Corrugator Mold Block Exchange via Segmented Return Tracks
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Solution Overview
Problem
Existing corrugators for producing tubular plastic products face challenges in efficient mold block exchange and sequence management, leading to increased setup efforts and potential production interruptions, especially when manufacturing small quantities or varying product geometries.
Innovation Solution
The proposed corrugator design incorporates multiple return tracks and a control system with RFID markings, allowing for continuous mold block movement and exchange without stopping the extrusion system, enabling seamless changes in mold block sequences and product geometry without interrupting production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If mold blocks are exchanged using conventional single return track designs, then the exchange process requires stopping the extrusion system, but this leads to production interruptions and increased setup time
Solution Approach 1:
The return track is divided into multiple parallel segments (first return track and second return track) that operate independently. This segmentation allows mold blocks to be exchanged on one track while other tracks continue transporting mold blocks, enabling exchange operations without stopping the entire extrusion system and maintaining production continuity.
2Ease of manufacture
If conventional mold block exchange methods are used, then setup efforts are increased, but this results in longer changeover time and reduced flexibility
Solution Approach 1:
Multiple return tracks are prepared in advance and can hold different sequences of mold blocks. When a product changeover is needed, the system can switch to a pre-prepared track configuration rather than exchanging mold blocks one by one during production, significantly reducing changeover time and setup efforts.
3Productivity
If mold blocks are exchanged without interrupting production, then productivity is maintained, but this requires complex multiple return track systems
Solution Approach 1:
The multiple return tracks act as intermediary storage and transport paths between the mold block storage area and the extrusion head. These intermediary tracks allow the system to buffer and resequence mold blocks without interrupting the main production flow, enabling continuous operation while managing the complexity through modular track design.
Data Source
Figure 1
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Figure 3~5
AI summary
A corrugator (4) for an extrusion system (1) for shaping a tubular plastic product (2), having a multiplicity of mould blocks (6, 9, 11), a guide track (13), along which the mould blocks (6, 9, 11) are guided in each case in pairs during the operation of the corrugator (4) from a starting region (14) of the guide track (13) towards an outlet region (15) of the guide track (13), a first return track (20, 21), along which the mould blocks (6, 9, 11) are guided during the operation of the corrugator (4) from the outlet region (15) towards the starting region (14), and a second return track (22, 23), with the aid of which individual mould blocks (6, 9, 11) can be removed from the first return track (20, 21) and/or can be inserted into the latter during the operation of the corrugator (4).