Roof Tile Press Error Sensor for Incomplete Blank Removal
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Solution Overview
Problem
Existing roof tile presses face issues with incomplete removal of blanks from the lower mold, leading to the formation of large blanks that damage molds and result in production downtime and material loss, as existing detection methods are inadequate for identifying incomplete removals, especially when the underside of the blank is not visible.
Innovation Solution
A roof tile press equipped with an error sensor positioned after the removal point and before the pressing point to detect any content remaining in the lower mold, allowing for immediate intervention to prevent further processing of faulty blanks and enabling the identification and sorting of defective products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a limit switch is used to detect double compression at the removal point, then large preforms can be identified, but the underside of the blank remains invisible and detection is incomplete
Solution Approach 1:
The patent transitions from detecting only at the removal point (one location) to detecting at multiple locations including after the removal point and before the pressing point. This spatial dimensionality change allows detection of blanks that were missed at the removal point, enabling identification of the underside condition without requiring direct visual access to all surfaces.
Solution Approach 2:
The patent introduces an intermediary detection system (error sensor) that indirectly detects the presence and condition of blank material through its interaction with the mold and press system, rather than requiring direct observation of the blank underside. This intermediary detection method overcomes the visibility limitation.
2Productivity
If remaining material in the lower mold is pressed with a new blank, then the press cycle continues, but mold damage occurs and production quality deteriorates
Solution Approach 1:
The patent implements preliminary detection of remaining material in the lower mold at the discharge point and before the pressing point, allowing the system to identify and exclude defective blanks before they enter the pressing cycle. This preliminary action prevents mold damage while maintaining continuous production of quality tiles.
Solution Approach 2:
The patent establishes a feedback loop where detection results from the error sensor inform subsequent pressing operations. When remaining material is detected, the system provides feedback to prevent pressing, thereby protecting the mold from damage while allowing continuous operation when conditions are normal.
3Quantity of substance
If large preforms are produced due to incomplete removal, then material volume increases, but energy is wasted on drying and firing unsellable products
Solution Approach 1:
The patent performs preliminary detection and sorting of large preforms on the conveyor before they enter the drying and firing processes. By identifying defective preforms early in the production line, the system prevents energy-intensive processing of unsellable products, thereby reducing energy waste while maintaining material throughput.
4Ease of operation
If inspection is limited to the visible top side of large-format pieces, then inspection is simpler, but defective pieces are difficult to identify
Solution Approach 1:
The patent uses an intermediary detection system that indirectly assesses the condition of the blank by detecting the presence of remaining material in the mold and the characteristics of the pressed preform, rather than requiring direct visual inspection of all surfaces including the hidden underside.
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
This solution reduces the likelihood of mold damage, minimizes production downtime, and prevents the production of defective bricks by ensuring only complete blanks are processed, thereby saving material and avoiding unnecessary drying and firing of unsellable products.
Implementation Method 1
The suction plate, mounted on a guide and dampened by springs, is pressed against the shaped tile, drawing it in.
Implementation Method 2
The suction plate, mounted on a guide and dampened by springs, is pressed against the shaped tile, drawing it in. During this process, the springs are compressed by a defined distance.
Data Source
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Figure 5
AI summary
The invention relates to a roof tile press for producing a pressed molded part (22) from a blank (2) and a method for operating such a press. The roof tile press (1) comprises a press ram (3) with an upper mold (4) and a movement unit (5) on which a lower mold (6), a pressing point (7), and a removal point (8) are arranged. The movement unit (5) moves the lower mold (6) cyclically from one processing point to the next, with the removal point (8) defining the starting point (9) of a cycle. A fault sensor (10) for detecting the contents (19) of the lower mold (6) is arranged after the removal point and before the pressing point. According to the method, the lower mold is filled with a blank, moved to the pressing point (7), then to the removal point (8), and subsequently back to the pressing point (7).After the molded part (2) is removed, before the sub-mold (6) reaches the pressing point (7) again, a fault sensor (10) detects whether any contents (19) remain in the sub-mold (6).