Project Overview

The client approached us with the task of reverse engineering a noise barrier concrete mould into a 3D model and 2D draft, along with implementing necessary modifications to enhance its efficiency. The mould is an essential element in infrastructure development, being used for making noise-proof pre-cast concrete slabs. Besides replicating the existing design we introduced structural improvements to reduce idle time and double production capacity through innovative mould and shutter mechanisms.

Challenges & Requirements

Reverse engineering the existing machine required accurate on-site measurements and a deep understanding of its structural and functional aspects. Additionally, the goal was to increase efficiency and automation through innovative design enhancements.

• Conducting on-site measurements of the existing noise barrier concrete mould for accurate replication.

• Creating a 3D model and a 2D draft for manufacturing reference.

• Designing and integrating a secondary mould that slides into the shutters when the primary mould is removed, minimizing downtime and doubling production output.

• Engineering a shutter mechanism that automatically splits and separates the moulds once the concrete is cast.

• Ensuring the structural integrity and operational efficiency of all modifications.

• Estimated project duration: 12 months.

Our Approach

Ensuring seamless execution and optimization, our team of experts followed a systematic reverse engineering process to incorporate innovative design solutions to enhance productivity and automation.

1. Facility Visit & Measurement Collection: Our engineers visited the client's facility to manually measure the existing mould manually, ensuring precise data collection.

2. 3D Modeling & 2D Drafting: We recreated the 3D model and 2D draft, refining dimensions for manufacturing accuracy.

3. Designing the Secondary Mould: We introduced a secondary mould system, reducing idle time by allowing the next batch of concrete slabs to be prepared while the primary mould was in use.

4. Shutter Mechanism Development: Our team engineered an automatic splitting shutter mechanism, improving efficiency by streamlining the slab extraction process.

5. Validation & Refinements: The designs underwent multiple refinements and feasibility tests to ensure structural stability and manufacturing practicality.

Outcome & Impact

By integrating advanced design modifications and automation, we significantly enhanced the efficiency and production capacity of the noise barrier concrete mould.

• Successfully reverse-engineered the mould with precise 3D and 2D models for seamless manufacturing.

• Introduced a secondary mould system, reducing idle time and doubling production output.

• Engineered an automatic shutter mechanism, improving the extraction process and minimizing manual intervention.

• Optimized the overall manufacturing workflow, ensuring greater efficiency, consistency, and scalability.
  
  
  

Conclusion

Through detailed reverse engineering, innovative design improvements, and automation, we successfully optimized the noise barrier concrete mould for the client. This case study highlights our expertise in enhancing industrial machinery for increased productivity and efficiency.

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