Mold Block Return Transfer for Longer Corrugator Tunnel Length
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Solution Overview
Problem
Traditional pipe corrugators require a large number of mold blocks to maintain a sufficient mold tunnel length for forming large diameter corrugated pipes, leading to inefficiencies in mold block usage and reduced output.
Innovation Solution
Implementing a mold block transfer station with two distinct drives to quickly displace and rotate the last mold block away from the tunnel axis, allowing for a longer effective mold tunnel length with fewer blocks, enabling faster production and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a shallow outwardly angled diverging portion is used to separate mold blocks, then the mold blocks can be gradually separated from the product, but the length of the mold tunnel increases substantially (5 to 10 mold blocks)
Solution Approach 1:
The mold block separation process is divided into two distinct phases: first, rapid outward displacement to clear the product, then rotation to the return position. This segmentation eliminates the need for a long gradual transition section, reducing the mold tunnel length while ensuring complete separation from the formed corrugations.
Solution Approach 2:
The invention introduces a two-stage movement: initial displacement in the radial direction (perpendicular to the tunnel axis) followed by rotation in the tangential direction. This dimensional change allows mold blocks to clear the product more efficiently without requiring excessive longitudinal space.
2Productivity
If more mold blocks are used to increase the mold tunnel length, then the cooling time and output increase, but the number of mold blocks required increases
Solution Approach 1:
The mold blocks are made dynamically movable with a two-stage drive system that enables rapid separation and quick return. This dynamic capability allows the same number of mold blocks to effectively cover a longer tunnel length by reducing the space needed for separation, thereby increasing productivity without adding more blocks.
Solution Approach 2:
The invention changes the movement parameters of the mold blocks from gradual angular separation to rapid radial displacement followed by rotation. This parameter change reduces the effective space required for block separation, allowing increased tunnel length and output with the same number of blocks.
3Reliability
If the mold blocks are displaced outwardly several times the height of the corrugations, then the blocks can be rotated without striking corrugations, but the separation distance and mold tunnel length increase
Solution Approach 1:
The separation action is segmented into two distinct phases: rapid outward displacement to achieve clearance, then rotation to the return position. This ensures reliable clearance from corrugations while minimizing the total distance required, as the displacement is concentrated in a brief initial phase rather than distributed over a long gradual section.
Data Source
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AI summary
A two stage mold block transfer station is used the exit of a moving mold tunnel to quickly move mold blocks to a clear position relative to the molded product. Once in the clear position the mold block is rotated and provided to a return drive moving the mold block back to the inlet of the moving mold tunnel. By moving the last mold block of the moving mold tunnel primarily away from the longitudinal axis of the mold tunnel less mold blocks are required. Various arrangements for moving of the mold blocks can be used achieve this advantage.