Mobile Dry Ice Robot for Vulcanizing Mold Cleaning
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Solution Overview
Problem
Current cleaning methods for vulcanization molds, such as sandblasting and laser beam devices, are inefficient, hazardous, and not ergonomically friendly, while existing automatic dry ice cleaning devices are complex and bulky, making them unsuitable for all mold sizes and high-temperature environments.
Innovation Solution
A collaborative mobile robot equipped with a dry ice dispenser, sensors, and an articulated arm, which autonomously navigates to the mold, scans the environment, and performs precise cleaning using pre-programmed instructions, minimizing operator intervention and ensuring efficient and safe operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If sandblasting is used to clean the mold, then cleaning coverage is improved, but the mold surface and coating are damaged due to abrasion
Solution Approach 1:
The patent changes the physical state and properties of the cleaning medium from abrasive sand to non-abrasive dry ice particles. By transforming the cleaning medium from a solid particulate (sand) to a sublimating solid (dry ice), the process achieves effective cleaning without surface damage, as the dry ice particles disintegrate upon contact rather than abrading the mold surface.
Solution Approach 2:
The patent employs disposable dry ice particles that are projected at the mold surface and then disintegrate through sublimation. These short-living cleaning particles are replaced continuously, eliminating the need for complex removal systems and avoiding accumulation of cleaning residue on the mold surface.
2Productivity
If a laser beam device is used to clean the mold, then cleaning effectiveness is improved, but the device size and complexity increase significantly
Solution Approach 1:
The patent replaces the complex optical-mechanical laser beam system with a simpler pneumatic projection system. Instead of using high-energy laser beams requiring precision optical components and cooling systems, the invention uses compressed air to project dry ice particles onto the mold surface, achieving effective cleaning with a much more compact and simpler device.
3Productivity
If manual dry ice cleaning is used, then cleaning quality is improved, but operator safety and ergonomics deteriorate due to noise and temperature
Solution Approach 1:
The patent implements an automated cleaning system where the robot autonomously performs the cleaning operation without human intervention. The system self-manages the entire cleaning process including navigation to the mold, projection of dry ice particles, and monitoring of cleaning progress, thereby eliminating operator exposure to hazardous conditions while maintaining high cleaning quality.
Solution Approach 2:
The patent introduces a robotic system as an intermediary between the operator and the hazardous cleaning environment. The robot serves as a mediator that performs the dangerous tasks of approaching the hot mold and projecting dry ice particles, protecting the human operator from noise, extreme temperatures, and other hazards while maintaining operational effectiveness.
4Object-affected harmful factors
If an automatic dry ice cleaning device is used, then operator safety is improved, but device complexity and bulk increase
Solution Approach 1:
The patent divides the cleaning system into modular functional components: a mobile platform for navigation, an articulated arm for positioning, a dry ice storage container, a projection mechanism, and a control system. This segmentation allows each component to be optimized independently and facilitates easier integration and maintenance while reducing overall system bulk compared to monolithic designs.
Solution Approach 2:
The patent designs the robotic cleaning device with multi-functional capabilities, including autonomous navigation, obstacle detection, adaptive positioning, and cleaning execution. The articulated arm can position the projection nozzle at various angles and distances, and the system can adapt to different mold geometries, reducing the need for multiple specialized devices and minimizing overall system bulk.
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
The solution enables rapid, high-quality cleaning of vulcanization molds with reduced ergonomic risks and increased productivity, allowing for timely and efficient cleaning operations without waiting for operator availability or dry ice replenishment.
Implementation Method 1
The ice sublimates upon contact with the hot mold surfaces, instantly dislodging residues that are either carried away by the resulting gases or subsequently vented
Data Source
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AI summary
A method for cleaning a vulcanising mould for tyres in a curing press, using an apparatus (1) comprising a collaborative mobile robot (10), incorporating a computer program, the robot comprising an autonomous mobile platform (2) mounted on drive wheels and comprising power supply batteries, a dry ice dispenser (6), sensors for identifying the location of the mould to be cleaned and motors allowing the movement of same between a storage location where the apparatus is stored and the mould to be cleaned, and the movement of a hinged movable arm (3) of the robot, the arm carrying a spray nozzle (4) for spraying dry ice from the dispenser, in which the apparatus comprises means for communicating with a control unit. According to the invention, the control unit sends a mission instruction to the apparatus which navigates between a storage location and the location of the mould and automatically cleans the vulcanising mould.