Autonomous Mold Trolley Routing for Flexible Polyurethane Production

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Solution Overview

Problem

Existing manufacturing systems for molded polymer products, such as polyurethane products, face inefficiencies due to the requirement of large spaces, high initial investments, lack of flexibility in mold replacement and scaling production, and disruption during mold switching.

Innovation Solution

A method and system utilizing autonomous mobile platforms (AMPs) to move and engage with trolleys carrying molds, allowing for the assembly of self-propelled trolleys that can be moved between production and curing stations, enabling flexible production management and efficient mold replacement.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a fixed carousel system with interconnected trolleys is used, then production continuity is maintained, but manufacturing space requirements increase significantly

Engineering Contradiction:

Improveproduction continuityVSAvoidmanufacturing space

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The system divides the manufacturing process into separate functional zones (curing stations, production stations, non-production stations) that are spatially distributed. Trolleys move independently between these zones rather than following a fixed continuous carousel path, allowing compact arrangement of stations while maintaining production flow.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system transitions from a static fixed carousel to a dynamic flexible routing system where AMPs autonomously navigate and transport trolleys between stations based on real-time production needs, enabling space optimization through adaptive path planning rather than rigid fixed infrastructure.

Inventive Principle:

Principle #15Dynamics

2Ease of manufacture

If a fixed carousel system is implemented, then initial setup is complete, but flexibility in mold replacement and switching is lost

Engineering Contradiction:

Improveinitial setup completionVSAvoidmold replacement flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The system enables dynamic reconfiguration where molds can be replaced at any station by detaching from a trolley, and AMPs can be reassigned to different trolleys based on current production requirements, providing continuous adaptability rather than fixed predetermined sequences.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The AMP acts as an intermediary between the fixed infrastructure (stations) and the movable molds on trolleys, enabling flexible mold replacement and reassignment without requiring changes to the underlying station infrastructure or fixed production sequences.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If a long fixed carousel system is used, then production capacity is maximized, but scaling up or down becomes difficult

Engineering Contradiction:

Improveproduction capacityVSAvoidproduction scaling flexibility

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The manufacturing system is segmented into independent functional stations that can be selectively activated. AMPs can be dynamically allocated to serve different numbers and combinations of stations based on current production capacity requirements, enabling easy scaling without reconfiguring a fixed carousel infrastructure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

AMPs serve multiple functions by being able to transport any trolley to any station based on production needs. This universal capability allows the same AMP fleet to support varying production capacities by adjusting the number and arrangement of active stations rather than requiring physical expansion or contraction of fixed infrastructure.

Inventive Principle:

Principle #6Universality (Multi-functionality)

4Productivity

If molds are fixedly mounted on interconnected trolleys, then production flow is maintained, but disruption occurs during mold replacement

Engineering Contradiction:

Improveproduction flowVSAvoidproduction stability during mold replacement

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The AMP serves as a mediator that can detach from a trolley during mold replacement operations and reattach to another trolley, maintaining continuous production flow while allowing mold changes on one trolley without disrupting other trolleys in the system.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system segments the production flow into independent trolley-AMP units that can be managed separately. When mold replacement is needed on one trolley, only that specific unit is temporarily affected while other AMP-trolley units continue production uninterrupted, maintaining overall system stability.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS12337507B2Method and system for managing production of molded polyurethane products

Publication Date: 2025.06.24 RIM POLYMERS INDS PTE

AI summary

The disclosure relates to method and system for managing production of molded polymer or polyurethane products. In the various embodiments, a plurality of autonomous mobile platforms (AMPs) are interchangeably engageable with mold-carrying trolleys to provide self-propelled trolleys. Each self-propelled trolley is advanced through production station(s) and curing station to complete a production cycle. Between production cycles, the trolley may be diverted away for non-production task, e.g. mold replacement, without delaying subsequent or other trolleys. During curing, an AMP may be disengaged from a trolley and redeployed to other trolleys.