Brick Layering System Gravity Compaction
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Solution Overview
Problem
Conventional brick manufacturing and handling methods result in imprecise positioning of bricks due to gaps and shape changes during handling, leading to increased breakage, rejection rates, and inefficient packaging, which affects productivity and shipping costs.
Innovation Solution
A brick layering system comprising a support frame with a table top and mechanical stop assemblies that use gravity and a pusher mechanism to compact and index bricks, removing gaps and ensuring precise positioning, and a method involving an incline with perpendicular straight edges to further rearrange and remove gaps within brick layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional brick positioning methods are used with gaps between bricks, then the brick handling process is simpler, but the positioning precision deteriorates leading to mispositioning and breakage
Solution Approach 1:
The system uses gravity as the primary force to automatically move bricks into position on the inclined table top. The bricks self-index against the stop assemblies without requiring active positioning mechanisms, reducing device complexity while improving positioning precision.
Solution Approach 2:
The patent replaces complex active mechanical positioning systems with a passive gravitational field-based system. The inclined table top substitutes for motors, sensors, and active control mechanisms, achieving precise positioning through gravity-driven movement and geometric constraints.
2Volume of stationary object
If gaps are maintained between bricks during handling, then the brick manufacturing process is simpler, but the volume efficiency deteriorates increasing shipping costs
Solution Approach 1:
The system dynamically adjusts brick spacing through the inclined table top mechanism. Bricks start with gaps on the incline but are compacted together by gravity as they move toward the lower intersection point, achieving dense packing without complex compaction equipment.
Solution Approach 2:
The patent changes the spatial parameters of brick arrangement by using the inclined table top to transform brick positions from spaced-out configurations to compacted configurations. The geometric parameters of the incline and stop assemblies control the final packed density.
3Productivity
If manual packaging methods are used for brick layers with gaps, then the packaging process is simpler, but the productivity deteriorates due to increased cycle time
Solution Approach 1:
The system performs preliminary compaction and indexing of bricks onto the pallet before the packaging operation begins. The gravity-driven compaction on the inclined table top prepares the brick layer in advance, eliminating the need for manual adjustment and reducing packaging cycle time.
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 system effectively reduces brick breakage and rejection rates by ensuring precise positioning and compacting, thereby improving productivity and reducing shipping costs through efficient packaging by eliminating unnecessary volume.
Implementation Method 1
bricks within the brick layer that is received on the flat surface of the table top are moved by gravity towards the virtual intersection of the two straight edges
Data Source
AI summary
A brick layering system includes an infeed conveyor that brings layers of bricks, one or more brick layer compacting systems that remove unwanted gaps in the layers of bricks, an outfeed carousel for receiving compacted piles of bricks and a robot arms that moves the brick layer between the infeed, outfeed and compacting systems. The brick layer compacting system includes a table top having a generally flat surface for receiving the brick layer; and two mechanical stops secured to the table top on the generally flat surface so as to define two straight edges on the table top that are perpendicular to each other. The table top is oriented so that a virtual intersection of both straight edges is lower than any other parts of the two straight edges. Bricks received on the flat surface are moved by gravity towards the virtual intersection of the two straight edges, thereby removing gaps between the bricks and indexing the bricks relative to both straight edges.