Corrugator Return-Track Mold Block Exchange During Production
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Solution Overview
Problem
Existing corrugator systems require downtime for mold block exchange when changing pipe profiles, leading to increased down-time and reduced productivity.
Innovation Solution
A system and method for exchanging mold blocks in a corrugator while it is in operation, allowing replacement mold blocks to be inserted into the mold block chain while it is in motion, using staging platforms and push arms to displace existing blocks on parallel return tracks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mold blocks are exchanged by stopping the corrugator, then the exchange process is simple and safe, but production downtime increases and productivity decreases
Solution Approach 1:
Replacement mold blocks are staged on staging platforms before being needed, and the exchange mechanism is pre-positioned on the return track. This allows the exchange to be executed quickly when needed without requiring complex real-time decision-making or complex exchange mechanisms.
Solution Approach 2:
A push arm acts as an intermediary mechanism between the staged replacement mold blocks and the moving mold block chain. The push arm transfers blocks from the staging platform to the chain without requiring direct manual handling or complex robotic manipulation systems.
2Productivity
If mold blocks are exchanged while the corrugator is running, then productivity is maintained, but the exchange process becomes more complex and difficult to implement
Solution Approach 1:
The mold block exchange operation is extracted from the production area and relocated to the return track. This separates the exchange operation from the active molding process, allowing exchanges to occur in a controlled environment without interfering with pipe production while maintaining continuous operation.
Solution Approach 2:
The system uses the existing motion of the return track and mold block chain to facilitate the exchange process. The moving chain presents blocks to the push arm in sequence, and the staged replacement blocks are automatically positioned for transfer, reducing the need for complex control systems or manual intervention.
Data Source
AI summary
A system and method for replacing or substituting mold blocks in a corrugator, the corrugator comprising first and second tracks for carrying respective chains of mold blocks, each of the tracks comprising return tracks, wherein the system advances replacement mold blocks towards the return tracks to displace corresponding mold blocks in the mold block chains while the corrugator is in production and while the mold block chains are in motion.