Concrete Mold Form Powered Carriage Mechanism
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Solution Overview
Problem
The existing concrete mold form process for casting large bridge girders is expensive and inefficient, requiring complex crane operations to move side forms away from the cured girders for removal.
Innovation Solution
A concrete mold form with parallel tracks and powered carriages equipped with hydraulic motors and chain drives allows for smooth movement of side forms between molding and release positions, eliminating the need for cranes and reducing the risk of motion skewing, while minimizing clutter and trip hazards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If cranes are used to move side forms away from the cast girder, then the side forms can be moved for removal, but the operational complexity and cost increase
Solution Approach 1:
The side forms are equipped with self-propulsion capability through hydraulic motors mounted on the carriages, allowing them to move autonomously along the tracks without external crane assistance. This self-service mechanism eliminates the need for complex crane operations while maintaining ease of form movement.
Solution Approach 2:
The patent replaces the external mechanical crane system with an integrated hydraulic propulsion system mounted directly on the carriages. This substitution eliminates the need for heavy crane equipment and complex rigging operations, simplifying the overall system while maintaining effective side form movement capability.
2Ease of operation
If cranes are used to move side forms, then the forms can be repositioned, but the risk of motion skewing increases
Solution Approach 1:
The side forms are mounted on carriages that can dynamically adjust their position along the tracks through controlled hydraulic motor operation. This dynamic positioning system allows for precise, controlled movement without the sudden shifts and skewing risks associated with crane-based repositioning.
Solution Approach 2:
The parallel track system provides a stable, level pathway for carriage movement, ensuring that side forms move uniformly without skewing. The tracks are positioned to maintain equal elevation and alignment, creating an equipotential movement environment that prevents motion errors.
3Productivity
If traditional molding processes are used, then girders can be cast, but the process is expensive and inefficient
Solution Approach 1:
The molding system is divided into modular components: multiple independent carriages spaced along parallel tracks, each capable of independent movement. This segmentation allows for efficient, coordinated operation of form components and facilitates rapid assembly and disassembly, improving productivity while managing complexity through standardization.
Solution Approach 2:
The carriages serve multiple functions: they support the side forms during casting, provide powered movement for form repositioning, and enable precise positioning for girder removal. This multi-functionality consolidates several operations into a single integrated system, improving efficiency without proportionally increasing complexity.
Data Source
AI summary
A concrete mold form (10) is provided to form concrete products such as concrete bridge girder (12). The form (10) has first and second side forms (14, 16) which are supported on carriages (22) riding on tracks (24) for moving the side forms (14, 16) between a closed position to cast the product and an open position to allow the cast product to be removed. At least one of the carriages (22) is a powered carriage (22P, 22M) which rotates a roller (28, 70) engaging the track with a hydraulic motor (38) to move the side form between the closed and open positions.