Continuous Golf Ball Casting with Variable-Speed Dispensing
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Solution Overview
Problem
Conventional casting techniques for golf ball covers require discontinuous 'stop-and-go' processes, leading to increased cycle time and reduced productivity due to the need for multiple halts at material dispensing, core/mantle insertion, mold assembly, and demolding stations.
Innovation Solution
A method and system that utilize moving mold portions along different paths with a dispensing member capable of varying speeds to continuously dispense material into hemispherical cavities, combined with dual rotary index tables for core insertion and mold assembly, and infrared curing and cooling stations to streamline the casting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional discontinuous casting techniques are used, then material dispensing, core/mantle insertion, and mold assembly can be performed with simple equipment, but productivity is reduced due to stop-and-go operations and increased cycle time
Solution Approach 1:
The patent implements continuous movement of mold portions through a casting system with multiple stations arranged in sequence. The dispense head moves continuously along the path, dispensing material into moving mold cavities without stopping. This eliminates idle time between operations and maintains continuous productive action throughout the casting process.
Solution Approach 2:
The system uses variable speed control of the dispense head to match the movement speed of mold portions at different stations. The dispense head can accelerate and decelerate dynamically to synchronize with mold entry/exit speeds while maintaining overall continuous motion, optimizing material dispensing at each station without breaking the continuous flow.
2Area of stationary object
If conventional casting with stationary molds is used, then equipment complexity is minimized, but the system footprint becomes large to accommodate stop-and-go operations
Solution Approach 1:
The patent transitions from linear stop-and-go casting to a continuous path system where mold portions move through multiple stations in sequence. By arranging dispensing stations along a continuous path and moving molds through them, the system compactly sequences operations in space rather than requiring large areas for multiple stationary stations operating independently.
Solution Approach 2:
The casting system is divided into multiple discrete stations (material dispensing, core/mantle insertion, mold assembly, demolding) arranged along a continuous path. Each station performs a specific function while mold portions move continuously through all stations, allowing compact arrangement of complex functions without requiring all equipment to be simultaneously accessible.
3Manufacturing precision
If continuous movement during material dispensing is implemented, then productivity is improved and cycle time is reduced, but precision of material placement and mold alignment becomes more difficult to maintain
Solution Approach 1:
The system employs sensors and control systems to monitor the position and speed of mold portions and the dispense head in real-time. This feedback enables dynamic adjustment of dispensing parameters and movement speed to maintain precise material placement and mold alignment throughout continuous operation, ensuring quality standards are met while maintaining high productivity.
Solution Approach 2:
The patent replaces manual positioning and alignment mechanisms with automated control systems that use sensors, motors, and computer control to maintain precise positioning during continuous movement. This substitution of mechanical adjustment with automated control enables both high speed continuous operation and precise material placement.
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 reduces unnecessary pauses and improves productivity by maintaining continuous movement during material dispensing and assembly, enhancing the quality and concentricity of golf balls while minimizing the footprint of the casting system.
Implementation Method 1
infrared curing and cooling stations
Implementation Method 2
infrared curing and cooling stations
Data Source
AI summary
A system includes a dispensing station and top and bottom mold portion paths. The dispensing station is configured to dispense materials into one or more hemispherical cavities of a plurality of top mold portions and a plurality of bottom mold portions. The plurality of top mold portions are conveyed at a first speed along the top mold portion path, and the plurality of bottom mold portions are conveyed at a second speed along the bottom mold portion path. The dispensing station can include at least one nozzle coupled to a six-axis robotic member that is configured to move at variable speeds.