Three-axis Rotational Moulding Machine with Nested Frames
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Solution Overview
Problem
Existing rotational moulding machines are limited by their physical dimensions, which restrict the size of the moulds they can accommodate, leading to increased manufacturing and operational costs as the machine size grows, making it difficult to produce products with complex geometries or large dimensions.
Innovation Solution
A rotational moulding machine with a unique three-axis rotational system, featuring a fixed frame, a support arm, a movable frame, and an actuation system that allows the mould to rotate freely about three axes without the need for concentric frames, thereby increasing the usable volume and reducing encumbrances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If concentric frames are used to provide three-axis rotation, then rotational capability is improved, but machine footprint and manufacturing costs increase
Solution Approach 1:
The support arm is rotationally coupled to the fixed frame, and the movable frame is rotationally coupled to the support arm, creating a nested rotational system where each rotational component is positioned within the envelope of the previous one. This nesting arrangement provides three-axis rotation capability while minimizing the overall machine footprint compared to concentric frame designs.
Solution Approach 2:
The support arm's second portion extends substantially parallel to the first axis of rotation, utilizing the dimensional space efficiently. This configuration allows the mould to access three rotational degrees of freedom while the machine maintains a compact footprint by optimizing the spatial arrangement of rotational components across multiple dimensions.
2Volume of moving object
If larger moulds are accommodated, then product size capability is improved, but manufacturing and operational costs increase
Solution Approach 1:
The support arm's second portion is configured to extend parallel to the first axis of rotation, creating a dynamic spatial arrangement that maximizes the usable volume within the machine envelope. This dynamic configuration allows larger moulds to be accommodated without requiring a proportional increase in machine dimensions, thereby controlling manufacturing and operational costs.
3Volume of moving object
If machine dimensions are increased to accommodate larger moulds, then mould size capability is improved, but energy consumption and operational costs increase
Solution Approach 1:
The nested rotational configuration allows the machine to accommodate larger moulds within a compact envelope by efficiently nesting the rotational components. This reduces the overall machine dimensions required, thereby lowering energy consumption for operation while maintaining the capability to produce large products.
Data Source
AI summary
Rotational moulding machine (1) comprising a fixed frame (2), a support arm (3) comprising a first (4) and a second portion (5) rigidly joined together, the support arm (3) being rotationally fixed to the fixed frame (2) only at the first portion (4) to rotate about a first axis of rotation (101) substantially horizontal, a movable frame (6) rotationally fixed to the support arm (3) to rotate about a second axis of rotation (102) substantially perpendicular to the first axis of rotation (101), the movable frame (6) comprising a supporting portion (7) lying in a plane substantially perpendicular to the second axis of rotation (102), and an actuation system (8) rigidly fixed to the movable frame (6) at the supporting portion (7) and structured to secure a mould (20) and rotate the mould (20) about a third axis of rotation (103) substantially perpendicular to the second axis of rotation (102).