Concrete Pump Water Box Level Sensor Monitoring
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Solution Overview
Problem
Conventional concrete pumps rely on manual observation to detect water level and seal wear in the water box, leading to potential catastrophic wear and premature failure of seals, as operators often miss timely signs of water loss or clouding, which can result in inefficient operation and reduced pump lifespan.
Innovation Solution
An automated system using a water level sensor and a Programmable Logic Controller (PLC) to monitor the water level in the water box, generating alerts and executing actions such as sounding alarms or shutting down the pump when the water level falls below a threshold, ensuring timely replacement of seals and maintaining optimal pump operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual observation is used to detect water level and seal wear, then device complexity is reduced, but reliability of seal operation deteriorates due to missed signs of water loss
Solution Approach 1:
The patent replaces manual visual observation with an automated optical sensor system. The sensor detects water level and cloudiness automatically, converting optical signals into electrical signals that trigger alerts or pump shutdown. This substitution eliminates human error in monitoring while maintaining relatively simple system architecture.
Solution Approach 2:
The system enables self-monitoring and self-protection of the concrete pump. The sensor continuously observes water conditions and automatically initiates protective actions (alerts or shutdown) without human intervention, allowing the system to protect itself from seal damage caused by low or cloudy water.
2Reliability
If automated monitoring system is implemented, then reliability of seal operation is improved, but device complexity increases due to additional sensors and control systems
Solution Approach 1:
The patent employs an optical sensor system that detects water level and cloudiness by measuring light transmission. The sensor converts optical changes into electrical signals that directly trigger control actions, providing reliable automated monitoring without requiring complex mechanical or electronic systems.
Solution Approach 2:
The optical sensor acts as an intermediary between the water condition and the control system. It translates physical water properties (level, clarity) into electrical signals that the control system can process, bridging the gap between physical monitoring and automated response with a simple, reliable interface.
3Duration of action of stationary object
If real-time monitoring and automated shutdown is implemented, then seal lifespan is extended, but productivity decreases due to pump shutdowns
Solution Approach 1:
The system takes preliminary protective action by detecting early signs of water loss or cloudiness and triggering alerts or shutdowns before seal damage occurs. This preventive approach extends seal lifespan by avoiding catastrophic failure, while the early warning capability allows operators to address issues during planned maintenance windows rather than causing unexpected shutdowns.
Solution Approach 2:
The system provides continuous feedback on water conditions through sensor monitoring and operator alerts. This feedback loop enables operators to maintain optimal water levels and clarity, preventing seal damage while allowing continuous operation under normal conditions, thus extending seal life without significantly impacting productivity.
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 automated system prevents undue wear on concrete pump seals by providing real-time monitoring and alerts, optimizing the lifespan of seals and the concrete pump, reducing downtime and maintenance costs.
Implementation Method 1
a water level sensor to generate signals corresponding to a water level in the water box
Data Source
AI summary
An apparatus and method for preventing undue wear on a concrete pump relies upon monitoring a volume of water in a water box for cooling and lubricating pumping seals on a material pumping piston within a material pumping cylinder. The apparatus includes a water level sensor to generate signals corresponding to a water level in the water box. The signals are received at a computing device including a central processing unit (CPU) to apply an algorithm drawn from the memory to determine whether the water level in the water box is sufficient for operation of the concrete pump and if not sufficient, to generate a water level alert. The CPU sends a water-level alert and in response to the alert, to execute a pump-preserving action. Such a pump-preserving action may include sounding a klaxon alarm; displaying an alert; playing a recorded warning; and shutting down operation of the concrete pump.