Method for operating a mold extraction assembly in a concrete products forming machine

Abstract

A method for moving a mold assembly from a mounted position within a concrete products forming machine includes extending an extraction assembly forwardly from a retracted position at a rear of the concrete products machine to an intermediate position so that terminal ends of the extraction assembly are positioned below a carrying surface of the mold assembly. The extraction assembly is raised at the rear portion of the concrete products machine so that the terminal ends of the extraction assembly contact and raise the carrying surface of the mold assembly up off mold mounting surfaces on the concrete products machine. The extraction assembly is then moved to a fully extended position so that the mold assembly is moved forwardly from the mold mounting surfaces to an operative position whereby the mold assembly can be removed from the extraction assembly and replaced with a replacement mold assembly.

Claims

1. A method for moving a mold assembly to and from a mounted position within a concrete products forming machine (CPM), the method comprising: mounting an extractor assembly to a feed box assembly at a rear of a concrete products forming machine, the extractor assembly including a guide rail assembly, an extractor fork assembly, and an extractor arm assembly; vertically moving the extractor assembly and feed box assembly together with respect to a mold mounting structure in a CPM center section; moving the extractor fork assembly to an intermediate extended position just below the mold mounting structure; lifting the extractor fork assembly up against a mold assembly resting on the mold mounting structure so that the mold assembly is carried off the mold mounting structure; moving the mold assembly forwardly to a fully extended position at a mold transfer assembly; and lowering the mold assembly onto the mold transfer assembly.

2. The method of claim 1, wherein the step of moving the extractor fork assembly to an intermediate extended position includes extending the extractor arm assembly horizontally along the guide rail assembly to an intermediate extended position just below the mold mounting structure.

3. The method of claim 1, wherein the step of moving the mold forwardly to a fully extended position includes extending the extractor fork assembly horizontally along rails affixed to the extractor arm assemblies.

4. The method of claim 1, further including the step of telescopically nesting the extractor fork assembly about the extractor arm assembly.

5. The method of claim 1, further including the steps of coupling a hydraulic cylinder between the feed box assembly the extractor arm assembly and moving the extractor arm assembly along the guide rail assembly using the hydraulic cylinder.

6. The method of claim 5, further including the steps of coupling a second hydraulic cylinder between the arm assembly and the fork assembly and extending the fork assembly with respect to the arm assembly using the second hydraulic cylinder.

7. The method of claim 1, further including the step of coupling a hydraulic cylinder between the arm assembly and the fork assembly and extending the fork assembly with respect to the arm assembly using the hydraulic cylinder.

8. The method of claim 1, further including the steps moving the extractor assembly between three operative positions including a fully retracted position, an intermediate extended position where either the arm assembly is fully extended along the guide rail assembly or the fork assembly is fully extended with respect to the arm assembly, and a fully extended position where both the arm assembly and fork assembly are in a fully extended position.

9. The method of claim 1, further including the step of carrying the mold assembly on tapered alignment blocks located on top sides of the extractor fork assembly that are configured to be received within complementary structures on an underside of the mold assembly.

10. The method of claim 1, wherein the step of lifting the extractor fork assembly up against a mold assembly includes moving an upwardly tilted top surface of the fork assembly against the mold assembly so that the mold assembly is carried off the mold mounting structure and causes the fork assembly to sag under a weight of the mold assembly so that the mold assembly and top surface of the mold assembly are disposed approximately parallel to a mold mounting surface on the mold transfer assembly.

11. The method of claim 1, further including the step of extending the extractor assembly from an attachment point on an underside of a top plate assembly of the feed box assembly.

12. The method of claim 11, where the attachment point is on a top plate assembly of the feed box assembly.

13. The method of claim 1, further including the step of fitting the extractor assembly within an envelope of the feed box assembly when the extractor assembly is in a fully retracted position.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1 is a perspective view of a mold extractor assembly of the present invention in a first extended position relative to a mold box assembly and mold cassette assembly.

(2) FIG. 2 is a perspective view of the mold extractor assembly of FIG. 1 shown in a retracted position.

(3) FIGS. 3A and 3B are perspective and top plan views, respectively, of the mold extractor assembly of FIG. 1 shown in a fully extended position.

