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 and time-consuming, generating silica dust that poses health risks to workers.
Innovation Solution
A system comprising a joint identification device, work tools, and a computer control system that automates the mortar removal process, including a containment system to manage dust and debris, and an access system for efficient operation on masonry structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual hand tools and powered hand tools are used for mortar removal, then the process can be performed with simple equipment, but the labor intensity and time consumption increase significantly
Solution Approach 1:
The patent replaces manual mechanical tools with an automated robotic system equipped with sensors, computer control, and automated work tools. The system uses optical shape recognition sensors to detect joint locations and a computer control system to automatically guide the work tool along the joint, eliminating manual labor while significantly improving productivity and reducing time consumption.
2Ease of manufacture
If manual tools are used for mortar removal, then equipment cost is low, but worker exposure to silica dust increases health risks
Solution Approach 1:
The patent converts the harmful silica dust byproduct into a manageable element by incorporating a dust collection system that captures dust at the source. The system includes a dust collection device positioned to collect silica dust generated during mortar removal, transforming the health hazard into a controlled process parameter that can be filtered and disposed of safely.
3Productivity
If automated systems are introduced to reduce labor intensity, then productivity improves, but device complexity increases
Solution Approach 1:
The patent integrates multiple functions into a single robotic platform: the joint identification device detects joint locations, the computer control system processes this information and generates control signals, the work tool performs mortar removal, and the dust collection system captures dust. This multi-functional integration achieves high productivity while managing overall system complexity through consolidation rather than separate independent systems.
4Loss of time
If automated work tools are used to remove mortar, then labor time is reduced, but precision control requirements increase
Solution Approach 1:
The patent employs optical shape recognition sensors that continuously detect the joint location and provide feedback to the computer control system. The control system processes this feedback in real-time and adjusts the work tool's position and movement to precisely follow the joint path, ensuring accurate mortar removal while maintaining high speed and reducing overall repointing time.
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.
Implementation Method 1
the joint identification device comprises an optical shape recognition sensor to optically sense the location of at least one of the plurality of joints
Implementation Method 2
the dust and debris generated when the at least one work tool removes mortar from at least a portion of one of the plurality of joints along the work path is contained and removed
Data Source
AI summary
A method and system for removing mortar from a plurality of joints between a plurality of masonry units in a masonry structure is provided. The steps for accomplishing the method include sensing the location of at least one of the plurality of joints between the plurality of masonry units and transmitting joint location data to a computer control system. The computer control system computes a work path based upon the joint location data and controls the position and operation of at least one work tool such that the work tool moves along the a portion of the work path to remove mortar from a portion of one of the plurality of joints along the work path.