Automated Concrete Mould Release via Servo Flexing
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Solution Overview
Problem
Manual extraction of cast concrete products from flexible and deformable moulds is labor-intensive, time-consuming, and can cause product damage, with existing machines often requiring calibration and being limited to specific mould shapes and sizes.
Innovation Solution
An automated system using conveyor belts and rotating brushes to separate products from moulds, allowing for quick, cost-effective, and safe extraction of products with adaptable functionality for various mould sizes and shapes, without the need for manual labor or rigid mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual extraction procedures are used, then flexibility in handling different mould sizes is maintained, but labor costs and time consumption increase significantly
Solution Approach 1:
The system changes the key parameter from manual force application to controlled mechanical flexing parameters (amplitude, frequency, duration). The microprocessor controls the servomotor to apply precise flexing movements that adapt to different mould sizes while maintaining high extraction speed through automated sequencing
Solution Approach 2:
The patent replaces the manual mechanical extraction system with an automated mechanical system consisting of a servomotor, microprocessor control, and programmable sequence. This substitution eliminates labor-intensive operations while maintaining adaptability through software control rather than physical adjustment
2Productivity
If rigid mechanisms are used to force mould flexing, then extraction speed increases, but the rubber material may be overstressed and damaged
Solution Approach 1:
The system transitions from static rigid mechanisms to dynamic controlled flexing. The servomotor provides controlled motion with adjustable parameters (amplitude, frequency, duration) that adapt to the specific mould and product characteristics, preventing overstress while maintaining extraction speed through optimized motion sequences
Solution Approach 2:
The microprocessor-controlled system incorporates feedback mechanisms to monitor the flexing process and adjust parameters in real-time. This ensures the rubber material is flexed within safe limits while achieving complete product extraction, preventing material damage through continuous process optimization
3Extent of automation
If existing mould-release machines are used, then automation is achieved, but they are limited to specific mould shapes and sizes requiring calibration
Solution Approach 1:
The system achieves universality through a programmable microprocessor that can store and execute multiple extraction sequences for different mould types and sizes. The single machine can handle various concrete products (pavers, tiles, curbs, gutters) by loading appropriate programs, eliminating the need for physical recalibration or dedicated machines for each product type
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
Enables efficient, automatic, and safe mould-release of cast concrete products with their shaped surface facing upwards, reducing labor costs and minimizing product damage, while accommodating diverse mould dimensions and geometries.
Implementation Method 1
a mould-release machine (22) which consists of a plurality of apparatuses, typically consisting of movable and rotating brushes, configured to separate each product from the respective mould
Data Source
Figure 1
Figure 2A~2C
Figure 3A~3B
AI summary
A system for the automatic release of cast concrete products from flexible and deformable moulds is described. The system comprises an apparatus configured to supply the moulds and carry out the pre-mould-release of the products contained within such moulds. The apparatus comprises a first conveyor belt associated with a first pre-mould-release group and a second conveyor belt associated with a second pre-mould-release group, in which the second conveyor belt is placed downstream of the first conveyor belt and in which both pre-mould-release groups are configured to facilitate the subsequent mould-release of the products. The system further comprises a mould-release machine arranged downstream with respect to both the first conveyor belt and with respect to the second conveyor belt. The mould-release machine comprises a mould-release group, configured to carry out the extraction of the products from the respective moulds, and a plurality of conveyor belts, configured to move the moulds and the products inside the mould-release machine. The mould-release group is provided with a plurality of mould-release means configured to carry out the detachment of each product from the respective mould by means of a forced flexion of such a mould.