Carousel Production Line for Molded Columns

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Solution Overview

Problem

The conventional centrifugal molding process for manufacturing molded columns is labor-intensive and space-consuming, leading to increased costs in commercial production, and existing methods struggle with efficiently extracting molded columns from single-piece molds without damaging the column or the mold.

Innovation Solution

A production line incorporating a carousel of molding machines with a circular conveyor and extraction equipment using air pressure to axially extract molded columns from single-piece molds, which are designed with flexible sidewalls and an expandable plug to facilitate safe removal without marring the column or damaging the mold.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional centrifugal molding process is used, then molded columns can be produced, but labor and space requirements increase leading to higher manufacturing costs

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidproduction line complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into an integrated production line system where the carousel structure simultaneously serves as both the conveying mechanism and the molding machine support, merging material handling, molding, and extraction functions into a unified automated system that reduces overall complexity

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The carousel platform serves multiple purposes: it conveys molding machines, supports the molding process, and facilitates extraction of finished columns. This multi-functional design eliminates the need for separate conveying systems and extraction equipment, reducing space and labor requirements

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If two-part mold is used for centrifugal molding, then molding can be performed, but seam lines are created requiring additional sanding operations

Engineering Contradiction:

Improvemolding process simplicityVSAvoidsurface quality

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The mold is divided into two separate parts (first and second molds) that can be independently removed after molding. This segmentation allows each mold half to be extracted separately without creating seam lines, as the columns are formed against a single continuous surface rather than a joint between mold halves

Inventive Principle:

Principle #1Segmentation

3Reliability

If single-piece mold with flexible sidewalls is used, then column extraction without damage is achieved, but mold design complexity increases

Engineering Contradiction:

Improveextraction safetyVSAvoidmold structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The mold incorporates flexible sidewalls made of elastomeric material that can deform during the extraction process. This flexibility allows the mold to expand or contract slightly, enabling the molded column to be removed without damaging either the column or the mold, while maintaining a relatively simple overall mold structure

Inventive Principle:

Principle #30Flexible shells and thin films

4Ease of operation

If manual extraction method is used, then columns can be removed from molds, but labor intensity and risk of damage increase

Engineering Contradiction:

Improveextraction easeVSAvoiddamage risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent replaces manual mechanical extraction with an automated extraction system that uses controlled mechanical forces. The extraction equipment automatically positions, grips, and removes columns from molds with precise force control, eliminating the need for manual labor and reducing the risk of damage from human error or excessive force

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach reduces labor and space requirements, enhances efficiency in column manufacturing, and allows for the production of columns with complex features like rings and sculptural reliefs without surface damage, thereby lowering production costs and improving output.

Implementation Method 1

The molding machines are actuated to rotate the molds as the molding machines are being conveyed from the pouring station to the unloading station

Methodology Applied

Scientific EffectCentrifugal force: Centrifugal Force

Implementation Method 2

extraction equipment using air pressure to axially extract molded columns from single-piece molds

Methodology Applied

Scientific EffectAir pressure: Pressure Increase

Data Source

PatentUS10377063B1Production line for manufacturing molded columns

Publication Date: 2019.08.13 DIGGER SPECIALTIES

AI summary

A production line for manufacturing molded columns comprises a plurality of molding machines, a carousel to convey the molding machines along a closed path, a pouring station disposed adjacent the closed path, and an unloading station disposed adjacent the closed path generally opposite the pouring station. A molding material is poured into molds in the molding machines as the molding machines are conveyed past the pouring station. The molding machines are actuated as the molding machines are being conveyed from the pouring station to the unloading station. At the unloading station, the molding machines are stopped and the molds are unloaded from the molding machines. The unloading station may include extraction equipment to extract the molded columns from the molds.