(4) FIG. 4 is a side elevation view of the mold extractor assembly of FIG. 1 installed within a feed box assembly of a concrete products forming machine with a mold assembly and mold cassette assembly shown in broken lines.

(5) FIG. 5A through 5C are side elevations views of the mold extractor assembly in progressive extension and elevation steps during a mold extraction process.

(6) FIG. 6 is a front elevation view of the mold extractor assembly taken along lines 6-6 in FIG. 4.

(7) FIG. 7 is a front elevation magnified view showing a portion of the mold extractor assembly lifting a mold assembly off of shelves and alignment dowels of a concrete products forming machine according to teachings of the invention.

(8) FIG. 8 is a side elevation section view of FIG. 7.

DETAILED DESCRIPTION

(9) FIG. 1 shows a mold extraction assembly 10 in combination with a mold assembly 110 and mold cassette assembly 210. Extraction assembly 10 includes a set of inner guide rails 12, 14 coupled along their length to a top plate assembly 312 of the feed drawer section 310 of a concrete products forming machine (FIG. 6). Guide rails 12, 14 extend parallel to a mold extraction path 16 and include grooves running longitudinally along the length of the rails on opposed sides. A pair of mold extraction arms 18, 20 are disposed just underneath the inner guide rails 12, 14 and are slidingly connected thereto via sets of guide blocks, such as extraction arm guide block 22, that are affixed to upper ends of the arms 18, 20 and slide within the grooves formed in the sides of the guide rails.

(10) Extraction arms 18, 20 are coupled together via a front bracing plate 24 and a rearwardly disposed cross-bracing plate 26 running between top ends of the arms. A hydraulic cylinder 28 is positioned along a central axis of the extraction assembly 10 and includes a cylinder mount block 30 at a rear end and a cylinder support block 32 at a front end mounted upward to the top plate assembly 312 of the feed drawer section 310 (FIG. 6) of the concrete products forming machine. A cylinder housing 34 is fixedly coupled between the mount block 30 and support block 32 and receives a hydraulic piston 36 (FIG. 3A). A terminal end of the hydraulic piston 36 is coupled to an underside of the cross-bracing plate 26 spanning between extraction arms 18, 20. Actuation of the hydraulic cylinder 28 causes the piston 36 to extend out of the end of the housing 34 and push the plate 26, thereby causing the connected arms 18, 20 to slide forwardly along the inner guide rails 12, 14 to an extended position. Likewise, the hydraulic piston 36 may be retracted into the housing 34 and withdraw the arms 12, 14 to a retracted position as shown in FIG. 2.

(11) Mold extraction assembly 10 further includes a set of outer guide rails 38, 40, with each affixed to outside walls of respective extraction arms 18, 20 and extending parallel to the inner guide rails 12, 14 and mold extraction path 16. A pair of mold extraction forks 42, 44 are telescopically nested about the arm assembly and slidingly coupled to respective arms 18, 20 via a set of guide blocks, such as extraction fork guide block 46 (hidden in FIG. 1, but shown in FIG. 3B), that allow the forks to move slidingly along the length of the rails 38, 40 and extend the forward reach of the mold extraction assembly 10. Forks 42, 44 are coupled together at a front end by a spreader plate 48. Each of the forks includes a tapered alignment block, such as blocks 50, 52, that extend upward from a top surface of the forks and mate (see broken lines) with complementary apertures (FIG. 7) formed on the underside of a mold assembly 110. The tapering narrows to the upper surface of the alignment blocks 50, 52, preferably in the direction of extraction 16 so as to accommodate for tolerances with positioning the forks in relation to the mold assembly 110 as described further below. More preferably, the tapered surface has a principal taper in a direction parallel with the outside track, and a minor taper in a horizontally orthogonal direction to that track. Forks 42, 44 are profiled with an angled surface 54 coupling the thicker rear end with the narrower front end to optimize section stiffness and weight, and with an upwardly tilted top surface from back to front that is slightly angled on an unloaded mold extraction assembly 10. The tilted top surface of the forks 42, 44 are intended to accommodate the natural sag that would occur when a heavy mold assembly is carried on the forks 42, 44 so that, when the forks are loaded with the heavy mold assembly, the top surfaces (and thus the carried mold assembly) are disposed nearly parallel to mold mounting surfaces on the mold cassette assembly 210.

