Note: Descriptions are shown in the official language in which they were submitted.
CA 02485851 2004-10-25
SYSTEM 1FOR MOLDING CORRUGATED PIPE
BACKGROUND OF THE INVENTION
Large diameter corrugated pipe employed for water runoff control, culverts
and the like was introduced to the construction industry as a steel product.
It's
corrugate shape afforded good resistance against necessarily imposed
compressive
stresses, however, the undulatory pipe interior has not been one providing an
efficient fluid flow characteristic. Over the somewhat recent past, as plastic
technologies have advanced, opportunities for forming these structures from
high
density plastics arose.
The general approach to fabricating plastic corrugated pipe has been to
extrude viscous thermoplastic material from a die assembly having an annular
exit
cross section. This extrudate is formed against the internal, corrugated
surface of a
continuing sequence of indexed mold sets. As the plastic extrudes through
gauge
defining extrusion die lip assemblies, it is drawn into the moving and riow
mated die
sets, for instance, by an externally imposed vacuum. These mold sets, when
united,
define a dynamic forming tunnel moving along the production axis. . . .
The plastics involved in this process, for example, high density polyethylene,
are problematic in terms of their workability. In this regard, the material is
introduced
or cut at homogenization stations at the entrance of the extruding die with
primary
distributors in a plurality of streams. At this step in the process, the
material has a
somewhat putty-like consistency. These primary distribution streams discharge
under high pressure into homogenization spiraling channels through which they
progress in the form of a multiple thread. The depth of these helical channels
,~
progressively diminishes in the axial or extrusion direction. It is assumed
that the
stream progressing under pressure through one spiral divides itself into two
partial
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CA 02485851 2004-10-25
streams. One of these divisional streams flows axially over a land formed
between
two spirals and the other follows the course of the spiral channel in a
helical
direction. Ultimately, the material flow is only in the axial direction and
this resultant
stream is formed by the superpositioning of the divisional streams. By this
arrangement, a desired mechanical homogeneity of the now annular melt stream
is
achieved.
Control over the polymeric material as it progresses through the die both in
terms of temperature maintenance and mass distribution has been problematic
and a
variety of control approaches have been advanced. One earlier such approach to
maintaining product wall thickness or gauge consistency included, for example,
the
provision of adjustable annular extrusion die lips. Such "tweaking" at the
gauge
defining extrusion output now is being supplanted by modern computer modeling
approaches. Temperature excursions within the extrusion system have resulted
in a
variety of anomalies in the resultant byproduct. For example, a lack of
effective
temperature control can result in a warped pipe product sometimes referred to
as
"banana pipe".
Effective movement of the necessarily bulksom and heavy mold sets or blocks
also has proven to be problematic. In the course of the continuous molding
process,
each mold set is parted from the moving and now molded pipe at a downstream
release location, whereupon it must be returned to the molding commencement
region
of the die to be closed and abuttably indexed against the next axially
forwardly
adjacent closed mold set. The thus conjoined closed mold sets are axially
driven in
tandem at a rate controlled in consonance with the extrusion activity. Any
vagaries
encountered in this continuous process will result in any of a variety of
product
defects including pipe wall thickness deviations and corrugation pitch changes
sometimes referred to as the °accordion effect". Pitch variations will
be manifested
not only as an irregular wall surface, but also as a pipe length alteration. A
variety of
mold set transporting, parking, joining or closing and indexing schemes have
been
advanced, perhaps the more popular being a chain driven clamshell-like mold
set
wherein the molds are supported by pivotal mounts which ride, in turn upon
continuous chains. With the arrangement, the mounts and molds are returned in
an
open orientation above the molding process, whereupon they are turned
downwardly
into alignment with the process axis and closed for indexing. This
mechanically
complex technique imposes a limitation on the number of mold sets which can be
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CA 02485851 2004-10-25
accommodated by the system. As a consequence, production system flexibility is
limited. Mold sets which are tied to a common mold conveyor system such as
chain
mechanisms also are necessarily involved in relatively awkward release and
return
maneuvers. This limits the number of mold sets which function to establish the
moving forming tunnel length.
Other mold set manipulation approaches have involved rack and pinion based
systems wherein a rack component is associated with each mold which performs
in
conjunction with a gear drive; systems wherein each mold is driven by a
discrete
electric motor with associated electrical leads or umbilicals; and shuttle-
based
systems.
Each mold of a mold set is designed to establish a sub-atmospheric pressure
effective to draw extruded thermoplastic material against a generally
corrugated
internal mold surface and to establish a cooling capability at the outward
surface of a
mold. Such Gaoling typically is derived by an outboard air flow, particularly
in the
course of what often is a complex system start-up procedure. Often the mold
designs require that vacuum be drawn over diverse distance through relatively
elaborate and difficult to access vacuum distribution channels. These
configurations
lead to production difficulties and product anomalies. Where the cooling 'air
distribution channels are excessively lengthy or air flow is but minimally
controlled,
undesirable product variations may be encountered.
Originally produced plastic corrugated pipe exhibited an amount of undesirable
flexibility. Such flexation attributes led to the implementation of internal
liners which
are co-extruded with the outer corrugated wall from annular extrusion nozzles
located adjacent the outer wall extrusion annulus. As this inner finer or wall
engages
and attaches to the inwardly depending troughs of the outer wall, . it moves
axially
along a cooling sleeve or mandrel.
BRIEF SUMMARY OF THE INVENTION
The present invention is addressed to system and apparatus for producing
corrugated pipe wherein mold and carriage assemblies are drawn together at a
paired mold receiving region and advanced along an extrusion die assembly to
develop a highly accurately defined dynamic mold tunnel. This accurate tunnel
,~
defining movement is achieved with a translation assembly extending in
parallel with
the production system axis which engages 'the carriage assemblies of the mold
sets
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CA 02485851 2004-10-25
and controls their movement in a stable and accurate tandem relationship. Such
accuracy and stability is accomplished by implementing the translation
assembly as
an elongate, continuous screw with a screw thread pitch. Each carriage
assembly
mounted mold of a conjoined mold set incorporates a connector assembly
configured
as a threaded nut half or partial nut fixed to a component of the carriage
assembly
and exhibiting the same thread pitch as the continuous translational screw. To
assure proper entry of each threaded connection assembly onto the
translational
screw, the succession of abutting molds on the screw defining a forming tunnel
exhibit a mold-to-mold abutting or reference distance wherein either that
reference
distance or the some of reference distances for a sequence of molds is an
integer
multiple of the common thread pitch of the connector assembly and the screw.
With
the arrangement, the threads of the connector assemblies are positioned to
define an
effective, uninterrupted and continuous thread pitch association with the
threads of
the translational screw.
Entrance of mold pair connector assemblies onto the translational screws is
by movement along the system axis and in mutually abutting combination with a
next
forwardly adjacent reference mold set, the connector assemblies of which have
previously engaged the screw.
The carriage assembly supporting each mold is structured having a rail
mountable primary carriage to which the translational screw engaging threaded
connector assemblies are fiixed. This primary carriage also establishes the
noted
reference distance as the distance between forward and aft or rearward
bumpers.
In general, the primary carriage is configured for movement in parallel with
the
production system axis. Mounted upon the primary carriage is a mold supporting
secondary carriage which is moveable between mold defining and release
orientations in a direction generally transverse to the production system
axis.
Through the utilization of cam tracks and secondary carriage mounted cam
followers,
molds may be transversely moved between the two noted orientations, for
example,
at the end of the forming tunnel, the cam followers will follow a diagonally
oriented
cam track to move from a mold defining to a release orientation and as the
carriage
assemblies with associated molds are returned to the entrance to the molding
system
translational cam tracks will cause the followers to move the mold carrying
secondary carriages to their mold defining orientations toward the production
system
axis.
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Movement of the molds and associated carriage assemblies about the system
is through the utilization of release and feed assemblages, each of which
incorporates respective recovery and feed trolleys onto which the primary
carriages
ace driven. In this regard, the release assemblies utilize recovery trolleys
which are
driven in mutually opposite directions at either side of the system axis to
deposit a
mold or mold half and associated carriage assembly at a return assembly.
