Automated Mold Changing via Robot Extraction
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Solution Overview
Problem
Current mold changing processes for manufacturing containers are time-consuming and require significant operator intervention, leading to increased manufacturing costs due to frequent machine stoppages and the need for precise tool handling, especially in rotary-type machines.
Innovation Solution
A method and system for changing molds that involves controlling the fixing means to release and lock half-molds while the mold carriers are in the closed position, allowing for the formation of a transportable unitary sub-assembly that can be extracted and reassembled using a robot with gripping means, enabling faster and more efficient mold changes without the need for extensive tool handling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manual mold changing methods are used with operators handling tools, then flexibility and adaptability are maintained, but the time required for mold changes increases and productivity decreases
Solution Approach 1:
The mold changing system is designed to perform mold replacement operations autonomously without requiring external operators or tools. The robot executes the entire mold changing sequence automatically, from approaching the mold carrier to securing the new mold, enabling the system to service itself and eliminating idle machine time.
Solution Approach 2:
Manual mechanical operations performed by operators using screwdrivers and other tools are replaced by an automated robotic system. The robot uses specialized end effectors to perform fastening and unfastening operations, substituting human mechanical actions with automated mechanical systems that operate faster and more consistently.
2Ease of operation
If operators manually handle tools for fastening and unfastening operations, then ease of operation is maintained, but device complexity increases due to the need for precise tool handling and positioning
Solution Approach 1:
The robot system is designed with universal capabilities to perform multiple functions within the mold changing process. A single robotic platform executes approach, fastening, unfastening, and withdrawal operations, replacing multiple specialized tools and operations with one multi-functional automated system that simplifies the overall process.
Solution Approach 2:
The robot acts as an intermediary between the control system and the physical mold changing operations. It translates high-level commands into precise mechanical actions, mediating between the operator's intent and the complex task of mold replacement, thereby simplifying the user interface while managing device complexity internally.
3Adaptability or versatility
If frequent mold changes are performed to manufacture different container shapes, then adaptability improves, but manufacturing costs increase due to repeated machine stoppages
Solution Approach 1:
The system prepares for mold changes in advance by positioning the robot and pre-configuring fastening operations. The robot approaches the mold carrier and begins fastening operations while the machine is still in operation or during minimal interruption, reducing the overall stoppage time and enabling more frequent mold changes without proportionally increasing downtime.
Solution Approach 2:
The mold changing system is designed to be dynamic and responsive, allowing rapid adaptation to different production requirements. The robot can quickly switch between different mold types and adjust its operations based on the specific mold being installed, enabling frequent changes between different container shapes while maintaining high productivity through optimized motion paths and operations.
Data Source
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AI summary
The device has two mold holders (14) movably mounted with respect to each other between an open position and a closed position. Two half molds (22) are respectively mounted in the mold holders and provided with a half-cavity. Fixation units are provided for fixing the half molds to the mold holder in a detachable manner and movably mounted between a fixation position and a release position, where displacement of the fixation units between the fixation and release positions are controlled when the mold holders are in the closed position.