Concrete Slump Calculation Using Drum Sensors

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Solution Overview

Problem

Mobile concrete mixing trucks face challenges in accurately adjusting the liquid component of concrete mixes during delivery, leading to issues with slump tests and structural strength, especially in cold weather conditions where water supplies can freeze, affecting operational efficiency and economic viability.

Innovation Solution

A system equipped with temperature sensors to monitor drum and contents temperature, accelerometer sensors to account for truck tilt and movement, and a communication system for data sharing and software updates, enabling precise slump calculations and adjustments, including automatic water addition and chemical additive control.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If water is added manually to adjust concrete slump, then the concrete becomes easier to work with, but the structural strength is compromised and the adjustment is imprecise

Engineering Contradiction:

Improveworkability of concreteVSAvoidstructural strength of concrete

Core Design Contradiction:

Ease of operationVSStrength

Solution Approach 1:

The system continuously monitors drum rotation speed and hydraulic pressure, using this feedback to automatically calculate and adjust water addition requirements, replacing manual guessing with closed-loop control that maintains both workability and strength

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system performs self-adjustment by automatically adding water based on real-time sensor data and slump calculations, eliminating the need for manual operator intervention and the associated imprecision and strength compromise

Inventive Principle:

Principle #25Self-service

2Ease of operation

If excess water is added to concrete, then the concrete becomes easier to work with, but the mix fails slump tests and requires return to depot for correction

Engineering Contradiction:

Improveworkability of concreteVSAvoidslump test compliance

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The system performs preliminary slump calculations and water adjustments before delivery, using real-time monitoring to ensure the concrete mix is correctly adjusted in advance, preventing the need for return trips to depot

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system replaces manual mechanical water addition with an automated electronic control system that calculates precise water requirements based on sensor data, eliminating over-addition and ensuring slump test compliance

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If the truck returns to depot to add particulate ingredients after excessive water, then the slump problem is corrected, but time is lost and economic efficiency decreases

Engineering Contradiction:

Improveconcrete mix qualityVSAvoiddelivery time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The system performs preliminary water adjustment and slump optimization during the delivery process itself, eliminating the need for return trips to depot and associated time losses while maintaining mix quality

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system maintains continuous monitoring and adjustment capabilities throughout the delivery process, ensuring concrete quality is maintained without interruption or return trips, keeping the delivery process continuous and efficient

Inventive Principle:

Principle #20Continuity of useful action

4Device complexity

If temperature is not monitored in cold weather, then the system remains simple, but water supply freezes and operations are disrupted

Engineering Contradiction:

Improvesystem complexityVSAvoidoperational reliability in cold weather

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The system performs preliminary temperature monitoring and alerts operators before freezing conditions affect water supply, enabling preventive action without complex heating systems

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The temperature sensor acts as an intermediary that provides early warning of freezing conditions, allowing operators to take preventive measures such as adding antifreeze or insulating water lines before operational disruptions occur

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS8746954B2Method and system for calculating and reporting slump in delivery vehicles

Publication Date: 2014.06.10 VERIFI LLC

AI summary

A system for managing a concrete delivery vehicle having a mixing drum 14 and hydraulic drive 16 for rotating the mixing drum, including a rotational sensor 20 configured to sense a rotational speed of the mixing drum, a hydraulic sensor 22 coupled to the hydraulic drive and configured to sense a hydraulic pressure required to turn the mixing drum, a temperature sensor for sensing temperature of the drum, and a communications port 26 configured to communicate a slump calculation to a status system 28 commonly used in the concrete industry, wherein the sensing of the rotational speed of the mixing drum is used to qualify a calculation of current slump based on the hydraulic pressure required to turn the mixing drum. Temperature readings are further used to qualify or evaluate a load. Also, water purge connections facilitate cold weather operation.