Within the
return assemblies at each side of the system, molds or mold halves are
maneuvered
in parallel with the system axis to queue regions prior to their introduction
to feed
trolley implemented feed assemblies directing each mold half to the earlier
noted
receiving region.
Each carriage assembly mounted mold or mold half is configured as a
generally semi-cylindrically shaped mold body having an internal mold cavity
region
configured with an outwardly depending sequence of mold crests spaced apart to
define a sequence of inwardly depending vacuum support regions. Each mold body
further has an outward surface with outwardly disposed annular standoff
structures
spaced apart to define cooling regions. A sequence of annular insert
components,
one of each being positioned over an inwardly depending vacuum support region
serve to form mold valleys and define readily accessible and uniform vacuum
cavities
with vacuum openings positioned to draw thermoplastic material toward the mold
valley. A cover plate assembly is connectea across the moia nosy stanaon
structures to define a dual directional cooling airflow system of cooling
chambers.
The system also incorporates a mold set configured to form a bell structure.
In this regard, the conventional mold body sequence of spaced apart mold
crests
extend from the vicinity of one mold side surface to the commencement of a
bell
cavity extending, in turn, to the vicinity of a mold side surface opposite the
one side
surface. The mold body outward surface is configured having one or more
outwardly depending wall pairs defining vacuum support regions. One or more
bell
vacuum cover components, each positioned within an outwardly depending wall
pair
of the vacuum support region functions to define an outward vacuum cavity. A
bell
mold insert component having a bell defining mold profile is positioned within
the bell
cavity and connected to the mold body internal mold cavity region. This mold
insert
has one or more vacuum openings communicating with the outward vacuum cavity
for drawing thermoplastic material towards the bell defining mold profile.
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CA 02485851 2004-10-25
Other objects of the invention will, in part, be obvious and will, in part,
appear
hereinafter.
The invention, accordingly, comprises the system and apparatus possessing
the construction, combination of elements and arrangement of parts which are
exemplified in the following detailed description.
For a fuller understanding of the nature and objects of the invention,
reference should be made to the following detailed description taken in
connection
with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Fig. 1 is a top partially schematic view of a corrugated pipe molding system
according to the invention;
Fig. 2 is a partial sectional view taken through the plane 2-2 shown in Fig. 1
Fig. 3 is a sectional view taken through the plane 3-3 shown in Fig. 1;
I S Fig. 4 is a sectional view showing an enlarged portion of Fig. 3;
Fig. 5 is a front elevational view of a mold employed with the system of the
invention;
Fig. 5A is a partial sectional view of the mold of Fig. 5 showing a seal and
seal
cavity;
Fig. 6 is a side view of the mold of Fig. 5;
Fig. 7 is a partial sectional view taken through the plane 7-7 shown in Fig.
5;
Fig. 8 is a side elevational view of a bell-forming mold employed with the
system of the invention;
Fig. 9 is a partial sectional view of the mold of Fig. 8;
Fig. 10 is an external side view of the mold of Fig.B;
Fig. 11 is a partial sectional view illustrating a bell-based union of two
pipes
molded in accordance with the system of the invention;
Fig. 12 is an end view of a mold supporting carriage assembly according to
the invention;
Fig. 13 is a side view of the carriage assembly of Fig. 12;
Fig. 14 is a top view of the mold transporting components of the system of the
invention;
Fig. 15 is a top view of a pusher conveyor based mold positioning assembly
according, to the invention;
CA 02485851 2004-10-25
Fig. 16 is a side view of the mold positioning assembly of Fig. 15;
Fig. 17 is a top view of a pulley conveyor assembly employed with the system
of the invention;
Fig. 18 is a side view of the conveyor assembly of Fig. 17;
Fig. 19 is a partial top view of a return assembly shown in Fig. 14 revealing
the position of primary and secondary mold supporting carriages in phantom;
Fig. 20 is a top view of a release rail assembly and associated recovery
trolley of a release assembly;
Fig. 21~is a side view of the assembly of Fig. 20;
Fig. 22 is an end view of a trolley employed with the system of the invention;
Fig. 23 is a side view of the trolley shown in Fig.22;
Fig. 24 is a top view of a rail conveyor assembly according to the invention;
Fig. 25 is a side view of the rail conveyor assembly of Fig. 24;
Fig. 26 is a partial sectional view showing the association of a keeper pin
assembly and a primary carriage;
Fig. 27 is a partial side view of a carriage assembly according to the
invention
showing its association with a keeper pin assembly within a queue region of
the
system;
Fig. 28 is a partial side view of Fig. 27 illustrating the keeper pin
assembly;
Fig. 29 is a partial top view of the system of the invention showing one
orientation of molds during its operation;
Fig. 30 is a partial top view of the system of the invention showing another
orientation of molds in the course of its performance;
Fig. 31 is another partial top view of the system of the invention showing the
maneuvering of molds in the production of corrugated pipe; and ,
Fig. 32 is another partial sectional top view of the system of the invention
illustrating the maneuvering of recovery and feed trolleys.
DETAILED DESCRIPTION OF THE INVENT70N
In the discourse to follow the molding system for producing polymeric
corrugated pipe is generally described, whereupon the structuring of the
shuttle
maneuvered mold pairs is addressed. Next, the discussion turns to the unique,
endless screw-based dynamic forming tunnel of the system, after, which the
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CA 02485851 2004-10-25
techniques for recovering mold pairs at the end of the forming tunnel and
shuttling
them to a queue region is described.
Looking to Fig. 1, the molding system is represented generally at 10.
Thermoplastic material is combined with, for example, carbon black at a mixing
station
represented schematically at block 12. While one source of material and
formulation
is indicated at block 12, the system 10 can perform with thermoplastic
material
exhibiting different chemical formulations and/or colors. Mixed thermoplastic
materials
are transported by a conveyor represented schematically at 14 to apportioning
bins
or hoppers 16 and 18. Bin 16 is dedicated to providing material for forming
the outer
corrugated wall of the produced pipe, while bin 18 apportions material for
forming the
inner liner of the pipe product. Bin 16 provides thermoplastic material to a
heated
extruder 20. From extruder 20 hot thermoplastic material under substantial
pressure
is directed through a heated, dual elbow pipe configuration represented
generally at
22, whereupon material is directed through a somewhat elongate heated input
pipe
24. Heating is provided by numerous electrically energized band heaters, one
of
which is represented at 26. Pipe 24 inserts melted heated thermoplastic
material, for
example, at about 400°F, into a manifold or block 28. Block 28 may be
seen to be
symmetrically disposed about the system axis 30.
In similar fashion, bin 18 provides thermoplastic material to a heated
extruder
32 which expresses thermoplastic material under pressure through a dual elbow
pipe
configuration represented generally at 34 which, in tum, extends to an input
pipe 36.
Pipe 36 delivers the heated material under pressure through an elbow
connection 38
to a side surface located port of manifold 28. As before, a substantial number
of
band heaters are coupled with pipe 36, one of which is represented at 40.
Control to
these heaters is provided from a floor-mounted control console 42.
Molded corrugated pipe is represented generally at 44 being continuously
extruded by the system 10 along axis 30. The pipe is shown having bell
components
as at 46 and progresses continuously to a cut-off station represented
generally at 48.
Station 48 is configured with rotary cut-off saws and is designed to move with
the
pipe 44 during the process of clamping on to it and carrying out sawing
activity.
