Automatic Shoe Component Mold Replacement for Product Variety
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Solution Overview
Problem
Injection molding systems for shoe components are limited to specific models and sizes, making it difficult to meet diverse consumer demands for a wide variety of products in both small and large quantities.
Innovation Solution
A mold automatic replacement system that includes multiple molds with independently assigned bits, a rack for mold accommodation, an injector, and a robot that interacts with the injector to automate mold replacement, enabling the production of various models and sizes without limitations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a single mold is used in the injection molding system, then the system is simple to operate and maintain, but it cannot produce diverse shoe components in various models and sizes
Solution Approach 1:
The injection molding system is designed with multi-functionality to handle diverse shoe components. The system can switch between different molds (first mold for shoe soles, second mold for shoe uppers) and produce various models and sizes by changing molds rather than requiring separate dedicated systems for each product type.
Solution Approach 2:
The system incorporates dynamic mold replacement capability where molds can be automatically changed during operation. The mold replacement device enables the system to adapt its configuration dynamically, switching between different molds based on production requirements for various shoe components.
2Productivity
If manual mold replacement is used, then the system structure is simple, but mold replacement time is long and productivity is limited
Solution Approach 1:
The system incorporates automatic mold replacement functionality where the mold replacement device autonomously performs mold changes without requiring manual intervention. The control unit automatically controls the replacement process, enabling the system to service itself during mold changes and maintain continuous production.
Solution Approach 2:
The manual mechanical process of mold replacement is substituted with an automated mechanical system. The mold replacement device uses mechanical mechanisms (such as the fourth conveyor and positioning devices) to automatically remove and install molds, replacing the need for manual handling and significantly reducing replacement time.
3Adaptability or versatility
If multiple molds for various models and sizes are maintained, then diverse consumer demands can be met, but storage space and system complexity increase
Solution Approach 1:
The system merges multiple mold storage and replacement functions into a single integrated mold replacement device. Instead of maintaining separate storage areas for different molds, the device combines storage, selection, and replacement operations in one automated system, reducing the overall space required while maintaining the capability to handle multiple molds for various shoe components.
Data Source
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AI summary
An automatic mold replacement system for shoe components is provided. The automatic mold replacement system for shoe components includes a plurality of molds that have independently assigned bits, forming mold cavities of various models and sizes to manufacture shoe components in various models and sizes; a rack that accommodates the molds in independent seating jigs; an injector that selects a mold from among the molds and proceeds with injection into the mold inserted into a turntable; and a robot that interacts with the injector to extract the mold matching the bit from the injector and seat the mold in a seating jig of the rack or remove the mold matching the bit from the seating jig of the rack and insert the mold into the injector.