Patterned Conveyor Belt for Slip Forming Concrete Barriers
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Solution Overview
Problem
Current slip forming methods struggle to efficiently incorporate aesthetic designs into concrete structures, leading to reduced production rates, increased costs, and inconsistencies due to the limitations of existing slip forming apparatuses, which fail to consistently impress patterns into concrete barriers with varying concrete slumps and inadequate support.
Innovation Solution
A conveyor mold system with a belt having a pattern on both front and rear rollers, synchronized with the slip forming machine's speed, and supported to prevent sagging, allowing for consistent and reproducible pattern imprinting on concrete barriers without requiring special tooling or labor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional form lining methods are used to incorporate aesthetic designs, then design detail quality is improved, but production rate decreases dramatically from 125 linear feet per hour to 100 linear feet per day
Solution Approach 1:
The patent replaces the traditional mechanical form lining system with a slip forming apparatus that uses a vibrated mold and roller mechanism. The mold is vibrated to settle concrete, and a roller with a patterned surface imprints the design directly onto the concrete barrier as it is being formed, eliminating the need for separate form lining operations and dramatically increasing production speed while maintaining design quality
Solution Approach 2:
The design pattern is pre-configured into the roller surface before the slip forming operation begins. As the concrete is poured and vibrated into the mold, the roller simultaneously imprints the aesthetic design pattern onto the concrete surface, performing the design application in advance of any post-forming operations and ensuring consistent pattern application throughout production
2Manufacturing precision
If a roller apparatus is used to imprint patterns into concrete, then design incorporation is achieved, but pattern consistency and edge crispness deteriorate due to minimal contact time and roller displacement
Solution Approach 1:
The patent merges the pattern imprinting function with the primary slip forming operation. The roller is positioned to contact the concrete barrier while it is still within the mold and being vibrated, combining the design application with the concrete placement and initial setting process. This ensures the pattern is imprinted during the concrete's most receptive state, maximizing pattern consistency and edge definition
Solution Approach 2:
The concrete barrier is vibrated and settled into the mold before the roller applies the pattern imprint. This preliminary vibration and settling ensures the concrete is properly positioned and receptive to the pattern application, preventing displacement and deformation that would occur if the roller applied pressure to unset concrete
3Manufacturing precision
If pressure is applied manually to the roller apparatus, then pattern imprinting is achieved, but pressure distribution becomes non-uniform requiring trial and error adjustment
Solution Approach 1:
The roller apparatus is designed to be self-adjusting through the natural vibration and settling of the concrete during the slip forming process. As concrete is vibrated into the mold, it automatically applies uniform pressure to the roller surface, eliminating the need for manual pressure adjustment. The system self-regulates pressure distribution based on the concrete's own weight and vibration characteristics, ensuring consistent pattern imprinting without trial and error
4Manufacturing precision
If the roller apparatus is positioned beyond the rear limits of the paving mold, then design imprinting is achieved, but concrete structure support becomes inadequate causing displacement or deformation
Solution Approach 1:
The patent repositions the roller apparatus from a location beyond the rear limits of the mold to a position where it contacts the concrete barrier while it is still within the mold cavity. This spatial repositioning allows the roller to imprint the pattern during the concrete's initial setting phase when the mold provides structural support, preventing displacement or deformation while achieving design imprinting
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 enables faster and more consistent production of concrete barriers with reproducible patterns, reducing time, labor, and costs, while ensuring uniform pattern impression and structural integrity by using a motor-driven belt system with integrated supports.
Implementation Method 1
the roller apparatus has pressure applied to it by use of a turnbuckle device to make pattern on the roller apparatus contact the concrete structure
Implementation Method 2
The concrete is transferred to a paving mold and then vibrated extensively to produce a concrete structure in the shape of the paving mold
Data Source
AI summary
A conveyor mold system for slip forming a concrete barrier has a concrete paving machine having a main frame having machine legs and machine tracks, an auger system for receiving concrete, a barrier paving mold having a hopper for receiving concrete from the auger system, a conveyor assembly main frame having a front roller and a rear roller, and a belt having a pattern with the belt positioned on the front roller and the rear roller.