Higher quality and less wear
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Fig. 1 Mold assembly with FlexWay
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Fig. 2 Large-size, wear-resistant sliding elements...
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Fig. 3 Nearly contactless immersion of the shoes...
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Fig. 4 High wear caused by eccentric immersion.
FlexWay is the name of the innovative mold slip system from Rampf Formen GmbH. The worldwide novelty for concrete block manufacturers minimizes the wear of concrete block molds many times. The new system, which can be used for all Rampf concrete block molds, noticeably increases the quality of the manufactured concrete blocks. In addition, it steps up cycle times and reduces scrap rates.
The system, which optimizes the manufacturing process in block production, has been making waves ever since its presentation in May. As already reported in our issue of 06/09, the company presented its worldwide novelty FlexWay on the occasion of its in-house exhibition earlier this year. Trade experts are sure that the new patent will revolutionize concrete block production around the globe. The ingenious systems was designed during the past years in the in-house development department of Rampf Formen GmbH and tested in long test series with partner companies for everyday use. The result of the many years of work is impressive. The Swabian manufacturer promises concrete block manufacturers that use the new mold slip system higher cycle rates through less wear and higher productivity through fewer rejects as well as a block surface of proven higher quality. A system, moreover, that involves very little handling costs.
The system, to put it in a nutshell, divides the conventional mold top in two. The upper part is replaced by the FlexWay unit. Of great advantage is that the modular system can be installed on different mold top components in just a few easy steps. It can therefore be flexibly used on all types of paving blocks and can be reused several times. The setup times for installing the molds remain therefore unchanged. The mold assembly is installed as usual, except that the previously customary in-vibration process is eliminated. The precise centering of the individual components reduces wear on the shoes and the mold assembly. In contrast to conventional mold assemblies, the head assembly now moves synchronously with the bottom assembly of the mold. The robust and wear-resistant sliding elements in the FlexWay ensure that this movement is carried out smoothly and without using force. In this way, no horizontal forces can arise between the cavities of the mold and the shoes. Retraction forces generated by horizontally clamped oscillating metals on the upper part of the mold do not arise. The engineers controlled the horizontal mobility through an integrated pneumatic brake. The brake is released as soon as the shoes dip into the mold cavities. The pneumatic brake closes as soon as the shoes move out of the mold cavities during demolding. The current position of the shoes relative to the mold cavities is in this way memorized and used for non-contact immersion during the next cycle. This results in 100-percent centering from one cycle to the next.
The new FlexWay system has been available on the international market only for six months. Already during this short time it has been used with great success by concrete block manufacturers around the globe.
The Rampf group is represented in the most important growth markets. International corporate groups, associations and medium-sized family enterprises in the construction products business are among the customers of Rampf Formen. Subsidiaries in the USA, Canada, Switzerland, Hungary, Poland, Mexico and China generate an export share of approx. 80%.
The continuous further development of the products makes the company a competent partner for the construction products industry also in the future. ¢
