Direct Charge Concrete Mixer Drum Automation
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Solution Overview
Problem
Conventional concrete mixing systems face challenges in efficiently loading and maintaining the mixing drum, as the structures surrounding the opening are heavy and burdensome to clean and maintain, leading to inefficiencies in material handling and increased maintenance needs.
Innovation Solution
A concrete mixer vehicle equipped with a mixing drum assembly that includes a mixing drum, a mixing element, a collector, and a chute, along with a controller that positions the outlet of the mixture delivery system within the drum to directly charge it with material, reducing the need for manual loading and minimizing material misplacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional structures surround the opening of the drum for loading material, then the drum can be loaded with material, but the structures are heavy and burdensome to clean and maintain
Solution Approach 1:
The patent removes the conventional heavy surrounding structures (hopper, chutes, supports) and extracts only the essential function of material delivery. The drum opening is simplified to minimal edges, eliminating the burdensome structures that required extensive cleaning and maintenance while preserving the loading capability.
Solution Approach 2:
The loading function is segmented from the drum structure itself. Rather than having integrated heavy surrounding structures, the system separates the material delivery function (performed by the mixing element) from the drum container, allowing the drum opening to be simple and easy to maintain.
2Productivity
If conventional structures are used to load the drum, then material can be delivered, but material misplacement occurs and increases maintenance needs
Solution Approach 1:
The mixing element performs multiple functions: it mixes the material and simultaneously delivers it to the drum opening. This self-service capability eliminates the need for separate delivery structures, ensuring material is placed precisely where needed without misplacement or loss.
Solution Approach 2:
The mixing element is designed with universal functionality, serving both as a mixing device and a material delivery mechanism. This multi-functionality consolidates the loading process, preventing material misplacement that would occur with separate delivery structures while maintaining high productivity.
3Ease of operation
If the mixing drum rotates in first direction, then the mixing element mixes the material, but the mixing element must also drive material towards the aperture when rotating in second direction
Solution Approach 1:
The mixing element operates in periodic cycles: rotating in the first direction to mix material, then rotating in the second direction to deliver material to the aperture. This periodic alternation between mixing and delivery functions allows the single element to handle both tasks without requiring complex additional mechanisms.
Data Source
AI summary
A concrete mixer vehicle includes a chassis, a mixing drum assembly, and a controller. The mixing drum assembly includes a mixing drum, a mixing element, a collector, and a chute. The mixing drum defines an aperture and a volume. The mixing element is positioned within the volume and is coupled to the mixing drum. The controller is configured to determine a state of the concrete mixer vehicle, determine a state of a mixture delivery system of a batch plant, obtain and apply a setpoint value to an actuator of the concrete mixer vehicle or the mixture delivery system, and activate the mixture delivery system to output material through the outlet of the mixture delivery system such that the material is deposited directly into the volume of the mixing drum to thereby directly charge the concrete mixer vehicle with material.