Concrete Forming Machine Vertical Vibration and Electric Drive
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Solution Overview
Problem
Existing concrete product forming machines are inefficient due to time-consuming mold changes, horizontal vibration causing wear, messy material handling, and reliance on noisy and maintenance-intensive hydraulic systems.
Innovation Solution
A concrete products-forming machine with vertical vibration control using leaf spring-like parallel bars and torsion bars, automatic mold transfer, air knife for material containment, electric drive system, and spring-activated seals to improve efficiency and reduce wear and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If horizontal vibration is used to spread concrete material, then the concrete material is spread evenly within the mold cavities, but the shoes impact against the interior of the mold cavities causing increased wear
Solution Approach 1:
The patent inverts the traditional horizontal vibration approach by implementing vertical vibration only. The vibration system is configured to vibrate the mold box vertically, causing the concrete material to spread evenly through gravity and vertical motion rather than horizontal shaking. This eliminates the harmful horizontal components that caused shoe impact and wear while maintaining the desired even distribution of concrete material within the mold cavities.
Solution Approach 2:
The patent changes the vibration parameter from horizontal direction to vertical direction. By modifying the orientation of the vibration force vector from horizontal to vertical, the system achieves even concrete distribution without the harmful side effects of horizontal vibration. The vibration frequency and amplitude are optimized to ensure effective material spread while maintaining strictly vertical motion to prevent shoe-mold cavity impact.
2Power
If hydraulic power systems are used, then the machine has sufficient power for compression and vibration, but the system is noisy, energy inefficient, requires high maintenance, and is unwieldy with hoses and tubes
Solution Approach 1:
The patent replaces the hydraulic power system with an electric motor system. The electric motors provide the necessary power for compression and vibration operations without the complexity of hydraulic hoses and tubes. This substitution eliminates the noisy operation, energy inefficiency, and maintenance requirements associated with hydraulic systems while maintaining the required power output for effective concrete product formation.
Solution Approach 2:
The patent extracts and removes the hydraulic system components from the machine design. By taking out the hydraulic power system, the patent eliminates the associated complexity of hoses and tubes routed through the machine. The electric motor system provides a cleaner, more efficient alternative that does not require the same level of mechanical infrastructure.
3Productivity
If feed drawer moves concrete material over the top of the mold assembly, then the material can be dispensed into the mold cavities, but the process is messy and requires frequent clean-ups
Solution Approach 1:
The patent applies preliminary action by pre-positioning the feed drawer directly above the mold cavities and using vertical vibration to guide the concrete material downward. The feed drawer is designed to move material vertically into the mold rather than horizontally over the top, reducing spillage and mess. The vertical vibration helps control the material flow and prevents excessive spreading beyond the mold boundaries.
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 machine efficiently produces high-quality products with reduced wear, minimal maintenance, and improved cleanliness, achieving high output and adaptability to various product configurations.
Implementation Method 1
a vibration system shakes the mold assembly to spread the concrete material evenly within the mold assembly cavities
Implementation Method 2
Air springs, mounted within the die supports and acting as shock absorbers for the vibrating mold box
Implementation Method 3
The vibration direction control means includes pairs of leaf spring-like parallel bars, coupling the die supports to the main frame
Implementation Method 4
a torsion bar, coupling the die supports to each other
Data Source
AI summary
A concrete products forming machine including a main frame, feed drawers, die supports and mold and head assemblies. The feed drawer is moved into position over the mold using an electric belt drive system and includes a vibrating strike off plate to improve surface quality of the molded product, zoned agitators to control movement and placement of concrete, a spring loaded seal system between the walls and floor of the feed box, and quick-release agitator design with urethane sleeves to effect easy and clean removal, replacement and cleaning of the agitators. The concrete products forming machine includes torque tube and leaf spring supports to effect substantially vertical vibrational movement of the mold with air inflatable springs for controlled force between the mold bottom and the pallet. The pallet itself is vibrated from below using phased, counter rotating shafts coupled to the pallet table on which the pallet rests. Vibration induced into the pallet by the vibrating pallet table is transferred to the mold resulting in material compaction. After the molding process, the mold is lifted in a stripping process to remove the molded product for curing or drying.