(12) Horizontal movement of the arm assembly is implemented by a pair of hydraulic cylinders 58, 60 coupled via a bracket (e.g. bracket 62) affixed to a back end of respective extraction arms 18, 20. Cylinders each include a cylinder housing 64 fixedly coupled to bracket 62 and a hydraulic piston 66 received in the housing and extending parallel to the extraction path 16. A terminal end of the hydraulic piston 66 is coupled to a rear end of a respective fork 44. Actuation of the hydraulic cylinders 60 causes the piston 66 to extend out of the end of the housing 64 and push the fork 44, thereby causing the fork assembly to slide forwardly along the outer guide rails 38, 40 to an extended position. Likewise, the hydraulic piston 66 may be retracted into the housing 64 and withdraw the forks 42, 44 to a retracted position as shown in FIG. 2.

(13) Vertical movement 56 of the mold extraction assembly 10 via means described further below acts to approach and lift the mold assembly 110 from below so it can be placed on either the concrete products machine shelves 134 or the cassette assembly 210 shelves 264, 266 during a mold exchange process. Retraction and extension of the mold extraction assembly occurs in three phases: (1) the fully retracted position is shown in FIG. 2; (2) the partially extended position is shown in FIG. 1 so that the forks 42, 44 are positioned below mold assembly 110 mounted on a CPM; and (3) the fully extended position as shown in FIGS. 3A/3B where both the forks and the arms are extended along respective rails/tracks 38, 40, 12, 14.

(14) The mold assembly 110 includes a mold box portion 112 and a head assembly portion 114 that are fitted together in alignment with one another for mounting together onto a concrete products forming machine as described further below. Assemblies 112 and 114 are constructed to form molded concrete products having a certain size and configuration, whereas different mold assemblies can have differently configured assemblies resulting in different products. As the exchange of one mold assembly with another on a concrete products forming machine typically requires a large amount of manual labor and downtime, enabling an automated exchange of one mold assembly with another using the extraction assembly described herein is a key goal of the invention.

(15) Generally, mold box 112 includes a body with a front wall and a back wall joined together with side walls and having cavities for receiving and molding the concrete products. The side walls each have a side face that spans between a bottom facing surface of the side face and a top facing surface.

(16) A mounting bracket extension 132 is coupled to each side wall of the mold box 112 to extend the width of the mold assembly 110. In use, the front and back walls of the mold box 112 are sized for extending substantially between a pair of shelves 134 (FIG. 7), also referred to as die supports 134, on a concrete products forming machine to thus allow the mold box 112 to sit directly on top of and span between the shelves. The mounting bracket extensions 132 can be used to extend narrower mold boxes to mount to various CPMs, although such features may not be necessary if the bottom facing surfaces of the sidewalls are wide enough to accommodate the die alignment and mold transfer features described further below. The mounting bracket extensions 132 in combination with the side walls thus form the lower mounting surface of the mold assembly onto these shelves 134 of the concrete products forming machine.

(17) Formed in an underside of this lower mounting surface are die alignment holes 136 (FIG. 7) adjacent an outer periphery of the mold box. When a mounting bracket extension 132 is necessary for extending the width of the mold assembly 110, these die alignment holes 136 are formed in each mounting bracket extension and configured to receive a respective alignment dowel 138 (FIG. 7) extending upward from the shelves of the concrete products forming machine.

(18) Mold transfer locators 140 (FIG. 7) are formed on the lower mounting surface of the mold box 112, inboard of the die alignment holes and shelves of the concrete products forming machine. In one embodiment, locators 140 are recesses formed in the lower mounting surface that extend to an inner wall of the mold side walls. Locators 140 are configured to precisely locate the mold box onto mold extractor forks 42, 44 when the mold box is lifted off of the alignment dowels by the mold extractor forks during a mold extraction process as described further below. In use, these mold transfer locators 140 receive the tapered alignment blocks 50, 52 formed atop the forks 42, 44 of the mold extraction device 10. The forks 42, 44 of the extraction device 10 are configured to move between the CPM shelves 134 and lift upward against the inward portion of the lower mounting surface of the mold assembly, this inward portion being that portion that does not sit directly atop the CPM shelves. FIG. 7 illustrates fork 44 lifting up against a lower portion of mold box 110 that is inboard (e.g. to the left) of the bracket extension 132. The tapered alignment blocks are received within the mold transfer locators—e.g. block 52 received within locator 140—and the mold assembly 110 is lifted off of the shelves 134 for transport away from the CPM. A new mold box is then installed on the CPM in a reverse process and the production cycle is then restarted to form newly configured molded products.

