Alternative rotational molding process with increment of pre and post heating chamber sections: development of a prototype.
Rotomolding machine. Rotational molding process. Energy efficiency. Physical properties of materials. Measurement uncertainty.
This work presents results of the development of an alternative rotomolding process with the increase of pre- and post-heating chamber sections, carried out with the construction of a rotomolding prototype-machine. This invention covers some gaps that have limited conventional processes, which are characterized by long cycle times and energy waste. The work was initially focused on the main objective: the reduction of cycle time; from this, consequently, the other gains and modeling of the new process were provided. This was only possible with the manipulation and reuse of the heat generated by the process, thanks to the purpose of a new architectural arrangement. The proposed method included the construction of the prototype for the production of samples, followed by tests to certify the quality of the main physical properties of the product produced and an energetic study of the process. The results showed a reduction in the cycle time and, consequently, a reduction in energy consumption, due to the reuse of the heat itself, which was previously wasted on the environment at the end of each cycle; then, machined parts had their main mechanical properties validated through their measurement uncertainties, evaluated in accordance with the internationally recognized method concerning this task, namely the GUM framework. From the general results obtained from the proposed prototype, it appears that the production maintained the quality of the main physical properties evaluated, including the uniformity of the samples, which proves the guarantee of stability of this prototype in the serial production of parts in scale industrial; also, there was a reduction in production costs; this fact allows a future investor to visualize that, for each monetary unit spent in kWh of energy consumed, a percentage of cost reduction is obtained in each production cycle. These gains prove the feasibility and superiority in efficiency and performance of this prototype machine compared to the other renowned manufacturers of industrial rotational molding machines.