Dual Pipe Manufacturing Cell for Corrugated Pipe Production
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Solution Overview
Problem
Manufacturing cells for large diameter corrugated pipes occupy significant space in production facilities, leading to inefficient use of floor space and poor utilization due to inconsistent demand for larger pipes.
Innovation Solution
A dual pipe manufacturing cell system that allows simultaneous production of two corrugated pipes, utilizing a configuration with multiple extruders, flow dividers, and adjustable mold blocks to efficiently utilize space by converting from single large pipe production to dual medium pipe production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single manufacturing cell produces large diameter pipes, then the pipe size capability is improved, but the space utilization and productivity deteriorate due to idle time and large footprint
Solution Approach 1:
The manufacturing cell is segmented to produce multiple smaller pipes simultaneously rather than one large pipe at a time. The extrusion system divides material flow to multiple die heads, and the molding system uses multiple mold blocks arranged in parallel, enabling concurrent production of multiple medium diameter pipes to improve space utilization and productivity
Solution Approach 2:
The manufacturing cell is designed with universal components that can handle both large and medium diameter pipes. The extrusion system with flow dividers and the molding system with adjustable mold blocks provide multi-functionality, allowing the same equipment to produce different pipe sizes based on demand, thus improving adaptability while maintaining productivity
2Productivity
If manufacturing cell equipment is increased to meet peak demand, then the productivity is improved, but the cost and floor space requirements increase significantly
Solution Approach 1:
Multiple production functions are merged into a single manufacturing cell. The system combines multiple extrusion streams and multiple molding stations in one integrated cell, enabling concurrent production of multiple pipes. This merging allows the facility to meet peak demand without adding separate manufacturing cells, thus avoiding increased floor space requirements and costs
3Productivity
If multiple extruders and mold blocks are used for dual pipe production, then the productivity is improved, but the device complexity increases
Solution Approach 1:
The system incorporates dynamic flow division mechanisms that can adjust material distribution between multiple die heads. Flow dividers and adjustable mold blocks provide dynamic adaptability, allowing the system to optimize material flow and production parameters for different pipe sizes and production rates, managing complexity through controlled flexibility rather than rigid fixed configurations
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
Enhances space utilization in manufacturing facilities by allowing flexible production of both large and medium diameter pipes, optimizing floor space and reducing idle time of larger manufacturing cells.
Implementation Method 1
a first extruder configured to provide a first flow of pipe material to a first pipe die head and a second extruder configured to provide a second flow of pipe material to a second pipe die head
Implementation Method 2
The die may include one or more channels configured to evenly distribute the polymer to the inner surfaces of a series of corrugated mold blocks within a pipe corrugator. The corrugator may form the polymer into a corrugated pipe shape
Implementation Method 3
cool it into a hardened structure via internal or external cooling channels
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
A corrugated pipe manufacturing cell is configured to produce multiple corrugated pipes in parallel. The manufacturing cell may comprise an extrusion system that is capable of providing multiple independently regulated flows of plastic piping material to multiple die heads. The multiple die heads may feed a set of mold blocks having dual cavities for forming he multiple corrugated pipes. The pipe manufacturing cell may be converted between a first mode for producing large diameter single corrugated pipes, and a second mode for producing smaller diameter, plural corrugated pipes.