Concrete Mixer Motor Power Feedback for Slump Control
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Solution Overview
Problem
Current concrete mixing systems lack the ability to accurately and consistently achieve the desired slump or workability, leading to inefficiencies and increased rejection rates due to operator-dependent mixing times and inconsistent readings across different mixers.
Innovation Solution
An improved slump meter system that provides a stable digital output and automatic water feeding process, allowing for real-time monitoring and adjustment to achieve a target slump, coupled with a human-machine interface to train operators on optimal mixing cycles, ensuring consistent concrete production across various mixer types and sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If operator-dependent mixing times are used, then flexibility in operation is maintained, but manufacturing precision and consistency of slump achievement deteriorate
Solution Approach 1:
The system continuously monitors mixer motor power consumption and compares it against target values to automatically adjust water addition, creating a closed-loop feedback system that maintains consistent slump without operator intervention
Solution Approach 2:
The mixing system performs self-adjustment by automatically detecting power deviations and controlling water addition based on pre-programmed algorithms, eliminating the need for operator judgment and manual timing
2Reliability
If extended mixing times are used to ensure proper mixing, then mixing completeness is improved, but productivity decreases due to operator delays and over-mixing
Solution Approach 1:
The system provides real-time feedback on mixing progress through power monitoring, automatically determining when the target slump is achieved and signaling batch completion, preventing both under-mixing and over-mixing
Solution Approach 2:
The system replaces operator-based timing and judgment with automated electronic monitoring and control, using power consumption data to objectively determine mixing completion rather than relying on operator experience or fixed time intervals
3Quantity of substance
If multiple readings are taken across different mixers, then comprehensive data collection is achieved, but measurement precision deteriorates due to inconsistent readings across mixers
Solution Approach 1:
The system changes the measurement parameter from direct slump measurement (which varies by mixer) to power consumption measurement (which is consistent across mixers), allowing standardized comparison and control across different equipment
Solution Approach 2:
The power monitoring system serves multiple functions: it measures mixing progress, determines slump achievement, controls water addition, and signals batch completion, providing a universal measurement approach that works across all mixer types in the fleet
4Manufacturing precision
If automatic water feeding is implemented, then manufacturing precision of target slump is improved, but device complexity increases
Solution Approach 1:
The control system uses the existing power monitoring infrastructure for multiple purposes including slump control, mixing progress tracking, and batch completion detection, avoiding the need for separate specialized systems
Solution Approach 2:
The system uses simple feedback loops where power deviations trigger predetermined water addition responses, maintaining precision through automated control while keeping the logic straightforward and based on pre-programmed algorithms
Data Source
AI summary
A system and method for automatically controlling concrete batch mixing cycles and for training an operator to minimize the mixing cycles, includes receiving real time mixer motor power measurements; detecting an initial peak value among the real time mixer motor power measurements; determining, by a processor, an initial amount of water to add to a concrete batch; waiting a first time period to determine a first supplemental amount of water to add to a concrete batch; and, then, periodically determining additional supplemental amounts of water to add to a concrete batch; until, the real time mixer motor power measurements meet a pre-determined target mixer motor power value, responsive to which, one or more outputs are activated, such as a user interface indicator that the batch is ready, or an optional electronic signal to a batch control system to dump the batch, or both.