Pre-assembled Female Mould Arrangement Assembly
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Solution Overview
Problem
The existing methods for assembling female moulds on moulding machines are complex, time-consuming, prone to errors, and costly due to the need for precise positioning of numerous components, which can lead to inaccuracies and increased thickness and cost of the moulds, especially with the use of angular phasing elements like pins.
Innovation Solution
A pre-assembled female mould arrangement is created using an assembly tool with angular positioning elements, allowing for easier and more accurate assembly by reducing the number of components and eliminating the need for direct angular phasing elements, enabling the mould to be centered and positioned accurately on the machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If individual components of the female mould are assembled one after the other on the moulding machine, then the mould can be assembled with standard components, but the assembly process becomes complicated and time-consuming
Solution Approach 1:
The assembly process is segmented into two distinct phases: pre-assembly of the female mould components on a separate assembly tool, and subsequent mounting on the moulding machine. This segmentation allows the complex assembly to be performed in a controlled environment away from the machine, reducing assembly time on the production equipment.
Solution Approach 2:
The female mould components (ring, plate, annular forming element, and other elements) are preliminarily assembled into a complete female mould assembly on an assembly tool before being mounted on the moulding machine. This preliminary action ensures all components are correctly positioned and secured, eliminating the need for sequential assembly on the machine itself.
2Manufacturing precision
If phasing elements like pins are used to ensure angular positioning, then the female mould can be positioned accurately, but the mould thickness and cost increase
Solution Approach 1:
The angular positioning function is extracted from the female mould components themselves and transferred to the assembly tool. The assembly tool incorporates angular positioning elements that guide the relative angular positioning of components during pre-assembly, eliminating the need for bulky phasing pins within the mould structure.
Solution Approach 2:
The assembly tool acts as an intermediary device that provides the angular positioning functionality. Instead of incorporating positioning pins directly in the mould components, the assembly tool mediates the positioning process during assembly, allowing the mould itself to remain thin and cost-effective.
3Ease of manufacture
If multiple individual components are positioned sequentially on the moulding machine, then the assembly can be done with standard parts, but errors are prone and difficult to detect
Solution Approach 1:
Multiple positioning and assembly functions are merged into the assembly tool structure. The tool integrates support surfaces, angular positioning elements, and clamping mechanisms into a single unified device, ensuring that all components are positioned and secured together in a coordinated manner, reducing the opportunity for errors.
Solution Approach 2:
The manual sequential positioning process is replaced by a mechanical assembly tool system that provides guided positioning and automatic alignment. The tool's structured geometry and positioning elements mechanically ensure correct placement of components, reducing reliance on operator skill and detecting errors through the tool's design constraints.
4Ease of operation
If components are positioned one after the other on the support, then the assembly can be completed with basic tools, but the components may be accidentally displaced
Solution Approach 1:
The female mould components are nested together in a hierarchical assembly sequence on the assembly tool. The ring is positioned first, followed by the plate, then the annular forming element, with each component fitting into and being constrained by the previous ones. This nested arrangement provides inherent stability and prevents displacement.
Solution Approach 2:
The assembly tool is designed to self-constrain the components during assembly through its geometric features and positioning elements. Once components are placed on the tool, the tool's structure automatically maintains their positions and prevents displacement, eliminating the need for continuous external adjustment or monitoring during the assembly process.
Data Source
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AI summary
A method for assembling a female mould (1) on a moulding machine, comprises the steps of: providing a pre-assembled female mould arrangement (64), the pre- assembled female mould arrangement (64) comprising a plurality of components including at least a base (33), forming means having a forming cavity (3) and a fastening element (13) which renders the forming means fixed relative to the base (33); placing the pre-assembled female mould arrangement (64) on a support (42) of the moulding machine; - fixing the pre-assembled female mould arrangement (64) to the support (42).