Elastic Tool Shafts for Bulbous Shaped Brick Processing
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Solution Overview
Problem
Existing machines for processing shaped stones, such as those made of cement or concrete, often fail to produce a visually appealing quarry-like structure and bulbous shape effectively, struggling to break edges and create a natural stone appearance.
Innovation Solution
A processing device with an elongated shaft and multiple support elements, where processing tools are attached elastically, allowing for adjustable extensions and orientations to intensively process the edges and surfaces, creating a bulbous shape by varying the angle of rotation and tool contact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional processing machines with hammer-like tools are used, then the edges can be broken and quarry-like structure can be created, but the stones cannot be given a bulbous shape and the visual appeal is insufficient
Solution Approach 1:
The processing machine divides the processing function into multiple specialized units: at least one processing unit for creating quarry-like structure and breaking edges, and at least one additional processing unit for creating bulbous shape. This segmentation allows each unit to optimize its specific function without compromising the other, resolving the contradiction between edge breaking and bulbous shape formation.
Solution Approach 2:
The machine applies different processing qualities to different regions of the stone: the first processing unit applies aggressive hammer-like impacts primarily at edges and corners to create quarry-like structure, while the second processing unit applies more controlled forces to create the bulbous shape in the central areas. This local differentiation of processing intensity and method enables both edge breaking and bulbous shaping to coexist.
2Manufacturing precision
If multiple hammer-like tools are used for processing, then the quarry-like structure can be created, but the processing time increases and productivity decreases
Solution Approach 1:
The machine merges multiple processing functions into a single integrated system where multiple processing units operate simultaneously on the stone during one pass. The hammer-like tools for quarry-like structure and the tools for bulbous shape work in parallel, eliminating the need for sequential processing and thereby maintaining high productivity while achieving both processing qualities.
Solution Approach 2:
The processing units are arranged and coordinated to operate continuously as the stone moves through the machine, with no idle time between different processing operations. The hammer-like tools and bulbous-shape tools operate in continuous succession or parallel, ensuring that every moment of stone contact with the processing machine performs useful work, thereby maximizing productivity.
3Device complexity
If the processing tools are fixed in position, then the machine structure is simple, but the ability to create customizable patterns and varying material removal is limited
Solution Approach 1:
The processing tools are mounted on movable supports that can adjust their position relative to the stone surface. This dynamic capability allows the tools to adapt to different stone sizes, shapes, and processing requirements, enabling pattern customization and variable material removal while maintaining a relatively simple overall machine structure through modular design.
Solution Approach 2:
The machine incorporates adjustable parameters such as tool position, processing force, and rotation speed that can be modified to create different processing patterns and material removal rates. These parameter changes enable versatility in processing outcomes without requiring complex reconfiguration of the entire machine structure, resolving the contradiction between simplicity and adaptability.
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 device achieves a high-quality, visually appealing stone surface with a bulbous shape, mimicking natural stones, by intensively processing the edges and surfaces, allowing for customizable patterns and increased material removal at edges compared to the central area.
Implementation Method 1
at least two first processing tools (4.1A, 4.1B) are elastically attached to the first terminal support element (T1)
Implementation Method 2
The shaft (3) is designed such that it can be set into a rotational movement about its rotational axis (R) by the drive unit (2)
Implementation Method 3
Chains suspended from the transport element serve as processing elements, which, as the transport element rotates, strike the surface of the stones or their edges
Data Source
Figure 1
Figure 2A~2C
Figure 3
AI summary
A processing device 1 for processing shaped bricks F is described, wherein the processing device 1 comprises at least one drive unit 2 and at least one elongated shaft 3 having an axis of rotation R. The shaft 3 is designed such that it can be set into a rotational movement about its axis of rotation R by the drive unit 2. At least three annular support elements T1, T2, Tx are arranged on the shaft 3 and are fixedly connected to the shaft 3, wherein a first terminal support element T1 is arranged on the shaft 3 adjacent to the end of the shaft 3 adjacent to the drive unit 2, a second terminal support element T2 is arranged on the shaft 3 adjacent to the end of the shaft 3 furthest from the drive unit 2, and at least a third support element Tx is arranged on the shaft 3 between the first terminal support element T1 and the second terminal support element T2.At least two machining tools are elastically attached to each of the support elements. Each of the machining tools 4.1A, 4.1B, 4.2A, 4.2B, 4.xA, 4.xB has a machining head 5 at its end spaced apart from the support element T1, T2, Tx, for interaction with a surface of the molded blocks F to be machined, and a tool axis oriented radially outwards from the respective support element. The first machining tools 4.1A, 4.1B attached to the first terminal support element T1 have a first extension A1 in the direction of their respective tool axis WA1, the second machining tools 4.2A, 4.2B attached to the second terminal support element T2 have a second extension A2 in the direction of their respective tool axis WA2, and the third machining tools 4.xA, 4.xB arranged on the at least one third support element Tx have an extension Ax in the direction of their respective tool axis WAx.The first extension A1 of the first machining tools 4.1A, 4.1B and the second extension A2 of the second machining tools 4.2A, 4.2B are larger than the extension Ax of the third machining tools 4.xA, 4.xB.