Concrete Block Mould with Level Differences for Kerbstone Production
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Solution Overview
Problem
Existing methods for producing concrete kerbstones or blocks with large level differences (>40 mm) are resource-intensive and inefficient, requiring manual vibration tables or wet casting, which are costly and labor-intensive, and often result in inconsistent product quality due to complex mold designs and maintenance challenges.
Innovation Solution
A casting equipment system comprising a mould with a cellular bottom part and a top part with thrust plates, a filling cart, and a backboard, all with level differences to facilitate efficient concrete distribution and compression, allowing for rapid production of kerbstones or blocks with large level differences and cavities on concrete block machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual vibration tables or wet casting are used to produce kerbstones with large level differences, then product quality can be achieved, but production cost and resource consumption increase significantly
Solution Approach 1:
The patent replaces the manual vibration table mechanical system with an automated concrete block machine that uses vibration motors integrated into the mold assembly. This substitution automates the vibration process and eliminates the need for separate manual vibration tables, reducing resource consumption while maintaining product quality
Solution Approach 2:
The mold assembly serves multiple functions: it acts as both the molding cavity and the vibration source through integrated vibration motors. The same mold assembly can produce different kerbstone designs by changing inserts or configurations, reducing the need for multiple specialized molds and thereby reducing overall resource consumption
2Manufacturing precision
If complex coverings or movable flaps are added to the filling cart to control concrete distribution, then large level differences can be produced, but device complexity and maintenance difficulty increase
Solution Approach 1:
The patent removes the complex movable flaps and coverings from the filling cart system. Instead, concrete distribution is controlled by the fixed mold cavity shape and the vibration process itself, which naturally directs concrete to the correct levels. This extraction of unnecessary components simplifies the filling cart while maintaining level difference control
Solution Approach 2:
Rather than using active components (movable flaps) to control concrete flow, the patent uses the passive geometry of the mold cavity and the vibration field to achieve control. The inversion is from active control mechanisms to passive geometric control, reducing device complexity
3Productivity
If traditional vibration table processes are used, then products can be cast, but production speed is slow and labor requirements are high
Solution Approach 1:
The patent replaces the manual operation of placing molds on vibration tables with an automated concrete block machine that automatically positions molds, delivers concrete, applies vibration, and ejects finished products. This mechanical substitution eliminates manual effort and significantly increases production speed
Solution Approach 2:
The automated concrete block machine operates continuously with molds being rapidly cycled through filling, vibration, and ejection phases. The system maintains continuous production flow without the interruptions and manual repositioning required by traditional vibration table methods, thereby increasing productivity
4Adaptability or versatility
If thrust plates with complicated downwardly projecting elements are used to reach core elements, then cavities can be formed, but cleaning difficulty and device complexity increase
Solution Approach 1:
The patent extracts the complicated downwardly projecting elements from the thrust plates. Instead, cavity formation is achieved by positioning cores within the mold cavity and using the vibration process to displace concrete around them. This extraction simplifies the thrust plate design to a flat plate, making it easy to clean while maintaining cavity formation capability
Solution Approach 2:
The cavity shape is created by the physical presence of core elements within the mold rather than by complex thrust plate geometry. The cores act as negative templates that the concrete flows around during vibration, copying their shape into the final product's cavity structure
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
This system enables faster production cycles, improved product uniformity, and reduced resource consumption by automating the process, allowing for 2-4 products to be made in 20-30 seconds compared to 2-3 minutes on vibration tables and ½-1 minute for wet casting, with automatic palletizing and reduced manual effort.
Implementation Method 1
the mold assembly is subjected to strong vibrations in order to compress the concrete in the mold
Implementation Method 2
the concrete hardens, typically 1⁄2 - 1 day
Data Source
Figure 1
Figure 2a~2c
Figure 3~5
AI summary
Mould (2, 4) with level differences for a concrete block machine/ concrete casting machine of the kind typically used for making cast items in the form of concrete blocks (58) for solid blocks with cavities or recesses, paving, wall construction or elements. By the level differences blocks (58) with large level differences, typically more than 40 mm, can be made with or without cavities (60, 74), for example kerbstones with integrated drain. By the invention is indicated a mould bottom part (2) with associated back table (6) and filling cart (8) as well as core drawing arrangement (22), including means that ensure the concrete product can be made with large level differences with or without cavities.