Dynamically Adjustable Mold Vibration for Height and Density Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing concrete product forming machines face issues with fixed amplitude vibration causing damaging impacts and vibrations, especially when dealing with tall or cored products with stringent height tolerances, requiring large power spikes and longer cycle times.
Innovation Solution
A vibration system with independently controlled first and second drives and eccentrically coupled vibrator rods, allowing for variable amplitude and frequency adjustments through cams and living hinges, enabling independent control of vibration amplitude and frequency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If fixed amplitude vibration is used, then the vibration system is simple, but it causes damaging impacts and vibrations when mold weights are high or product thicknesses are low
Solution Approach 1:
The vibration system transitions from fixed amplitude to variable amplitude vibration through the use of eccentric cam mechanisms that dynamically adjust the vibration characteristics. The cam profile is designed to provide maximum vibration amplitude during filling operations and reduced amplitude during compression operations, preventing damaging impacts while maintaining effective vibration throughout the molding cycle.
Solution Approach 2:
The system changes the vibration amplitude parameter dynamically during operation. By using eccentric cams with specific radial distances from the rotation axis, the system varies the vibration amplitude based on the operational phase (filling vs. compression), allowing the same mechanical system to provide different vibration intensities at different times without requiring multiple separate vibration systems.
2Object-affected harmful factors
If known variable amplitude vibration systems are used, then damaging impacts are reduced, but they require large power spikes during operation
Solution Approach 1:
The vibration system uses periodic cam mechanisms that rhythmically vary the vibration amplitude in sync with the molding cycle. The eccentric cam rotates at a constant speed, providing smooth periodic variation in vibration amplitude without sudden spikes. This periodic action ensures that power consumption remains relatively constant while still achieving variable amplitude vibration effects.
3Object-affected harmful factors
If known variable amplitude vibration systems are used, then vibration control is improved, but cycle times are longer
Solution Approach 1:
The cam mechanism is pre-configured with the optimal vibration profile for the entire molding cycle. The eccentric cam profile is designed to provide maximum vibration amplitude during the filling phase before compression begins, eliminating the need for lengthy acceleration phases. This preliminary setup of vibration characteristics allows the system to maintain optimal vibration levels throughout the cycle without extending operation time.
4Ease of operation
If fixed amplitude vibration is used, then the system is simple to operate, but it cannot handle different product requirements with varying height tolerances
Solution Approach 1:
The vibration system becomes dynamically adaptable to different product requirements through the eccentric cam mechanism. By changing the cam profile or the radial distance of the eccentric point, the system can be quickly adjusted to provide different vibration amplitudes suitable for various product types and height tolerances. This dynamic adjustability maintains operational simplicity while significantly enhancing versatility.
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
Achieves consistent height and density control of molded products, reduces energy spikes, and enhances versatility by allowing for unique combinations of amplitudes and frequencies, thereby improving the forming process.
Implementation Method 1
first and second, vertically extending vibrator rods eccentrically coupled at lower ends to respective first and second drives and at upper ends to the yoke
Data Source
AI summary
In a method and apparatus for vibrating a mold box of a type having a plurality of mold cavities sized and shaped to yield a predesignated molded product, the system comprises mounting the mold box to a frame within the expanse of a product forming machine and moving left and right sides of a yoke upward and downward independently through phases of a vibration sequence. The vibration sequence for each has a maximum and minimum lifting height such that the left and right sides of the yoke tilt with respect to one another dependent upon the vibration sequence. A central vibration rod couples between a central portion of the yoke and the frame so that the frame is vibrated at an approximate average between the upward and downward movement of the left and right sides of the yoke. Vibration frequency, amplitude, and phase difference can be adjusted to affect the vibration profile of the central vibration rod.