Corrugator Mold Block Exchange on Return Tracks Without Downtime
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Solution Overview
Problem
Existing corrugator systems require downtime for mold block exchange when changing pipe profiles, leading to increased down-time and reduced productivity.
Innovation Solution
A system and method for exchanging mold blocks in a corrugator while it is in operation, allowing replacement mold blocks to be urged into position while the mold block chain is in motion, using staging platforms and push arms to displace existing blocks on the return tracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mold blocks are exchanged while the corrugator is in operation, then productivity is improved and downtime is reduced, but device complexity increases due to the need for staging platforms and push arms
Solution Approach 1:
The mold block exchange system is segmented into separate functional components: staging platforms for holding replacement blocks, push arms for displacement, and return tracks for block circulation. This segmentation allows each component to perform its specific function independently, enabling continuous operation while maintaining manageable complexity.
Solution Approach 2:
Replacement mold blocks are staged in advance on staging platforms positioned along the return track before they are needed. This preliminary positioning allows the exchange to occur smoothly when the blocks are needed, eliminating downtime while the system complexity is distributed across multiple pre-positioned components.
2Loss of time
If mold blocks are exchanged while the mold block chain is in motion, then loss of time is reduced, but the difficulty of operation increases due to the need to coordinate replacement with moving blocks
Solution Approach 1:
The system is designed to operate dynamically with the moving mold block chain. The staging platforms and push arms are positioned to interface with blocks during their motion on the return track, and the push arms apply force in the direction of motion to facilitate seamless displacement without requiring the chain to stop.
Solution Approach 2:
The push arm acts as an intermediary mechanism between the stationary staging platform and the moving mold block. It transfers the replacement block from the platform to the moving chain, mediating the interaction between stationary and moving components to simplify the exchange operation.
3Device complexity
If traditional mold block exchange is performed by stopping the corrugator, then device complexity is minimized, but productivity is reduced due to increased downtime
Solution Approach 1:
The mold block exchange occurs continuously during the return track operation without interrupting the corrugator's production cycle. The staging platforms and push arms enable block replacement to occur as part of the continuous motion, eliminating idle time and maintaining continuous useful action throughout the system.
Data Source
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AI summary
A system and method for replacing or substituting mold blocks in a corrugator, the corrugator comprising first and second tracks for carrying respective chains of mold blocks, each of the tracks comprising return tracks, wherein the system advances replacement mold blocks towards the return tracks to displace corresponding mold blocks in the mold block chains while the corrugator is in production and while the mold block chains are in motion.