Hydraulic Telescoping Mold Extraction Assembly
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Solution Overview
Problem
Conventional methods for changing molds in concrete products forming machines are labor-intensive and result in significant downtime, leading to lost revenue due to the need for manual labor and external lifting devices.
Innovation Solution
A two-stage, hydraulically actuated telescoping mechanism is integrated into the feed drawer section of the machine, allowing for precise positioning of the mold assembly using existing vertical motion, eliminating the need for dedicated actuators and reducing the risk of horizontal misalignment during mold changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional manual methods are used for changing molds, then labor intensity is high and downtime is significant, but the machine structure remains simple and cost-effective
Solution Approach 1:
The mold extraction assembly is designed to be self-contained and self-operating, using the machine's existing vertical motion system to power the mold exchange process without requiring external lifting devices or complex dedicated actuators. The system serves itself by utilizing already-available mechanical energy in the machine structure.
Solution Approach 2:
The existing vertical motion system of the concrete products forming machine is repurposed to perform dual functions: its original function and the additional function of powering the mold extraction assembly. This eliminates the need for separate dedicated actuators and reduces overall system complexity while improving productivity.
2Loss of time
If automated mold exchange systems are implemented, then downtime is reduced, but the risk of horizontal misalignment increases without proper guidance mechanisms
Solution Approach 1:
Guided rails are introduced as an intermediary element between the mold assembly and the extraction assembly. These rails act as a mediator that physically guides the mold during the extraction and replacement process, ensuring horizontal alignment is maintained throughout the automated exchange operation, thereby preventing misalignment while maintaining speed.
Solution Approach 2:
The guidance mechanism adds a constraint in the horizontal dimension by using guided rails, while the primary actuation occurs in the vertical dimension through the existing vertical motion system. This separation of dimensions allows automated operation without compromising alignment precision.
3Force
If external lifting devices are used for mold changes, then lifting capability is sufficient, but the cost and complexity of the system increase
Solution Approach 1:
The system utilizes the existing vertical motion system already present in the concrete products forming machine to provide the necessary lifting force for mold extraction. This self-service approach eliminates the need for external lifting devices, reducing both cost and system complexity while maintaining sufficient lifting capability.
Solution Approach 2:
The lifting function is merged with the existing vertical motion system of the machine. Instead of adding a separate lifting mechanism, the design combines the mold extraction function with the already-available vertical actuation capability, thereby reducing overall system complexity and cost.
4Ease of operation
If manual mold exchange is performed, then equipment cost is low, but operator risk exposure increases due to manual handling
Solution Approach 1:
The manual mechanical handling of molds by operators is replaced with an automated mechanical extraction assembly. This substitution removes operators from direct contact with heavy molds during the exchange process, improving safety while simultaneously increasing efficiency through automated operation.
Solution Approach 2:
The mold extraction assembly operates autonomously to perform the mold exchange task that would otherwise require manual operator intervention. This self-service capability improves operator safety by eliminating manual handling while maintaining or improving productivity through automated operation.
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 solution enables automated mold exchange without hand tools or external lifting devices, reducing operator risk and minimizing downtime, while being modular and cost-effective for integration into existing machines.
Implementation Method 1
a two stage, hydraulically actuated telescoping mechanism
Data Source
AI summary
A method for moving a mold assembly from a mounted position within a concrete products forming machine includes extending an extraction assembly forwardly from a retracted position at a rear of the concrete products machine to an intermediate position so that terminal ends of the extraction assembly are positioned below a carrying surface of the mold assembly. The extraction assembly is raised at the rear portion of the concrete products machine so that the terminal ends of the extraction assembly contact and raise the carrying surface of the mold assembly up off mold mounting surfaces on the concrete products machine. The extraction assembly is then moved to a fully extended position so that the mold assembly is moved forwardly from the mold mounting surfaces to an operative position whereby the mold assembly can be removed from the extraction assembly and replaced with a replacement mold assembly.