Eight mold pairs or mold sets 50a, 50b - 57a, 57b are employed with
exemplary system 10 and are transported about a main frame or structure having
"
horizontally disposed tables within a common place which support guide rails
and
cam tracks. Conveyance of molds about the system is facilitated through the
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CA 02485851 2004-10-25
utilization of dual carriage-based mold supports. In the figure, mold pair
50a, 50b
have been joined and located at a receiving region represented generally at
58. At
this location, a carriage assembly supporting mold pair 50a, 50b is being
pushed or
compressibly urged against a similar carriage supporting mold pair 51 a, 51 b
which is
located at a reference region represented generally at 60. Reference region 60
is
located at the entrance of a dynamic forming tunnel. Mold set 54a, 54b is
somewhat
out of the forming tunnel and each mold of the pair will commence to be parted
by a
release assembly in the manner shown at mold set 55a, 55b. The release
assembly
is comprised of paired pulley conveyors performing in conjunction with table
mounted
parting cam tracks which are engaged by the carriage assembly associated with
each mold 55a, 55b, the release assembly being symmetrically disposed on
either
side of axis 30. The pulley conveyors will be seen to draw each mold as at
55a, 55b
onto a respective exit transport or pulley trolley shown in general at 62a,
62b. These
exit transport or pulley trolleys in general are configured with cam tracks
receiving a
mold carriage assembly follower which are then driven transversely outwardly
to
receiving positions shown respectively at 64a, 64b. From these receiving
positions
each mold or mold set half is drawn into a mold return assembly represented
generally at 66a, 66b. These mold return assemblies will be seen to be formed
with
table mounted rails, cam tracks and conveyor assemblies. The return assemblies
66a, 66b move the mold halves to respective queue regions 68a, 68b. In this
regard
molds 56a, 56b and 57a, 57b are within respective regions 68a and 68b. At
those
regions, the mold return assemblies 66a, 66b will have positioned the mold
halves
with about a one inch axial spacing. In appropriately timed fashioned, the
mold return
assemblies 66a, 66b will position a mold half onto the table and rail mounted
trolleys of
respective mold feed assemblies shown generally at 70a and 70b. Those trolleys
will
move the mold halves mutually inwardly into receiving region 58. In this
regard, united
mold pair 50a, 50b is shown positioned at that region. When at region 58, the
carriage assemblies of these mold pairs are pushed or urged axially into
abutment
with the carriage assemblies of the mold pair 51 a, 51 b located at reference
region 60.
This positioning achieves a proper engagement with an endless screw based
transport assembly functioning to drive the mold sets defining a forming
tunnel region.
Shown additionally in Fig. 1 is a vacuum pump function represented at block
90. Function 90 may be comprised of, for instance, 4 twenty-five horsepower
vacuum pumps. The vacuum output of function 90 is represented at line 92
extending
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CA 02485851 2004-10-25
to a vacuum manifold and valve assembly represented generally at 94 from which
an
array 96 of discrete vacuum lines extend to a four compartment vacuum manifold
98.
Manifold 98 is supported upon a frame represented generally at 100. Frame 100
is
wheel mounted and also supports an air blower assembly represented generally
at
102 and comprised of an air blower function 104; an over and under duct
assembly
represented generally at 106 which supplies air to axially disposed air
manifolds 108
and 110 from each of which flexible hoses depend inwardly to respective mold
engaging air manifolds 112 and 114. Those manifolds 112 and 114 supply cooling
air
centrally to outward chambers formed within each mold of the mold sets within
the
forming tunnel. Also shown in the figure is a floor mounted control console
116.
Additionally mounted upon the facility floor are access rails 117 and 118 upon
which
the wheel mounted frame 100 rides. This frame maneuvering feature permits more
facile access to components such as the die assembly of the system.
Referring to Fig. 2, the die assembly as well as components of the transport
assembly of system 10 functioning to move the mold sets along and defining the
forming tunnel are revealed. The die assembly is represented generally at 120
and is
described in detail in co-pending application for United States patent by
Karr, et al.,
serial No. 101715760 entitled "Die Apparatus for Forming Corrugated Pipe"
filed
November 18, 2003 and incorporated herein by reference. Assembly 120 is seen
supported in cantilever fashion at die entrance 122 by a robust and adjustable
die
support assemblage represented generally at 124. In this regard an upstanding
flange assembly 126 of the support 124 is coupled to a die mounting ring 128
which,
inter olio, supports a heater band enveloped outer wall surface 130 extending
to an
annular outer wall forming extrusion nozzle represented generally at 132.
Located
axially forwardly of the outer wall nozzle 132 is an inner wall, forming
extrusion
nozzle represented generally at 134. Material flow and die lip concentricity
adjustment assemblages as represented generally at 136 and 138 are located
immediately upstream of the respective nozzles 132 and 134. It may be noted
that an
annular access region represented generally at 140 is protected by a semi-
cylindrical
shield 142. Attached to the die adjacent inner wall extrusion nozzle 134 is a
cylindrical cooling sleeve represented generally at 144 incorporating a spiral
pattern
of vacuum notches 146. Water circulation inlet and outlet hoses are identified
»
respectively at 148 and 150.
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CA 02485851 2004-10-25
The bottom or main frame of the mold set transportation assemblage of system
is represented in the figure in general at 152. Mold sets 50a, 50b - 57a, 57b
are
supported upon this main frame 152 in conjunction with a carriage assembly
configured for movement over table mounted rails in association with a
centrally
5 disposed transport assembly and a combination of conveyors and trolleys.
Mold
components 50a through 54a are seen in the figure to be affixed to respective
mold
support stands 156 - 160. Stands 156 - 160, in turn, are mounted upon
respective
carriage assemblies represented generally at 166a - 170a. Carriage assemblies
166a - 170a are configured with forwardly and rearvuardly disposed bumpers
which
10 are engageable from mold set to mold set in freely abuttable fashion. One
forward
bumper is shown at 176 in connection with carriage assembly 170a, while a
rearwardly disposed bumper is shown at 178 in connection with carriage
assembly
166a.
The forming tunnel generally is considered to extend the axially length of
IS vacuum manifold 98. Mold sets are maneuvered along this tunnel by a
translation
component implemented as a continuously rotating endless screw 180. In this
regard,
partial or half follower nuts are seen extending downwardly from respective
carriage
assemblies 166a - 169a. Of these follower nuts, nut 183a is engaged with screw
180 at the reference region 60 representing the entrance of the forming
tunnel.
Within the tunnel region, follower nuts 184a and 185a are engaged with screw
180
and mold set 54a, 54b is just exiting the forming tunnel region, its follower
nut 186a
having come off of the threaded portion of screw 180 and the transverse motion
of
its mold path to release from the corrugation surface of pipe 44 having
commenced.
The translation component 180 continuous screw is mounted between bearings 192
and 194 and is driven from an electric motor assembly196. ,
The maneuvering of the paired mold set at the receiving region 58 for
engagement of its follower nut with the rotating screw 180 is critical with
respect to
the avoidance of misaligning of the threads of the associated follower nut.
While the
pitch of the threaded component of the follower nuts is made to equal the
pitch of the
rotating screw 180, the pitch of the follower nut at the receiving region 58,
for
example, follower 182a must be so aligned as to, in effect, create a
continuous pitch
with the screw 180. This calls for a very accurate spacing between the forward
and rearward bumpers as at 176 and 178 for each mold set. That spacing must
correspond with an integer multiple of the pitch for one or more carriage
assemblies.
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CA 02485851 2004-10-25
For example, where the common pitch at hand is four threads per inch, then the
spacing between the bumpers at each mold set carriage assembly may be 33
inches.
That accurate bumper-to-bumper spacing far each mold set then is employed in
conjunction with receiving region 58. At that region, two pusher conveyors,
one of
which is represented in general at 200a urges the downstream or forward bumper
of
the mold set at the receiving region against the corresponding upstream or
rearward
bumper of that mold set located at the reference region 60. For example, in
Fig. 2 the
forward bumper of carriage assembly 166a is being pushed in freely abutting
fashion
against the rearward bumper of carriage assembly 167a within the reference
region
60. Within that region follower nut 183a is engaged with screw 180.
Accordingly,
the continuous pitch spacing is established.
The paired molds are transversely separated upon exiting the forming tunnel
by release assemblies positioned on each side of the axis 30. These assemblies
include pullet conveyors one of which is revealed in the figure in general at
198a.
Fig. 2 also reveals that the main frame 152 is configured with inter connected
steel
box beams or tubes certain of which are identified at 202
Referring to Fig. 3, a sectional view of system 10 is presented wherein paired
molds 53a and 53b are seen to be positioned upon their respective carriage
assemblies 168a and 168b in a mold defining orientation wherein they are
joined
together about die assembly 120. Mold halves 56a and 56b are seen carried by
respective mold support stands 162a and 162b and carriage assemblies 172a and
172b. Carriage assembly 172a is located at the queue region 68a of mold return
assembly 66a. Correspondingly, mold 56b of the mold pair is supported upon
mold
support stand 162b and carriage assembly 172b within queue region 68b of mold
return assembly 66b. Carriage 66a is seen mounted upon a rail ,supporting
table
represented generally at 216a which comprises an upwardly disposed steel plate
218a supporked by box beams as at 202 and generally C-shaped rails represented
generally at 220a and 221 a. The mold halves are maintained in stationary
fashion at
the queue region 68a by a pneumatically actuated keeper assembly as at 211 a.
