Pneumatic Mortar Conveyor with Pressure Equalization
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Solution Overview
Problem
Current mortar delivery systems face challenges in efficiently conveying earth-moist mortar or screed masses, particularly with a water/cement factor below 0.45, leading to low delivery rates, drying out, and pellet formation, which impairs mortar quality and causes blockages, limiting conveying capacities to around 2 m3/h with significant pressure increases and mechanical disruptions.
Innovation Solution
A compressed air-based mortar and screed conveyor system with a filling tank and conveyor tank, utilizing a pressure equalization line and bypass pressure line to maintain consistent delivery pressure, allowing for continuous and efficient transport of earth-moist mortar with a water/cement factor below 0.45, achieving conveying capacities of up to 10 m3/h without quality impairment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If known mortar delivery systems are used to transport earth-moist mortar over distances more than 50 meters, then conveying capacity is reduced to low delivery rates, but system complexity and operational simplicity are maintained
Solution Approach 1:
The patent applies pneumatic principles by using compressed air to fluidize and transport mortar through a conveying hose. The air-mortar mixture is propelled by pressure differential created by the compressed air source, enabling high-speed transport over long distances without mechanical friction that would otherwise limit conveying capacity
Solution Approach 2:
The patent changes the physical state of mortar from a dense, friction-bound material to a fluidized, air-supported suspension. By introducing compressed air and controlling the air-to-mortar ratio, the system transforms mortar properties to enable high-velocity flow through the conveying hose, achieving conveying capacities exceeding 10 m³/h
2Productivity
If concrete pumps are used to transport earth-moist mortar, then conveying capacity increases, but the system cannot handle mortar with water/cement factor below 0.45 due to mechanical disruption
Solution Approach 1:
The pneumatic conveying system uses compressed air instead of mechanical pumping, eliminating direct mechanical contact with mortar aggregates. This prevents the mechanical disruption and segregation that occur in pump systems, maintaining mortar homogeneity and quality while achieving high conveying capacities
Solution Approach 2:
The system employs vibration of the conveying hose to prevent material settling and blockages during transport. The vibrational energy keeps the air-mortar mixture in constant motion, ensuring smooth flow without mechanical disruption to the mortar structure
3Productivity
If truck mixers are used to deliver fresh mortar, then conveying capacity increases, but mortar quality deteriorates due to drying out and pellet formation during transport
Solution Approach 1:
The pneumatic conveying system enables continuous transport of mortar from the mixing station directly to the application point without intermediate stopping or transfer. This continuous action eliminates the delays and exposure to air that cause evaporation and pellet formation in truck mixer systems
Solution Approach 2:
The system controls the moisture content and flow characteristics of mortar during transport by adjusting air pressure and flow rate. This maintains the mortar in an optimal state for transport without the drying out that occurs in open truck mixers
4Length of stationary object
If conveying hose length is increased to 50 meters, then transport distance increases, but delivery rate decreases to approx. 2 m3/h due to friction losses
Solution Approach 1:
The pneumatic system uses compressed air pressure to overcome friction losses in the conveying hose. The air-mortar mixture is propelled by pressure differential, allowing long-distance transport at high velocities without the friction-based limitations of mechanical conveying systems
Solution Approach 2:
Vibration of the conveying hose reduces friction between the mortar particles and hose walls, minimizing energy losses over long distances. The vibrational energy keeps particles suspended and moving smoothly, maintaining delivery rates even at 50+ meter hose lengths
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 continuous and efficient transport of earth-moist mortar with a water/cement factor of 0.42-0.5 at 10 m3/h over 20 meters and 7-7.5 m3/h over 60-70 meters, preventing blockages and maintaining mortar quality by managing pressure and filling levels through a control unit, ensuring high throughput without mechanical disruptions.
Implementation Method 1
a compressed air source (30) for pressurizing the conveying tank (3)
Implementation Method 2
The filling tank (2) is connected to the conveying tank (3) via a pressure equalization line (100)
Implementation Method 3
bypass pressure line (200) to maintain consistent delivery pressure
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The method involves locking a transported material passage arranged between filling boiler (2) and conveying boiler (3). A pneumatic source is attached at the mortar and screed conveyer. A conveying boiler of the mortars and screed conveyer (1) is filled with transported material, which is obtained from a filling boiler of the mortar and screed conveyor. The minimum pressure is obtained perpendicular while conveying in the conveying boiler, which is greater than the atmospheric pressure. An independent claim is also included for a mortar and screed conveyer comprises filling boiler and conveying boiler.