Ceramic Mould Clamping via Single Axis Sliding
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Solution Overview
Problem
Existing machines for producing ceramic sanitaryware are cumbersome, structurally heavy, and costly, with low productivity that fails to meet factory requirements, and lack modular and space-saving designs.
Innovation Solution
A machine with a four-part mould that allows easy changeability and maintains other operating parts in a fixed position, using a single movement axis for clamping and containing units, and inflatable elements to oppose casting forces, along with a robotized unit for demoulding and mould changing, reducing overall costs and complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional single-mould machines use multiple movement cylinders for each mould part, then the machine can withstand casting forces, but the structure becomes extremely heavy and cumbersome
Solution Approach 1:
The machine structure is segmented into a fixed base and movable clamping units that can be independently positioned. The clamping units are separated from the main machine body, allowing only the necessary components to move during operation, thereby reducing overall structural weight while maintaining strength where needed.
Solution Approach 2:
The clamping units are designed to perform multiple functions: they clamp the mould parts, provide movement along the single axis, and serve as supporting structures. This multi-functionality eliminates the need for separate heavy structural components, reducing machine weight while maintaining structural integrity during casting.
2Manufacturing precision
If traditional machines use multiple movement cylinders and heavy frames for each mould part, then clamping precision is maintained, but device complexity and installation cost increase
Solution Approach 1:
Multiple functions previously performed by separate components (clamping, movement, positioning) are merged into integrated clamping units. Each unit combines the clamping mechanism with movement capability along the single axis, reducing the total number of components and simplifying the overall system while maintaining precision.
Solution Approach 2:
The complex hydraulic systems and multiple movement cylinders are extracted and replaced with a simplified single-axis movement system. The clamping units are designed to move along a predetermined axis without requiring complex hydraulic control, thereby reducing device complexity while maintaining clamping precision through the fixed guide rails and controlled movement mechanism.
3Reliability
If traditional single-mould machines are designed with fixed machine frames and multiple clamping units, then operational reliability is maintained, but productivity is insufficient for factory requirements
Solution Approach 1:
The machine transitions from a static fixed-frame design to a dynamic system where clamping units can move along a single axis. This dynamic capability allows for faster mould opening and closing cycles, enabling higher productivity while maintaining reliability through controlled movement and precise positioning mechanisms.
Solution Approach 2:
The clamping units are pre-positioned and guided along fixed rails, allowing for rapid and repeatable mould operations. The preliminary setup of the single-axis movement system enables consistent, high-speed cycling without compromising the reliability that would result from complex real-time adjustments.
4Stability of the object's composition
If traditional machines use cumbersome heavy structures to withstand casting forces, then structural stability is ensured, but the machine occupies excessive space and installation cost increases
Solution Approach 1:
The structure is segmented into a compact fixed base and movable clamping units. Only the essential supporting structure remains fixed, while clamping functions are performed by movable units. This segmentation allows the machine to maintain structural stability during casting while occupying minimal space, as the heavy stable base is minimized to only what is necessary for force resistance.
Solution Approach 2:
The clamping units are designed to nest within or alongside the fixed base structure when not in use. The movable components can be retracted or positioned compactly, allowing the machine to have a small footprint during idle periods while maintaining full structural stability during operation. This nesting arrangement reduces the overall space requirement without compromising casting stability.
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
The machine is simpler, lighter, and more cost-effective, with increased productivity and automation, enabling modular and space-efficient installations with reduced need for costly hydraulic units, allowing for faster and more efficient ceramic product production.
Implementation Method 1
at least one inflatable element (7) for opposing the forces acting on the parts (2, 3, 4, 5) of the mould S during a step of casting, made as a single part
Data Source
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AI summary
A machine (1) for the production of ceramic products (M) comprises at least: a mould (S) made up of at least four parts (2, 3, 4, 5) adapted to form, in a closed configuration, a cavity (C) for casting the ceramic product (M); means (6, 7) for clamping and containing the mould (S) acting on the mould (S) in the closed configuration; the means (6, 7) having a tubular shaped, open-ended body, matchingly shaped to be coupled to the mould (S) to enable the mould (S) to be enclosed on four closing surfaces or outsides of it; and movement means (8) acting between the clamping and containing means (6, 7) and the mould (S) to enable the clamping and containing means (6, 7) themselves and the mould (S) in the closed configuration to slide relative to each other along a single, horizontal movement axis (X) between a first, non-operating position, where the mould (S) and the clamping and containing means (6, 7) are apart, and a second, operating position, where the mould (S) and the clamping and containing means (6, 7) are matchingly coupled inside one another.