Air Nozzle Plate Cleaning for Concrete Block Passages
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Solution Overview
Problem
During the fabrication of concrete blocks, debris often lodges in the passages of the blocks, which can cure and create obstructions, necessitating manual removal that is labor-intensive, costly, and poses safety risks.
Innovation Solution
An automated device that uses nozzles mounted on a plate, actuated by a system connected to a source of compressed air, to direct jets of air into the passages of concrete blocks as they are conveyed, effectively removing debris without manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual debris removal is used, then debris can be removed from passages, but labor costs increase and safety risks arise
Solution Approach 1:
The system uses the block's own movement on the conveyor to position it for automated cleaning. The block serves itself by being conveyed into the correct position where the nozzle can clean it without requiring external manual intervention for positioning.
Solution Approach 2:
The patent replaces the manual mechanical cleaning process with an automated pneumatic system. A compressed air nozzle delivers high-velocity air jets to remove debris, substituting human labor with an automated mechanical-pneumatic system that reduces labor intensity and safety risks.
2Reliability
If manual debris removal is used, then debris can be removed from passages, but production efficiency decreases
Solution Approach 1:
The system continuously cleans blocks as they move along the conveyor belt without interrupting the production flow. The cleaning action occurs continuously during block conveyance rather than requiring separate manual intervention steps, maintaining continuous productive action throughout the manufacturing process.
Solution Approach 2:
Blocks are automatically cleaned by the system as they pass through the conveyor, eliminating the need for separate manual cleaning operations. This self-service mechanism maintains production efficiency by integrating cleaning into the existing conveyor workflow without adding separate processing steps.
3Productivity
If automated air jet cleaning is used, then labor requirements are reduced, but device complexity increases
Solution Approach 1:
The system extracts only the essential cleaning function from the complex manual process. By using a simple compressed air nozzle mounted on the conveyor, it isolates and automates just the debris removal aspect without requiring complex robotic manipulators or sophisticated control systems, thereby reducing overall device complexity while maintaining automation benefits.
Solution Approach 2:
The conveyor system serves multiple functions: it transports blocks through the manufacturing process and simultaneously positions them for automated cleaning. This multi-functionality reduces the need for separate dedicated cleaning equipment, thereby reducing device complexity while achieving automation.
4Productivity
If debris is not removed, then production flow is maintained, but passage obstructions occur
Solution Approach 1:
The system performs debris removal as a preliminary action immediately after block formation and during the conveying process, before the blocks are used in construction. This preventive cleaning approach ensures passages remain clear before they are needed for their intended function, maintaining both production flow and passage reliability.
Solution Approach 2:
The continuous cleaning action during conveyance prevents debris accumulation that would lead to obstructions. By maintaining continuous removal of loose debris throughout the production process, the system ensures passage functionality is preserved without interrupting production flow.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device enables efficient and simultaneous debris removal from multiple passages, reducing the risk of damage to the blocks and eliminating the need for additional labor, thus aligning with the high-volume production capabilities of automated concrete block manufacturing.
Implementation Method 1
An automated device that uses nozzles mounted on a plate, actuated by a system connected to a source of compressed air, to direct jets of air into the passages of concrete blocks
Implementation Method 2
direct jets of air into the passages of concrete blocks as they are conveyed, effectively removing debris
Data Source
AI summary
A device for removing concrete debris from passages within modular blocks is disclosed. The device includes nozzles mounted to a plate at locations corresponding to the passages on the modular blocks. An actuator is secured to the block molding machine, supports the plate, and moves the plate from a retracted position to an extended position in close proximity to the conveyor. The nozzles are operatively connected to a source of compressed air and are arranged to enter within the passages of the modular block when the plate moves to the extended position. A control system directs operation of the device such that when a modular block reaches a predetermined location on the conveyor, the actuator moves the mounting plate to the extended position causing the nozzles to enter within the passages of the modular block and emit jets of compressed air to remove concrete debris from within the passages.