Mobile Limestone Block Stamping Apparatus
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Solution Overview
Problem
Existing methods for producing construction blocks, such as concrete and limestone blocks, face challenges with conveyor mechanisms that limit block size and efficiency, and batching plants designed for concrete cannot effectively produce limestone blocks due to consistency issues.
Innovation Solution
A mobile block making apparatus that uses a modified batching plant to create a mixture of crushed limestone, cement, and a small amount of water, along with additives like plasticizers, which is then transferred to a mobile stamping machine for efficient production of limestone blocks without the need for extensive conveyor systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conveyor mechanism is used to transport formed blocks, then blocks can be moved away from the stamping machine, but the conveyor mechanism requires sufficient length so that recently formed blocks have time to cure enough to hold their shape
Solution Approach 1:
The formed blocks cure in place on the ground surface rather than being transported on a conveyor mechanism. The blocks self-support their own weight during curing by resting directly on the cured surface, eliminating the need for an extensive conveyor system to provide structural support during the curing process.
2Productivity
If a conveyor mechanism is used to transport formed blocks, then blocks can be conveyed away for stacking and storage, but the conveyor mechanism has a weight limit that limits the size of blocks that can be produced
Solution Approach 1:
Large blocks are formed and cured directly on the ground surface where they can support their own full weight during curing. The ground surface provides unlimited weight-bearing capacity compared to a conveyor mechanism, allowing production of large, heavy blocks that would exceed conveyor weight limits.
3Device complexity
If a mobile block producing machine is used to make limestone blocks, then conveyor mechanism problems are eliminated, but the dry limestone mixture would clog up the mobile block producing machine
Solution Approach 1:
The limestone mixture parameters are modified by adding a liquid binding agent (such as cement slurry or adhesive) to the dry limestone aggregate. This changes the mixture from a dry, free-flowing state that would clog the machine to a damp, cohesive state that flows properly through the mobile block producing machine's feeding and forming mechanisms.
4Productivity
If batching plants designed for concrete are used to make limestone mixtures, then concrete production capability is available, but the plants cannot be used to make limestone mixtures due to consistency and stickiness issues
Solution Approach 1:
The mixture composition parameters are adjusted by using dry limestone aggregate as the base material instead of wet concrete ingredients, and adding a controlled amount of liquid binding agent. This parameter change creates a mixture with different consistency characteristics that is compatible with batching plant equipment designed for concrete, allowing the same equipment to produce limestone blocks.
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
This method allows for the efficient production of large, high-density limestone blocks with compressive strengths between 800 psi and 1,200 psi, overcoming the limitations of traditional block making technologies by enabling on-site block formation and curing without the need for conveyor systems.
Implementation Method 1
a compression apparatus adapted to compress the mixture through the open top side of the mold box and against the surface
Implementation Method 2
the cement acting as a binder and curing the at least one construction block until it is rigid and dry
Data Source
AI summary
A method for making reconstituted limestone blocks includes using a batching plant to make a mixture comprising crushed limestone and cement. The mixture may additionally include water and an additive, such as a plasticizer. The batching plant has been modified to be compatible with the mixture. Next, the mixture is transferred from the batching plant to a mobile stamping machine having a mold box, a hopper, and a feed apparatus configured for transferring the mixture from the hopper to the mold box. Finally, the mobile stamping machine is activated so that the mobile stamping machine forms a construction block by transferring the mixture from the hopper to the mold box, depositing the construction block out of the mold box, and then moving to a next location. The mobile stamping machine is configured to produce approximately 100 construction blocks per hour.