Oscillating Filling Box for Uniform Mold Compaction
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Solution Overview
Problem
Existing filling devices for molds with pourable mold material face challenges in ensuring uniform distribution and minimizing segregation of the starting material, particularly in achieving the desired bulk density and compaction in stone production processes.
Innovation Solution
A filling device with a flexible filling box and carriage system that incorporates oscillating and heating elements, along with a toothed rack and gear mechanism, to facilitate even filling and reduce material adhesion, utilizing elastic elements and PTFE-coated surfaces for improved mass distribution and reduced sticking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If gravity is used for mass flow of starting material, then filling is simple, but uniform mass distribution and minimized segregation cannot be ensured
Solution Approach 1:
The filling box is equipped with a vibrating mechanism that generates vibrations during the filling process. These vibrations prevent the starting material from segregating and ensure uniform mass distribution throughout the mold cavity, while still maintaining the simplicity of gravity-based filling.
Solution Approach 2:
The filling box is designed to be movable rather than fixed, allowing it to oscillate and adjust during the filling process. This dynamic approach enables better control over material flow and distribution, improving uniformity without complicating the overall filling mechanism.
2Device complexity
If filling box is stationary, then structure is simple, but material adhesion to box walls increases
Solution Approach 1:
The filling box is transformed from a stationary component to a movable one that can oscillate during filling. This motion prevents material from adhering to the box walls by continuously disrupting the contact between the starting material and the box surface, thereby reducing adhesion without requiring complex anti-sticking coatings or mechanisms.
3Ease of manufacture
If filling box is rigid, then manufacturing is easy, but mass distribution uniformity deteriorates
Solution Approach 1:
The filling box incorporates a vibrating mechanism that allows it to oscillate during operation. This dynamic capability improves mass distribution uniformity by preventing material segregation, while the overall rigid structure remains easy to manufacture using conventional fabrication methods.
Solution Approach 2:
A vibrating mechanism is integrated into the rigid filling box structure. The vibrations generated during operation ensure uniform mass distribution of the starting material without requiring changes to the fundamental rigid construction, maintaining ease of manufacture while improving filling precision.
4Manufacturing precision
If filling device moves slowly, then material distribution is uniform, but productivity decreases
Solution Approach 1:
The vibrating mechanism enables the filling process to occur more rapidly while maintaining uniformity. The vibrations prevent segregation and ensure even distribution even at higher filling speeds, thus increasing productivity without sacrificing filling quality.
Solution Approach 2:
The movable and oscillating filling box allows for optimized filling kinetics. By controlling the motion and vibration characteristics, the system achieves both high filling speeds and uniform material distribution, resolving the trade-off between speed and uniformity.
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 device ensures consistent and efficient filling of molds with pourable materials, enhancing the uniformity of the filling process and reducing material segregation, thereby improving the quality of the final product by maintaining the desired bulk density and compaction.
Implementation Method 1
at least one heating device for heating the filling box, which is arranged in particular on or in at least a portion of the box wall of the filling box
Implementation Method 2
at least one flexible element, in general at least three flexible elements, by which the filling box (3) is flexibly mounted on or in the filling carriage (2)
Implementation Method 3
at least one oscillating drive which is arranged or fastened on or in the filling carriage and drives the filling box in an oscillating movement
Implementation Method 4
PTFE-coated surfaces for improved mass distribution and reduced sticking
Implementation Method 5
Gravity is generally used for the mass flow of the starting material
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to a filling device for filling moulds, in particular of block forming machines or block presses, with a pourable moulding material, comprising a) a filling box (3) for receiving and/or transporting the moulding material (M), b) a filling carriage (2), on or in which the filling box is flexibly mounted by means of at least one spring element (5, 6, 7), c) at least one oscillating drive (60 to 68), which is arranged or fastened on or in the filling carriage and is connected to the filling box (3) to drive the filling box in an oscillating movement, d) at least one traversing drive (20, 21, 40, 41, 50, 51) for making the filling carriage traverse with the filling box between at least one filling position for filling at least one mould with moulding material from the filling box and a charging position for charging the filling box with fresh moulding material.