Self-supporting intermediate wall for concrete casting moulds
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Solution Overview
Problem
Traditional concrete casting equipment with fixed, welded moulds faces issues of inefficient space utilization, tolerance inaccuracies due to material shrinkage, and the need for frequent replacement due to wear, leading to suboptimal production and increased waste.
Innovation Solution
A self-supporting intermediate wall construction with bolted, replaceable parts that securely lock into the mould frame, allowing for precise control of tolerances and easy replacement of worn components, ensuring consistent cell sizes and efficient production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional fixed welded moulds are used, then structural strength is ensured, but manufacturing precision deteriorates due to material shrinkage during welding
Solution Approach 1:
The mould is divided into separate segments (side walls, end walls, intermediate walls) that are manufactured independently with precise tolerances and then assembled using bolted connections. This segmentation eliminates welding-induced material shrinkage while maintaining structural integrity through the bolted joint system.
Solution Approach 2:
Bolts serve as intermediary elements that join the mould segments together without requiring welding. The bolts transmit mechanical loads between segments while allowing for thermal expansion and contraction without inducing distortion, thus preserving manufacturing precision.
2Stability of the object's composition
If thicker intermediate walls are used in fixed welded moulds, then structural stability is improved, but space utilization deteriorates leading to wasted production area
Solution Approach 1:
The intermediate walls are segmented into thin, replaceable plates that are bolted between the side walls. This segmentation allows the use of thinner walls (reducing space consumption) while maintaining structural stability through the bolted connection system that distributes loads effectively.
Solution Approach 2:
The bolted connection system provides localized reinforcement at critical joints without requiring thick walls throughout the entire structure. This allows thin walls in non-critical areas (maximizing space utilization) while maintaining stability at connection points.
3Strength
If fixed welded moulds are used, then initial structural integrity is ensured, but reliability deteriorates over time due to wear requiring frequent complete replacement
Solution Approach 1:
The mould is segmented into replaceable wear parts (intermediate walls, end walls, partitionings) and permanent structural parts (side walls, bolt system). This allows replacement of only the worn segments while retaining the durable structural framework, significantly extending the overall mould life and improving long-term reliability.
Solution Approach 2:
Wear-prone components are designed as disposable or replaceable parts that can be individually replaced when worn, while the main structural components are recovered and reused. This selective replacement strategy maintains reliability without requiring complete mould replacement.
4Stability of the object's composition
If fixed welded moulds are used, then structural rigidity is maintained, but adaptability deteriorates as the mould cannot be reconfigured for different product sizes
Solution Approach 1:
The mould is segmented into modular components that can be independently added, removed, or repositioned. This modular architecture allows reconfiguration for different product sizes and shapes while maintaining structural rigidity through the bolted connection system that ensures tight joints in any configuration.
Solution Approach 2:
The mould transitions from a fixed static structure to a dynamic reconfigurable system. The bolted connections allow for easy assembly and disassembly, enabling the mould to adapt to different production requirements while maintaining structural integrity during each casting cycle.
Data Source
AI summary
Self-supporting intermediate walls (12) for cellular division of mould lower parts in a concrete casting machine of the kind typically used for making cast items in the form of concrete blocks for wall construction and elements, solid blocks or blocks with cavities or recesses in two or more rows. By the self-supporting design, the distance between rows of products may be reduced for better utilization of the production plate while at the same time maintaining the replaceability of wear parts. By the invention is indicated a self-supporting intermediate wall (12) consisting of two halves, an intermediate wall with lower pins (18) and an intermediate wall with upper pins (20) which, when the two halves are assembled with the pins engaging a partitioning plate (8), form a self-supporting intermediate wall (12). For moulds with core supports (28), intermediate wall parts (22 and 23) are used with a recess (25) in which the boss (29) on the core support iron (28) fits.