Vacuum Transfer of Hollow Fibre Products Between Mould Cavities
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing process for hollow moulded fibre products, such as bottles, is inefficient and prone to product damage due to the delicate nature of partially formed products, necessitating improved handling and transfer methods.
Innovation Solution
A manufacturing system with a plurality of first and second mould cavities and a transfer device that automates the transfer of partially formed products between these cavities, ensuring sufficient second mould cavities are available for further processing, and uses vacuum contact surfaces to handle products delicately.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual handling methods are used for partially formed products, then the handling process is simple, but product damage occurs due to the delicate nature of the products
Solution Approach 1:
The patent replaces manual mechanical handling with an automated transfer device that uses vacuum contact surfaces. The vacuum mechanism gently adheres to and transports partially formed products without physical contact that could cause damage, thereby improving product integrity while introducing automated handling systems.
Solution Approach 2:
The transfer device employs vacuum (pneumatic) contact surfaces to hold and transfer partially formed products. The vacuum pressure creates a gentle holding force that secures the delicate products during transfer without mechanical gripping or contact that could cause damage, resolving the contradiction between simple handling and product protection.
2Productivity
If a two-mould process is used to form pulp moulded articles, then the manufacturing process is established, but manufacturing efficiency is reduced due to the need to transfer delicate partially formed products between moulds
Solution Approach 1:
The automated transfer device enables continuous operation by seamlessly transferring partially formed products from first mould cavities to second mould cavities without interruption. The vacuum-based transfer mechanism operates continuously, maintaining production flow and eliminating downtime associated with manual handling, thereby improving manufacturing efficiency while minimizing transfer time.
3Productivity
If more second mould cavities are provided compared to first mould cavities, then product throughput is increased, but system complexity increases
Solution Approach 1:
The transfer device is designed with universal functionality to handle multiple product configurations and transfer between varying numbers of mould cavities. The vacuum contact surfaces and automated control system can adapt to different cavity arrangements, allowing the system to accommodate more second mould cavities for increased throughput while managing complexity through a flexible, multi-functional transfer mechanism.
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 manufacturing efficiency and reduces product damage by allowing for automated, precise, and efficient transfer of products without human intervention, thereby increasing productivity and yield.
Implementation Method 1
The transfer device is configured to apply the vacuum to the vacuum contact surface to retain the product in contact with the vacuum contact surface
Data Source
AI summary
A hollow moulded fibre product manufacturing system, comprises a transfer device comprising a vacuum contact surface. The transfer device is configured to: (i) move the vacuum contact surface towards a product located at a first location when the product is at the first location. The product is a partially formed hollow moulded fibre product or a hollow moulded fibre product. The transfer device is further configured to: (ii) apply a vacuum to the vacuum contact surface to retain the product in contact with the vacuum contact surface, and (iii) move the vacuum contact surface relative to the first location while the vacuum is applied to the vacuum contact surface to retain the product in contact with the vacuum contact surface, such that the transfer device carries the product towards a second location.