Rising Concrete Probe Tracking for Real-Time Shaft Dimension Checks
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for verifying drilled shaft dimensions during cement curing, such as Thermal Integrity Profiling (TIP), are time-consuming and do not allow for immediate correction of radius deviations, leading to delays and additional expenses on construction sites.
Innovation Solution
A dimension monitoring apparatus comprising a spool, cable, probe, rotary encoder, tension sensor, and motor assembly that allows for real-time measurement of foundation dimensions by extending, retracting, and bobbing the cable, using a rotary encoder to record length and a tension sensor to detect engagement with the foundation surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If Thermal Integrity Profiling (TIP) is used to verify shaft dimensions, then measurement precision is achieved, but measurement time is extended requiring multiple days to reach maximum temperature
Solution Approach 1:
The patent replaces the thermal-based measurement system (TIP) with a mechanical measurement system using a probe that physically contacts the foundation surface. The probe is lowered through the drilled shaft via a cable mechanism, and its position is measured using a rotary encoder, providing immediate mechanical measurement without waiting for thermal conditions to develop
Solution Approach 2:
The measurement system uses the foundation material itself as the reference surface for measurement. The probe engages directly with the foundation surface, and the cable mechanism uses the weight and tension of the probe-cable assembly to automatically position and measure the foundation dimension without requiring external thermal or mechanical testing equipment
2Manufacturing precision
If TIP is used to assess shaft quality, then manufacturing precision is verified, but productivity is reduced due to delays in correction
Solution Approach 1:
The patent implements real-time feedback by continuously monitoring the probe position and foundation surface engagement during the pouring process. The rotary encoder provides immediate data on the foundation dimension, allowing operators to detect deviations and correct them while the concrete is still fresh, eliminating the delays associated with waiting for TIP measurements
Solution Approach 2:
The measurement system is deployed and activated during the concrete pouring process itself, rather than after the foundation has cured. This preliminary measurement action allows for immediate detection and correction of dimensional issues while the foundation is still formable, preventing rework delays
3Measurement precision
If multiple days are required for TIP measurement, then measurement precision is achieved, but device complexity and operational complexity increase
Solution Approach 1:
The patent extracts the essential measurement function from the complex TIP system and implements it through a simple mechanical probe and cable mechanism. The measurement capability is separated from the thermal processing requirements, allowing for immediate measurement without the need for thermal sensors, heating elements, or extended curing periods
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
Enables immediate detection and correction of shaft radius deviations, reducing construction delays and costs by providing real-time dimension verification during the pouring process.
Implementation Method 1
a rotary encoder comprising at least one wheel, in which the at least one wheel may be configured to be in contact with at least one portion of the cable, such that a relative linear distance and/or relative direction of the at least one portion of the cable may be recorded in real-time via passive tracking by the clockwise rotation and/or counterclockwise rotation of the at least one wheel
Implementation Method 2
the at least one pulley may be temporarily affixed to at least one spring, such that when the at least one portion of the probe is disengaged with the at least one surface of the foundation, the at least one spring may be configured to decompress, translating the at least one pulley toward a limit switch of the tension sensor
Implementation Method 3
a motor assembly configured to be in mechanical communication with the spool, in which the motor assembly may be configured to extend, retract, and/or bob the cable, via rotatably translating the spool
Data Source
AI summary
Described herein relates to a system and method of verifying a dimension in real-time of a foundation being poured during construction. The dimension monitoring apparatus may automate and/or expedite a measurement of a foundation during pouring. As such, the dimension monitoring apparatus may simultaneously monitor a flow of concrete via at least one pump stroke and/or at least one flow meter, in addition to a rising concrete level using at least one motor assembly. Additionally, the dimension monitoring apparatus may comprise a probe configured to track the level of the rising foundation throughout the entire foundation pouring process. The dimension monitoring apparatus may continuously track and/or refine a dimension and/or depth profile of a foundation and/or may identify potential anomalous cross sectional dimensions which may have occurred during the foundation pouring process.