Modular Concrete Vibrator With Remote Battery Weight Distribution
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Solution Overview
Problem
Concrete vibrators powered by internal combustion engines are difficult for operators to carry on construction sites due to their weight and bulk.
Innovation Solution
A portable concrete vibrator system featuring a vibrating head with an onboard electric motor, powered by a battery pack and controlled via a cable, allowing for interchangeable battery packs and vibrating heads, and a modular design that reduces the weight carried by the operator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If concrete vibrators are powered by internal combustion engines, then sufficient power is provided for construction operations, but the device becomes difficult to carry by operators due to weight and bulk
Solution Approach 1:
The system is divided into separate modular components: a battery pack unit, a motor control unit, and a vibrating head unit. This segmentation allows the heavy power source to be distributed and carried separately from the vibrating head, reducing the weight burden on operators during actual concrete vibration operations.
Solution Approach 2:
The internal combustion engine is replaced with an electric motor powered by a battery pack. This substitution eliminates the need for fuel storage, exhaust systems, and complex mechanical components associated with combustion engines, significantly reducing overall system weight and bulk while maintaining adequate power output for concrete vibration applications.
2Device complexity
If the concrete vibrator is designed as a single integrated unit, then structural simplicity is achieved, but operator mobility and ease of carrying are reduced
Solution Approach 1:
The concrete vibrator system is segmented into multiple independently carryable units connected by cables. The battery pack and motor control unit can be carried separately from the vibrating head, allowing operators to position the heavy power source in convenient locations while maintaining flexibility in where the vibrating head must be used.
Solution Approach 2:
A cable connection serves as an intermediary between the power source and the vibrating head, allowing physical separation of components while maintaining functional integration. This intermediary enables operators to separate the weight burden from the work location while preserving system functionality.
3Adaptability or versatility
If battery packs are made interchangeable and removable, then ease of replacement and adaptability are improved, but connection reliability and electrical contact stability may be compromised
Solution Approach 1:
A universal electrical connector design is implemented that accommodates different battery pack configurations while maintaining consistent electrical contact standards. This universal interface enables interchangeable battery packs of varying capacities while ensuring reliable electrical connections through standardized contact points and engagement mechanisms.
Solution Approach 2:
The connector design incorporates self-aligning and self-latching features that automatically ensure proper electrical contact when battery packs are attached. This self-service mechanism compensates for minor variations in connection positioning, maintaining reliable electrical contact without requiring precise manual alignment during battery pack replacement.
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
Enables efficient and ergonomic operation of concrete vibrators by distributing the weight of the power source and allowing for easy switching of vibrating heads, reducing operator fatigue and improving site mobility.
Implementation Method 1
a battery pack configured to provide electrical current to the motor
Implementation Method 2
an onboard electric motor configured to provide torque to the shaft, thereby causing the shaft to rotate
Implementation Method 3
a shaft having a center of mass radially offset from a rotational axis of the shaft
Data Source
AI summary
A concrete vibrator system comprises a vibrating head including a shaft. The shaft has a center of mass that is radially offset from a rotational axis of the shaft. The vibrating head also includes an onboard electric motor configured to provide torque to the shaft, causing the shaft to rotate. The concrete vibrator system further comprises a portable power unit including a battery pack configured to provide electrical current to the motor. A cable extends between the portable power unit and the vibrating head. The cable is configured to transmit electrical current from the battery pack to the motor and a motor control signal from the portable power unit to the motor.