Shoe Mold Temperature Sensing for Real-Time Hot-Press Control
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Solution Overview
Problem
Existing shoe material manufacturing processes face inefficiencies due to manual temperature sensing line embedding, leading to incorrect detection results, increased energy consumption, and reduced production capacity, as they rely on non-real-time temperature controls.
Innovation Solution
A real-time temperature measuring system with temperature-sensing rods and a central controller is integrated into the manufacturing apparatus to accurately measure and control temperatures during hot-press molding and cooling shaping, allowing for timely process adjustments based on real-time data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual temperature sensing line embedding is used to detect temperature, then production quality can be monitored, but the detection results are incorrect and the operation is difficult
Solution Approach 1:
The patent extracts the temperature sensing function from the manual embedding process and integrates it directly into the mold structure. Temperature sensing elements are built into the mold cavities, eliminating the need for separate embedding operations and ensuring correct positioning for accurate temperature detection throughout the material.
Solution Approach 2:
The patent introduces an automated temperature sensing system as an intermediary between the mold and the control system. This intermediary automatically captures temperature data from multiple points within the material and transmits it to the control system, eliminating manual intervention and improving both accuracy and ease of operation.
2Reliability
If heating time is increased to ensure material reaches melting temperature, then production quality is ensured, but production capacity is reduced and energy consumption increases
Solution Approach 1:
The patent implements a real-time temperature feedback system that continuously monitors the actual temperature of the material during heating. The control system receives this feedback and automatically adjusts the heating process, allowing the operation to be stopped as soon as the material reaches the required melting temperature. This eliminates the need for excessive heating time while maintaining production quality.
Solution Approach 2:
The patent incorporates temperature sensing elements into the mold structure before production begins. This preliminary integration ensures that temperature monitoring is already in place when heating starts, enabling immediate detection and response to temperature changes, thus optimizing the heating duration without compromising quality.
3Reliability
If heating time is extended to ensure material reaches melting temperature, then production quality is maintained, but energy consumption increases
Solution Approach 1:
The real-time temperature feedback system enables the control system to monitor material temperature continuously and terminate heating immediately when the melting temperature is reached. This prevents unnecessary energy consumption while ensuring the material achieves the required temperature for quality production.
Solution Approach 2:
The patent replaces manual temperature monitoring and estimation with an automated electronic temperature sensing and control system. This substitution provides precise temperature measurement and automatic control, eliminating the need for extended heating times and reducing energy consumption while maintaining production quality.
4Productivity
If multiple stations are used for hot-press molding and cooling shaping, then production efficiency is improved, but device complexity and time consumption increase
Solution Approach 1:
The patent combines hot-press molding and cooling shaping operations into a single integrated mold station. The mold structure incorporates both heating elements for hot-press molding and cooling channels for cooling shaping, allowing both operations to be performed sequentially in one location without requiring physical transfer between stations, thus reducing device complexity while maintaining production efficiency.
Solution Approach 2:
The mold is designed with multi-functionality, serving both as a heating device for hot-press molding and as a cooling device for cooling shaping. This universal design eliminates the need for separate dedicated stations for each operation, reducing overall device complexity while preserving production efficiency through integrated operation.
5Productivity
If multiple stations are used for hot-press molding and cooling shaping, then production efficiency is improved, but time consumption increases
Solution Approach 1:
By merging hot-press molding and cooling shaping into a single mold station, the patent eliminates the time required to move the mold between separate stations. The material remains in the same mold throughout both operations, removing transportation time from the production cycle while maintaining efficiency through integrated processing.
Solution Approach 2:
The integrated mold design allows for continuous processing where hot-press molding transitions directly into cooling shaping without interruption or material handling. This continuity of useful action eliminates idle time associated with moving materials or molds between stations, reducing overall time consumption while maintaining high production efficiency.
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 system enhances production efficiency and reduces energy consumption by ensuring precise temperature control and optimizing manufacturing times, resolving issues of manual temperature sensing and energy wastage.
Implementation Method 1
The at least one temperature-sensing rod is configured to measure the real-time temperature inside the foamed shoe material while the mold is closed
Implementation Method 2
a device for heating and pressing to melt the surface of the shoe material blank
Implementation Method 3
the shoe material blank with the surface having the texture can be cooled and shaped
Data Source
AI summary
An apparatus for manufacturing a shoe material with a real-time temperature measuring system and a method for manufacturing a shoe material are provided and include a real-time temperature measuring system used in hot-press molding and cooling shaping processes and configured to measure a real-time temperature of a foamed shoe material in a mold while a device performs a temperature controlling process on the mold. The real-time temperature is compared with a temperature threshold stored in a central controller. When the real-time temperature is greater than or is less than the temperature threshold, the central controller sends a control signal to stop the temperature controlling process on the mold by the device. Therefore, the manufacturing time of the shoe material in the hot-press molding and cooling shaping processes could be shortened, the production efficiency could be improved, and the energy consumption of the device could be reduced.