Vacuum Profiling Assembly for Reinforced Hollow Body Molding
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Solution Overview
Problem
Existing hollow body manufacturing methods, such as those for fuel tanks, face limitations in achieving high pressure-resistant ranges due to the use of vertical support posts, which have poor stability and fail to meet drop and impact test performance requirements.
Innovation Solution
A hollow body molding aid and method utilizing a profiling assembly with vacuum chucks and inductive switches for precise positioning of reinforced housing components within a mold, eliminating the need for multiple air cylinders and preventing offset issues during molding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If vertical support posts are disposed in the fuel tank to support wall plates, then the anti-pressure capability of the fuel tank is enhanced, but the manufacturing stability deteriorates and drop and impact test performance requirements cannot be met
Solution Approach 1:
The patent replaces the traditional mechanical support structure (vertical support posts) with a molding aid system that uses vacuum suction force to position and fix the reinforced housing during the molding process. This substitution eliminates the need for separate support posts while achieving both positioning stability and manufacturing reliability through precise vacuum-based positioning.
Solution Approach 2:
The molding aid performs preliminary positioning and fixing of the reinforced housing before the actual molding process begins. The vacuum chucks pre-position the housing halves on the profiling assemblies, ensuring correct placement and stability before molten material is introduced, thereby preventing manufacturing defects and ensuring consistent quality.
2Manufacturing precision
If multiple air cylinders are used for positioning reinforced housing, then positioning capability is achieved, but offset issues occur during molding
Solution Approach 1:
The patent replaces the pneumatic system (multiple air cylinders) with a vacuum-based positioning system. The vacuum chucks mounted on the profiling assemblies create reliable suction force that firmly holds the reinforced housing in position without the mechanical linkages and potential offset issues associated with air cylinders. This provides both precision and stability throughout the molding process.
3Device complexity
If a simplified positioning system is used, then device complexity is reduced, but positioning precision deteriorates
Solution Approach 1:
The molding aid integrates multiple functions into a unified system: the profiling assemblies serve both as positioning structures and as mounting bases for vacuum chucks, while the vacuum chucks simultaneously position and secure the reinforced housing. This multi-functional design achieves precise positioning without requiring separate complex positioning mechanisms for each function.
Solution Approach 2:
The patent replaces complex mechanical positioning systems with a simpler vacuum-based system. The vacuum chucks provide precise positioning through suction force, eliminating the need for multiple mechanical adjustment mechanisms, screws, and linkages while maintaining or improving positioning accuracy through the uniform distribution of vacuum force.
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
The solution ensures improved manufacturing quality and pressure-resistant properties of hollow bodies by accurately positioning reinforced housing components, enhancing stability and avoiding offset problems, thus meeting stringent performance requirements.
Implementation Method 1
the first profiling assembly is used to fix one half of the reinforced housing through the action of vacuum suction force
Data Source
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AI summary
The present invention discloses a hollow body molding aid and a hollow body molding method. The molding aid includes a body, a connector, a first profiling assembly, a second profiling assembly, and a positioning mechanism. The connector is fixedly connected to the body. The first profiling assembly is fixedly disposed on one side of the body and is configured to position one half of a reinforced housing. The second profiling assembly is fixedly disposed on an other side of the body and is configured to position an other half of the reinforced housing. The positioning mechanism is disposed on the first profiling assembly and the second profiling assembly. By means of the hollow body molding aid and the hollow body molding method provided in the present invention, a reinforced housing can be positioned, thus guaranteeing molding quality of the reinforced housing and blanks. In addition, the reinforced housing can be accurately positioned in a cavity of a mold through a manipulator, without the need to use a plurality of air cylinders for step-by-step driving. In the meanwhile, in the case that a plurality of interlinked air cylinders are adopted, a problem that the reinforced housing is offset from a mold after the reinforced housing is placed in the mold due to a loosened screw at a position on an air cylinder can be avoided.