In similar fashion, carriage assembly 172b is supported upon a rail supporting
table 216b which includes an upper steel plate 218b which in turn supports C-
shaped
rail assemblies 220b and 221 b. Motd half 56b is retained in stationary
position at the .,
queue region as in 68b by pneumatic keeper assembly represented generally at
211b.
Carriage, assemblies 172a and 172b ace shown in an orientation positioning
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CA 02485851 2004-10-25
respective mold halves 56a and 56b in a mold defining orientation which is
repeated in
connection with carriage assemblies 168a and 168b.
Now looking in general to the structuring of system 10 at the forming tunnel
region it may be seen that two table structures represented generally at 224
and 226
are arranged in parallel with and at each side of axis 30. These tables are
formed
with respective elongate steel plates 228 and 230. Plate 228 is seen to
support two
parallel C-shaped main rails represented generally at 232a and 232b in
addition to a
main cam track assembly represented generally at 234. Table structure 226 is
similarly structured, plate 230 supporting main C-shaped rails represented
generally at
236a and 236b. Additionally, plate 230 supports a main cam track assembly
represented generally at 238.
Fig. 4 is an enlarged detail of this center region represented in Fig. 3.
Looking
momentarily to that figure, it may be observed that carriage assembly 168a is
configured with a bumper 240a and a vertically disposed cam follower assembly
represented generally at 242a which is configured having a roller component
244a
which is movably engaged with main cam track 234. In similar fashion, carriage
assembly 168b is configured having a downstream or forward bumper 240b and a
cam follower represented generally at 242b which is configured with a roller
component 244b. Roller component 244b is engaged in follower fashion with cam
track assembly 238. The mechanical association of cam follower assemblies 242a
and 242b with respect to cam track assemblies 234a and 234b provide for the
manipulation of respective mold halves 56a and 56b along a locus of travel
generally
transverse to axis 30 between the mold defining orientation shown and an
outboard
release orientation.
Figure 4 further shows pusher conveyor 200a as revealed in Fig. 2 and
pusher conveyor 200b disposed opposite axis 30. As noted above, these pusher
devices engage the rearwardly disposed bumpers of mold set carriages at
receiving
region 58 (Fig. 1 ) to urge the carriage bumpers into freely abuttable and
compressive
engagement with the bumpers of those mold set carriages then located at
reference
region 60 and thus engaged with screw 180.
Now looking to the structuring of each mold or mold half of the mold set,
reference initially is made to Figs. 5-7. Figs. 5 and 6 reveal a mold as
represented
generally at 250 which comprises a generally semi-cylindrically shaped
aluri~inum
mold bod~r represented generally at 252 which is disposed about a mold set
axis
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CA 02485851 2004-10-25
represented at 254. Mold set axis 254 in general will coincide with system
axis 30.
Mold body 252 is configured with an internal mold cavity region represented
generally
at 256 which is formed with an outwardly depending sequence of integrally
formed
mold crests certain of which ace revealed in Figs. 6 and 7 at 258. Mold crest
258
correspond with the valleys of the ultimately produced pipe 44. Mold crests
258 are
spaced apart to define a sequence of inwardly depending vacuum support regions
as identified at 260 in Fig. 7. Note that regions 260 have a rectangular cross
section.
Mounted over each of these vacuum support regions 260 are relatively thin, T-
shaped
insert components certain of which are identified at 262. Fig. 7 reveals that
the stem
of each T-shaped insert component 262 functions as a form of standoff as well
as
threaded bore for receiving the ends of cap screws 364. With this arrangement
a
mold valley is created as well as a vacuum cavity at support regions 260.
Looking to
Figs. 5 and 6, vacuum is applied to those vacuum cavities from an upwardly
disposed
mold manifold 266. Manifold 266 is configured with an upwardly disposed
contact
IS surface 268 which cooperates with the vacuum source manifold described at
98 in
Figs. 1 and 2. Fig. 6 reveals that the manifold is structured to provide
discrete bore
parts as at 270 which extend to each of the vacuum cavities defined at support
regions 260. The mold valleys established by the insert components 262 also
are
formed with vacuum openings certain of which are identified at 272 in Figs. 6
and 7.
These openings 272 preferably are formed by providing notches within the
insert
components 262 to achieve the slit-like shape.
Mold body 252 also is configured with an Outward surface represented
generally at 274; extends along mold set axis 254 between oppositely disposed
generally flat mold side surfaces 276 and 278, and extends about mold set axis
254
between oppositely disposed, generally flat mold mating surfaces 280 and 282.
Figs. 5 and 7 reveal that vacuum passageways as seen at 284 extend to mold
side surface 276 and are in vacuum communication with one outboard vacuum
cavity. These small bores are provided to assure a proper low pressure at each
mold-to-mold interface. Mold-to-mold integrity further is enhanced with the
positioning
of seals at mold side surtace 276 as well as at mold mating surfaces 280 and
282.
One such seal 286 is seen in Fig. 5 at side surface 276. Additionally, a seal
288 is
seen at mold mating surface 280 and a seal 290 is seen at mold mating surface
282.
Looking momentarily to Fig. 5A, seal 286 is seen to be configured as a
dovetail-
shaped notch 292 within which is inserted a flexible or soft silicon cord 294.
One
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CA 02485851 2004-10-25
such seal pair as at 288 and 290 is provided for each mold set. Also one seat
pair as
at 286 is provided at either the upstream or downstream side surfaces of each
mold
set.
Fig. 7 reveals that mold body outward surface 274 is configured with
integrally formed annular, outwardly depending standoff structures 300-303.
These
standoff structures are configured to establish three cooling regions along
the upper
half and lower half of the whole outward surface 274. Fig. 7 reveals the three
cooling regions 306-308 in the upper half of outward surface 274. These
regions are
developed as chambers by the attachment of two cover plates to the standoffs.
For
instance, a top cover plate 310 extends over regions 306-308 and as seen in
Fig. 5, a
lower cover plate 312 creates air chambers in the lower half of the mold. Fig.
5
reveals that standoff structures are configured to provide a solid air
diverting region
314 which permits cooling air to be directed both upwardly and downwardly. To
accommodate this arrangement, cover plate 310 is configured to define an air
inlet at
316 and an air outlet 318 in the vicinity of mold mating surface 280. In
similar fashion,
cover plate 312 is configured to provide an air inlet 320 adjacent region 314
and an air
outlet 322 adjacent mold mating surface 282. This provides upwardly directed
air
flow as represented by arrows 324 and 326 and a lower directed air flow as
represented at arrows 328 and 330.
Mofd body 252 is supported upon a mold support stand represented generally
at 332. Stand 332, in turn, is mounted upon a carriage assembly shown in
phantom
and represented generally at 334.
!n general, one mold set of the collection employed with system 10 is utilized
to
form bell structures as described at 46 in Fig. 1. A mold or mold half of such
a mold
pair is represented in general at 340 in Figs. 8-10. Mold 340 is formed, as
before,
with a mold body represented generally at 342 of generally semi-cylindrical
shape
which is disposed about mold set axis (not shown). The mold body 342 is
configured
having an internal mold cavity region represented generally at 344 which, as
before,
is configured with an outwardly depending sequence of mold crests 346 which
are
spaced apart to define a sequence of three inwardly depending vacuum support
regions 348. As seen in Figs. 9 and 10, the mold 340 further is configured
having an
outward surface represented generally at 350 with outwardly disposed spaced
apart
annular standoff structures certain of which are revealed at 352. To form the
corrugatipnal components preceding the. bell structure, as before, the vacuum
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CA 02485851 2004-10-25
support regions 348 are combined with a sequence of annular insert components
configured and installed identically with those described at 260 in Fig. 7 and
shown in
the instant figures at 354. Mold 340 is seen to extend axially between side
surfaces
356 and 358 and about its mold set axis (not shown) between oppositefy
disposed
S generally flat mold mating surfaces 360 and 362. A mold manifold 364 is
positioned at
the top of mold 340 adjacent mating surface 360. For the corrugation defining
valleys
and vacuum support region, as before, paired bores or passageways represented
in
general at 366 communicate between the mold manifold 364 top surface 368 and
the
vacuum support regions 348. As before, the vacuum support regions 348
communicate in vacuum transfer relationship with a sequence of slit-defining
notches
formed within the insert components 354, certain of which ace represented at
370.
