Harmonic Mold Compaction With Hydraulic Pulse Control
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Solution Overview
Problem
Existing compaction devices for mineral mixtures, such as concrete, suffer from inhomogeneous compaction leading to quality issues, excessive vibrations, noise, and high maintenance costs, with hydraulic systems requiring expensive components and complex lubrication for deep-drawing processes.
Innovation Solution
A compacting device utilizing a machine frame with two piston-cylinder arrangements, one for lifting and vibrating a mold element and another for maintaining a holding force with a punch, employing a closed pressure system with pressure pulse generators to generate sinusoidal hydraulic fluid volume flows, reducing the need for additional pressure lines and enhancing compaction homogeneity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If impact impact compaction devices are used to compact concrete mixtures quickly, then productivity is improved, but manufacturing precision deteriorates due to inhomogeneous compaction
Solution Approach 1:
The patent applies mechanical vibration through a piston-cylinder arrangement that generates harmonic vibrations during compaction. The piston moves reciprocally within the cylinder, creating controlled vibrations that propagate through the concrete mixture in the mold frame, ensuring uniform compaction without the inhomogeneity caused by impact methods while maintaining high productivity.
2Productivity
If impact impact compaction devices are used to achieve rapid compaction, then productivity is improved, but object-generated harmful factors worsen due to severe vibrations and noise
Solution Approach 1:
The patent uses controlled mechanical vibration through a piston-cylinder system that generates harmonic vibrations at controlled frequencies and amplitudes. This replaces the uncontrolled severe vibrations and noise of impact methods with gentle, controlled vibrations that achieve compaction without generating harmful environmental effects, eliminating the need for soundproofed machine halls.
3Manufacturing precision
If hydraulic cylinders are used to move the mold element, then manufacturing precision is improved, but device complexity worsens due to expensive braking devices and special hydraulic hoses
Solution Approach 1:
The patent extracts and eliminates the complex braking devices and special high-pressure hydraulic hoses from the hydraulic system. The piston-cylinder arrangement operates without requiring expensive braking mechanisms or specialized hydraulic components, simplifying the overall system while maintaining precise control over the mold element's movement and position.
4Productivity
If impact forces are applied to the workpiece carrier, then productivity is improved through rapid compaction, but reliability worsens due to high wear and tear on the device
Solution Approach 1:
The patent replaces high-impact forces with controlled mechanical vibrations generated by the piston-cylinder system. This vibration-based compaction method achieves rapid compaction without the severe mechanical shocks and impact forces that cause high wear and tear, significantly improving device reliability and reducing maintenance requirements while maintaining high 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 solution achieves targeted compaction energy distribution, reducing vibrations and noise, improving product quality, and lowering maintenance costs by ensuring uniform compaction and eliminating the need for expensive hydraulic hoses, while maintaining high holding forces during the deep-drawing process.
Implementation Method 1
a first piston-cylinder arrangement which is connected to the machine table and is designed in such a way that lifting and lowering forces can be exerted on a mold element
Implementation Method 2
the first piston-cylinder arrangement serves to exert lifting and lowering forces on a mold element... through which the mineral mixture or concrete mixture is compacted
Implementation Method 3
employing a closed pressure system with pressure pulse generators to generate sinusoidal hydraulic fluid volume flows
Implementation Method 4
another for maintaining a holding force with a punch
Data Source
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AI summary
The invention relates to a device for the compacting, in particular the harmonic compacting, of mineral mixtures, in particular concrete mixtures in the production of all types of concrete products, or for deep drawing. The invention also relates to a machine frame (10) having a machine head (12), a machine table (14), and at least two side elements (16a, 16b) connecting the machine head (12) and the machine table (14). A first piston-cylinder assembly (39), which is connected to the machine table (14), is designed in such a way that lifting and lowering forces are exerted on a form element (42, 24) that can be filled with mineral mixture, in particular with concrete mixture, or a form element on which a sheet metal or plastic blank can be laid, said piston-cylinder assembly also being designed to lift and/or lower and/or vibrate the form element (42, 24). A second piston-cylinder assembly (44), which is connected to the machine head (12), is designed in such a way that a punch (58), which can enter into the form element (42, 24), is held using a holding force greater than or equal to the maximum lifting force of the first piston-cylinder assembly. The invention also relates to a method for compacting or deep drawing using the device.