(19) FIG. 1 shows details of the cassette 210 used in mold transfer assembly. Cassette 210 includes two C-section frames 252, 254 coupled together at the top by a central weldment post 256 on which sits a top plate 258. Cassette frame sections 252, 254 are coupled together at the bottom by a spreader plate 260 that maintains the spacing between the frame sections. Spreader plate is located at the lowest portion of the cassette 210 so as to provide a large central opening 262 within the cassette through which a mold assembly, such as assembly 110, may be received.

(20) Coupled on either side of the spreader plate 260 are features configured to guide and retain a mold assembly within the cassette. A pair of shelves 264, 266 are spaced on each side of the spreader plate 260. The shelves are spaced an identical distance apart as the shelves or die supports 134 on the CPM to which the mold assemblies are operatively mounted. The pair of shelves 264, 266 are separated by a central expanse configured to receive the forks 42, 44 of a mold exchange assembly, noting that the spreader plate 260 is located below the bottom surface of the shelves to establish a height of the vertical expanse between the shelves 264, 266. The height of the vertical expanse—and in this case the height of shelves 264, 266—is large enough so as to accommodate the height of a front end of the mold extractor forks 42, 44 and prevent collision with the spreader plate 260 when the forks have set the mold assembly 110 onto the top surface of shelves 264, 266 and is then withdrawn back to a retracted position.

(21) A pair of inwardly sloped guide plates 268, 270 are coupled to outside peripheral sections of the shelves. These plates 268, 270 are angled from a wider top spacing to a narrower bottom spacing and are configured to provide surfaces that guide the mold onto the shelves. Mold alignment dowels 272 are centrally located on a top surface of each of the shelves 264, 266. In use, the mold extraction device 10 would lift mold assembly 110 from the shelves 134 on the CPM and carry it through the opening 262 of cassette 210. The mold extraction device would then lower the mold assembly 110 onto cassette shelves 264, 266 so that apertures on an underside of the mold assembly receive dowels 272.

(22) FIG. 4 shows a side view of the mold extraction assembly 10 coupled to the underside of a feed drawer assembly 310. Feed drawer assembly 310 is a structure located to the rear of a CPM center section (not shown) and the mold 110 mounted thereon (shown in broken lines). The mold extraction assembly 10 is coupled to a mounting plate 312 affixed to the underside of the feed drawer 314 of assembly 310. Vertical movement 316 of the feed drawer 314 and coupled mold extraction assembly 10 is implemented via a set of screw lifts 318, 320 that would ordinarily be part of the feed drawer assembly system in a conventional CPM such as that available from Columbia Machine, Inc. The mold extraction assembly 10, when in a fully retracted position as shown in FIG. 4, fits within the envelope of the feed drawer assembly 310 and uses the preexisting vertical lift system 318, 320 to raise and lower, particularly the forks 42, 44 of the extraction assembly 10 into contact with an underside of the mold assembly 110. The mold assembly 110 is then lifted and carried forward along extraction route 16 to the cassette assembly 210 whereupon the mold is set down onto the cassette shelves 264, 266 and onto alignment dowels 272.

(23) FIGS. 5A-5C illustrate three separate extension phases of the mold extraction device 10. In FIG. 5A, the mold extraction forks 42, 44 are pushed forward 70 via hydraulic cylinders 58, 60 to an extended position so that the mold alignment block structures 50, 52 on the tops of the forks 42, 44 are aligned with complementary structures on the underside of mold assembly 110. The feed box lifting structure 318, 320 then raise 72 the feed box and attached mold extraction assembly 10, and alignment blocks 50, 52 are received within the complementary structures on the mold assembly and the mold is lifted off of the CPM shelves.

(24) FIG. 5B shows the mold extraction assembly in a fully extended and raised position while retaining the mold assembly 110. The mold extraction arms 18, 20 are pushed forward 74 via hydraulic cylinder 28 to an extended position so that—in combination with the mold extraction forks 42, 44 also having been fully extended—the mold alignment block structures 50, 52 are aligned within the opening of the cassette assembly 210 and spaced above its shelves 264.

