Automated Elastomer Stopper Manufacturing with Double-Cutting Matrix
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Solution Overview
Problem
Current manufacturing processes for elastomer stoppers are not fully automated, requiring manual loading and unloading of elastomer plates, leading to low production efficiency and increased manufacturing time.
Innovation Solution
An automated device featuring a double-cutting matrix on a movable table with a cutting head and a rotating arm for scrap removal, allowing for synchronized movement through multiple work areas to increase production and reduce time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual loading and unloading of elastomer plates is used, then device complexity is reduced, but productivity decreases
Solution Approach 1:
The device is divided into distinct functional modules: a loading station for manual plate placement, a cutting station with multiple punches, and a scraping station with rotating arms. The matrix is segmented into multiple cavities that can be independently filled and cut, allowing parallel processing of multiple stoppers simultaneously, thereby increasing productivity without requiring complete automation of the entire system.
Solution Approach 2:
The scraping arms are designed to automatically remove excess elastomer material from the matrix cavities after cutting, without requiring manual intervention. This self-service mechanism clears the workspace for the next loading cycle, improving productivity while maintaining relatively simple device architecture by automating only the necessary cleanup function.
2Loss of time
If manual removal of scraps and residue is used, then device complexity is reduced, but loss of time increases
Solution Approach 1:
The scraping arms rotate continuously or in sequence to clear excess material from all matrix cavities immediately after cutting. This continuous action eliminates idle time between cutting cycles by preparing the matrix for the next loading operation without interruption, thereby reducing total manufacturing time while using a relatively simple rotating mechanism rather than complex automated systems.
Solution Approach 2:
The scraping operation is performed immediately after cutting while the material is still in position, preparing the matrix cavity for the next elastomer plate loading. This preliminary preparation eliminates the need for separate cleaning steps and reduces waiting time between production cycles, achieving time reduction with minimal additional device complexity.
3Productivity
If single-cutting matrix is used, then device complexity is reduced, but productivity decreases
Solution Approach 1:
The matrix is designed with multiple cavities arranged in a two-dimensional array rather than a single cutting position. This spatial arrangement allows multiple punches to cut multiple stoppers simultaneously from a single elastomer plate, dramatically increasing production output. The complexity increase is minimal, involving only the addition of more cavity positions and corresponding punches rather than fundamentally changing the device architecture.
Data Source
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AI summary
This invention relates to an automated device for manufacturing elastomer stoppers, comprising: a frame (1), a cutting matrix, a cutting head (3) provided with vertically movable cutting punches (31), a double-cutting matrix (2) mounted on a movable table (4) and which has a number of cavities equal to double the number of punches (31) of the cutting head (3); runners (41) for movement of the movable table (4) on longitudinal rails (11) of the frame (1), a spindle (42) that acts on runners of the movable table and that is connected to a motor (43) that causes linear movement of the movable table (4) through a series of work areas, comprising: - a loading area of elastomer plates (P); - a first cutting area; - a second cutting area and; - a scrap removal area.