Movable Mold Groups for Concrete Sleeper Production
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Solution Overview
Problem
Existing methods for producing prestressed concrete construction elements, such as concrete railway sleepers, require decentralized operations, leading to increased internal logistics effort, space requirements, and safety hazards due to suspended loads, with high efforts needed for mold changes and reduced productivity.
Innovation Solution
A method where multiple molds are arranged in a line with transverse mobility, allowing for central cleaning, preparation, and reuse, reducing transport routes and enabling automated mold handling to minimize risks and contamination, with a central station for release agent management and product changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If molds are arranged in a long line and remain stationary during production, then the production process can be continuous, but the logistics effort and space requirements increase significantly
Solution Approach 1:
The patent applies the dynamics principle by making the mold groups movable instead of stationary. The mold groups can be transported along the production line on a conveyor system, allowing them to move to different positions for casting, cleaning, and storage. This dynamic arrangement reduces the overall space requirement while maintaining continuous production capability.
2Ease of manufacture
If molds are cleaned and prepared at decentralized locations along the production line, then the production process can proceed, but contamination of the environment and disruption of the production process occur
Solution Approach 1:
The patent merges all mold cleaning and preparation operations into a single centralized station. Instead of having multiple decentralized cleaning points along the production line, all mold groups are transported to one dedicated cleaning station where they are cleaned and prepared. This consolidation eliminates the dispersion of cleaning agents and materials throughout the production area, preventing environmental contamination while maintaining ease of manufacture.
3Ease of operation
If operating personnel work with suspended loads for mold handling, then the production process can proceed, but occupational safety hazards increase
Solution Approach 1:
The patent implements automated mold handling systems that perform mold transport, positioning, and exchange operations without human intervention. The conveyor system and automated handling mechanisms enable the production process to proceed with improved occupational safety, as personnel are eliminated from suspended load operations. The system serves itself by automatically managing mold groups throughout the production cycle.
4Adaptability or versatility
If product changes require mold exchanges, then different products can be manufactured, but very high effort is required and productivity is reduced
Solution Approach 1:
The patent applies preliminary action by preparing and staging different mold groups in advance for different product types. When a product change is required, pre-prepared mold groups are already available and can be quickly exchanged with minimal disruption to the production process. This eliminates the need for time-consuming on-site mold modifications or exchanges, maintaining both adaptability and productivity.
Data Source
AI summary
The method involves providing mold groups with multiple molds which are arranged transverse to the lines. The units for rail drivability are formed at the molds or mold groups. The lifting- and transporting units are provided for filling the mold groups and molds with wet concrete.