For the instant bell-forming mold 340, the sequence of mold crests 346 extend
from the vicinity of mold side surface 356 to the commencement of a bell
cavity 372
which extends to the vicinity of mold side surface 358. Opposite this cavity
372 the
1S mold body outward surface 350 is configured having outwardly depending
paired
walls as seen in Fig. 9 at 374a, 374b - 376a, 376b. Walls 374a, b,- 376x, b
are
formed with respective shoulders 378a, b - 380a, b below which are formed a
respective outward vacuum cavity region 382-384. Each of these outward vacuum
cavity regions 382-384 is covered with a respective bell vacuum cover
component
386 -388. Each of the bell vacuum cover components 386-388 is configured with
side edge O-rings, two of which are revealed at 390 and 391 in connection with
cover component 388.
Connected within the bell cavity 372 are two bell mold insert components 394
and 396 which combine to define a bell mold profile. Connection of these
inserts 394
2S and 396 is provided by cap screws, certain of which are revealed at 398.
Vacuum is asserted at the bell mold insert components 394 and 396 through
slit-shaped openings certain of which are revealed at 400 in Fig. 9. Vacuum is
communicated from vacuum manifold 98 (Fig. 1 ) to the belt shaping region via
paired
bores represented in general at 402. Fig. 9 shows that these paired bores
communicate through the cover components to the vacuum support regions 382-
384.
From those support regions, passageways or bores, certain of which are shown
at
404 communicate with vacuum compartments 406 and 408 formed outwardly of the
,,
respective insert components 394 and 396. Bores or passageways, certain of
which are shown at 410 the communicate from the vacuum compartments 406 and
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CA 02485851 2004-10-25
408 with the slit or slot-shaped opening at 400. Note in Fig. 9 that bell mold
insert
component 394 is configured having a triangular-shaped ridge forming cavity
416
also being formed with slit-shaped openings, one of which is revealed at 418.
Similarly, bell mold insert component 396 is formed with two such ridge
forming
cavities as at 420 and 422. Cavities 420 and 422 also are formed with slit-
shaped
openings similar to that shown at 418. These cavities 416, 420 and 422 serve
to form
reinforcing ridges extending outwardly from the belt structures. These
reinforcing
ridges function to maintain the circular integrity of the bell structures
where
associated corrugated pipe lengths are improperly stored such that bell
distorting
forces are created.
Fig. 10 reveals that upper covers as at 428 and Power covers as at 430 are
coupled by machine screws to the standoffs as at 352. The covers are
confiigured
so as to provide air outlets as described in connection with Fig. 5 as well as
air inlets
as shown respectively at 432 and 433. These inlets are arranged with a solid
air
diverting region 434 in the same manner as described at 328 in Fig. 5.
One, half mold of a mold pair, for instance, mold 340 additionaNy is
configured
with seals in the same manner as described in connection with mold 250. Two
such
seals are seen in Fig. 8 at 438 and 440 within respective mold mating surfaces
360
and 362. As in the case of mold 250, mold 340 is supported by mold support
stand
represented generally at 444 in Fig. 8 which, in turn, is mounted upon a
carriage
assembly, components of which are shown in phantom and in general at 446.
Looking to Fig. 11, the profile of a bell structure developed by molds as at
340
is revealed in connection with mated pipe links 450 and 452. The latter pipe
is
configured with corrugation crests certain of which is shown at 454-457; an
inner
liner 458; and extends to a pipe end or edge 460. Pipe 450 is seen, far
example
having corrugation crest 462 adjacent a bell structure represented generally
at 464.
Note that that structure incorporates an annular seal cavity 466 within which
an
annular seal 468 is adhesively attached. Note additionally the presence of
bell
reinforcing ridges 470-472.
Referring to Figs. 12 and 13, the mold support stand and carriage assembly
associated with each mold or mold half are revealed at a higher level of
detail. In the
figures, a mold body portion is shown at 480 supported by a mold support stand
.,
represented generally at 482 which, in turn, is supported by a carriage
assembly
represented generally at 484. Carriage assembly 484, is supported upon the
upper
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steel plate 486 of a table within mainframe 152 (Fig. 2). Connected to the
upper plate
486 are two generally C-shaped, outwardly opening elongate and spaced apart
rails
represented generally at 488 and 490. Rail 488 is configured with a tower
disposed
wear plate 492; an elongate spacer 494 and an upwardly disposed capture plate
496. In similar fashion, rail 490 is configured with a lower disposed wear
plate 498,
spacer 500 and a capture plate 502. Located parallel with and between the
rails 488
and 490 is a cam track (Fig: 12) represented generally at 504 configured with
spaced
apart elongate cam members 506 and 508.
Carriage assembly 484 is formed of a primary carriage represented generally
at 510. Primary carriage 510 generally is configured such that principally it
may be
drivably moved along a locus of travel which is generally parallel with system
axis 30
(Fig. 1 ). It is configured with a flat base assembly 512 to which are coupled
oppositely disposed somewhat elongate blocks 516 and 518. Four cavities are
machined into these blocks 516 and 518. fn this regard, Fig. 12 shows a cavity
520
IS machined in block 516 and a cavity 522 machined in block 518. Cavity 518
reappears
in Fig. 13 along with a cavity 524 also machined in block 518.
Four axle structures are mounted within the four cavities in blocks 516 and
518. For instance, Fig. 12 reveals an axle structure 526 mounted within cavity
520
and an axle structure 528 mounted within cavity 522. Axle structure 518
reappears
in Fig. 13 along with an axle structure 530 mounted within cavity 524. The
four axle
structures rotatably support four steel wheels. Fig. 12 reveals that axle
structure
526 supports wheel 534 which is captured between wear plate 492 and capture
plate 496. The figure further reveals that axle structure 528 rotatably
supports wheel
534 which is captured between wear plate 498 and capture plate 528. The
remaining
two wheels and associated axle structures are generally at the opposite
corners of
the primary carriage 510. The secondary carriage of carriage assembly 484 is
represented generaNy at 542.
Fig. 13 reveals that secondary carriage 542 comprises two generally G
shaped mutually inwardly opening rails represented generally at 544 and 546.
Rails
544 and 546 are configured in the same manner as primary carriage rails 488
and
490, incorporating wear plates, capture plates and spacers. Rails 544 and 546
support four steel wheels for captured movement of secondary carriage 542
along a ,,
locus of travel transverse to system axis 30 and between mold defining and
release
orientations. Fig. 13 illustrates two axle structures, 548 and 549 rotatably
supporting
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CA 02485851 2004-10-25
respective wheels 556 and 557. Axle structure 548 reappears in Fig. 12 in
conjunction with a third axle structure 551. These axle structures are mounted
within
respective blocks 562 and 564 which, in turn, are fixed to a steel plate or
base 566.
An adjustable cam follower 568 is coupled to block 562 and extends downwardly
therefrom. Fig. 12 reveals that cam 568 incorporates a cam roller 570 which is
movably engaged between cam members 506 and 508 of a given mainframe table.
Figs. 12 and 13 reveal that coupled to secondary carriage 542 is a forward or
downstream steel bumper 572. Fig. 13 shows that spaced along the primary
carriage
locus of travel or system axis 30 is a rearward or upstream bumper 574. Bumper
574 is configured with an abutment surface which is formed of an ultra high
molecular weight plastic (UHMW) . Bumper 572 is slightly canted such that upon
release of a given mold half, it will be moved slightly forwardly or
downstream in the
process to avoid damage to the seals described in connection with Figs. 5 and
6.
