A translation device, connected to the fork assembly, is used to drive the fork assembly to move in a direction perpendicular to the production line, so as to push the mold in or pull it out. A lifting device, connected to the fork assembly, is used to drive the fork assembly to lift and lower, so as to pick up or release the mold.

11. The system according to claim 1, characterized in that, It also includes an off-line mold processing station located on the side of the production line and a transfer vehicle for carrying molds, the transfer vehicle being able to transfer molds between the off-line mold processing station and the production line.

12. The system according to any one of claims 1-11, characterized in that, A safety light curtain is installed in the interaction area between the mobile mold changing device and the production line.

13. An online mold changing method, characterized in that, Including the following steps: Control at least one mobile mold changing device to move synchronously with the transport vehicle on the production line; During synchronous movement, a releasable connection is established between the mobile mold-changing device and the transport vehicle; In the connected state, the mold is transferred between the mobile mold changing device and the transport vehicle.

14. The method according to claim 13, characterized in that, Controlling at least two mold-changing vehicles to work together to change molds includes the following steps: Control the first mold-changing cart to carry the mold to be replaced and move it to the waiting position; The second mold-changing vehicle is controlled to move synchronously with the transport vehicle carrying the mold to be replaced, connect and transfer the mold to be replaced; Control the second mold-changing vehicle to detach from the transport vehicle; The first mold-changing vehicle is controlled to move synchronously and connect with the transport vehicle, and the mold to be replaced is transferred to the transport vehicle.

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