(25) FIG. 5C shows the mold extraction assembly in a fully extended and lowered position. From the position shown in FIG. 5B, the feed box lifting structure 318, 320 lowers 76 the feed box and attached mold extraction assembly 10 to thus set the mold assembly 110 onto the shelves of the cassette assembly 210. More specifically, the mold assembly is lowered so that alignment dowels 262 located on a top surface of the shelves are received within complementary apertures formed on the lower surface of the mold assembly, outboard of the structures for receiving the alignment blocks on the forks. With the mold assembly now mounted on the cassette assembly 210, the extraction assembly is retracted to the intermediary position shown in FIG. 1. Retraction of the extraction assembly forks 42, 44 is preferably just enough to move the forks out of the way of a mold transfer assembly that moves a new cassette and mold assembly into place for transfer to the concrete products machine 110. In this way, it is preferred that the forks retract to the intermediary position shown in FIG. 1 rather than the fully retracted position as shown in FIG. 2 so as to save time.

(26) FIG. 6 shows a front elevation view of the mold extraction assembly 10 mounted via a bottom plate 312 to a feed box 314 within an assembly 310. The mold extraction assembly is mounted upward against an underside of plate 312 as via bolts 78, 80 so that the assembly may be raised and lowered by means 318, 320 in fixed relation to the feed box 314.

(27) FIG. 7 shows a magnified view of a right portion of the mold extraction assembly, and particularly fork 44 of such assembly lifting upward against a bottom side of the mold assembly 110, and particularly upward against mounting bracket extension 132. The extractor fork assembly is narrower than a space between the mold mount shelves so that the extractor fork assembly may fit within a space between the shelves and beneath the mold box mounted thereon. Upward movement of the fork 44 causes the alignment block 52 to be received within complementary aperture 140 formed inboard from the mold alignment aperture 136 on the bottom side of the mold assembly 110. Further upward movement causes the mounting bracket extension 132 to be lifted off of CPM shelf 134 and particularly off of mold alignment dowel 138.

(28) FIG. 8 shows a side elevation view in partial section of FIG. 7 showing the mold assembly 110 lifted above the top level of CPM shelf 134. When the dowel 138 is fully disengaged from aperture 136, the mold extractor may be moved 16 (FIG. 16) to a fully extended and lifted position as shown in FIG. 5B.

(29) In summary, therefore, the mold extractor assembly is comprised of a mold extractor fork assembly which during mold change supports the mold assembly and is supported by the mold extractor arm assembly. Hydraulic cylinders are used to move the mold extractor fork assembly horizontally relative to the mold extractor arm assembly.

(30) The mold extractor fork assembly is comprised of two extractor forks to support the mold assembly, tapered alignment blocks that indicate the correct position of the mold assembly on the two extractor forks, and mounted linear runner blocks that guide the mold extractor fork assembly on horizontal guide rails mounted to the mold extractor fork assembly. Each extractor fork has means for attaching to the rod end of a hydraulic cylinder to move the extractor forks relative to the mold extractor arm assembly.

(31) The mold extractor arm assembly is comprised of two extractor arms that support the mold extractor fork assembly and are mounted to the top plate assembly of the rear feed drawer section. Horizontal guide rails are mounted to the extractor arms that support and guide the mold extractor fork assembly. Runner blocks are mounted to the extractor arms that are supported by guide rails mounted to the top plate assembly. The mold extractor arm assembly has a means for attaching the rod end of a hydraulic cylinder to move the mold extractor arm assembly relative to the top plate assembly.

(32) The mold assembly is comprised of two main sections, the mold head assembly and the mold box assembly. These two sections are placed together by the center section assembly to be ready for transport by the mold extractor assembly. The position of the mold assembly for transport by the mold extractor assembly is indicated by tapered alignment blocks fitting into like holes in the mold box assembly.

(33) Having described and illustrated the principles of the invention in a preferred embodiment thereof, it should be apparent that the invention can be modified in arrangement and detail without departing from such principles. For instance, it is understood that the hydraulic cylinders are just one aspect of drive means that can extend and retract the forks and arms of the mold extraction device and can take the form of hydraulics, pneumatics, electric screw-driven mechanisms, etc. We claim all modifications and variation coming within the spirit and scope of the following claims.