Modification for developed molding machine for brassiere Cups

Following the trial of the bra cup molding machine, we'd like to propose some modifications to
enhance its functionality for full-scale production.

Mold Positioning Challenges-

• Initiate Mold Position: Currently, setting the correct position for a mold after changing
them is difficult due to standard mold setting height molds cannot be specifically given to
machine before start production. This complexity makes parameter adjustments time-
consuming for operators and it can be caused to damage fabric by mold edges.

AUTO Mode Issues

• When the machine in AUTO mode feed plate got in the position but bell and mold were
lagging the same position and the program was not continued, Machine should be restart to
start production.
• When the feed plate become in position, Rear molds are getting two cycles to get cooking
position.it was get two cycles (up and down twice) to get top position before molding start
(Not frequently).Machine should be restart to fix this problem.

Fluctuating Temperatures:

During production, the mold temperature fluctuates significantly, sometimes reaching extremes.
This instability can cause fabric damage due to overheating, affecting the quality of the bra cups.

Feed Table Speed: The current feed plate speed is insufficient for both production and safety. Also
gear slip on rack at the start of moving of the feed plate. Compared to the pisani machine control of
mold and bell speed was not performing (time saving from the speed variation was not much
performing as the discussion before due to the mold travel height is large). That fact was directly
affected by the production rate.

Piston Performance: The pistons malfunction under current factory air pressure (Sudden drops of
mold and bell), causing vibrations and mold damage and equipment damage and these vibration
impact to the operator safety.

Pre-shape depth: Depth of pre-shaped fabric was not in stability range throughout the production.
Feeding the material for the rear plate and measure pre-shaped depth was difficult for the operator
in current design.

Projection Marking: The machine should be equipped with a projection marking system.

Reducer Plate Misalignment:

The reducer plate is not properly secured to the feed table. If it’s not correctly fitted, it can misalign
and attach to the disc incorrectly, leading to further misplacements and operational issues.
Safety Concerns

Safety of machine operator during production is more important. Machine parts should be Fix in
safe during the production otherwise operator can be damage from the machinery parts

Safety of feed table operations, covering the molding area was crucial to prevent injuries and
ensure the operator's safety.

Operational Developments

Mold Changing Procedure: The new design should include a documented and efficient mold
changing procedure.

One-Sided Mold Change Difficulty: Changing molds while operating one side of the machine is
challenging.

Machine Footprint Reduction: The current machine footprint is too large.

Operator Movement Optimization: Current design affect efficient operator movement.

Difficult Rear Plate Feeding: Feeding the material for the rear plate is difficult for the operator in
current design.

Double Pre-Shape Challenge: The machine struggles to handle double pre-shape styles.

Material Handling: The current design lacks a proper material handling system.

Machine space should be reduced.