Concrete Mixer Loading Hopper Cleaning System
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Solution Overview
Problem
The existing methods for cleaning the inlet funnel of concrete mixers are inefficient, time-consuming, and pose safety risks, while also leading to undefined water addition to the concrete and increased cycle times.
Innovation Solution
A device and procedure that position the concrete mixer under the collective funnel, using a drip protection device with a cleaning system that includes adjustable spray nozzles to efficiently clean the inlet funnel without repositioning the mixer, thereby reducing water consumption and cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual cleaning is used, then the inlet hopper can be cleaned, but the process is time-consuming and poses safety risks
Solution Approach 1:
The cleaning system is automatically activated after loading and performs cleaning without operator intervention. The system self-regulates the cleaning process, eliminating manual labor and associated safety risks while maintaining effective cleaning performance.
Solution Approach 2:
Manual mechanical cleaning actions are replaced by an automated spray system that uses water jets delivered through nozzles. This substitution eliminates the need for operators to physically contact the inlet hopper, removing safety hazards while reducing cleaning time.
2Reliability
If a separate cleaning station is provided, then cleaning can be performed, but the cycle time increases due to repositioning requirements
Solution Approach 1:
The cleaning system is merged with the loading station infrastructure. The spray nozzles are integrated into the existing loading hopper structure, allowing cleaning to occur at the same location where loading takes place, thus eliminating the need for repositioning and reducing cycle time.
Solution Approach 2:
The loading station is given multiple functions: it serves both as the loading point and as the cleaning station. This multi-functionality eliminates the need for a separate dedicated cleaning station and the associated repositioning operations, thereby improving productivity.
3Reliability
If manual cleaning is performed, then the inlet hopper is cleaned, but an undefined amount of water is added to the concrete
Solution Approach 1:
The cleaning water is directed locally and precisely at the inlet hopper surface using targeted spray nozzles. This localized application ensures water is applied only where needed for cleaning and does not contaminate the concrete in the mixing drum, providing controlled water addition.
Solution Approach 2:
The spray nozzle system acts as an intermediary that delivers cleaning water in a controlled manner. The nozzle design and positioning ensure water is directed specifically at the inlet hopper interior surface, preventing uncontrolled water from entering the concrete mixture and allowing precise measurement of water usage.
4Reliability
If a separate cleaning station is installed, then cleaning can be performed, but space and cost increase
Solution Approach 1:
The cleaning system components (spray nozzles, water supply lines, control mechanisms) are integrated into the existing loading station structure. This merging approach eliminates the need for a separate standalone cleaning station, reducing spatial requirements and overall system complexity while maintaining full cleaning capability.
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 solution enables efficient and safe cleaning of the inlet funnel, reducing water consumption and cycle time, while eliminating the need for a separate cleaning station, thus improving operational efficiency and safety.
Implementation Method 1
The cleaning system comprises at least two spray nozzles (131) for flushing the inlet hopper (210) with water
Implementation Method 2
The pivoting movement of the drip guard device ensures that the water jet generated by the cleaning system hits the surface of the inlet funnel at varying angles, improving the cleaning of the inlet funnel surface
Data Source
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AI summary
The invention relates to a device for loading concrete mixers with fresh concrete, wherein the device has a collection hopper for dispensing concrete into an inlet hopper of a concrete mixer, wherein the device further has a drip protection device to catch any concrete that runs out of the collection hopper after loading has been completed, and wherein the drip protection device has a drip catcher and a cleaning system with more than one spray nozzle for rinsing the inlet hopper with water, wherein the cleaning system is attached directly to the drip catcher.