The axial distance between the abutting surface or surfaces of bumpers 572 and
574
is deemed a reference distance. Additionally, coupled to secondary carriage
544 is a
connector assembly configured as a half or partial nut 576. The threaded nut
includes a thread pitch which corresponds to the thread pitch of the screw 180
(Fig.
2). These connector assemblies 576 ultimately engage screw 180 in a system
axial
direction when the molds are in their mold defining orientations establishing
a mold set
or pair. To assure proper engagement with the threads of screw 180, the
reference
distance between the abutting surfaces of bumpers 572 _and 574 becomes
critical. ft
is established to provide what is considered a continuous thread pitch with
respect to
screw 180. Thus, the summed reference distances of a combination of abutting
mold
sets must be an integer value of a multiple of the pitch of the screw and
partial nut
576.
Secondary carriage 542 is guided for transverse movement upon primary
carriage 510 with a primary carriage mounted cam bar 600. Cam bar 600 is
engaged
by four follower rollers, two of which are revealed at 601 and 602. Follower
rollers
601 and 602 are supported from secondary carriage 542 by a bracket 606. See
Fig.
27 to observe secondary carriage wheels 558 and 559 with associated axle
structures 550 and 551 as well as follower rollers 603 and 604.
Mold support stand 482 is mounted upon plate or base 566 utilizing two cleats.
In this regard, a fixed cleat attached to plate 566 is shown in Figs. 12 and
13 at 578
and a removable cleat is shown in Fig. 12 at 580.
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CA 02485851 2004-10-25
Fig. 13 reveals that the support stand 482 is configured with three angular
webs 582-584 affixed to plate 566 and extending to connection with an aluminum
plate. Welded to that aluminum plate 586 are four blocks 588 - 591. Machine
screws,
certain of which are revealed at 594 extend through plate 586 and blocks 588-
591 to
attachment with mold body 480. Finally, the blocks as at 516 and 518 are
configured
having locking or engagement holes formed in their peripheries for utilization
in
primary carriage maneuvering. Two such locking holes are shown in Fig. 12 at
596
and 597 and third is shown in Fig. 13 at 598.
Referring to Fig. 14, a plan view of the frame and table arrangement along
with conveyors and trolleys is presented. With system 10, paired molds or mold
sets
are maneuvered along axis 30 by a translation assembly represented generally
at 610
comprised of centrally disposed screw 180 mounted between bearings 192 and 194
and rotatably driven by the motor assembly represented generally at 196. The
translation assembly 610 also is configured with main tables represented
generally at
I S 224 and 226 and provided with respective earlier-described upper plates
228 and
230. Mounted in spaced relationship on these upper plates and in parallel
relationship
with system axis 30 are earlier described C-shaped main rails. In this regard,
main
rails 232a and 232b are mounted upon plate 228 and main rails 236a and 236b
are
mounted upon plate 230. Note that these main rails extend from adjacency with
receiving region 58 to pickup regions 614a and 614b within respective release
assemblies 62a and 62b. Main cam track 234 reappears from Fig. 4 as mounted
upon
plate 228 and extending from a main cam track entrance 616a to a main cam
track exit
618a. In similar fashion, main cam track 238 extends from main cam track
entrance
616b to main cam track exit 618b. These main cam tracks 234 and 238 engage the
follower component of a mold half. Such followers have been described at 568
as
extending from secondary carriage 542 (Fig. 12). Main cam track 234 is
configured
with main cam members 620a and 622a and, correspondingly, main cam track 238
is
configured with main cam members 620b and 622b. Note that the transversely
outwardly disposed main cam members 620a and 620b are mounted with an array of
spring retainers certain of which are revealed at 624. Retainers 624 permit
horizontal
outward transverse movement of the main cam members 620a and 620b in the event
of an anomaly occurring with respect to a given mold half during movement
through
the forming tunnel region. The cam members 620a and 620b are thus permitted to
move transversely outwardly against a spring bias.
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CA 02485851 2004-10-25
Returning to pair mold receiving region 58, paired pusher conveyors 200a and
200b of a mold positioning assembly are seen having respective drive pulleys
630a
and 630b coupled in driven relationship with a motor and torquing assembly
represented generally at 632.
Turning momentarily to Figs. 15 and 16, pusher conveyors 200a and 200b are
illustrated in enlarged detail. Fig. 15 reveals motor and torquing assemblage
632 as
being connected by shaft 634 to drive pulleys 630a and 630b. Pulleys 630a and
630b
are mounted upon respective box beams 636a and 636b which additionally support
idler pulleys 638a and 638b. A belt fi40a extends over pulleys 630a and 638a
and a
similar belt 640b extends over pulleys 630b and 638b. As seen in Fig. 16, the
ends of
these belts are attached to conveyor trolleys, one being seen in the figure at
642b
slidably mounted upon a support 644b and coupled to belt 640b at coupling
positions
646b and 648b. Conveyor trolleys as at 642b function additionally to support
conveyor plates. In this regard, Fig. 15 reveals conveyor plates 650a and
650b.
Connected across these conveyor plates is a pusher assembly represented in
these
figures in general at 652. Assembly 652 is configured having upstanding pusher
components as seen at 654a and 654b. Pusher components 654a and 654b engage
the rearward bumpers of a mold set when the mold set is positioned at
receiving
region 58. Such rearward bumpers have been described at 572 in connection with
Fig. 13. As described in connection with Fig. 2, when activated, the pusher
conveyors 200a and 200b engage the bumpers of the mold set at the receiving
region
58 and moves them synchronously axially forwardly such that the forward
bumpers
of the mold set carriage assemblies abuttably engage the rearward bumpers of a
mold set within the reference region. It may be recalled that the partial nut
connector
assemblies of the paired molds at the reference region will have been
threadably
engaged with screw 180. By virtue of the computed reference distance between
the
bumpers, proper entrance of the next mold pair upon screw 180 is essentially
assured.
Returning to Fig. 14, as a mold set emerges from the forming tunnel exit to
encounter the release assemblies as described at 62a and 62b, the follower
components of the mold secondary carriages will move beyond the main cam track
termini 618a and 618b and through the entrances of respective release cam
tracks
shown at 660a and 660b. Inasmuch as the followers engaged within the upwardly
diagonally oriented release cam tracks 660a and 660b are coupled with the
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CA 02485851 2004-10-25
secondary carriages, the molds will be moved along a locus transverse to
system
axis 30 to outboard release orientations. However, the primary carriages will
continue moving along the main rail pairs into the pickup regions 614a and
614b.
Movement through the pickup regions is carried out by the paired pullet
assemblies
S 198a and 198b. These conveyor assemblies respectively will pull the primary
carriages of each mold onto a recovery trolley. These two recovery trolleys
are
represented generally at 662a and 662b which in the instant figure are located
at
respective receiving positions 64a and 64b. However, the conveyors 198a and
198b
will load these trolleys at respective pickup regions or positions 614a and
614b.
Looking momentarily to Figs. 17 and 18, pullet conveyors 198a and 198b are
illustrated at an enhanced scale. Conveyors 198a and 198b incorporate
respective
drive pulleys 664a and 664b and idler pulleys 666a and 666b. These pulleys are
mounted upon respective box beams 668a and 668b. Extending over pulleys 664a
and 666a is a belt 670a and extending over pulleys 664b and 666b is belt 670b.
Motor
and gear assembly 196 is seen providing common drive to drive pulleys 664a and
664b through a shaft assembly 672. Fig. 18 reveals that belt 670b is coupled
at
connection position 674b to a conveyor trolley 676b. The opposite side of belt
670b is
seen to be connected to conveyor trolley 676b at connection location 680b.
Attached to the top of each conveyor trolley are conveyor plates 682a and
682b. Note in Fig. 18 that conveyor plate 682b supports a pneumatically
actuated pin
assembly represented generally at 684b. When actuated, engagement pins as at
686a and 686b are driven upwardly to engage holes or bores formed upwardly
into
the bottoms of the primary carriage assemblies. Such a hole has been described
at
598 in connection with Fig. 13.
