Linear-Translation Concrete Pump Valve for Minimum Waste
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Solution Overview
Problem
Existing concrete pumps generate significant post-operation waste, requiring lengthy cleaning processes and frequent lubrication of bearings, which increases maintenance costs and environmental impact.
Innovation Solution
A double-piston alternative-type pump valve with an inlet and outlet conduit system that performs linear translation movement, minimizing waste generation and eliminating the need for constant lubrication by using hydraulic fluid for commutation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single conduit valve system is used, then the device complexity is reduced, but the waste retention increases and cleaning time increases
Solution Approach 1:
The valve system is segmented into multiple independent conduits (first discharge conduit and second discharge conduit) that operate alternately. Each conduit has its own wear plate and sealing mechanism, allowing the system to divide the concrete flow path into separate segments that can be independently cleaned or replaced, thereby reducing overall waste retention while maintaining manageable complexity
Solution Approach 2:
The patent introduces a vertical dimension to the valve structure by stacking multiple conduits and wear plates in a layered configuration. This multi-level arrangement allows concrete to be directed through different vertical levels and pathways, enabling more complete evacuation of the hopper and reducing residual waste in traditional single-level systems
2Ease of operation
If rotary movement valve is used, then the commutation is achieved, but the bearing lubrication requirement increases and maintenance frequency increases
Solution Approach 1:
The patent replaces the traditional rotary mechanical valve system with a linear reciprocating mechanism driven by hydraulic cylinders. Instead of rotating bearings that require lubrication, the system uses linear motion of the valve body along guide rails, eliminating the need for bearing maintenance and reducing operational complexity while maintaining effective commutation between discharge conduits
Solution Approach 2:
The valve commutation is achieved through hydraulic actuation rather than mechanical rotation. Hydraulic cylinders provide the force to move the valve body linearly between positions, using fluid pressure to control the switching between different discharge pathways. This hydraulic control system eliminates mechanical wear associated with rotary joints and bearings
3Reliability
If constant lubrication is applied, then the bearing operation is maintained, but the operational costs increase and environmental impact increases
Solution Approach 1:
By replacing the rotary bearing system with a linear reciprocating valve mechanism guided by rails, the patent eliminates the need for continuous lubrication. The linear motion system has significantly reduced friction requirements and no sealed bearings that need periodic greasing, thereby eliminating operational costs associated with lubrication maintenance and reducing environmental impact from grease disposal
4Object-generated harmful factors
If equipment is displaced for waste disposal, then the waste can be disposed of properly, but the productivity decreases and operational costs increase
Solution Approach 1:
The segmented conduit system allows each discharge pathway to be independently optimized for complete concrete evacuation. The alternating use of multiple conduits ensures that concrete is thoroughly discharged from all areas of the hopper, minimizing residual waste that would otherwise require equipment displacement for proper disposal, thereby maintaining productivity while ensuring compliant waste management
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 reduces waste retention after operation, enhances the durability and efficiency of the pump, decreases cleaning time, and minimizes maintenance needs, thereby lowering operational costs and environmental impact.
Implementation Method 1
cylindrical nozzles arranged on both sides, which are telescopically connected to the conduit nozzles through a spring that keeps the wear plates pressed against the structure walls
Implementation Method 2
jacket equipped with projections fixed at the structure points and connected to the hydraulic flow to promote the linear movement of the rods and conduits
Implementation Method 3
The unloading of the concrete into the hopper arranged along with opening of the cover of the structure, wherein the concrete flows by gravity into the inlet conduit
Data Source
AI summary
The valve for the minimum waste concrete pump, object of the present invention, comprises a valve for the minimum waste concrete pump that comprises a double-piston alternative-type pump valve provided with an inlet conduit (20) and a discharge conduit (30) installed inside the valve container (10) and arranged next to a concrete reception hopper located above the container, allowing to pump concrete and other pasty substances, such as: sludge, mining residues, grout, mortar, dirty water, and similar. The embodiment of the valve generates the minimum of waste retained after the equipment operation, improving the durability and efficiency of use of the pumps, besides reducing the cleaning time, resulting in a great reduction of operational costs, avoiding the unnecessary displacement of the pump equipment to the central. In addition, this new embodiment results in a valve performing a linear translation movement that reduces component wear and minimizes the need for maintenance on the equipment, as its embodiment does not require constant lubrication.