Project Overview

The client entrusted us with the task of generating a 3D model of a Battery Mould from an existing 2D file. The mould is a fundamental component in producing pre-cast concrete slabs. It ensures uniform shaping and efficient manufacturing. In addition to 3D modeling, we also designed and drafted a shutter-split mechanism that enables the concrete moulds to automatically split once the concrete is cast, using pneumatic cylinders. 

Challenges & Requirements

Generating a precise 3D model from a 2D reference required a comprehensive understanding of the design specifications. Additionally, introducing an automated shutter-splitting mechanism needed a careful analysis and implementation of the calculations. 

• Translating the provided 2D file into a fully functional 3D model.

• Designing an automatic shutter-split mechanism that enables automatic mould splitting after concrete casting, using pneumatic cylinders.

• Ensuring accurate and precise alignment of the moulds for pre-cast slab formation.

• Integrating the pneumatic cylinders into the design also facilitates the automatic opening and closing of the mould.

• Estimated project duration: 6-7 months

Our Approach

Our team devised a strategic process to ensure that the 3D model and shutter-split mechanism met both functional and manufacturing requirements:

1. 3D Modeling: Our experts carefully analyzed the given 2D file and translated it into a working 3D model, while refining the measurements for precision. 

2. Shutter-Split Mechanism: Our team engineered a fully automated mould-splitting mechanism, using pneumatic cylinders for seamless operation. 

3. Manual Calculations & Drafting: The new mechanism was designed from scratch, with thorough manual calculations to ensure accuracy and smooth functionality. 

4. Validation & Refinements: The design underwent multiple quality checks and reiterations to ensure structural integrity and operational efficiency.

Outcome & Impact

With advanced 3D Modeling and precise mechanical design, we successfully delivered a functional and efficient battery mould, optimized for pre-cast slab production.

• Provided a fully detailed and functional 3D Model, enabling seamless manufacturing and assembly, while being scalable for future modifications.

• Engineered a highly efficient shutter-splitting mechanism, ensuring smooth mould operation.

• Improved production efficiency by automating mould-splitting, reducing manual intervention.

• Integrated pneumatic cylinders, enhancing automation and reliability in concrete slab production. 

Conclusion

By leveraging 2D for 3D modeling and applying mechanical engineering expertise for the shutter speed mechanism, we successfully optimized the battery mould design for the client. This case study showcases our ability to deliver high-precision industrial solutions that enhance manufacturing efficiency and automation.

Looking for expert mechanical design and automation solutions? Contact us today!