Automated Mortar Removal System with Dust Containment
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Solution Overview
Problem
Current methods for removing deteriorated mortar from masonry joints are labor-intensive, time-consuming, and expose workers to silica dust, posing health risks such as silicosis and carpal tunnel syndrome.
Innovation Solution
A system comprising a joint identification device, work tools, and a computer-controlled containment system that automates the mortar removal process, using tools like circular blades and router-type bits, and a suction hood with a vacuum system to contain and remove dust and debris.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual hand tools are used for mortar removal, then the process is simple and equipment complexity is low, but labor intensity and time consumption increase significantly
Solution Approach 1:
The patent replaces manual mechanical tools with a powered mechanical system featuring an automated mortar removal device that uses a rotating cutting element to remove mortar. This substitution dramatically increases productivity while the system remains relatively simple in design, requiring only basic power transmission components and a cutting head.
Solution Approach 2:
The mortar removal device is designed to be self-propelled along the masonry surface, using its own cutting action to advance forward. The device automatically positions itself and maintains contact with the masonry units, reducing the need for manual positioning and operation while maintaining equipment simplicity.
2Device complexity
If manual hand tools are used for mortar removal, then equipment simplicity is maintained, but worker exposure to silica dust and health risks increase
Solution Approach 1:
The patent introduces a dust collection system as an intermediary between the cutting operation and the worker environment. This system captures silica dust at the source using a vacuum or filtration mechanism, preventing exposure while adding minimal complexity to the overall device structure.
Solution Approach 2:
The harmful silica dust is extracted and separated from the work environment through a dedicated dust collection and removal system. This extraction approach eliminates the harmful factor while maintaining relative equipment simplicity by using separate, modular dust control components.
3Productivity
If automated computer-controlled work tools are used, then productivity and precision are improved, but device complexity and initial cost increase
Solution Approach 1:
The automated system is divided into separate functional modules: a joint detection system that identifies mortar joint locations, a control system that plans the removal path, and an execution system that performs the cutting. This segmentation allows each component to be optimized independently while maintaining overall system manageability and reducing complexity through modular design.
Solution Approach 2:
The system performs preliminary detection and mapping of the masonry surface to identify joint locations before the actual mortar removal begins. This preliminary action allows the computer control system to pre-calculate optimal removal paths, increasing productivity during the actual cutting phase while keeping the control algorithms relatively simple.
4Manufacturing precision
If computer control systems with joint detection are used, then manufacturing precision and joint preparation quality are improved, but device complexity and measurement requirements increase
Solution Approach 1:
The joint detection system creates a digital copy or map of the masonry joint locations and geometries. This digital representation allows the control system to precisely plan removal paths without requiring complex real-time sensing during cutting, simplifying the measurement system while maintaining high precision through pre-planned automated execution.
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 significantly reduces labor and time required for mortar removal, enhances worker safety by minimizing dust exposure, and prevents injuries associated with manual tools, while ensuring precise removal and preparation of joints for new mortar.
Implementation Method 1
a suction hood for enclosing the at least one work tool, and a vacuum system for removing dust and debris from the suction hood
Data Source
AI summary
A method and system for performing work from a suspension work platform incorporating a work tool attached to an articulating arm system.