Flexible Mold Demolding via Unsmooth Path and Rotatable Support
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Solution Overview
Problem
Current automated demolding systems for wet-cast concrete products, especially smaller or differently sized products, often result in sticking or uncontrolled ejection due to vacuum creation and uncontrolled movement paths, leading to labor-intensive processes and product damage.
Innovation Solution
A method and system that involves moving a flexible mold through a passage with a rotatable mold-support member and a mold-moving system that grips the mold's edge and guides it along an unsmooth path with at least one sharp point to minimize friction and break the vacuum, ensuring controlled demolding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a smooth arcuate path is used for demolding, then the mold can be easily removed, but smaller products get stuck in the mold due to vacuum creation
Solution Approach 1:
The patent employs an arcuate (curved) path for mold movement, which is a form of spherical/curved motion. The mold is moved along a defined arcuate trajectory that combines vertical lifting with horizontal displacement, creating a curved motion path that prevents sudden vacuum formation while ensuring complete mold release from the product surface.
Solution Approach 2:
The demolding process uses dynamic motion control where the mold velocity and acceleration are carefully managed along the arcuate path. The system transitions from static mold positioning to dynamic curved motion, optimizing the speed profile to break vacuum seals progressively rather than suddenly, preventing product sticking while maintaining operational ease.
2Productivity
If automated demolding systems are used, then labor requirements are reduced, but products may be uncontrollably ejected or broken
Solution Approach 1:
The automated demolding system incorporates feedback control mechanisms that monitor mold position, velocity, and product status throughout the demolding process. Sensors detect vacuum levels, mold displacement, and product movement, adjusting the motion profile in real-time to prevent uncontrolled ejection or product breakage while maintaining automated operation.
Solution Approach 2:
The system applies preliminary counter-actions to prevent harmful effects before they occur. By anticipating vacuum formation and product ejection risks, the control system pre-adjusts motion parameters, applies counter-forces, and modifies the demolding trajectory to neutralize potential damaging effects before they manifest, ensuring product integrity during automated demolding.
3Force
If high vacuum is created during demolding, then the mold releases easily, but smaller and differently sized products get stuck
Solution Approach 1:
The demolding system applies local quality variations by creating different vacuum conditions in different zones of the mold cavity. The arcuate motion path causes progressive vacuum breakdown from one region of the mold to another, allowing products of different sizes and geometries to experience optimized local forces that prevent sticking while maintaining overall mold release effectiveness.
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
This approach effectively prevents sticking and damage by providing a controlled demolding process for wet-cast concrete products, reducing labor requirements and ensuring safe ejection of products from the mold.
Implementation Method 1
a mold-support member being rotatable about an axis parallel to the passage to minimize friction in the passage
Implementation Method 2
This is caused by the concrete creating a vacuum on the mold, resulting in a tight connection between the products and the mold
Data Source
AI summary
The problem of wet-cast concrete products getting stuck or being uncontrollably ejected from a flexible mold during demolding is solved by moving the flexible mold through a passage, defined by both a mold-receiving surface and a rotatable mold-support distanced therefrom, while moving an edge of the flexible mold along an unsmooth path that includes at least one sharp point.