Mobile Volumetric Concrete Mixing With Continuous Hopper Agitation
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Solution Overview
Problem
Existing methods for backfilling small trenches with flowable concrete mixes face challenges such as the need for continuous agitation to prevent hardening, difficulty in pouring into narrow trenches, and inefficiencies in reusing trench spoils, leading to increased costs and time due to void formation and overflow.
Innovation Solution
A mobile volumetric concrete mixing system that vacuums up trench spoils, screens them for particle size, mixes with water and cement on-site, and uses a hopper with continuous agitation to prevent hardening, facilitating controlled pouring into narrow trenches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If rapid-setting concrete mixes are used for backfilling, then setting time is reduced, but the mixture hardens too quickly requiring continuous agitation
Solution Approach 1:
The patent applies preliminary action by pre-positioning the hopper with agitation mechanism before the concrete mix is discharged. The hopper is designed with internal agitation components that are ready to operate immediately upon receiving the rapid-setting mix, preventing hardening before the mixture can be poured into the trench.
Solution Approach 2:
The patent implements continuity of useful action through the hopper's continuous agitation mechanism that operates throughout the discharge process. The hopper maintains constant movement and mixing of the concrete mixture as it is being discharged, ensuring the mixture remains workable from mixing until it is placed in the trench.
2Adaptability or versatility
If traditional equipment designed for wide trenches is used, then equipment availability is maintained, but pouring into narrow trenches is difficult resulting in voids and overflow
Solution Approach 1:
The patent applies segmentation by dividing the backfilling operation into controlled stages: mixing, hopper discharge control, and trench placement. The hopper acts as a separate controlled discharge mechanism that can be precisely regulated to match the narrow trench dimensions, separating the mixing function from the placement function to enable better control.
Solution Approach 2:
The patent implements dynamics through the hopper's movable and adjustable discharge mechanisms. The hopper can be positioned, tilted, and discharged at controlled rates to adapt to the specific dimensions and location of narrow trenches, transforming a static equipment design into a dynamic system that can adjust to varying field conditions.
3Ease of repair
If trench spoils are collected and transported away for screening, then material reuse is achieved, but time and cost increase
Solution Approach 1:
The patent merges the functions of trench spoil collection, screening, and concrete mixing into a single integrated system. The hopper receives and processes trench spoils directly at the work site, combining multiple previously separate operations into one continuous process that eliminates transport time and on-site screening requirements.
Solution Approach 2:
The patent applies self-service by enabling the system to process and reuse trench spoils autonomously at the work site. The integrated hopper system automatically collects, screens, and mixes the spoils into backfill material without requiring external intervention or off-site processing, making the system self-sufficient.
4Productivity
If flowable backfill is poured into narrow trenches, then trench backfilling is completed, but voids form and material overflows requiring clean-up
Solution Approach 1:
The patent implements feedback control through the hopper's regulated discharge mechanism that monitors and adjusts the flow rate of concrete mixture based on trench conditions. This controlled discharge prevents both overflow and void formation by matching the discharge rate to the trench capacity in real-time.
Solution Approach 2:
The patent applies parameter changes by adjusting the discharge parameters of the hopper (flow rate, position, angle) to match the specific requirements of narrow trenches. The system modifies these parameters dynamically to optimize the pouring process and prevent defects like voids and overflow.
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 system enhances efficiency and reduces costs by reusing trench spoils on-site, minimizing hardening, and reducing clean-up time and material overflow, while maintaining controlled mixture placement.
Implementation Method 1
a suction system configured to draw aggregate into the aggregate-storage chamber from an external source
Implementation Method 2
a vibrating aggregate screen disposed between the aggregate-storage chamber and the conveyor
Data Source
AI summary
A mobile volumetric concrete mixing system includes a suction system that vacuums up trench spoils while a trench is being cut. These trench spoils are then screened on-site for particle size to be reused and mixed with water, cement, and/or other admixtures at an auger mixer to form a backfill mixture. This backfill mixture may then be loaded into a hopper that continuously agitates the mixture so that the mixture does not harden before pouring. The agitating hopper is coupled to a discharge chute of the auger mixer and includes one or more augers disposed at various orientations that the backfill mixture is channeled through. From the agitating hopper, the backfill mixture is channeled to an applicator that moves along the trench and that enables the mixture to be quickly poured into the trench with little clean-up required.