Returning to Fig. 14, as a mold pair moves off of the threads of screw 180
pullet conveyors 198a and 198b will be actuated to move the conveyor plates
682a
and 682b axially upstream until the engaging pins 686a and 686b enter
corresponding
holes within the primary carriages of each mold. The conveyor then is reversed
and
the primary carriages then are drawn along the translation assembly main rails
to the
pickup positions 614a and 614b, whereupon the carriage assemblies are loaded
on
the recovery trolleys as at 662a and 662b which will be located at those
pickup
positions.
Referring additionally to Fig. 19, the functioning of these release assemblies
is
illustrated. In the figure, primary carriages are represented in phantom at
690a-692a.
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CA 02485851 2004-10-25
These primary carriages are associated with secondary carriages represented in
phantom respectively at 694a-696a. The partial nut couplers fixed to the
secondary
carriages are represented at 698a-700a. Forward bumpers coupled to primary
carriages 690a-692a are shown respectively at 702a-704a and corresponding
rearvvard bumpers shown respectively at 706a-708a. Note that the partial nut
couplers 698a and 699a of respective primary carriages 690a and 691a are
engaged
with the threads of screw 180, these secondary carriages being in their mold
defining orientation within a forming tunnel. However, primary carriage 692a
has
been engaged by the engaging pin 686a of pullet conveyor 198a. Accordingly,
the
follower of the secondary carriage 696a will have entered and engaged with
release
cam track 660a to commence movement of the secondary carriage 696a
transversely
outwardly from system axis 30. Note that the partial nut connector assembly
700a of
primary carriage 692a remains adjacent the unthreaded portion of screw 180 as
it
continues to ride upon main rails 232a and 232b. To protect the seals
described in
connection with Fig. 5, forward bumper 703a is canted a slight amount causing
bumper 708a of primary carriage 692a to move forwardly with primary carriage
692a.
Thus the mating surfaces are parted as the secondary carriage commences to
move
transversely towards it release orientation.
Note that pullet trolley 662a is at the pickup position 614a and that
generally G
shaped pullet trolley rails 710a and 712a are aligned with respective main
rails 232a
and 232b. Additionally its recovery trolley cam track 714a is now aligned with
the exit
of release cam tract 660a. This arrangement is repeated in release region 62b.
Returning to Fig. 14, release assemblies 62a and 62b are seen having
respective paired release rails 720a, 722a and 720b, 722b extending
transversely
outwardly from system axis 30 over which respective wheeled recovery trolleys
662a and 662b are driven. Additionally, intermediate these rails are
respective
recovery trolley cams 724a and 724b. Drive is imparted to recovery trolleys
662a and
662b by respective motor and gear train assemblies represented in general at
726a
and 726b. Note that the assemblies 726a and 726b are situated in axially
reversed
orientations. With that exception, the release rails, recovery trolley cams
and
associated drive arrangements are identical.
Looking additionally to Figs. 20 and 21, these components at release region "
62a are illustrated at enhanced scale level. Fig. 20 reveals plate base
members 728a
and 730a over which the release trolley rails 720a and 722a ultimately are
supported.
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CA 02485851 2004-10-25
Motor assembly 726a is seen to comprise the electric motor 732a and a gear
assembly 734a associated in driven relationship therewith. Gear assembly 734a
is
coupled with a drive pulley 736a. Spaced from drive pulley 736a is an idler
pulley
738a. A drive belt 740a extends over pulleys 736a and 738a and is coupled in
driving
relationship to recovery trolley 662a.
Looking to Fig. 21, generally C-shaped rail 722a reappears being supported by
an upper plate 742a, in turn supported by box beam 202 which is mounted upon
the
base members 728a and 730a. Fig. 21 reveals recovery trolley 662a in
conjunction
with a carriage assembly. Such carriage assemblies have been described above
in
connection with Figs. 12 and 13. Accordingly, the same identifying numeration
is
employed with respect to the components thereof. To lock the components of the
carriage assembly 484 in place during transit on the trolley such as recovery
trolley
662a, a pneumatically actuated pin assembly represented generally at 744a is
actuated to engage a portion of it. Additionally shown in Fig. 21 is one of
the wheel
supporting recovery trolley side blocks 746a.
Looking to Fig. 22, recovery trolley 662a reappears in an end view fashion.
Note that the assembly is configured with a plate-shaped recovery trolley base
750a
and supporting recovery trolley rail 712a and downwardly depending wheel
supporting side blocks 746a and 748a. Blocks 746a and 748a support four steel
wheels, two of which are revealed at 752a and 753a. Rail 722a is seen to be
formed
with a wear plate 758a, a spacer 760a and a capture plate 762a. The latter
capture
plate 764a functions to retain the recovery trolley 662a from overturning.
Release rail 720a is similarly structured, having a wear plate 764a, a spacer
766a and a capture plate 768a. Also shown in Fig. 22 are two of four trolley
cam
follower rollers 770a and 771 a which are mounted upon a roller mount 774a
depending downwardly from base 750a. Note that follower rollers 770a and 771a
are in rolling and following engagement with sides of recovery cam 724a.
Looking to Fig. 23, follower roller 771 a reappears in conjunction with roller
mount 774a. Spaced from that follower assemblage is another follower
assemblage
comprised of roller mount 776a and cam follower roller 772a. The figure
further
reveals the attachment of belt 740a with trolley 662a. In this regard, the
belt is
coupled to base 750a at attachment positions 778a and 780a.
Returning to Fig. 14, recovery trolleys 662a and 662b are shown positioned at
the respective receiving positions 64a and 64b of mold return assemblies 66a
and
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CA 02485851 2004-10-25
66b. As is apparent, return assembly 66b is a mirror image of return assembly
66a.
Return assemblies 66a and 66b are configured with respective return rails
220a,
221 a and 220b, 221 b. These return rails are seen to be parallel with axis 30
and
extend from respective receiving regions 64a, 64b and associated queue regions
68a
and 68b to forwardmost mold positions represented respectively at 76a and 76b.
The
return rails are mounted upon respective table defining upper plates 218a and
218b.
Additionally mounted on upper plates 218a and 218b are respective rail cam
tracks
represented generally at 790a and 790b. These rail tracks are seen to be
parallel
with axis 30, extend from respective forwardmost feed positions 76a and 76b to
respective return entrance positions 792a and 792b. Note that cam tracks 790a
and
790b are positioned such that the secondary carriage cam followers engaged
between them will be retained in a mold defining orientation disposed inwardly
towards system axis 30. The entrances 792a and 792b of the rail cam track
assemblies are connected with the exits of respective return transition cam
tracks
IS represented generally at 794a and 794b. These transition cam tracks extend
diagonally inwardly toward axis 30 from respective receiving positions 64a and
64b
and when engaged by a secondary carriage follower will cause the associated
secondary carriage to move from its release orientation and toward its mold
defining
orientation.
Note additionally in Fig. 14 that the recovery trolley cam tracks 714a and
714b
of respective recovery trolleys 662a and 662b are aligned with the entrances
of the
respective return transition cam tracks 794a and 794b. Thus, the followers of
the
secondary carriages readily will be engaged within return transition cam
tracks 794a
and 794b.
Movement of the primary carriages within mold return assemblies 66a and 66b
is provided by return conveyor assemblies represented in general at 796a and
796b.
These return conveyor assemblies are formed with respective return engagement
components 798a and 798b which are driven over respective return box beams
800a
and 800b by respective return belt assemblies 802a and 802b. Return belt
assemblies 802a and 802b are driven by respective electric motor assemblies
represented generally at 804a and 804b.
Referring to Figs. 24-26 the return conveyor assembly 796a is illustrated at
an »
enhanced scale. Assembly 796b is a mirror representation of assembly 796a. In
Figs. 24 and 25 return box beam 800a is shown to be supported from angle
supports,
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CA 02485851 2004-10-25
certain of which are identified at 806. The beam 800a, in turn, supports
return drive
pulley 808a and an idler pulley 810a, a return belt 812a extends over pulleys
808a
and 810a and is attached to return engagement component 798a at attachment
positions 816a and 818a. Drive pulley 808a is seen in Fig. 24 to be coupled in
driven
relationship with motor assembly 804a. Return engagement component 798a is
configured with a return plate component 820a. As seen in Figs. 25 and 26,
return
plate component 820a is mounted upon a return conveyor trolley 822a which is
retained and positioned upon beam 800a by an elongate return cam bar assembly
represented generally at 824a. Follower members (not shown) mounted with the
return conveyor trolley 822a follow along this cam bar assembly 824a as the
return
engagement component 798a is driven from motor assembly 804a. Engagement
components 798a is configured to engage the underside of the primary carriages
of
from one to three mold supporting carriage assemblies. Such engagement is
developed by solenoid actuated return engagement pin assemblies seen in Figs.
