Concrete Vibrator Speed Control for Consistent Energy Delivery
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Solution Overview
Problem
Conventional concrete vibrators lack the ability to gauge vibrator dynamics and assess the quality of concrete mixes, leading to variable energy delivery and potential material damage, as well as unplanned delays and cost overruns due to unsatisfactory concrete pours.
Innovation Solution
A concrete vibrator system with a motor and controller that adjusts voltage to maintain operating speed based on actual motor speed and voltage draw, including a remote device for controlling and monitoring the system to optimize vibration and assess concrete quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional vibrators operate at high speeds (11,000 to 17,000 rpms), then consolidation effectiveness is improved, but energy delivery becomes highly variable and material damage may occur
Solution Approach 1:
The patent implements feedback control by monitoring actual motor speed and voltage draw, then automatically adjusting voltage supplied to the motor to maintain consistent operating speed. This closed-loop system ensures reliable energy delivery while maintaining high-speed consolidation effectiveness.
Solution Approach 2:
The system dynamically changes electrical parameters (voltage supplied to motor) based on real-time operating conditions to maintain consistent motor speed. This parameter adjustment compensates for variations in concrete resistance and ensures reliable energy delivery across different operating scenarios.
2Device complexity
If conventional vibrators lack speed monitoring, then device complexity is reduced, but the ability to gauge vibrator dynamics and assess concrete quality is lost
Solution Approach 1:
The system uses feedback from sensors monitoring motor speed and voltage draw to provide real-time information about vibrator dynamics. This information enables assessment of concrete mix quality and consolidation progress without requiring complex additional sensing infrastructure.
Solution Approach 2:
The patent uses motor operating parameters (speed and voltage draw) as intermediary indicators to assess concrete quality. Rather than directly measuring concrete properties, the system infers concrete condition from the electrical load and speed characteristics of the motor driving the vibrator.
3Ease of manufacture
If conventional vibrators operate without automatic speed control, then manufacturing cost is reduced, but unplanned delays and cost overruns occur due to unsatisfactory concrete pours
Solution Approach 1:
The feedback control system automatically monitors and adjusts motor operation to ensure optimal consolidation, preventing unsatisfactory concrete pours before they cause project delays. This automation reduces the need for manual intervention and rework.
Solution Approach 2:
The system performs self-adjustment of operating parameters to maintain optimal consolidation conditions throughout the pouring process. This self-regulating capability ensures consistent concrete quality without requiring continuous operator attention or complex manual control procedures.
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
Ensures consistent energy delivery, reduces material damage, and improves the quality of concrete pours by providing real-time feedback and monitoring capabilities, thereby minimizing delays and costs.
Implementation Method 1
a motor operably connected to the vibratory head and operable to drive the vibratory head at an operating speed
Implementation Method 2
a controller operable to control a speed of the motor, wherein the controller automatically adjusts voltage supplied to the motor to maintain the operating speed based on data received from the motor
Implementation Method 3
Concrete vibrators are used for consolidating concrete in a form at a construction site by vibrating the concrete before it sets. The vibration releases entrapped air, encourages a lower slump concrete to flow into corners of the form
Data Source
AI summary
A concrete vibrator includes a vibratory head, a motor operably connected to the vibratory head and operable to drive the vibratory head at an operating speed, and a controller operable to control a speed of the motor, wherein the controller automatically adjusts voltage supplied to the motor to maintain the operating speed based on data received from the motor, wherein the data received from the motor is indicative of actual motor speed of the motor and/or voltage draw of the motor.