Precast Brick Panel Spacing Mechanism for Row Length Accuracy

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Solution Overview

Problem

The construction of brick walls using traditional manual laying methods is slow, costly, and prone to errors, with precast brick panels not having achieved widespread commercial success due to high costs, low productivity, and aesthetic issues related to row length accuracy.

Innovation Solution

A method and installation involving a conveyor, spacing station, and brick pattern assembly station to accurately space and align bricks, allowing for consistent row lengths and varied spacing to accommodate brick length variations, enabling the production of high-accuracy, aesthetically pleasing precast brick panels.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual laying of bricks is used, then skilled labor can achieve accurate brick placement, but the construction speed is slow and labor costs are high

Engineering Contradiction:

Improvebrick placement accuracyVSAvoidconstruction speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

Bricks are pre-spaced to accurate dimensions using automated spacing mechanisms before being embedded in the panel. This preliminary spacing action ensures precise brick placement without requiring skilled labor during actual construction, while maintaining high production speed through factory automation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The manual mechanical skill of bricklayers is replaced with an automated spacing system using conveyors and spacing mechanisms. These mechanical systems automatically space bricks to precise dimensions, eliminating the need for skilled manual labor while achieving both high accuracy and high productivity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If precast brick panels are manufactured with fixed spacing, then production is simplified, but brick length variations cause row length inaccuracy affecting aesthetics

Engineering Contradiction:

Improveproduction simplicityVSAvoidrow length uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The spacing system is designed to be dynamic rather than fixed. The spacing between bricks can be automatically adjusted based on the actual length of each brick, allowing the system to accommodate brick length variations while maintaining uniform row lengths. This dynamic adjustment is achieved through automated sensing and positioning mechanisms

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The spacing parameter between bricks is made variable rather than constant. The system changes the spacing parameter dynamically to compensate for variations in brick length, ensuring that the total row length remains uniform. This is achieved by measuring each brick's length and adjusting the spacing accordingly through automated control

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If traditional brick laying is used, then flexibility in construction timing is maintained, but weather conditions halt construction and extend project duration

Engineering Contradiction:

Improveconstruction scheduling flexibilityVSAvoidproject duration

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

Brick panels are manufactured in advance in a controlled factory environment where weather conditions do not affect production. This preliminary manufacturing action allows construction to proceed independently of weather conditions, significantly reducing project duration while maintaining scheduling flexibility for installation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The outdoor manual brick laying process is replaced with indoor automated panel manufacturing. This substitution moves the brick assembly process from weather-dependent outdoor construction to controlled indoor factory production, eliminating weather-related delays while maintaining the ability to schedule installations according to project needs

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11661755B2Precast brick panel and method of manufacture

Publication Date: 2023.05.30 BRICKWORKS BUILDING PROD

AI summary

A method for assembling a brick pattern for forming a precast brick panel. The method includes conveying bricks in a row to a spacing station, spacing the bricks apart in a row at the spacing station according to a predetermined row pattern and to a predetermined row length by allowing the spacing between adjacent bricks to vary if required. The method then involves transferring the row of spaced bricks onto a generally planar support surface of a brick pattern assembly station. By this method, a plurality of rows of spaced bricks are assembled adjacent each other on the support surface of the brick pattern assembly station to form a brick pattern.