24
I S and 25 at 826a, 828a and 830a. In this regard engagement pin assembly 826a
is
revealed in plan view in Fig. 26. As before, in Fig. 26 the general
identifying
numeration set forth with respect to carriage assembly 484 described in
connection
with Figs. 12 and 13 is carried forward.
At such time as return conveyor assembly 796a will have retrieved a mold or
mold half from a receiving position as described earlier at 64a it will return
while
engaged with an associated primary carriage utilizing return pin assembly 830a
to the
queuing region 68a where it will reengage, for instance, to primary carriages
including that at the forwardmost position. In Fig. 29, for example, the
return
engagement component 798 is represented as having engaged the primary carriage
components of molds 55a-57a. In this regard, return pin assembly 830a will
have
engaged the primary carriage of mold 55a; the pin assembly 828a will have
engaged
the primary carriage of mold 56a; and pin assembly 826a will be in engagement
with
the primary carriage of mold 57a. Mold 57a is shown schematically at the
forwardmost position 76a preparatory to being maneuvered onto the mold feed
assembly 70a. Assemblies as at 826a-828a and 830a are axially spaced such that
adjacent bumpers of the primary carriages are spaced apart about one inch when
located at the queue regions 58a and 58b. When at these two regions, the
primary
carriages are secured by appropriate ones of the pneumatic keeper assemblies
described in conjunction with Fig. 14 at 210a, b - 214a, b.
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CA 02485851 2004-10-25
Referring to Figs. 27 and 28, this keeper or securement arrangement is
illustrated at a higher level of detail. A portion of the primary carriage 510
of carriage
484 as described in connection with Figs. 12 and 13 is imported into the
instant
figures. Keeper assembly 211a is shown coupled to beam 202 supporting plate
218a
and C-shaped return rail 220a. The assembly 211a is comprised of a keeper pin
840a
which is driven upwardly from its home or un-extended orientation as shown
into
engagement with a notch as at 844a within a wheel supporting block of primary
carriage 510. This engagement is facilitated by a chamfering of the upper edge
of pin
840a. Assembly 211 a further includes a pin location sensor assemblage
represented
generally at 846a. Fig. 28 illustrates the upwardly disposed or keeping
orientation of
the keeper pin 840a.
Returning to Fig. 14, mold feed assemblies 70a and 70b are configured
essentially identically with the trolley and rail components of release
assemblies 62a
and 62b. In this regard, feed trolleys are shown at 850a and 850b. The upper
surface of feed trolley 850a is seen to support parallel axially aligned C-
shaped feed
trolley rails 852a and 854a. Correspondingly, the upper surface of feed
trolley 850b
is seen to support corresponding feed trolley rails 852b and 854b. The upward
surfaces of feed trolleys 850a and 850b further support respective feed
trolley cam
tracks represented generally at 856a and 856b. Feed trolleys 850a and 850b are
configured essentially identically with respective recovery trolleys 662a and
662b
with the exception of the location of these feed trolley cam tracks. Feed
trolley cam
tracks 856a and 856b are located for alignment with respective return cam
tracks
790a and 790b as well as main cam track assemblies 234a and 234b. Feed trolley
856a rides upon C-shaped feed rails 858a and 860a, while feed trolley 850b
rides
upon corresponding C-shaped feed rails 858b and 860b and is driven from
corresponding motor and belt assembly 862b. Mounted on the surface or plate
members supporting the feed rails are feed trolley cams 864a and 864b. C-
shaped
feed rails 858a, 860a and 858b, 860b as well as electric motor and belt
assemblies
862a, b and feed trolley cams 864a, b are configured identically as the
corresponding
components at release or at the transport assemblies 62a and 62b. However, for
the
feed operation, the feed trolleys 850a and 850b move between receiving region
58 as
shown in the figure and respective acquisition regions represented generally
at 866a
and 866b providing for alignment with the corresponding return assemblage.
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CA 02485851 2004-10-25
Figs. 29 - 32 illustrate the maneuvering of molds or mold halves 50a, b - 57a,
b
within the system 10. Looking to Fig. 29, mold pair 50a, 50b have been united
and
their partial nut connector assemblies have commenced to engage screw 180.
Mold
pairs 50a, b - 53a, b are establishing the forming tunnel. Mold pair 53a, b
are
approaching the release assembly 62a to be parted. Mold pair 54a, b are well
within
the release assemblies 62a, 62b and are approaching respective pickup regions
614a
and 614b. Mold pair 57a, b is being driven rearwardly in combination with mold
pairs
56a, b and 55a, b, molds 57a and 57b being maneuvered into respective
acquisition
positions 866a and 866b. Note that feed trolleys 850a and 850b are at those
positions for this loading procedure.
Looking to Fig. 30, feed trolleys 850a and 850b are maneuvering respective
molds 57a and 57b towards receiving region 58. United mold pair 50a, b now
represents a reference mold pair with respect to mold pair 57a, b. Molds 56a
and 56b
now are located within respective queue regions 68a, b at respective
forwardmost
IS positions 76a and 76b. Molds 55a and 55b also are in respective queue
regions 68a
and 68b and their bumpers are spaced about one inch from the rearwardly
disposed
adjacent molds. Downstream, recovery trolleys 662a and 662b are moving
respective molds 54a and 54b outwardly toward receiving positions 64a and 64b.
The dynamic mold forming tunnel continues to be established by mold pairs 50a,
b
53a, b.
Turning to Fig. 31, mold pair 57a, b have been joined at receiving region 58
and
have been pushed downstream by the pusher conveyors 200a, b of the mold
positioning assembly to the extent their half-nut connector assemblies have
engaged
screw 180. This pushing will have been against the reference mold pair 50a, b
and
the forming tunnel is being established by mold pairs 57a, b, 50a, b, 51 a, b
and 52a, b.
Molds 53a and 53b are releasing and a slight axial gap is being formed at the
abutting
bumper surfaces of the primary carriages of molds 52a and 53a by virtue of the
earlier-described slight cant or slope in the forwardmost bumper. Molds 54a
and 54b
are being moved off respective recovery trolleys 662a and 662b at receiving
positions 64a and 64b. This movement is driven by the earlier described return
conveyor assemblies 796a and 796b. Molds 56a, 56b remains at respective
forwardmost positions 76a and 76b, while molds 55a and 55b remain within "
respective queue regions 68a and 68b in slight spaced adjacency with respect
to the
forwardmQst positioned molds.
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CA 02485851 2004-10-25
Looking to Fig. 32, the partial nut connector assemblies of the primary
carriages of mold pair 57a, b remain engaged the translation assembly screw
180.
Thus the mold pair 57a, b continue to establish a forming tunnel additionally
comprised
of mold pairs 50a, b - 52a, b. Molds 53a and 53b are fully within respective
release
assemblies 62a and 62b and the recovery trolleys 662a and 662b are being
driven
inwardly towards respective pickup positions 614a and 614b. Molds 54a and 54b,
are being moved rearwardly within the respective return assemblies 66a and 66b
and
the secondary carriages thereof are being maneuvered from mold release
orientations toward mold defining orientations. Mold 56a and 56b remain
located at
the adjacent forwardmost position 76a and 76b of respective queue regions 68a
and
68b. Molds 55a and 55b remain in those respective queue regions 68a and 68b
while
feed trolleys 850a and 850b are driven transversely outwardly toward
respective
acquisition positions 866a and 866b.
Since certain changes may be made in the above system and apparatus
without departing from the scope of the invention herein involved, it is
intended that all
matter contained in the above description or shown in the accompanying
drawings
shall be interpreted as illustrative and not in limiting sense.
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