Modular Fixer Flutes for Concrete Casting Machines
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Solution Overview
Problem
Existing concrete casting machine superstructures are typically designed for specific types and heights of machines, making them inflexible and requiring costly heat-treatment to alleviate material stress from welding, and they lack easy adaptability to different machine types and product forms.
Innovation Solution
The use of detachable fixer flutes with adjustable spacers and varying rounding radii for vibration dampening, allowing for flexible mounting and easy exchange of components, enabling the casting upper part to adapt to different machines and reducing material stress through bolt connections and simple manufacturing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a welded superstructure is used to ensure precise fit for a specific machine type, then the structural strength and precision are improved, but the adaptability to different machine types deteriorates and additional heat-treatment is required to alleviate material stress
Solution Approach 1:
The superstructure is divided into separate components (superstructure elements) that can be individually attached to the casting upper part. This segmentation allows different elements to be used with different machine types without requiring complete redesign or heat-treatment, while maintaining structural strength through standardized connection methods.
Solution Approach 2:
The casting upper part is designed with universal mounting features that can accommodate multiple types of superstructure elements. This universality enables the same base structure to work with different machine types and product forms by simply changing the superstructure elements, eliminating the need for machine-specific custom designs.
2Manufacturing precision
If a welded superstructure is designed for a specific machine type, then the manufacturing precision for that type is improved, but the ease of manufacture and cost deteriorate due to required heat-treatment processes
Solution Approach 1:
By separating the superstructure into detachable elements, the manufacturing process is simplified. Each element can be manufactured independently with standard precision, eliminating the need for complex heat-treatment processes required by welded constructions. The standardized interfaces ensure precise fit without additional processing.
Solution Approach 2:
The connection method changes from permanent welding to detachable mechanical connections (such as bolts or clips). This parameter change in the joining method maintains manufacturing precision through standardized interfaces while dramatically improving ease of manufacture by eliminating heat-treatment requirements and enabling simpler, more cost-effective production.
3Reliability
If traditional hydraulic or pneumatic cylinders are used to retain the casting upper part, then the reliability of retention is improved, but the device complexity and cost deteriorate
Solution Approach 1:
The complex hydraulic or pneumatic cylinder system is extracted and replaced with a simpler retention mechanism. The essential function of retaining the casting upper part is maintained through a more straightforward design, likely using mechanical stops, clips, or simple fastening elements that eliminate the need for complex actuation systems.
Solution Approach 2:
The retention mechanism is designed to be simpler and more economical, potentially using readily available materials and standard components. The focus shifts from creating a complex, expensive retention system to using straightforward mechanical means that achieve reliable retention at lower cost and with reduced complexity.
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 solution allows for quick adaptation of the casting upper part to various concrete casting machines, reduces material stress, and enhances the smoothness of cast item surfaces by dampening vibrations, improving compression and protecting the machine from excessive vibrations.
Implementation Method 1
varying rounding radii for vibration dampening
Data Source
AI summary
Mounting device for a flexible constructed retainer means for retention of a casting upper part in a concrete casting machine of the type which typically is used for the production of casting items in the form of concrete blocks for pavements and wall constructions. Typically, two or three fixer flutes (10) are applied for each casting upper part, the length of the fixer flutes are adapted the depth of the casting upper part. In the invention, a flexible mountable fixer flute (10) consisting of two identical halves (12) is described. When the height of these fixer flute-halves exceeds a certain height, spacers (14) are mounted by means of bolting. The design of the fixer flute (10) leaves a space where the forks of fork lift trucks can be passed through, thus using the fixer flutes to also lift the casting upper part.